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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a National Stage Application of International Patent Application No. PCT/CN 2004/000983, with an international filing date of Aug. 25, 2004, which is based on Chinese Patent Application No. 03135662.1, filed Aug. 25, 2003.The contents of both of these specifications are incorporated herein by reference.
TECHNICAL FIELD
The invention relates to an overpass, and especially an interchange overpass suitable for city roads and highways.
BACKGROUND
In order to solve traffic jams at city intersections many types of overpasses have been employed. Generally, triple level and higher grade overpass intersections are built for channeling motor and non-motor vehicles and for enabling transfer without impact and interference. Such high grade overpasses with their extra long ramps inconvenience drivers and occupy too much space. Especially in cities where much repositioning has to be done, the compensation cost for relocation of residents may be high. Providing clover-type overpasses will cause traffic jams in case of increased vehicle flow due to entanglement between the turning vehicles and the circling vehicles.
SUMMARY OF THE INVENTION
The invention provides a single-level interchange overpass having simple construction and full functionality, and occupying less space.
The technical solution of the invention is as follows: a single-level interchange overpass according to this invention comprises a main road and an intersected road, wherein a U-shaped circle road is provided on the horizontal level at both ends of the main road, a inner semicircle road and a outer semicircle road are provided at an exit of the said U-shaped circle road, a common road is provided between the inner semicircle road and the outer semicircle road, the common road is connected to an on-ramp of the intersected road through the outer semicircle road, and an off-ramp of the intersected road is connected to the on-ramp of the main road through the inner semicircle road.
In the above-described technical solution, an arched separated bridge is provided on the main road of the single layer interchange overpass, semi-ramped overhead bridge stages are provided on the intersected road on both sides of the arched separated bridge, the said semi-ramped overhead bridges stages are connected with the arched separated bridge through a connection platform, U-shaped circle roads are provided on the horizontal level at both ends of the arched separated bridge, the arcuate end of the outer semicircle road and the inner semicircle road is connected to the U-shaped circle road, the other end of the outer semicircle road and inner semicircle road of the U-shaped circle road is connected to the connection platform, a branch common road is provided on the off-ramp of the arched separated bridge of the main road, the other end of the common road is connected to the connection platform, a right turn road is provided at the entrance of the upper and lower U-shaped circle roads, and the other end of the right turn road is connected to the on-ramp of the arched separated bridge.
In the technical solution of this invention, in the single layer interchange overpass, the main road can be a leveled driveway, and the intersected road can be an overhead bridge, the U-shaped circle road comprises the inner semicircle road and the outer semicircle road, the common road is connected with the entrance of the outer semicircle road of the U-shaped circle road on other side of the overhead bridge after passing through under the overhead bridge, and the inner semicircle road is connected to the on-ramp of the main road through the left turn driveway.
The effects of the invention are as follows:
Reduction of the traditional 3 or 4 layer overpass to a single layer overpass allowing for transfer of vehicles from different directions and for separation of the motor and non-motor vehicles without inference. Pedestrians can walk on the original road eliminating the need to pass through tunnels or pedestrian overpasses. Reduction of the number of layers in the structures leads to an economic benefit.
The ramp of the overpass is slow which provides significant advantages of energy saving, noise reduction and wasteful exhaust reduction.
The compact construction occupies less space, producing high efficiency ramps, while low height of the construction facilities reduction in costs, environmental protection, and improved aesthetic sense.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view and directional scheme of one embodiment of the invention;
FIG. 2 is a cross-sectional view along the line A-A of FIG. 1 ;
FIG. 3 is a plan view and directional scheme of another embodiment of the invention;
FIG. 4 . is a plan view and directional scheme of yet another embodiment of the invention.
In the FIGS: 1 —main road, 2 —arched separated bridge, 3 —intersected road, 4 —inner semi-circular road, 5 —outer semi-circular road, 6 —underpass tunnel, 7 —common road, 8 —semi-ramped overhead bridge, 9 —right on-ramp, 11 —bidirectional median, 12 —non-motor vehicle road, 13 —secondary road, 14 —left turning circle road, 17 —convergent secondary road, 18 —U-shaped circle road entrance, 19 —ventilating window, 23 —connection platform, 24 —U-shaped circle road, 25 —arcuate end, 26 —U-turn median, 27 —straight transition road, 28 —U-turn road, 29 —overhead bridge, 30 —left turn branch lane, 31 —right turn branch lane, 32 —right turn road, 33 —outer pass way.
DETAILED DESCRIPTION
Conventional circle-type intersections are associated with traffic jams caused by the entanglement and interference between vehicles making turns and vehicles circling on the overpasses. In order to solve this problem, in the overpass of the invention an outer semicircle road 5 and an inner semicircle road 4 are provided on the U-shaped circle road 24 on the upper side of the main road 1 to channel the turning vehicles and the straight-going vehicles. At the same time a common road 7 is provided between the outer semicircle road 5 and the inner semicircle road 4 to prevent the vehicles on the U-shaped circle road 24 from interfering.
The invention will now be described in detail in accordance with the drawings. In the embodiments the terms “left” and “right” refer to the travel direction of the vehicles, and the terms “upper” “lower” “left” and “right” refer to the orientation of the overpasses. With the overpass forming a base for an off-ramp and an on-ramp, the road entering the overpass is the off-ramp and the road exiting the overpass is the on-ramp.
EXAMPLE 1
As shown is FIG. 1 , an overpass is provided at an intersection. The intersection is divided into the upper, lower, left, and right roads in which the main road 1 accommodates vehicle flow in the upper and lower direction, and the intersected road 3 accommodates vehicle flow in the left and right direction. The four roads of the overpass are leveled with the driveway's surface and are connected therewith. The straight main road 1 on the overpass is the arched separated bridge 2 which has the highest height at a position where the main road 1 intersects the intersected road 3 . There is a ramp extending from the highest point of the arched separated bridge 2 down the upper and lower direction to connect it in the direction of the main road 1 . The semi-ramped overhead bridge stages 8 are provided at the left and the right of the intersected road 3 at both sides of the arched separated bridge 2 . One end of the semi-ramped overhead bridge stage 8 is connected with the arched separated bridge 2 at the same level and forms a connection platform 23 , and the other end is connected with the driveway in left and right directions, i.e., in the direction of the intersected road 3 . The arched separated bridge 2 and the semi-ramped overhead bridge stage 8 are provided with bidirectional driveways having off-ramps and on-ramps. The U-shaped circle road 24 which is leveled with the connection platform 23 is provided at a height of the upper and lower direction ramps of the arched separated bridge 2 . The U-shaped circle road 24 comprises entrances 18 and exits connected with the left connection platform 23 and the right connection platform 23 , respectively, and also the arcuate end 25 between the entrance 18 and the exit. The exit comprise an inner semi-circle road 4 in proximity to the interior of the main road 1 and an outer semi-circle road 5 positioned on the outer side of the main road 1 . The arcuate end 25 of the U-shaped circle road 24 is higher with respect to the ramp of the arched separated bridge 2 . The other end of the entrance 18 and the exit of the U-shaped circle road 24 are connected with the connection platform 23 of the left and right semi-ramped overhead bridge stage 8 , respectively. A closed-circle road is formed after connecting the upper and lower U-shaped circle roads through the connection platform 23 . The shape of the circle road is similar to that of the racetrack in a stadium. The unidirectional driveway running anticlockwise is used in the above-referenced circle road.
On the inner side of the outer semicircle road 5 of the upper and lower U-shaped circle road 24 , i.e., between the arched bridges 2 and the outer semicircle road 5 , an inner semicircle road 4 is provided. One end of the inner semicircle road 4 is connected with the arcuate end 25 of the U-shaped circle road and the other end is connected with the connection platform 23 of the arched separated bridge 2 .
A branch common road 7 is provided as the off-ramp of the arched separated bridge 2 of the main road 1 . The above-referenced common road 7 connects the road surface of the main road 1 with the connection platform 23 or the ramp of the arched separated bridge 2 after passing vertically under the accurate end 25 of the U-shaped circle road 24 . The connector of the common road 7 and the connection platform 23 is located between the connectors of the inner semicircle road 4 and the outer semicircle road 5 and the connection platform 23 , respectively. The inclusion of common road 7 effectively ensures the traveling of vehicles on the connection platform 23 and the U-shaped circle road 24 without interference.
The right on-ramp 9 is provided at the entrance 18 of the upper and lower U-shaped circle road 24 i.e. the right side of the upper U-shaped circle road 24 and the left side of the lower U-shaped circle road 24 . The other end of the right on-ramp 9 is connected with the on-ramp of the arched separated bridge 2 .
As shown in FIG. 1 , due to the design of overhead arched separated bridge 2 and the semi-ramped overhead bridge stage 8 , the non-motor vehicle road 12 for bicycles and pedestrians is provided under the overpass. The non-inference with motor vehicles in the areas of the existing intersections fully satisfies the condition of transfer of the pedestrians and bicycles. Therefore the inconvenience that would be caused by construction of the underground passage way is eliminated. In order to improve the illumination under the overpass, ventilation windows 19 passing through the surface of the overpass are formed at the connection platform 23 of the overpass.
Below the traveling directions of the vehicles on the overpass are explained with reference to arrows indicating the traveling directions in FIG. 1 . (1) Straight ahead from lower to upper side: vehicles pass over the overpass along the right entrance of the bidirectional driveway in the lower main road 1 through the arched separated bridge 2 straight ahead from the lower side under the arcuate part 25 of the U-shaped circle road 24 through to the on-ramp of the upper main road 1 . (2) Straight ahead from left to right: vehicles travel to the left connection platform 23 after entering the left semi-ramped overhead bridge stage 8 from the on-ramp of the bidirectional driveway in the left intersected road 3 , and then enter the connection platform 23 , turn right entering the entrance 18 of the outer U-shaped circle road 24 , again enter the right connection platform 23 from outer semi-circle or road 5 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 ; then turn right and travel across the overpass entering the right off-ramp of the intersected roads from the right semi-ramped over head bridge stage 8 , completing the straight way on the intersected roads via a zigzag manner instead of straight manner. (3) Turn from the lower main road 1 onto the right interested road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the right intersected road 3 and passing through the overpass. (4) Turn from the lower main road 1 onto the left intersected road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then continue straight up to the upper U-shaped circle road 24 , turning around into the left connection platform 23 along the upper outer semicircle road 5 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the left intersected road 3 and passing through the overpass.(5) Turn from the left intersected road 3 into the lower main road 1 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 vehicles enter the connection platform 23 , and then turn right into the lower U-shaped circle road 24 , enter the on-ramp of the lower main road of the right on-ramp 9 which is connected with the lower U-shaped circle road 24 , and so pass through the overpass. (6) Turn from the left intersected road 3 onto the upper main road 1 : after entering the semi-ramped overhead bridge stage 8 through the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 , turn right into the lower U-shaped circle road 24 , and then enter the right connection platform 23 from the inner semi-circular road 4 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 , and enter the on-ramp of the upper arched separated bridge 2 by merging left on the right connection platform 23 , and then pass through the overpass from the on-ramp of the upper arched separated bridge 2 accomplishing the convergence into the main road without interference with the convergent secondary road 17 , and pass through the overpass from the on-ramp of the upper arched separated bridge 2 . (7) Return to the lower main road 1 from the lower main road 1 : The vehicles enter the right common road 7 along the entrance of the bidirectional driveway in the lower main road 1 , and enter the right connection platform 23 from the common road 7 , straightway to the upper U-shaped circle road 24 , then enter the left connection platform 23 passing around the inner semicircle road 4 of the upper U-shaped circle road 24 along the upper U-shaped circle road 24 , and then enter the left connection platform 23 into the on-ramp of the lower arched separated bridge 2 by merging left off of the left connection platform 23 , turning back to the on-ramp of the lower main road 1 from the on-ramp of the lower arched separated bridge 2 . (8) Return to the left intersected road 3 from the left intersected road 3 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 and turn right into the lower part of connection platform 23 , then turn around into the inner semi circle road 4 of the lower U-shaped circle road 24 along the lower U-shaped circle road 24 , and then enter the right connection platform 23 , and then enter the upper U-shaped circle road 24 by bearing right on the right connection platform 23 , then enter the left connection platform 23 from the outer semi circle road 5 of the upper U-shaped circle road 24 , along the arcuate part 25 of the upper U-shaped circle road 24 , then turn right to enter the right on-ramp of the left intersected road 3 from the left semi-ramped overhead bridge stage 8 , thus accomplishing the turnaround.
From the foregoing it is clear that that the height of the overpass of the invention is reduced compared with the typical multilayer overpass, and also the occupied ground area and ramp size have been reduced. Compared with the clover-like overpass there is no interference on the main roads which facilities turning of the vehicles on the overpass in left and right direction and turning back.
Because the overpass of the invention is of single layer, not including the ground, therefore the height from the ground is limited only by the U-shaped circle road and generally is about 5 meters of clearance.
In order to increase the driving safety, the double solid line or the bidirectional median 11 between the bidirectional driveways is used to separate the driveways in two directions. In the case of driving to the on-ramp of the arched separated bridge 2 from the inner semicircle road 4 through the connection platform 23 , a convergent secondary road 17 is provided at the right side of the on-ramp of the arched separated bridge 2 for avoiding accidents caused by the abrupt entering of vehicles.
In this embodiment, vehicles are assumed to drive on the right side of the road; for other countries or regions where vehicles travel on the left side of the road, arrangement of the driveways on the overpass can be changed accordingly, and this is also contemplated by the invention.
EXAMPLE 2
The U-shaped circle road 24 is relatively long because the ramp length of the arched separated bridge 2 must satisfy the regulation of the ramp of the driveway and ensure clearance between the arcuate part 25 of the U-shaped circle road 24 and the arched separated bridge 2 . As shown in FIG. 2 , in order to shorten the length of the U-shaped circle road 24 , construction of the embodiment 1 is partially modified by allowing the height of the arcuate part 25 of the U-shaped circle road 24 to exceed the height of the connection platform 23 , so that the combination of the upper and lower U-shaped circle roads 24 has a saddle-like shape. Thus, in order to shorten the length of the U-shaped circle road 24 , vehicles will enter an up-ramp when traveling from the connection platform 23 onto the U-shaped circle road 24 , and will enter a down-ramp when traveling from the U-shaped circle road 24 onto the connection platform 23 .
Because vehicles enter an up-ramp after entering the entrance 18 of the U-shaped circle road 24 , the speed of the vehicles is automatically reduced and the margin for safely turning the vehicle on the arcuate end 25 increased.
If there is no need to provide non-motor vehicle and pedestrian ways under the overpass then the arched separated bridge 2 can be constructed as a flat driveway, and accordingly the connection platform 23 can be provided on the ground, thereby avoiding the need for vehicles to enter the connection platform 23 and the ramp of the arched separated bridge 2 . Raising the arcuate part 25 of the U-shaped circle road 24 to a certain height will ensure that the vehicles on the main road 1 pass under the arcuate part 25 of the U-shaped circle road thus allowing for a large reduction in the overall height of the overpass.
EXAMPLE 3
As shown in FIG. 3 in order to reduce the driving distance of vehicles turning around on the intersected road 3 in embodiments 1 and 2, medians 26 for turning around are provided on the left and right connection platforms 23 , respectively. The median 26 for turning around separates the connection platform 23 into the straight transit driveway 27 between the upper and lower U-shaped circle roads 24 and the U-turn driveway 28 , which not only ensures a straight-way driving between the upper and lower U-shaped circle roads 24 , but also allows vehicles turning around on the intersected road 3 to enter the on-ramp through the U-turn driveway 28 directly after entering the connection platform 23 from the off-ramp, thus decreasing the turnaround distance on the U-shaped circle road 24 .
If the topographic condition permits or if there is a need to expand capacity, an underpass tunnel 6 in the direction of the left and right intersected road 3 can be added beneath the walking way surface extending through the main road 1 . By doing so, the straight-driving vehicle from left to right or vice versa don't need to travel around the connection platform 23 and the U-shaped circle road 24 , and as a result vehicles can be driven faster and more conveniently, to meet the larger traffic flow. If there is no need to consider the pedestrian and non-motor vehicle ways under the overpass, such as in the highways and suburbs, then the underpass tunnel 6 can be constructed as a semi-sinking underpass tunnel passing the arched separated bridge 2 resulting in a reduction of construction costs and improvement in ventilation and in water-removal from the tunnel. Alternatively, it is also possible to provide the overhead bridge passing through the upper side of the connection platform 23 and the arched separated bridge 2 between the left and right intersected roads 3 . Therefore the vehicles on the intersected road 3 can travel straight-though, thus enabling the overpass to be constructed by several periods and added with one more layer of single span bridge to form another main road.
EXAMPLE 4
As shown in FIG. 4 , the overpass of the embodiment is suitable for use in highways and expressways. A level driveway is provided between the upper and lower sides of the main road 1 while at both sides of the main road 1 a secondary road 13 parallel with the main road 1 is provided. The outer pass way 33 connects the main road 1 and the secondary road 13 . The overhead bridge 29 passing above across the main road 1 is provided between the left and right sides of the intersected road 3 .
The U-shaped circle roads 24 are provided at the horizontal level at both the upper and lower sides of the main road 1 . The U-shaped circle roads 24 include the inner semicircle roads 4 and the outer semi circle roads 5 . The branch common road 7 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The lower common road 7 is connected with the entrance of the outer semicircle road 5 of the upper U-shaped circle road 24 after passing through under the overhead bridge 29 , while the upper common road 7 is connected with the entrance of the outer semicircle road 5 of the lower U-shaped circle road 24 after passing through under the overhead bridge 29 . The outer semicircle road 5 is connected with the on-ramp of the overhead bridge 29 after passing across the arcuate end 25 of the main road. The left turn branch lane 30 is connected with the on-ramp of the inner semicircle road 4 from the off-ramp of the overhead bridge 29 on the intersected road 3 while the inner semi circle road 4 is connected with the on-ramp of the secondary road 13 through the left turn driveway 14 after passing across under the arcuate end 25 of the main road.
The right turn branch lane 31 is provided between the overhead bridge 29 and the secondary road 13 connected with the on-ramp of the main road. The right turn branch lane 31 is connected with the secondary road 13 through the lower ramp. The right turn road 32 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The right turn road 32 is connected with the on-ramp of the overhead bridge 29 through the upper ramp. The pavement and non-motor vehicle way 12 are provided on the outer side of the secondary road 13 .
Below the driving directions of the vehicles on the overpass will be described with connection to the arrows in FIG. 4 indicating the driving direction of the vehicles. (1) Straight through from the lower side to the upper side: the vehicles travel straight-ahead to the upper part of the road along the lower part of the main road 1 . (2) Straight through from the left to right: the vehicles travel straight to the right part of the road from the left part of the road of the overhead bridge 29 on the intersected road 3 . (3) Turn from the lower main road 1 onto the right intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the right turn road 32 connected with the secondary road 13 turn right by the upper ramp entering the on-ramp of the overhead bridge 29 of the intersected road 3 . (4) Turn from the lower main road 1 onto the left intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the common road 7 connected with the secondary road 13 enter the on-ramp of the U-shaped circle road 24 after passing under through the overhead bridge 29 , then after entering the outer semicircle road 5 through the arcuate end 25 enter the on-ramp of the overhead bridge 29 . (5) Turn from the left intersected road 3 onto the lower main road 1 : the vehicles enter the on-ramp of the main road via the lower ramp of the right turn branch lane 31 of the over head bridge 29 . (6) Turn from the left intersected road 3 onto the upper main road 1 : the vehicles enter from the off-ramp of the overhead bridge 29 on the intersected road 3 onto the on-ramp of the inner semicircle road 4 through the left turn branch lane 30 , and then enter the secondary road 13 after passing through the left turn road 14 by the lower ramp of the arcuate end 25 , then enter the on-ramp of the main road 1 through the outer pass way 33 .
Since the height of the overpass of the embodiment is the height of the overhead bridge 29 or the arcuate end 25 of the U-shaped circle road 24 , the overpass belongs to a single laver type. The transfer of the vehicles on the overpass will not cause any inference.
It should be noted that while the foregoing description is aimed to illustrate the principle of the invention, those skilled in the art will appreciate that certain variations and modifications of the basic embodiments are possible.
Therefore, the invention is not limited by any particular construction of the embodiments, and all of the modifications are within the scope of the invention. | This invention discloses a single layer interchange overpass. The overpass comprises a main road ( 1 ) and an intersected road ( 3 ), a U-shaped circle road ( 24 ) is disposed at a predetermined level above both ends of the main road ( 1 ), an inner circle road ( 4 ) and an outer circle road ( 5 ) are disposed at the exit of each U-shaped circle road ( 24 ), a common ramp ( 7 ) is located between the inner and the outer circle roads ( 4, 5 ), the common ramp ( 7 ) is joined with an on-ramp of the intersected road ( 3 ) via the outer circle road ( 5 ); and an off-ramp of the intersected road ( 3 ) is joined with an on-ramp of the main road ( 1 ) via the inner circle road ( 4 ). |
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The present application claims priority in U.S. Provisional Patent Application Ser. No. 60/709,347 filed Aug. 18, 2005 and entitled “Sonde Housing.”
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application relates to drilling apparatus for directional drilling in utility installations and, more particularly, to housings for drill string instrumentation such as sonde transmitters and the like.
2. Background Description of the Prior Art
Horizontal Directional Drilling (HDD) is a means of boring horizontally underground to provide utility installations and remediation of utility installations already in place. While most open areas are “open trenched” with various trenching equipment, the HDD boring rigs are used to “drill” a bore path under obstacles such as rivers, roads, railroads, other existing utilities etc.
An HDD drill rig consist basically of a boring machine and a drill string including drill pipe, locating electronics (aka transmitter, sonde or transmitter beacon, typically configured as an instrument assembly for being enclosed or packaged within a tubular housing), and a boring bit attached to the front of the drill string. A bore path is plotted and laid out for the contractors. The drilling crew then drills at an angle into the ground along the bore path until the desired depth is reached. The bore is then leveled out and advanced under the obstacle. During this time the locating electronics instrumentation is installed between the drill bit and the drill pipe for transmitting the drill bit's depth, pitch and clock location (e.g., at 12, 3, 6, or 9 o'clock) to the surface. Once the desired bore length is reached under and past the obstacle, the bit is steered toward the surface. The pilot tool is then removed and a reamer can be used to open the hole to a larger diameter while pulling the drill pipe back. If the pilot hole is the desired size, the tool is removed and the pipe, conduit or “product” is pulled back through the hole. During drilling, the drill pipe is fed into the bore 10 to 15 feet at a time. Attached to the front of the drill pipe just behind the drill bit (or, alternatively, a mud motor) is the instrumentation package such as a sonde housing which houses and protects the sonde (transmitter).
With respect to the instrumentation package, currently there are two types of prior art sonde housing designs on the market. The first type of prior art housing is known as an “end load” sonde housing. The sonde is loaded from one end of the housing and secured therewithin. With no “door” or “lid” access to the sonde this design requires “breaking” the connection between housing and drill stem to obtain access to the sonde within the housing. However, this design allows for a full set of “water ports” to be machined within the wall space surrounding the sonde cavity allowing a large volume of drilling fluids to be pumped through the drill pipe and tool. The volume and pressure capacity of this design allow drillers to drive hydro/mechanical drilling tools in the hole often called “mud motors”
The “end load” design is preferred for its flow capabilities and the security it offers for the electronics in the sonde. Secured inside the end load housing, the sonde is rarely lost during the coarse of boring. However, since the transmitter is powered by batteries, the process of disconnecting the drill string from the housing and removing the sonde can be cumbersome and difficult. This is especially true on shorter, smaller diameter “in & out” bores where the tool usually remains on the drill pipe from bore to bore.
The second type of prior art housing is known as a “side load” housing. It is more popular for use with smaller machines without the large pump capacity for mud motor drilling. These rigs use a variety of bits that drill by rotational force from the drill rig transferred through the drill pipe. The side load design allows easy access to the sonde for maintenance, battery changes and replacement of the sonde. On a side load housing the sonde is installed through an opening in the side of the housing that is long enough for the sonde to be inserted laterally, with its axis parallel to the axis of the sonde housing. The sonde is inserted parallel with the housing and secured in place. A housing door or “lid” is then attached to the housing to cover and protect the transmitter.
The side load feature is a time saving design but reduces the number of water ports that may be provided to direct fluid from one end of the housing to the other. This fluid restriction is the primary reason this housing design is not used with the larger machines.
Another drawback to the side load design is that, on occasion during the drilling process, due to deterioration or extreme rotational torque, the side lids or doors become dislodged from the housing. Once the door is dislodged from a closed position or removed the sonde is completely exposed and typically protrudes from the housing or even falls out of the housing. At that point the sonde is usually irretrievable or damaged beyond repair. The cost associated with this failure is usually the loss of the sonde ($2,000-$5,000) plus the added expense of “tripping” out of the hole, making repairs” and tripping back into the bore.
What is needed is an instrument housing for a drill string that provides full protection for the instrumentation, allows full capacity water ports for use with mud motors, provides for ease of assembly into a drill string, and provides an easily adjusted clocking mechanism for the instrument package, and is low in cost of manufacture.
SUMMARY OF THE INVENTION
Accordingly, an instrument housing for a drill string is described herein, comprising: a cylindrical housing having a centered axial bore forming a cavity for receiving an instrument assembly such as a transmitter sonde, the dimensions of the cross section of the cavity exceeding the diameter of the instrument assembly by a predetermined clearance; an elongated side load opening disposed parallel with the longitudinal axis of the cavity, formed through a side of the cylindrical housing and into the cavity opening, the side load opening having a length substantially less than the length of the instrument assembly; and an elongated side load door assembly, having first and second ends and configured to fit within the side load opening, for enclosing and securing the instrument assembly within the cylindrical housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a side view of one embodiment of a sonde housing according to the present invention, having a sonde partially installed therewithin;
FIG. 2 illustrates an exploded side view of the embodiment of FIG. 1 including a clocking mechanism, a spacer assembly, and a side load door in position for assembly, and further having the sonde in place within the cavity of the sonde housing;
FIG. 3 illustrates a side view of the embodiment of FIGS. 1 and 2 following assembly;
FIG. 4 illustrates a cross section view of one embodiment of the sonde housing of FIG. 3 ; and
FIG. 5 illustrates a cross section view of an alternate embodiment of the sonde housing of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Disclosed herein and illustrated in FIGS. 1 to 4 is one embodiment of a new side load housing for and instrument assembly called a transmitter sonde, sometimes referred to as a ‘beacon.’ While the specific embodiment describe herein is a sonde housing according to the present invention, the principles of the invention are applicable generally to cylindrical instrument housings having round or rectangular cross sections, that enclose a generally tubular instrumentation assembly, and that are typically used in harsh environments.
The sonde housing of the present invention illustrated in the appended figures provides a side-loaded sonde housing that is more resistant to damage to the side loading door assembly, and to the transmitter sonde (or, simply, sonde) itself, that may result from the torque applied to the drill string during drilling. The novel sonde housing design not only reduces the possibility of door loss but also protects and secures the sonde in the event the door does fail. As will be described, the clocking mechanism for use with the sonde is simplified, to reduce the time required to load and calibrate the sonde within the housing. This design also allows for an increased number (3 or 4 or 5) of water ports to accommodate the water flow capacity requirements of mud motors, as compared with prior art side load designs. In the description that follows, the reference numbers identifying the various structural features remain the same throughout the five figures when they refer to the same structures.
Referring to FIG. 1 , the side load sonde housing 10 of the present invention is made from either a tubular product or a solid material with a center bore or cavity 14 disposed along the longitudinal axis of the housing. The center cavity 14 may have a round cross section, or the cross section may be rectangular having interior wall surfaces 16 as in the illustrate embodiment shown in FIGS. 4 and 5 . In other embodiments the cross section may have other shapes. The housing is typically fabricated from a heat treated and hardened 4140 or 4340 alloy of stainless steel. Around the center cavity 14 of the housing 10 in the body 12 (see FIG. 4 or 5 ) of the housing 10 , several water ports 110 may be drilled the length of the housing 10 . The size and number of these ports 110 is determined by the drill rig and pipe size and the type of tools being used. Typically there are at least 3 or 4 such water ports 110 , although in conventional side load sonde housings having a full length side load door, the number of such side ports is limited to one or two such ports.
The center cavity 16 may be “plugged” and welded to provide a seal on each end 18 , 20 . A side load door opening 30 is machined through the body 12 of the housing 10 . The door opening 30 , which is shorter than conventional side load sonde housings, and disposed near one end of the cavity, is approximately 60% to 80% of the length of the sonde 40 . Also machined in the body 12 of the sonde housing 10 are a series of narrow antenna ports 22 that permit the transmitted signal from the sonde or beacon 40 to be radiated from the sonde 40 . There are typically five such ports (two are shown in FIG. 1 ), including one cut through the door 80 , shown in a longitudinal cross section. In some embodiments, the antenna ports 22 are cut using a circular saw blade and produce an antenna port cross section as shown by the arcuate lines 96 in FIG. 2 . Further, FIG. 1 illustrates a drilled, tapped, and countersunk hole called a “flush port” 24 for receiving a ¾ inch flush plug. The flush plug may be removed for cleaning the sonde housing 10 after use to remove mud, debris and other materials that accumulate in the housing 10 during drilling operations. At each end of the sonde housing 10 , the housing is machined to be coupled with other drill string components at the tapered and threaded tool joints 26 , 28 .
Continuing with FIG. 1 , the interior notches 34 , 36 are machined in each narrow end of the opening 30 to allow the tabs 86 , 88 machined on the door 80 to engage the housing 10 . An interior ledge 32 is also machined around the perimeter of the opening 30 to support the door 80 and to eliminate any deflection of the door 80 into the cavity 14 by forces occurring in the drill string path. The body 12 of the housing 10 further includes a drilled and tapped hole 54 for a third bolt 94 to secure the door 80 to the body of the housing 10 . A drilled and tapped hole 54 is also formed in the floor of the cavity in the housing to receive a second bolt 70 for securing the spacer 66 to the housing. The third bolt 94 and the second bolt 70 , as well as a first bolt 64 to be described may each preferably be, for example, a nylon pelleted, socket head shoulder bolt.
To install the sonde 40 into the housing 10 , the first end 42 of the sonde 40 is configured to be inserted into the center cavity 14 at an angle 50 relative to the longitudinal axis of the housing 10 . Before insertion, the sonde 40 may be oriented rotationally, so that, in the position illustrated in FIGS. 1 , 2 , and 3 , the keyway or slot 46 is positioned at an initial position of “6 O'clock” and pushed into the enclosed portion of the housing 10 . Once fully inserted into the enclosed portion of the housing 10 , whereby the inside end 42 is positioned against the end 18 of the cavity 14 , and the indexing or exposed end 44 of the sonde 40 can be lowered into the cavity 14 and settled into position substantially inside the enclosed area of the housing 10 . Resilient collars 48 , such as O rings, are installed on the sonde 40 to center the sonde 40 within the cavity 14 and provide cushioning against mechanical shock. In the embodiment shown, for a typical sonde housing, approximately four inches of open space 100 (See FIG. 2 ) should remain in the open area of the cavity 14 after the sonde 40 is installed in the cavity 14 .
Referring to FIG. 2 , since the sonde 40 is to be “clocked” or indexed in respect to the drill bit's installed position, the sonde 40 may be rotated inside the cavity 14 to the desired position for indexing. In FIG. 2 , a two-piece “clocking mechanism” 60 is installed into the housing 10 and attached to the sonde 40 via the keyway or slot 46 formed in the end of the sonde 40 . This clocking mechanism 60 secures the sonde 40 in the proper rotational relationship (calibration) and partially secures the sonde 40 in the housing 10 . The clocking mechanism 60 itself may then be secured with a first bolt 64 . First bolt 64 may be a socket head shoulder bolt.
Continuing with FIG. 2 , once the clocking mechanism 60 is installed and secured with the first bolt 64 , the spacer 66 is inserted to fill the remaining open space 100 in the cavity 14 . The spacer 66 is designed with an extension or lip 67 that extends over the clocking mechanism 60 and a portion of the sonde 40 itself. The spacer 66 is secured to the bottom of the cavity 14 in the tapped hole 54 using the second bolt 70 and provides added measure of security for the sonde 40 should the door 80 (to be described) be lost. With the sonde 40 , clocking mechanism 60 and spacer 66 installed, somewhat less than about half the length of the sonde 40 is exposed if the door 80 is lost as compared to the exposure of the entire 18″ length of the sonde 40 when the prior art full length side load doors are lost.
The exploded view of the sonde housing 10 shown in FIG. 2 includes a door 80 for enclosing and securing the sonde 40 within the cavity 14 of the housing 10 . The door 80 includes an exterior surface 90 , a machined hole 92 for passage of the third bolt 94 therethrough, and an edge 98 on either side of the door 80 that fits along the interior ledges 32 of the sonde housing 10 when the door 80 is in place. After securing the spacer 66 , the first end 82 of the door 80 with machined tab 86 is slid at an angle completely into the first notch 34 in the housing 10 and then slid in the opposite direction along the supporting interior ledges 32 (See FIG. 1 ) within the bore 16 to engage the second tab 88 into the second notch 36 . The door 80 is then secured to the housing 10 using the third bolt 94 . The housing 10 may include tool joints 26 , 28 on either end, as previously described.
Continuing with FIG. 2 , a drill bit 102 having a threaded male end 104 is shown in an aligned position in preparation to be threaded into the female socket end of the tool joint 28 of the sonde housing 10 .
Referring to FIG. 3 , an instrument housing 10 for a transmitter sonde 40 according to the present invention is shown with the sonde 40 installed and indexed or “clocked” within the housing 10 in a proper orientation to correspond to the position of the drill bit (not shown) as described herein above. It will also be observed that once the door 80 is placed in its final position, a slight gap 106 remains between the end 82 of the door 80 and the end of the opening 30 that receives the door 80 . However, only part of the tab 86 is exposed, the rest (and most) of its length remaining within the housing 10 . Also shown in FIG. 3 is the ¾ inch (typically) “flush plug” 116 in place in the hole 24 provided. FIG. 3 further illustrates the drill bit 102 installed in position tool joint 28 .
Referring to FIGS. 4 and 5 there are illustrated cross sections of the sonde housing 10 with the transmitter sonde 40 installed, taken at the position indicated by the Roman Numerals IV and V respectively in FIG. 3 . FIGS. 4 and 5 depict respective embodiments of a sonde housing 10 having four water ports 110 disposed in the body 12 of the sonde housing 10 ( FIG. 4 ) and two water ports 110 disposed in the body 12 of the sonde housing 10 ( FIG. 5 ). The embodiment of FIG. 4 is especially suited for sonde housings used with mud motors, which require relatively large volumes of water be pumped through the body of the sonde housing. The embodiment of FIG. 5 is suited for drilling operations where a mud motor is not used.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof. For example, one version of the sonde housing 10 is available wherein the cross section may be any of three diameters adapted to 3.0″, 3.5″, and 4.5″ drill bits. The invention including its various component parts is readily scaled. | An instrument housing for a drill string, comprising: a cylindrical housing having a cavity for receiving an instrument assembly such as a transmitter sonde; an elongated side load opening disposed parallel with and toward one end of the cavity and formed through a side of the cylindrical housing into the cavity. The side load opening is substantially shorter than the length of the instrument assembly; and an elongated side load door assembly is configured to fit within the side load opening, to enclose and secure the instrument assembly within the cylindrical housing such that the instrument is protected from loss or damage due to loss or damage to the side load door during operation. |
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BACKGROUND OF THE INVENTION
This invention states a reinforcement element for concrete and a method how to fabricate such a reinforcement element. The element is of the kind that includes an extended, preferably continuously bundle of fibres, especially carbon fibres, impregnated, witch a plastic based matrix wish is cured.
DESCRIPTION OF THE RELATED ART
Use of traditional reinforcement of concrete, it is known to use steel rebar with profiled surface with the intention to increase the bond towards the concrete as example a ribbed bar. Such ribbed reinforcement bars can also be used as mesh and other reinforcing structures depending on what shall be produced or build in reinforced concrete. It is also known to use reinforcement elements or mesh based on non-metallic materials, especially elements based on fibres, also including carbon fibres. Also this type of reinforcement elements has been subjected for ribbed or similar surface treatment with the intention to ensure a proper adhesion when embedded in concrete.
Example on previous known executions can be found in U.S. Pat. No. 5,362,542 and U.S. Pat No. 6,060,163 and Japanese patent publications 020, 484,45A, 040, 596, 42A, 031, 502, 41A, 031, 502, 42A, 032,958,38A, 020,484,44A, 021,924,44A, 030,838,40A, and 010, 189, 50A.
SUMMARY OF THE INVENTION
In the light of the known technology, the present invention takes the starting point in a method where an extended preferably continuous bundle of fibres, especially carbon fibres, impregnates with a matrix based on a plastic material followed by curing.
The invention does it possible to achieve a better performance of reinforcement materials or mesh where the surface structure gives a very favourable foundation and adhesion in concrete being caste around, in addition as the fabrication of such elements can take place in a simple and effective manner to low cost. This to be achieved by assistance of the new and characteristic feature in accordance to the invention, as described in the patent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall in the following be explained closer by referring to the drawings, where:
FIG. 1 schematic show the first step in the production of a fibre bundle with impregnation of a plastic material,
FIG. 2 likewise show the first step in accordance to the invention, for treatment of the fibre bundle from FIG. 1 , to a more or less finished product in form of a treated reinforcement element,
FIG. 3 show an alternative performance compared to the one in FIG. 2 , namely for production of a continuously and flexible reinforcement element, as example as a band,
FIG. 4 show another alternative performance, where the reinforcement element is utilized to fabricate a dedicated reinforcement structure, as example with focus to pillar reinforcement, angular reinforcement or similar,
FIG. 5 show very elevated an example on a cross section of a fibre bundle and a coated reinforcement element in accordance to the invention.
FIG. 6 illustrates schematic the fabrication of a reinforcement net based on the method in accordance to the invention,
FIG. 7 show in relation to FIG. 6 , a slight simplified fabrication, namely with focus on pole type of reinforcement elements,
FIG. 8 show another modified performance from the one in FIG. 6 , for fabrication of a reinforcement mesh where the elements are crossing with variable angular, and
FIG. 9 show the cross section and elevated construction of crossing point of a reinforcement mesh from FIG. 6 , possibly also FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first part of the fabrication line, as illustrated on FIG. 1 , a large number of continuous single fibres or filaments 1 are pulled or supplied in a large number from the same amount of stock or spools R 1 and brought together down in a container with a bath of liquid plastic material or matrix 3 for impregnation. The gathered fibre bundle is lead into the bath 3 by assistance from rollers, as example marked R 2 and R 3 . Over the roller R 4 the impregnated fibre bundle is guided out of the bath, possibly by giving a pretension, which can take place by assistance from a pulling device 5 including double rollers, also acting to press out additional uncured plastic materials the fibre bundle is impregnated with. From there, the fibre bundle 10 is guided further to the following fabrication steps, with focus on fabrication of a continuous pole type reinforcement element, possibly a flexible band or equal or reinforcement mesh, respectively a tree dimensional reinforcement structure. Also twinning of the fibre bundle can be of interest.
In conjunction to FIG. 1 , it shall be pinpointed that the invention assume a significant number of single fibres 1 in the compound fibre bundle 10 , where the number of figures shall be in the magnitude of 1000 or may be up to 10,000,000 or more. In practice this is total realistic because the fibre diameter typical can be 7 microns. In the bath 3 the liquid plastic is thermo set or eventually thermo plastic. Examples for suitable plastic materials are polyester, vinyl ester, and epoxy materials. When the fibres or filaments 1 are impregnated for following composite association with each other, the high number of single fibres will have great importance. The increasing number of fibres and increasing fibre bundle dimension, the relative surface towards the surrounding environment is reduced. The surplus of the matrix or plastic material being applied, as partly will remain adhered on the outside of the fibre bundle, can vary depending on different temperatures and viscosities of the plastic material. Here a significant amount of variation possibilities is present with focus how to decide the required amount of plastic cover outside the composite fibre bundle, minding the required properties, as adhesion or shear capacities after embedded in concrete. When it comes to viscosity (after Brookfield, test in accordance to ASTM D 2196-86), this may be in the range of 100-1000 mPas (cP), which mainly will cover the actual alternative matrix materials .
In the following fabrication steps as illustrated on FIG. 2 (and FIG. 3 ) the impregnated fibre bundle 10 , while the impregnation material still is mostly uncured and near the liquid phase, is guided to cooperation with a particle shaped material 15 located in boxy type container 12 . In the bottom of the box 12 there are organized nozzles or holes 13 as appropriate with its cross section form gives the fibre bundle requested cross section profile. When the fibre bundle 10 from the holes 13 pass through the reservoir of particle shaped material 15 , as in accordance to the invention primarily is sand, the particles will adhere to the surface of the fibre bundle, and then be permanent rooted or fixated to the surface of the fibre bundle by curing in zone 17 . By assistance from a pulling device with rollers 18 the finished reinforcement element brought to a cutting and packing station not illustrated in FIG. 2 . There is an essential feature with the fabrication as illustrated on FIG. 2 , that the particle shaped material such as sand, adhere to the surface of the fibre bundle 10 mainly without coming in between the fibres. This is a great benefit because potential sharp particles potentially could penetrate in the cross section of the fibre bundle in between the single fibres, will potentially damage the fibres in this fabrication stage or potentially under following static or dynamic forces as the fibres will suffer, as in a cured reinforced concrete. As an example on cross section geometries that the hole 13 can give the fibre bundle 10 , a circular or rectangular shape is nearby, but it is clear that cross section geometries can freely be chosen depending on the use for the reinforcement element.
In conjunction for the above mentioned parameters in the fabrication steps in accordance to FIG. 1 and FIG. 2 , it calls here that a fabrication temperature or curing temperature in the zone or device 17 , can be in the range of 15-40° C., based on the most common curing systems. This is also with the thought for a potential manual placing or handling for fabrication of special reinforcement structures at later fabrication steps.
By use of sand as particle shaped material the grade can appropriate be in the range of 100 microns to 5000 microns particle diameter. Together with the previous parameters for the matrix material and so on, such sand will give an advantages adhesion to or shear capacity between the fibre bundle and the surrounding caste concrete. This allows an optimal utilization of the special fabricated composite fibre bundle. For use in concrete optimal shear capacity is 1-50 Mpa.
The fabrication steps in accordance to FIG. 3 segregates from the execution in accordance to FIG. 2 by that the finished reinforcement element winds up as a coil on a drum 19 also acting as a pulling device to pull the reinforcement element through the curing device 17 and to store the finished product, as in this case presuming to have sufficient flexibility or bend ability, achieved by suitable choice of the mentioned parameters and materials as entering in the fabrication.
The arrangement in FIG. 4 have the most steps like the illustration on FIGS. 2 and 3 , but here it is arranged a rotateable mould body 29 as the reinforcement material winds up on under the continues fabrication process. First of all the body 29 also serves pulling the reinforcement element from the previous fabrication step, and secondly the cross section of the body 29 and the guides of the reinforcement materials on this is adjusted so that the desired configuration is achieved. As an example, this can be a prefabricated reinforcement structure for a concrete pillars. It can be imagined a large number of variations such as cross section geometry of the mould body 29 , with focus on decided cross section or configuration of the reinforcement. Some of the cross section variations are shown on FIG. 4 by A, B, C, D and E.
A fibre bundle is shown as a cross section and strongly elevated at FIG. 5 . The left halve of this figure shows a fibre bundle of filaments 30 where the impregnation material or matrix is applied, where the plastic material has penetrated in to the fibre bundle cross section and filled the voids in between the single fibres 30 , and the outer surface 31 A mainly constitute this coating of the plastic material. This condition as illustrated on the left side of FIG. 5 correspond to the fabrication step ahead of applying of the particles, for example in form of sand, the cross section will be as shown on the right side of FIG. 5 . The shown particles 33 can have wide range of shapes and sizes, but as illustrated on FIG. 5 the particles can be considered to be drawn some decreased compared to the dimensions of the fibre bundle inside. Furthermore it is clear that the previous described curing of the reinforcement element result in a fixed foundation of the particles 33 in the surface layer 31 A of the curable plastic material 31 . For fabrication of reinforcement elements as reinforcement mesh or equal it is in accordance to the invention suggested performance as first of all schematic is illustrated on FIG. 6 . There it is shown a under layer surface or support 20 with the requested horizontal extent, for example with a couple metres side edge in a rectangular form adjusted to what kind of construction to be reinforced, such as a slab in a building. Along the edge of a supporting surface 20 it is shown a lot of guidance elements 1 - 8 as for example sticks or a spike organized in a predicted manner. It is also possible to organize (not shown) edge-or wall segments some elevated, compared to the supporting surface 20 along the edges, however not as elevated as the guiding elements 1 - 8 .
Based on an organization just described, a mesh geometry reinforcement geometry be fabricated by that a fibre 10 , coming from the previous fabrication step in accordance to FIG. 1 , be guided mechanically or manually between the guiding elements 1 - 8 for creation of a mesh for example with small rectangular meshes. This takes place while the impregnation of the fibre bundle still is not cured. The winding or guidance of the reinforcement element 10 can take place multiple or in several turns, so that it more or less layer on layer creates a reinforcement grid with a dedicated thickness of the individual straight parts of the fibre bundle creating the mesh.
The completed reinforcement grid is on FIG. 6 as a whole identified 28 .
While the impregnation material still is sticky, it is then supplied with particle shaped material as indicated by 25 , with other words preferable from above by suitable sprinkling or equal, so that this material can adhere to the fibre bundle over all and simultaneously be collected at the supporting surface 20 . The collection of the particle shaped material on this surface can possibly take place to such a thickness or height that the surface touches the fibre bundle in the reinforcement grid 28 resulting in a more intimate contact and adhesion. This collection of the particles can also be performed in advance prior to location of the fibre bundle, especially for good cover on the lower side of the fibre bundles.
After such a covering of the fibre bundle(s) they remain strapped until curing of the plastic material has taken place. This can for example take place by providing heat in an appropriate manner. Thereby the particle material get fixated to the surface of the fibre bundles as explained in connection to FIGS. 2 and 3 above.
Prior to or after removing the finished coated reinforcement mesh 20 , from the guiding elements on the supporting surface 20 , it can be convenient to remove the sand or particle material, by advantage this can take place by openings 26 in the supporting surface 20 . At this location, 4 positions 26 is shown, however in practices a larger number can be beneficial, as potentially can be closable. Suitable remedy for such removal of leftover particle material can be taken into action.
On FIG. 6 a crossing point 22 is marked in the reinforcement mesh, and a great enlargement such crossing point 22 is shown in the cross section on FIG. 9 . In the crossing layer of the fibre bundles there the upper cross section of the fibre bundle 10 A is shown, as mainly is a band shape with a certain plain pressure, rectangular cross section profile. Under the fibre bundle 10 A it is also shown altering crossing fibre bundles totally eight layers in this shown example for a crossing point 22 . The connection in the crossing point will in this way be very powerful, in high degree because of the impregnation and the following curing. Further more, it is of impotence in this connection that provided particle shaped material or sand (at position 25 on FIG. 6 ) not will have the tendency to penetrate in between the layers in the crossing point 22 . Consequently it is also here avoided that destructive pollutions or sharp particles can enter inn and harm the fibres in the crossing points.
Now it refer to FIG. 8 as show a modification of the mesh pattern in accordance to FIG. 6 , namely by that the provided fibre bundle 10 is guided in a more or less irregular and diagonal angular to creation of a reinforcement mesh with variations of the mesh geometry, namely basically a non rectangular mesh.
This can be advantages for some applications. Also here it is pin pointed at a crossing point, namely as indicated at 32 , where the layer construction can take place totally analogue with that illustrated on FIG. 9 .
Finally FIG. 7 show a utilization of the supporting surface 20 including guiding elements 1 - 7 for fabrication of straight length reinforcement elements, namely with lengths close to the length between edge of the surface 20 supplied with the guidance elements 1 - 7 . After completed winding as the situation is described on FIG. 7 , with the following applying of the particle formed material followed by curing, each individual straight length reinforcement element cut loose by cutting along line 39 A and 39 B as indicated on FIG. 7 . This execution can be taken as an alternative to the more continues fabrication in accordance to the illustration on FIG. 2 . A modification of the method in accordance to FIG. 7 can be to neglect to cut the elements, by that the whole structure is lifted up from the supporting surface and is bended or straight out to create of a longer, continues reinforcing element.
Considering providing with particle formed material, further alternatives than described above are present. Another alternative is to guide the fibre bundle threw a cyclone or equal where it maintain a swirl or “sky” of air and sand or other particle material.
It can be realized based on the description above that until curing of the impregnation or matrix material takes place, can the fibre bundles, or reinforcement elements, eventually the reinforcement grid or structure in three dimensions, be given near all different shapes from the simple straight poles or bands to more complicated configurations as described. In all cases it will be achieved a very favourable geometry for reinforcement elements wile embedded in concrete gives very good adhesion or anchoring as wanted. This get achieved in spite of very low investments in fabrication equipment and with limited need for energy consumption heating. | Procedure for fabrication of reinforcement elements for concrete, where an extended, preferably continuously fiber bundle ( 10 ), especially of carbon fibers, impregnates ( 3 ) by a matrix of a plastic material followed by curing. The fiber bundle ( 10 ), including a significant amount of single fibers, is brought after impregnation ( 3 ) and prior to curing ( 17 ) to cooperate with a particle shaped material ( 15 ), preferably sand, as adhere to the fiber bundle surface mainly without coming in between the fibers and fixate to the surface by curing, for creation of a reinforcement element. |
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This is a continuation of Application Ser. No. 194,752, filed Oct. 7, 1980.
This invention relates to insulating glass units which are essentially free of glass deflection, and to unique spacer bars for use in such insulating glass units.
BACKGROUND OF THE INVENTION
Insulating glass units generally consist of two or more parallel panes of glass which are spaced apart from each other and which have the space between the panes sealed along the peripheries of the panes to enclose an air space between them. The most commonly used insulating glass units are double glazed windows. A double glazed window consists of two usually rectangular panes of glass which are placed in congruent relationship. Spacer bars are placed along the periphery of the space between the two panes. The spacer bars are long, hollow prisms having cross sections which are generally shaped in the form of isosceles trapezoids. The peripheries of the two panes and the spacer bars lying between them are sealed with a sealing composition so that the air space enclosed between the panes is sealed from contact with the outside atmosphere. The surfaces of the spacer bars facing the interior of the enclosed air space are perforated or slotted and the spacer bars themselves are filled with a solid adsorbent capable of taking up water vapor and organic materials which may be present in the enclosed air space when the unit is sealed with an organic sealant or which may enter the enclosed air space by diffusion from the sealant after sealing. Air enclosed in the space between the panes diffuses through the slots or perforations in the spacer bars and contacts the adsorbent in the interior of the spacer bars with the result that water vapor and any solvent or organic material getting into the enclosed air space from the sealing compound are adsorbed on the adsorbent employed. The result is that cooling of the interior air does not cause deposition of water vapor or organic material on the interior surfaces of the panes.
Insulating glass units of this design are frequently subjected to deflection of the glass panes due to pressure changes when the temperature of the outside air changes, adsorption or desorption of nitrogen or other gases on or from the adsorbent, and changes in atmospheric pressure. When the pressure of the air in the space enclosed between the panes becomes less than the exterior pressure, the panes are forced closer together. When the pressure in the space between the panes is greater than the exterior pressure the panes are forced apart. Since the peripheries of the panes are held in pretty much fixed position by the sealant deflection is observed to occur in the area of the glass lying inside the peripheries of the panes.
Deflection gives rise to several problems which must be faced by the manufacturer and/or the user of the insulated glass units. When appreciable deflection occurs the reflected images from the windows are distorted and present an undesirable cosmetic effect. This effect is not functionally serious but users of the insulating glass units object to the distorted reflections. Deflection which results in the movement of the two panes of glass closer together or farther apart when the exterior pressure is greater or less than the pressure of the enclosed air space between the panes places stress on the sealing compounds which lie along the periphery of the insulating glass unit and gradually weaken the seals so that leakage of the relatively moist exterior air into the enclosed space occurs with the result that the capacity of the adsorbent in the spacer bars is exhausted and condensation of moisture at low temperature begins to appear in the windows. Deflection which results when the panes are forced closer together decreases the insulating properties of the unit since these properties are a function of the width of the air space between the panes. If the panes are forced into contact with each other insulating properties are lost. Serious deflection can also cause cracking and even breakage of the windows particularly along the peripheries of the panes.
The deflection problem has been recognized and steps have been taken to reduce the amount of deflection experienced during transportation or use of the insulating glass units.
For example, it has been recognized that pressure problems arise when insulating glass units are shipped from a point of manufacture to a point of use and the altitudes between the two points are substantially different. In these situations it has been common practice to insert a small open tube, commonly known as a "breather tube", into the side of the spacer bar facing the exterior of the insulating glass unit. The breather tube permits flow of air between the interior of the insulating glass unit and the ambient atmosphere and thereby equilibrates the pressure. Typically, the breather tube is sealed immediately after the unit is transported to the altitude at which it is to be installed.
More recently it has been found that if the diameter of the breather tube is sufficiently small (of the order of 0.01 inch) and sufficiently long (generally of the order of at least one foot or more) entry of outside air into the insulating glass unit by simple diffusion is minimized and the insulating glass unit will exhibit sufficiently long life even if a breather tube of these dimensions is not sealed. It should be noted that breather tubes of this kind generally enter the side of the spacer bar facing the exterior of the insulating glass unit, and gas flow as air is "inhaled" into the air space enclosed between the panes of the unit is through the breather tube, through a small segment of the spacer bar and a small segment of the adsorbent contained in it with the flow of gas essentially perpendicular to the length of the spacer bar, then through the crack or slot or perforations in the spacer bar into the air space enclosed between the panes of the unit. During "exhaling" the gas flow is in the reverse direction.
Only recently it has been recognized that a serious cause of deflection in insulating glass units is the fact that the adsorbents with which the spacer bars have been filled adsorb nitrogen when the temperature in the interior of the space between the panes is low and desorb nitrogen when the temperature of the space between the panes is high. Deflection caused by nitrogen adsorption and desorption as temperature changes has been substantially eliminated by using adsorbents to fill the spacer bars which are incapable of adsorbing nitrogen but which do adsorb water vapor. This reduction of the nitrogen adsorption problem as relating to deflection is described in U.S. Pat. No. 4,144,196.
BRIEF DESCRIPTION OF THE INVENTION
It has now been found that deflection of the panes of insulating glass units, however caused, may be substantially eliminated by employing a spacer bar so constructed that a portion of its surface which is in contact wirh the space between the panes (inner surface) is perforated or slotted and the remainder of the interior surface is imperforate and the opposite surface of the spacer bar has a small opening in its surface, which opening is opposite the imperforate portion of the inner surface. The small opening is in communication with the exterior atmosphere.
THE DRAWINGS
FIG. 1 of the drawings is an offset view of a double glazed window.
FIG. 2 of the drawings is a cutaway of a corner of a double glazed window, showing the construction of the window and of the spacer bar.
FIG. 3 shows another and preferred embodiment of the spacer bar of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 of the appended drawings shows a double glazed window generally indicated by the numeral 1. Outside glass pane 2 and inside glass pane 3 are rectangular sheets of glass and are placed in congruent relationship. Top spacer bar 4, bottom spacer bar 5, left-hand spacer bar 6 and right-hand spacer bar 7 lie between the peripheries of the two panes. The spacer bars and the panes are held together in the position shown by sealant 11 shown in FIG. 2. The sealant is typically a material such as a polysulphide resin or polyolefin resin. Spacer bars 4, 5 and 6 are conventional spacer bars and spacer bar 7 is the spacer bar of the invention which is shown in greater detail in FIG. 2. At least one of the two vertical spacer bars 6 and 7 is filled with a solid adsorbent having a high capacity for adsorption of water vapor. Suitable adsorbents are molecular sieve zeolites, alumina, and silica gel. In a preferred embodiment of the invention top spacer bar 4 is filled with a molecular sieve zeolite, such as 13X zeolite. The vertical spacer bars are filled with either a mixture of silica gel or alumina with a molecular sieve zeolite, preferably zeolite 3A or they may be filled with either silica gel or alumina. Space bar 7 is preferably filled with silica gel or alumina. Bottom spacer bar 5 may be left empty or it may be filled with adsorbent. In the preferred embodiment of the invention top spacer bar 4 and/or bottom spacer bar 5 are filled with adsorbent. Activated alumina, silica gel or molecular sieve zeolites or mixtures thereof or one or more of the aforementioned adsorbents in admixture with activated carbon are suitable adsorbents, but zeolites are the preferred adsorbent. In insulating glass units in which hydrocarbon vapors may be present or are likely to be released from the sealing composition, at least a portion of the adsorbent in the spacer bars, preferably 4 and/or 5 should have an average pore diameter which permits entry of benzene into the pore space so that solvent and hydrocarbon vapors will be adsorbed.
FIG. 2 of the drawings is a cutaway showing in detail the lower right corner of the double glazed window of FIG. 1. Panes 2 and 3 are the outer and inner panes of glass, respectively. Spacer bar 7 shows details of the improved spacer bar of the invention. Spacer bars are conventionally made by roll forming a long, narrow strip of metal usually aluminum. In the roll forming process the outer edges of the narrow strip are brought together to form the surface of the spacer bar which is in contact with the interior air space enclosed between the panes. Line 9 shows the junction of these two edges. The outer edges of the metal strip subjected to the rolling process may be roughened so that when the two edges are brought together there is a small, narrow space between them which is small enough in width to prevent the adsorbent with which the bar is filled from passing through the narrow opening but the opening is large enough to permit diffusion of air, water vapor and organic material escaping from the sealant contained in the space between the panes through the narrow opening and into contact with the adsorbent filling the spacer bar. Perforations or slot like openings between the edges of the spacer bar are indicated by the numeral 8. The portion of the spacer bar lying between the lowest of the perforations at the upper end of the spacer bar and the highest of the perforations at the lower end of the spacer bar is sealed either with a sealant or by soldering so that this segment of the spacer bar will not permit passage of air through it either into or out of the enclosed air space. Opening 10 is a small opening through the sealant and the surface of the spacer bar which faces the outer atmosphere and is located at or near the midpoint of the sealed segment of the bar. This opening normally ranges from about one hundredth to one tenth inch in effective diameter so that air under small pressure will pass through it in either direction but so small that no appreciable diffusion of air through the opening will occur when there is no pressure differential between the enclosed air space and the outer atmosphere. Opening 10 should be small enough to prevent passage of the adsorbent particles through it. The cross section of the spacer bar is somewhat in the form of an isosceles trapezoid. This shape is used so that there will be a small space between the panes of glass and the sides of the spacer bar adjacent the peripheries of the panes which is generally triangular in cross section and which permits the sealing composition to enter this space and seal the spacer bar to the pane. Elbow member 12, commonly referred to as a corner lock, is so shaped so that the arms of the elbow conform in cross section to the cross section of the spacer bar but the dimensions are slightly smaller so that each arm of the elbow will penetrate the end of a spacer bar at the corner. The purpose of the corner lock is to connect the spacer bars to form a peripheral metal rectangle and to hold adsorbent in place.
Corner locks are commonly made from solid organic polymers such as polyethylene, nylon and the like or from metal, usually zinc. The arms of the corner lock must fit tightly against the inner surfaces of the spacer bar to prevent leakage. A sealant may be applied to the junction of the corner lock arm and the interior of the spacer bar to ensure air-tight closure. Corner locks are usually solid but may be hollowed to provide a path of communication between the adsorbent masses in the spacer bars which meet at a corner if desired.
If spacer bar 7 were constructed as shown and described above, except that the bar was perforated throughout its whole length instead of having an imperforate segment lying above and below opening 10, then when the pressure inside the enclosed air space is lower than the outer air pressure, air will flow through opening 10 and take the path of least resistance directly through the adsorbent and through the perforations in the spacer bar into the space between the panes. This flow path would be essentially perpendicular to the length of the spacer bar and only a narrow band of the adsorbent would be contacted by the air entering the space between the panes. When the spacer bar is constructed as shown in FIG. 2, air flowing through opening 10 from the atmosphere into the spacer bar must travel a path parallel to the length of the spacer bar upwardly and downwardly through the mass of adsorbent until it rises and lowers to a point where it comes into contact with perforations 8 at which time it is able to pass through the spacer bar into the space between the panes. This path of air travel brings it into contact with a large mass of adsorbent before it enters the space between the panes. Moisture in the air traversing the mass of adsorbent lying between opening 10 and the upper and lower perforations is completely adsorbed. During daylight hours the window is exposed to direct contact with relatively warm outside air the air enclosed in the space between the panes is warmed and expands. The interior pressure then exceeds the pressure of the outside atmosphere and gas flow is from the interior of the window out into the atmosphere. In order for the gas to make its way from the interior of the window out it must pass through the perforations 8 above and below opening 10 and then pass through the mass of adsorbent lying between the perforations 8 and the opening 10. The warm air contacts the adsorbent which had previously picked up moisture from entering air and desorbs the moisture so picked up. The net result is that when the window "inhales" moisture is picked up by the adsorbent and when it "exhales" moisture is desorbed from the adsorbent so that the net pickup of moisture by the adsorbent after many cycles of inhaling and exhaling is very, very small.
FIG. 3 of the appended drawings shows an alternative and desired structure for the spacer bar of the invention. The spacer bar 7 is a hollow prism. Its cross section is generally of the form of an isosceles trapezoid having the longer base 15 of the trapezoid facing the interior of the space between the panes of the window and the shorter base 14 of the trapezoid facing the exterior atmosphere. The prism is filled with a solid adsorbent 13 as above described. The surface of the spacer bar facing the space between the panes is entirely closed from bottom almost to the top. At the top of the spacer bar communication between the interior of the spacer bar and the space between the panes is through perforations 8 which may simply be an unsealed portion of the junction 9 of the edges of the metal strip from which the spacer bar is conventionally roll formed. Alternatively, communication may be via slots 16 in the arm of the corner key which fits into the upper open end of the spacer bar or via both perforations 8 and slot 16. Small opening 10 through the sealant and the outer surface of the spacer bar is placed at the bottom of the spacer bar so that the opening lies just above upper surface of any corner lock which is inserted in the bottom of the bar. When the pressure of the outside atmosphere exceeds that of the space between the panes of the window air flows from the outer atmosphere through opening 10 and then passes through the entire column of adsorbent and escapes into the space between the panes through perforations 8 or slot 16 at the top of the bar. Corner lock 12, an arm of which fits into the spacer bar is shown in exploded position above. Instead of placing perforations on the inner face of the bar at its upper end, the entire inner face may be closed and slot 16 may be cut in the inner face of the lower arm of the corner lock to permit air to flow into or out of the space between the panes through the slot. This embodiment of the spacer bar may be formed by extrusion rather than by roll forming if desired. If formed by extrusion, then perforations 8 may be drilled through the upper interior surface of the spacer bar if desired or alternatively, slots in the face of the corner lock may provide the entire route for air to travel into the space between the panes or out of it. In the event that the spacer bar is made by roll forming then the rectangular metal sheet from which the bar is formed may be so rolled that the junction 9 of the edges of the sheet does not lie on the surface of the bar which is to face the space between the panes but lies instead on one of its other surfaces. Perforations then may be drilled at the top of the inner surface of the bar or slots 16 in the arm of corner lock 12 may be used to provide communication between the interior of the bar and the space between the panes.
Insulating glass units employing the spacer bar as described above permit continuous equalization of the pressure of the air lying in the space enclosed between the panes and the outer atmospheric pressure. When the pressure in the space between the panes becomes lower than the exterior atmosphere pressure then air flows from the atmosphere through the spacer bar into the space between the panes. Conversely, when the pressure of the air enclosed in the space between the panes exceeds that of the exterior atmospheric pressure, then air flows from the space between the panes to the exterior atmosphere. When air is flowing from the atmosphere into the space between the panes the arrangement of the spacer bar requires the air to traverse a long segment of the spacer bar filled with adsorbent before reaching a perforation in the spacer bar or a slot in the corner lock which permits the inflowing air to pass into the space between the panes. Conversely, when the pressure in the space in the panes exceeds that of the interior atmosphere then air flows from the space between the panes to the atmosphere and the flow path requires it to traverse a mass of adsorbent lying between the top of the spacer bar and the small opening 10 through which the outflowing air can pass into the atmosphere. During inflow all of the moisture contained in the entering air is adsorbed on the solid adsorbent particles filling the spacer bar. When the air flow path is from the space between the panes to the outer atmosphere the air moving outward enters the perforations in the spacer bar or the slots in the corner lock and then must traverse a mass of solid adsorbent before reaching opening 10 which permits it to escape into the atmosphere. The outflowing air contacts the solid adsorbent which had previously been exposed to moist entering air and desorbs moisture from the adsorbent. The most frequent cause of outflow of air from the space between the panes is expansion due to heating of that air by exposure to higher outer ambient temperature during daylight hours. This heating provides contact of warmed air with the solid adsorbent and assists in the desorption of moisture from the adsorbent. The desorption of adsorbed water which attends the outflow of air from the space between the panes when the spacer bar of the present invention is employed makes it possible to obtain long window life using less expensive silica gel or activated alumina as the adsorbents. They have all the capacity required to take up moisture from the air and the fact that during the flow of air from the interior of the space between the panes to the outside atmosphere desorption of moisture occurs extends the useful life of these materials and makes them competitive with the more expensive zeolites widely used at the present time.
Since a sealant coating is applied to the peripheries of the glass panes and the outer surface of the spacer bar, small opening 10 should be plugged during application of the sealant to prevent closure of opening 10 by the sealant and the plug removed when application of the sealant is completed. Alternatively, small opening 10 may be fitted with a short cylindrical tube which extends beyond the sealant coat to ensure that communicating means between the outside atmosphere and the interior of the spacer tube will exist.
The spacer bars of the invention should preferably be in a vertical rather than a horizontal position in the finished and installed insulating glass unit. This ensures better and more uniform contacting between the adsorbent and the air which flows into or out of the insulating glass unit. If the imperforate spacer bar is in a horizontal position, any settling of the adsorbent particles will result in a non-uniform distribution of the adsorbent particles with respect to the cross section of the spacer bar and a tendency to form an adsorbent-free space across the top of the channel. Under these conditions when the window inhales or exhales, the air flows along the path of least resistance which would be along the adsorbent-free space at the top of the spacer bar. Contact between the air and the adsorbent would thereby be reduced and the performance of the adsorbent would be diminished. Suitable steps can be taken, such as careful packing of the adsorbent in the spacer bar, so that horizontal imperforate spacer bars will yield favorable results, but these steps generally require extra effort and expense.
Small diameter breather tubes have been shown to minimize water vapor entry into an insulating glass unit, since small diameter tubes tend to be a better diffusion barrier than large diameter tubes. Breather tubes can be connected to the exterior opening of the spacer bar of the present design as a diffusion barrier. This can be particularly helpful in minimizing the possible entry of liquid water such as that which might condense on the metal surfaces of the insulating glass unit.
Maximizing the length of the imperforate segment of the spacer bar(s) is desirable to maximize the performance of the adsorbent and the life of the window. The imperforate zone need not be limited to a spacer bar along one side. If the spacer bars are properly filled and connected at the corners by suitable air-tight means such as welding or a tightly fitting hollow corner lock, the imperforate segment can comprise two or more of the spacer bars contained in an insulating glass unit. It is necessary only to provide a suitable impervious barrier(s) within the spacer bar(s) or corner key(s) to ensure that the air flow does not bypass any of the adsorbent-filled imperforate segment.
The improved spacer bars described above find use in insulating glass units which comprise more than two panes of glass with the panes separated along the periphery by spacer bars and the entire unit sealed along the periphery with a sealing compound. This results in two or more enclosed air spaces. In some designs small holes in the interior panes provide communication between the otherwise separate air spaces. Adsorbent in the spacer bars functions as described above. In multiple glazed unit without interconnecting holes, separate adsorbent-filled, imperforate spacer bars as described above would be employed for each of the air spaces.
When zeolite adsorbents are used to fill the spacer bars of the invention it is desirable to employ zeolite 3A as the adsorbent. Inhaling and exhaling of the window over a long period has a tendency to produce an increase in oxygen content in the space between the panes if an adsorbent which adsorbs nitrogen is used in the spacer bar. | A novel spacer bar for an insulating glass unit and an insulating glass unit filled with the spacer bar are disclosed. Deflection of the panes of the insulating glass unit, however caused, is essentially eliminated by the functioning of the spacer bar. The spacer bar is so constructed that a protion of its surface in contact with the space between the panes (inner surface) is perforated and a portion is imperforate and the opposite surface of the spacer bar has a small opening in its surface, which opening is opposite the imperforate portion of the inner surface. Means to place the small opening in communication with the exterior atmosphere is provided. |
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[0001] This is a continuation-in-part of U.S. patent application Ser. No. 10/797,410, filed Mar. 10, 2004, which is currently pending, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method of manufacturing a decorative fencing system, and, more particularly, to a method of manufacturing a decorative fencing system that includes multiple components and may be arranged in a potentially unlimited number of combinations and permutations, to be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or a combination thereof.
[0004] 2. Description of the Related Art
[0005] The art fails to specifically address either the problem or the solution reached by the applicant. Decorative fencing systems have long been known in the industry, as has the use of sectional fence structures to create various configurations for fencing systems. Some examples of such fencing systems are shown in references that date back to the mid to late 1800s.
[0006] A common shortcoming in the related art is inflexibility. In many systems, the fence can be assembled by the user in only a single configuration. In other systems, while more than one configuration is possible, it is complicated and time consuming for the user, after assembling the fence in one configuration, to disassemble it and reassemble it in another configuration.
[0007] There has long been a need for a decorative fencing system, which can be easily and quickly assembled in one configuration, easily and quickly disassembled, then easily and quickly reassembled in any one of a nearly limitless variety of different configurations.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a method of manufacturing a decorative fencing system having several components that may easily and quickly be arranged in one of a nearly limitless number of configurations or combinations, easily and quickly disassembled, and easily and quickly reassembled in another one of the nearly limitless number of configurations or combinations.
[0009] The present invention provides a method of manufacturing such a decorative fencing system that may be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or even a combination thereof.
[0010] The present invention further provides a method of manufacturing such a decorative fencing system that allows a user to purchase and use only those elements necessary to create the design or shape of his or her choosing.
[0011] The present invention further provides a method of manufacturing such a decorative fencing system that may be either permanently or temporarily affixed to the ground.
[0012] The present invention further provides a method of manufacturing such a decorative fencing system which includes all the elements necessary to create a standard fence, including base units, gates and end units.
[0013] The present invention further provides a method of manufacturing such a decorative fencing system which may include a variety of interchangeable, structural, functional, and decorative elements.
[0014] The present invention further provides a method of manufacturing such a decorative fencing system in which the individual components are manufactured from a variety of materials or be provided with a variety of finishes.
[0015] The present invention, as broadly disclosed herein, comprises a method of manufacturing a decorative fencing system, designed to be used as a small fence or decorative accent fence for an outdoor yard, or a combination thereof. The fencing system is manufactured to include several different components that may be joined in various combinations so as to create a limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be removably and interchangeably attached to the other components in any combination thereof. Each of these components are removably and interchangeably attached to post sections which are inserted through post rings or post hinges on the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections can be removably and interchangeably secured to the ground by means of stakes that are first driven into the ground.
[0016] In one embodiment, the post sections are removably and interchangeably insertable into respective sleeves in the stakes, to thereby provide support and stability for the fencing system. The fence components are removably and interchangeably attachable to selected post sections to create a desired fence configuration.
[0017] In another embodiment, the post sections are manufactured to be friction-fit to the stakes, the stakes driven into the ground, and the fence components are then removably and interchangeably attached to selected post sections, in order to create a desired fence configuration.
[0018] In still another embodiment, a lower portion of the posts are manufactured to be hollow, and the stakes are configured with a protruding extension. The hollow lower portions of the posts are removably and interchangeably insertable over a respective protruding portion of selected stakes, and the fence components are removably attachable to selected post sections to interchangeably create a desired fence configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The objects and advantages of the present invention will be apparent from the detailed explanation of the preferred embodiments of the invention in connection with the accompanying drawings, wherein:
[0020] FIG. 1 is a front elevational view of a portion of the decorative fencing system of the present invention showing various components thereof.
[0021] FIG. 1A is a top view of a post ring attached to a structural fencing portion in FIG. 1 .
[0022] FIG. 2 is an exploded side view of one embodiment of a post and stake of the present invention, wherein a diameter of a removable post is smaller than an internal diameter of a stake sleeve.
[0023] FIG. 2A is an exploded side view of another embodiment of a post and stake of the present invention, where an internal diameter of a removable post is substantially identical to an internal diameter of a stake sleeve.
[0024] FIG. 3 is an exploded side view of one embodiment of a post and stake of the present invention, wherein an internal diameter of a removable post is larger than a diameter of a post receiving extension on the stake.
[0025] FIG. 4 is a front elevational view of a fence base unit.
[0026] FIG. 5 is a front elevational view of a fence end unit.
[0027] FIG. 5A is a front elevational view of another embodiment of a fence end unit.
[0028] FIG. 6 is a front elevational view of fence gate units.
[0029] FIG. 7 is a front view of a decorative fence system in accordance with the invention.
[0030] FIG. 8 is a top perspective view depicting different arrangements of the decorative fence system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to the drawings and, in particular, to FIGS. 1, 1A , and 2 , the decorative fencing system of the present invention, referred to generally by reference numeral 10 , is illustrated. The fencing system 10 comprises separate structural components 12 including a base unit 14 , a gate unit 16 , and an end unit 18 , which are arranged and combined with each other so as to create a potentially limitless number of configurations for the decorative fencing system 10 .
[0032] The fence structural components 12 are manufactured to be attached to each other by means of one or more posts 20 to which the fence structural components 12 may be removably and interchangeably attached. In the preferred embodiment, the means for attaching the fence structural components 12 comprises post rings 22 , depicted in FIGS. 1 and 1 A, which are disposed on either end of the base units 14 or on one end of the end units 18 , shown in FIG. 5 , or by post hinges 24 , which are disposed on the outside edges of the gate units 16 shown in FIG. 6 . The post rings 22 are annular elements having an inner diameter slightly larger than the diameter or width of the posts 20 such that post 20 may be slidably inserted within the post rings 22 to thereby engage either the base unit 14 or end unit 18 . As broadly embodied herein, the inner diameter of the post rings 22 is approximately 21 mm and the diameter of the posts 20 is approximately 19.76 mm. Similarly the post hinges 24 , include annular elements similar to the post rings 22 coupled with a hinge 26 , that allows the individual gate elements 28 of the gate unit 16 to swing open and shut. In the preferred embodiment, the gate elements 16 comprise a pair of complementary doors that may be operated independently or concurrently, although other designs are possible so as to fit with the design and theme of the decorative fencing system 10 .
[0033] As illustrated in FIGS. 1 and 4 - 6 , each of the structural components 12 includes two post rings 22 or post hinges 24 at each end at which the component 12 may be attached to the post 20 . For example, the base unit 14 includes two post rings 22 on either side thereof, the gate unit 16 includes two post hinges 24 on the outside edge of each gate element 28 , and the end unit 18 includes two post rings 22 on one side thereof. In the preferred embodiment, the post rings 22 or post hinges 24 are attachable to a substantially vertical element 30 so that the post rings 22 or post hinges 24 are in alignment when receiving the posts 20 . Alternate embodiments are possible in which either the post rings 22 or post hinges 24 are attachable to horizontal components or other elements provided, however, that the post rings 22 or post hinges 24 are in alignment. Furthermore, while in the preferred embodiment only two post rings 22 or post hinges 24 are disposed along each vertical element 30 , more may be provided so as to further strengthen and secure the attachment of the structural components 12 to the posts 20 .
[0034] It should also be appreciated that while in the preferred embodiment, the post rings 22 and post hinges 24 are disposed at the top and the bottom of the vertical elements 30 , as shown in FIGS. 1 and 4 - 6 , they may be positioned at various heights along the length of the vertical elements 30 as may be desired. For example, as illustrated in FIGS. 1 and 4 - 6 , the height of the upper post ring 32 on the base unit 14 is higher than that of the upper post ring 22 on the end unit 18 , which, in turn, is higher than upper post hinge 24 on the gate unit 16 . This configuration facilitates the combination of two or more structural components 12 since the post rings 22 or post hinges 24 will not necessarily interfere with each other. It should also be appreciated that, in the preferred embodiment, contact should be avoided between the post hinges 24 and the post rings 22 so as to prevent interference with the operation of the hinges. Toward that end, it may be preferred to mount the lower post hinges 24 of the gate unit 16 as broadly depicted in FIG. 6 , above the lower post rings 22 of either the base unit 14 or the end unit 18 .
[0035] The decorative fencing system 10 is secured to the ground by means of one or more stakes 40 . The stakes 40 are designed to be driven into the ground and receive the posts 20 to thereby support the structural components 12 in place. In the preferred embodiment, the stakes 40 are manufactured to be wedge shaped or to include a plurality of fins so as to facilitate their insertion into the ground, although a variety of alternative designs are possible. Preferably, the stakes 40 are pointed at one end, so that the stakes can be forcibly driven into the ground. However, if the user prefers to dig a hole for the stakes 40 , this can be done, and these elements could be of practically any shape or size, provided they could receive and retain the posts 20 .
[0036] In one preferred embodiment, as broadly depicted in FIG. 2 , the stakes 40 receive and retain the posts 20 by means of a stake sleeve 42 , essentially a cylindrical recess or cavity within the body of the stake 40 having an internal diameter slightly larger than the diameter or width of the post 20 such that the post 20 will be received within and retained by the stake sleeve 42 only by means of frictional contact therebetween. The posts 20 preferably are manufactured to be removably held only by friction, so that they are removable from each stake sleeve 42 and insertable into another stake sleeve 42 , as desired. They are not welded or otherwise permanently affixed in place. As broadly embodied herein, in this embodiment the preferred internal diameter of the stake sleeves 42 is approximately 22 cm-22.5 cm, and the preferred external diameter is approximately 26.5-28 cm. There is some clearance between the post 20 and the internal surface of the stake sleeve 42 . In this embodiment, post 20 can be removed from stake 40 , leaving stake 40 in the ground, and reinserted into another stake 40 driven into the ground at a different selected location.
[0037] Alternatively, in another preferred embodiment, as broadly depicted in FIG. 2A , the posts are made larger, so that the diameter of the posts 20 are substantially identical to an internal diameter of the stake sleeve 42 . In this embodiment, the posts 20 are permanently friction-fit into the stake sleeves 42 . In this embodiment, removal of post 20 from the ground for movement to another selected location, also requires removal of the stake 40 from the ground.
[0038] In another preferred embodiment, as depicted broadly in FIG. 3 , stake 40 is manufactured with an extending solid post-receiving portion 44 , and the post 20 has a hollow portion 48 at its lower distal end, with a diameter larger than the diameter of the post receiving portion 44 . In this embodiment, each selected post hollow portion 48 fits over each selected post-receiving portion 44 , and the posts 20 are supported thereby. In this embodiment, like the embodiment of FIG. 2 , post 20 can be removed from stake 40 , without removing stake 40 from the ground, and moved to another stake 40 , which is driven into the ground at a different location.
[0039] Ideally, the stake sleeve 42 or post-receiving portion 44 should be of sufficient length so as to securely receive the post 20 , and the length of the portion of the stake 40 that is inserted into the ground, or the length of post hollow portion 48 that sits on top of post-receiving portion 44 should be sufficient to prevent the post 20 from toppling over when the decorative fencing system 10 is assembled. In a preferred embodiment, the length of the portion of the stake 40 that is inserted into the ground, or that sits on top of post-receiving portion 44 is approximately 10 cm, although longer stakes 40 may function just as well, and shorter ones may also serve effectively, provided the weight of the structural components and posts 20 are not too great, and the ground itself is firm enough to retain the stake 40 therein. Also in the preferred embodiment, the stake sleeve 42 should extend above the ground level by a sufficient height to allow the desired clearance between the bottom of the structural components 12 and the ground. As broadly embodied herein, a preferred height of the stake sleeves 42 is approximately 15-20 cm, with a height above the ground of approximately 5 cm-8 cm. This is most significant for the gate unit 16 , since the gate elements must clear any uneven ground in order to allow the gate elements to open and close properly. Furthermore, the combined weight of the post 20 and any structural components 12 attached thereto serve to force the post 20 within the stake sleeve 42 and prevent the post from sliding out prematurely.
[0040] The end units 18 , broadly depicted in FIGS. 5 and 5 A, serve to provide decorative termination points for the decorative fencing system 10 , and as such, include a decorative termination point 44 on the side opposite the vertical element 30 or the side to which the post rings 22 are attached. Rather than use a separate post 20 to anchor the termination point 44 to the ground, a separate stake pin 50 can be provided at the termination point 44 . The stake pin 50 extends below ground level when the end unit 18 is attached, thereby securing the end of the end unit 18 to the ground. As illustrated in FIGS. 5 and 5 A, in preferred embodiments the stake pin 50 can be thin to facilitate its insertion into the ground. It also is of approximately the same length as the stake 40 , although a shorter stake pin 50 would work just as effectively.
[0041] In the preferred embodiment of the method of manufacturing fencing system 10 , the components of fencing system 10 are manufactured from tubular steel, and both square and round stock. A powder coat finish may be provided on some or all of the elements. For example, a separate color or finish or a different material, such as bronze colored cast iron, may be used for decorative accents 48 such as finials 51 or decorative ball caps 52 .
[0042] Preferably, jigs are set up and all of the component pieces are cut from tubular steel, wire rod, and flat stock, i.e., the stakes 40 , the posts 20 , structural components 12 , post rings 22 , post hinges 24 , and so on.
[0043] Curved pieces are then formed at appropriate locations in the end structural components 12 , and some structural components 12 are shaped into end units 18 or gate units 16 .
[0044] The post rings 22 are cut, and stamped into their final shape.
[0045] Holding the components in jigs, decorative finials 50 may be welded into ends of the posts 20 or vertical pieces of structural components 12 , and hinges 24 are welded into place on gate units 16 . Rings 22 are also welded into appropriate locations on structural components 12 .
[0046] The components are prepared for powder coating either through insertion into a metal pellet sand blast chamber or through the use of an acid wash sequence that ends with drying to eliminate water in the crevices prior to coating.
[0047] Individual pieces are then powder coated.
[0048] Alternative manufacturing methods, or minor variations on the above method, are also contemplated, including manufacturing individual components out of solid iron or steel pieces, then welding and then finishing by powder coating or painting. The components may be produced as individual cast iron pieces and finished with various paint techniques to create different appearances.
[0049] It should be appreciated that the design of the individual structural components shown in the drawings represent one possible design for the decorative fencing system 10 of the present invention. A variety of different designs and decorative accents 48 are contemplated, such as a Victorian design or a more modern design. The only limitation is that the design of the system 10 is embodied by the structural components 12 and tied together by the posts 20 , post rings 22 and post hinges 24 , and that the structural components 12 and posts 20 are removable and interchangeable so that a wide variety of fence configurations can be assembled, as explained below.
[0050] The process of assembling the fencing system 10 is designed to be simple and easy to alter. In the preferred embodiment, a stake 40 is driven into the ground, and the individual structural components 12 are held into place above the stake 40 . A post 20 is inserted through the post rings 22 and/or post hinges 24 , are then removably inserted into the stake sleeve 42 of the stake 40 , or in another embodiment friction-fit into the stake sleeve. The process is repeated as necessary until the desired configuration is achieved, allowing for a potentially infinite number of combinations and angles between the structural components. Some examples of these variations are illustrated in FIGS. 7 and 8 . Since each of the structural components 12 may be purchased separately, the decorative fencing system 10 may be as large or as small as the user.
[0051] Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. | A method of manufacturing a decorative fencing system for use as a small fence or decorative accent fence for a yard or garden. The fencing system comprises several different structural components that may be joined in various combinations so as to create a nearly limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be attached to the other components in any combination thereof. Each of these components are attached to post sections which are removably and interchangeably inserted through post rings or post hinges or welded onto the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections are removably and interchangeably secured to the ground by means of stakes that are driven into the ground and the post section is then inserted into a sleeve in the stake, or alternately onto a post-receiving extension on the stake to thereby provide support and stability for the fencing system, with the post section being held by the stake, either removably or permanently. |
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BACKGROUND OF THE INVENTION
[0001] The use of highway signs to warn “wrong way” drivers driving in one or more adjacent lanes wherein vehicles are moving in opposite directions is well known, so as to reduce the incident of serious and often fatal accidents. In order to achieve this objective, such signs have been positioned in a variety of different ways, with more or less success. In some cases, the drivers fail to see the signs as positioned, and in some cases the signs are positioned so as to be clearly seen by drivers going in the correct direction, startling them and causing them to panic and react inappropriately, sometimes in a dangerous manner. In the case of roads wherein there are multiple lanes moving in the same direction, for example, such signs positioned on the outside shoulders of the outer lanes are not seen by drivers going the wrong way in the inside lanes. This problem is aggravated by the tendency of drivers to look rightward to view signs, and to disregard signs to their left, which is where the “wrong way” signs would be positioned as they proceeded in the wrong direction. In order to remedy this problem, in some cases “wrong way” signs have been positioned in the roadway median between opposite moving lanes. This has led to the problem referred to above, namely that drivers going in the correct direction also clearly view such signs, and are startled, especially drivers new to that particular sign usage area. Also, drivers who see such “wrong way” signs often soon come to ignore them, so will likely continue to ignore them when they are, in fact, going in the wrong direction. There is thus a need in the art for sign assemblies which will remedy these problems, and also reduce the number of signs needed, and according the cost of placing such signs. This is true both in the case of multilane roads, and in the case of roads with only a single lane in each direction.
SUMMARY OF THE INVENTION
[0002] The present invention relates to sign assemblies primarily designed to be positioned at an inclined angle in or above roadway medians or between railroad tracks and having view obstructing means thereon, or adjacent to their lateral edges, which permit drivers going the wrong way on roads or in trains to clearly see such warning indicia as ‘WRONG WAY’, but which at least partially obstruct the view of such indicia by drivers going the correct way, so as not to confuse them. It also relates to methods of positioning such assemblies between such roads or railroad tracks. It has utility in the medians of multilane roads, in the medians of two lane roads and mounted on bridges or overpasses. It could also be used between walking paths or industrial paths, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a plan view of a multilane roadway having a preferred embodiment of the invention installed in the median, wherein such indicia as “WRONG WAY” is used on both sides of the signs.
[0004] FIG. 2 is a plan view of one existing prior art arrangement of “WRONG WAY” signs on a multilane road.
[0005] FIG. 3 is a plan view of a modified type of sign assembly wherein such indicia as “WRONG WAY” is used on only one side of each sign, on opposite sides of the two signs shown.
[0006] FIG. 4 is an elevation view of the type of sign used in FIG. 3 .
[0007] FIG. 5 is a plan view of the type of sign used in FIG. 3 .
[0008] FIG. 6 is an elevation view of the type of sign shown in FIG. 1 .
[0009] FIG. 7 is a plan view of the type of sign used in FIG. 1 .
[0010] FIG. 8 is an elevation of the type of sign used in FIG. 1 , with a modified mounting means comprising a pole, and utilizing a top support bar.
[0011] FIG. 9 is a plan view of the sign of FIG. 8 .
[0012] FIG. 10 is an elevation of the type of sign used in FIG. 1 , but utilizing modified mounting means comprising dual support elements.
[0013] FIG. 11 is a plan view of a prior art “wrong way” sign arrangement used on a two lane road.
[0014] FIG. 12 is a plan view of an arrangement wherein the FIG. 1 type of sign is used in the median of a two lane road.
[0015] FIG. 13 is an elevation of a sign assembly mounted on the vertical face of a bridge or overpass.
[0016] FIG. 14 is a plan view of the sign assembly shown in FIG. 13 .
[0017] FIG. 15 is a plan view of a sign having ends of the projecting means bent backwards to form smooth edges.
[0018] FIG. 16 is a plan view of our invention positioned between railroad tracks.
DETAILED DESCRIPTION
[0019] Illustrated in FIG. 1 is a plan view of a portion of a four lane road having a median 3 , two north-bound lanes 20 , two south-bound lanes 21 , and an embodiment of the present invention mounted in the median comprising two ‘WRONG WAY’ signs 1 , which may be of the same or similar construction, more particularly as shown in FIGS. 6-10 , for example. These signs may display such indicia as “WRONG WAY” on both faces, and may be mounted by any of various mounting means 14 , 15 or 18 as shown in various of FIGS. 6-10 , for example. As also shown in all of these figures, the signs have partial view obstructing means 2 projecting from their vertical edges, or adjacent such edges, and have faces which are inclined relative to the direction of travel of the vehicles in lanes 20 and 21 . Partial view obstructing means 2 would of course at least partially obstruct view of the indicia from positions generally forward of and lateral relative to the faces of the signs. The correct direction of travel in all of the lanes is indicated by solid arrows 4 , and an incorrect direction of travel is indicated by dashed arrows 5 .
[0020] It will be seen that the view of the indicia by drivers going the correct direction in all of the lanes will be partially obstructed by view obstruction means 2 , especially as they approach and pass the signs. However, the view of the indicia by any drivers going the incorrect way in any of the lanes will be unobstructed, so that they will have a clear view of indicia, such as “WRONG WAY.” Consequently, drivers going in correct directions will immediately recognize that the signs are not applicable to them, and drivers going in incorrect directions will immediately recognize their error. Drivers going the wrong way will, in fact, observe indicia such as “WRONG WAY” at an optimum angle of 90 degrees.
[0021] It may be noted that signs 1 will be located to the right of any drivers going in incorrect directions 5 , which is especially desirable, because drivers are accustomed to looking to their right for controlling signs. Lanes 20 and 21 are labeled as running in north-south directions merely to facilitate understanding of the invention. Of course, the invention would be equally useful when used between lanes running in any two opposite directions, such as east-west.
[0022] Such variables as the most useful angle of inclination of the signs relative to the direction of travel of the vehicles, the size of the signs, the height of their mounting, the height or angle of obstructing means 2 on their edges, or the size and wording of the indicia, are subject to variation, based on experience. The most useful angles of inclination between the direction of travel and the faces of the signs may be in the range of substantially 120 to 135 degrees. The most useful angle of the obstructing means 2 relative to the faces of the signs may be in the range of 90 degrees. But those angles are obviously subject to variation depending on experience or particular usage. View obstructing means 2 would at least partially obstruct view of the indicia from positions located generally forward of and lateral relative to the face of the sign by drivers going the correct way, as noted above. Such positions could, for example, be in the range of substantially 140 to 160 degrees relative to the face or faces of the sign.
[0023] It is presently believed that the most useful height at which to mount the signs would be at a moderate height relative to ground or grade level, such as approximately at or a little above the average eye-level height of vehicle drivers passing the signs.
[0024] The indicia could be made from a reflective material, so as to be more clearly visible at night, or could be illuminated by solar-powered means.
[0025] FIG. 2 shows a portion of a prior art four lane road comparable to the four lane road of FIG. 1 . As is the case in FIG. 1 , there are two northbound lanes 20 and two southbound lanes 21 . Mounted at 18 is a sign with “WRONG WAY” displayed on only the south-facing face, and intended to warn drivers going in the wrong direction in either of lanes 21 of their error. Mounted at 19 is a sign with ‘WRONG WAY’ displayed on only the north-facing face, and intended to warn drivers going the wrong way in either of lanes 20 of their error. Mounted in median 3 at 6 is a sign having “WRONG WAY” displayed on both faces, and intended to warn drivers going in the wrong direction in any of lanes 20 or 21 of their error. It will be seen that the faces of all of signs 6 , 18 or 19 are positioned at 90 degrees relative to the direction of vehicle travel. Sign 6 is seen to be needed, in addition to signs 18 and 19 , because drivers going the wrong way might not see either of signs 18 or 19 , especially because these signs would be located to the left of such wrong-way drivers, where they would not expect to see signs controlling their movement. However, use of this sign arrangement causes drivers going in the correct direction in any of lanes 20 and 21 to get a full and very confusing view of the ‘WRONG WAY’ indicia on sign 6 . This might well startle drivers going in a correct direction, and cause them to panic and react in a dangerous manner. In addition, drivers frequently passing this prior art sign arrangement soon become accustomed to seeing ‘WRONG WAY’ signs, such as sign 6 , in full and close view, and consequently could be expected to just continue to ignore such signs if they were, in fact, going in the wrong direction.
[0026] The FIG. 1 embodiment of our invention eliminates all of these problems caused by confusing sign 6 , and results in an arrangement by which wrong-way drivers are more likely to realize and correct their error. Although two signs 1 are shown close together in FIG. 1 for purposes of illustration, only one such sign would be needed on a particular extended portion of a road, or roads. In other words, signs 1 could be spaced far apart on roads. One might be placed near to where any access roads presented locations where drivers could enter in the wrong direction. Signs such as signs 18 and 19 could continue to be used, of course, or could be eliminated as unnecessary to reduce expense, all of signs 6 , 18 and 19 being replaced by a single sign 1 .
[0027] FIG. 3 shows another embodiment of our invention wherein signs 7 and 8 are used to warn drivers going the wrong way. In this embodiment, sign 8 has ‘WRONG WAY’ displayed on only its north (or, more precisely, northeast) facing face, to warn drivers going the wrong way in lane 20 of their error, and sign 7 has “WRONG WAY” displayed on only its south (or, more precisely, southwest) facing face, to warn drivers going the wrong way in lane 21 of their error. It will be apparent that this embodiment of our invention differs from our FIG. 1 embodiment in that signs 7 and 8 , unlike sign 1 as used in FIG. 1 , have ‘WRONG WAY’ displayed on only one face, and have view obstructing means 2 projecting from only one such face. Drivers going the correct way in lane 20 would not be able to see “WRONG WAY” on the north face of sign 8 , since it would appear on only the side of sign 8 that faced away from them as they approached sign 8 . Likewise, drivers going the correct way in lane 21 would not be able to see “WRONG WAY” on the south face of sign 7 , since it would appear on only the side of sign 7 that faced away from them as they approached sign 7 . Drivers going the correct way in lane 20 would have their view of “WRONG WAY” on the south face of sign 7 partially obstructed by view obstructing means 2 on sign 7 . Drivers going the correct way in lane 21 would have their view of “WRONG WAY” on the north face of sign 8 partially obstructed by view obstructing means 2 on sign 8 . It may be seen that signs 7 and 8 do, in fact, have exactly the same construction, although they are mounted in rotated positions relative to each other. Because they would be so rotated relative to each other when mounted, they have been given different reference numerals, even though they would be of the same construction. Signs 7 and 8 could be mounted relatively close together, as shown in FIG. 3 , or spaced far apart. They could also be used to control multi-lane roads, as shown in FIGS. 1 and 2 , as well as to control two lane roads, as shown in FIG. 3 . Additional signs such as signs 18 and 19 could continue to be used, or they could be omitted, as desired.
[0028] FIGS. 4 and 5 show elevation and plan views, respectively, of a sign 7 that is secured to a mounting channel 9 by bolts 10 . Channel 9 would extend up from the ground to road grade and hold sign 7 at a moderate elevation, which could be at eye level or, for example, somewhat above eye level.
[0029] FIGS. 6 and 7 show elevation and plan views, respectively, of a sign 1 as shown in the FIG. 1 embodiment, being mounted by bolts 13 to a cross piece 14 , which in turn is mounted to a support 11 by bolt 12 .
[0030] FIGS. 8 and 9 show elevation and plan views, respectively, of a sign as shown in the FIG. 1 embodiment, having alternate mounting means comprising a slotted cylindrical post 15 , and having an optional strengthening bar 17 secured to the top of the sign, to make it more wind resistant and stronger. Strengthening plates could be used in lieu of bar 17 , of course, as well as at the bottom of sign 1 .
[0031] FIG. 10 shows an elevation view of the FIG. 1 type of sign, wherein it is mounted by bolts 19 to two channel or post members 18 .
[0032] FIG. 11 is a plan view of a prior art arrangement similar to the prior art arrangement of FIG. 2 , except with signs intended to control two lanes, instead of four lanes. Signs 22 , 23 and 24 would be constructed in the same manner as signs 6 , 19 and 18 , respectively. And since sign 22 would have ‘WRONG WAY’ on both sides, as does sign 6 , it would also cause the same problems.
[0033] FIG. 12 is a plan view using a sign as shown in our FIG. 1 embodiment, having “WRONG WAY” on both faces, mounted in median 3 , for warning drivers going in the wrong direction in either of lanes 20 or 21 . This would be an improvement on the prior art arrangement of FIG. 11 in that all of signs 22 , 23 and 24 could be omitted, eliminating the confusion caused by sign 22 , and reducing costs, since three signs could be replaced by a single sign 1 . In addition, it will be seen that even if sign 22 was omitted in the FIG. 11 prior art arrangement—that is, if only signs 23 and 24 were used—these two signs could be replaced by a single sign 1 . In fact, sign 1 would be more likely to be seen because it would be to the right of drivers going the wrong way, unlike signs 23 and 24 .
[0034] FIGS. 13 and 14 are elevation and plan views, respectively, of a ‘WRONG WAY’ sign 28 mounted on an overhead bridge or overpass 25 by means of a mounting element 26 secured to the bridge or overpass 25 and to sign 28 by bolts 27 . Sign 28 would be inclined to the direction of vehicle travel on the road or roads below, as in our previous embodiments, and might also be inclined in a downward direction in order to facilitate its viewing by a driver on the road below, as shown. As in the previous embodiments, view obstructing means 2 would at least partially obstruct the view of “WRONG WAY” by a driver going the correct way in a lane to the right side of sign 28 , but would permit a clear view of same by a driver going the wrong way in a lane below or to the left of sign 28 . Of course, many different types of mounting means could be used in lieu of mounting means 26 and 27 .
[0035] FIG. 15 is a plan view of our FIG. 1 type of sign constructed of a relatively thin sheet of material 31 bent back upon itself at the outer edges of view obstructing means 2 to form a stronger and perhaps more visually appealing sign. Of course, this could also be done in the embodiment of FIGS. 4 and 5 .
[0036] FIG. 16 is a view of our invention wherein a sign 1 as described above is positioned between northbound railroad tracks 33 and southbound tracks 34 .
[0037] Although various embodiments of our invention have been described by way of example, it will be apparent to those skilled in the field that modifications may be made to such embodiments without departing from the scope of the invention. | Highway or railroad sign assemblies having partial view obstructing means on their edges, mounted at an inclined position between or above road lanes or railroad tracks wherein vehicles or trains are traveling in opposite directions, and adapted to warn drivers that are going in the wrong direction without confusing drivers going the right way, and methods for so positioning such sign assemblies. |
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TECHNICAL FIELD
[0001] This invention relates generally to retaining walls, and more specifically to retaining walls for use in controlling land erosion in contact with water.
BACKGROUND OF THE INVENTION
[0002] Over the many years, there has long existed the problem of land erosion adjacent waterways, rivers, lakes and oceans wherein seawalls of various types have heretofore been constructed of wood, steel or cement. Heretofore, efforts have been made to provide a series of seawall elements which are laterally aligned and in some manner interconnected and pounded down into the ground and anchored. Illustrative of earlier prior art efforts to provide a seawall, constructed of reinforced concrete, is U.S. Pat. No. 1,332,655 issued to R. B. Willard in 1920. The problem then as recognized by the inventor and thereafter, has been the enormous pressures and loads applied to the seawall which have ultimately destroyed the connection between adjacent seawall elements to render the seawall less than effective and ultimately requiring replacement and repairs.
[0003] It is known to form seawalls of a plurality of panels formed of extruded PVC material and interconnected edge to edge, as shown in Berger, U.S. Pat. Nos. 4,674,921 issued Jun. 23, 1987 and 4,690,588 issued Sep. 1, 1987. In Berger, panel strips of corrugated or sinusoidal shape are formed with alternating groove edges and tongue edges, permitting the panels to be interlocked along their vertical marginal edges. Wale elements are mounted along outer surfaces of the panel strips and accept tie bolts or tie rods extending to ground anchors on the opposite side of the seawall. Berger also discloses angled strips for making corners, and connectors for joining adjacent strips in edge-to-edge relation.
[0004] Sinusoidal or corrugated sheets have been mounted in facing relation and connected or joined by tie rods, and the spaces therebetween have been filled with concrete or mortar to provide a water-tight joint, to form a revetment, as shown in Schneller, U.S. Pat. No. 3,247,673 of Apr. 26, 1966.
[0005] Sinusoidal or corrugated panel sections have been used to make up retaining walls or seawalls, with wale elements on a front surface tied back to anchors, as shown in a number of prior patents. Caples, U.S. Pat. No. 1,947,151 of Feb. 13, 1934 shows panel sections formed with interconnecting locking vertical edges in alternating inwardly and outwardly directed portions to form a sinusoidal wall. In Caples, the interlocking ends are identical. In Frederick, U.S. Pat. No. 3,822,557 of Jul. 9, 1974, one panel vertical edge is formed with a tongue and the opposite panel vertical edge is formed with a groove proportioned to receive the tongue of an adjacent panel.
[0006] Another example of a retaining wall made of interlocking sections of sheet material is McGrath, U.S. Pat. No. 2,968,931 of Jan. 24, 1961. In McGrath each panel section is bent into three angular portions, and each panel section is reversed when connected, edge to edge to form a sinusoidal-like pattern.
[0007] Earlier examples of wall systems having interlocking panel sections which are assembled in longitudinal alignment, with interlocking vertical edges, include Clarke, U.S. Pat. No. 972,059 of Oct. 4, 1910; Boardman et al, U.S. Pat. No. 1,422,821 of Jul. 18, 1922; and Stockfleth, U.S. Pat. No. 1,371,709 of Mar. 15, 1921.
[0008] It is also known to use a series of individual arcuate sections which are then joined or interconnected to form a retainer wall, as shown in Van Weele, U.S. Pat. No. 4,407,612 of Oct. 4, 1983.
[0009] While walls formed by corrugated panel sections are extensively shown in the prior art in which the corrugations or the axes of the corrugations run vertically, is also known to form panel sections in which the axes of the corrugations run horizontally, as shown in Sivachenko U.S. Pat. No. 4,099,359 of Jul. 11, 1978. FIGS. 7 and 8 also show opposed facing pairs of corrugated sections in which the spaces therebetween may be filled with concrete to form a revetment.
[0010] It is common to use wale brackets or wale elements in combination with panel-type seawalls or retainer walls. Berger, Schnabel, Jr. and Caples show wale elements in longitudinal alignment. Schnabel, Jr., U.S. Pat. No. 3,541,798 of Nov. 24, 1970 shows individual longitudinally spaced wale elements along the wall front face. The wale elements receive tie-back rods, which rods extend through or between the panels to suitable anchors.
[0011] Essentially two-dimensional polymeric retaining wall members with interlocking members along the edges that are universally mateable to like members are illustrated in U.S. Pat. No. 4,863,315, issued Sep. 5, 1989 to Wickberg while a wall system which employs a plurality of individual panels formed of extruded polymer joined in edge-to-edge relation including wale members which are vertically offset and interlocked at end portions thereof with adjacent wale members is shown in U.S. Pat. No. 4,917,543, issued Apr. 17, 1990 to Cole et al.
[0012] A shoreline erosion prevention bulkhead system which employs a series of interlocking fiberglass panels is shown in U.S. Pat. No. 5,066,353 issued Nov. 19, 1991, to Bourdo while a plastic structural panel and ground erosion barrier is illustrated which in general is a stretched Z-shaped cross-sectional design with opposed male and female interlock edges for mating association with adjacent panel strips in U.S. Pat. No. 5,145,287 issued Sep. 8, 1992 to Hooper et al.
[0013] Corner adapters for use with corrugated barrier sections are disclosed in U.S. Pat. No. 5,292,208 issued Mar. 8, 1994 to Berger and a sheet piling extrusion with locking members is illustrated in U.S. Pat. No. 6,000,883 to Irving et al. A reinforced Z-shaped configuration of the same with strengthening ribs is illustrated in U.S. Pat. No. 6,033,155 issued Mar. 7, 200 to Irvine et al. A generally U-shaped seawall panel is disclosed in U.S. Pat. No. 6,575,667 issued Jun. 10, 2003 to Burt et al.
[0014] This invention was developed to continue to advance the state-of-the-art for retaining walls, particularly extruded polyvinyl chloride (PVC) retaining walls which offer easier installation and greater structural integrity than those found in the Prior Art.
SUMMARY OF THE INVENTION
[0015] It is an aspect of the present invention to provide a modular barrier or retaining wall, particularly for use in tidal environments where land erosion is a particular problem.
[0016] It is another aspect of the invention to provide a modular barrier wall which utilizes linear U-shaped (optionally polygon-shaped—whether open or closed polygon) channel modules and angled (optionally polygon-shaped—whether open or closed polygon) channel modules which through mating engagement of male projections and female receptacles, effect wall construction which is self-aligning.
[0017] It is still yet another aspect of the invention to provide a modular retaining wall which permits wall construction to angle either outward or inward by inserting the appropriate end of an angled module, the angled module being essentially a mirror-image of each other as viewed through a bisecting horizontal line through the angled module.
[0018] It is a further aspect of the invention to improve on existing seawall “sheet pilings” of plastic material by exposing a smooth face toward both the sea and the land using a substantially rigid three-dimensional structure which employs a double connection system which is locked into a fixed location. A connection hook is employed which allows for clearing of external material during installation. The final structure is hollow and can be filled with gravel, concrete, etc., to achieve a higher strength. The smooth surfaces are not only more visually appealing, but also make installation easier due to the ease of concrete form construction. Additionally, angled modules are provided which allow for a radiused appearance.
[0019] It is still a further object of this invention to employ a two point connection that makes for faster installation because the three-dimensional profile cannot twist or bow to the degree of existing two-dimensional products. This means less driving energy will be absorbed by the pile making it faster to drive. It also reduces rework required to correct misplaced piles in that they will not have to be withdrawn and replaced.
[0020] To the accomplishment of the foregoing and related ends the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
[0022] FIG. 1 is a perspective view of the modular retaining wall illustrating a 45° bend interposed therein with end caps positioned at opposed ends of the wall;
[0023] FIG. 2 is a top plan view of one module of FIG. 1 ;
[0024] FIG. 3 is a top plan view of FIG. 1 ;
[0025] FIG. 4 is a top plan view of an embodiment of the modular retaining wall illustrating the incorporation of a middle retaining rib and a different linking geometry;
[0026] FIGS. 5-7 are top plan views of alternative embodiment of the modular retaining wall illustrating alternative linking geometries including middle side wall support;
[0027] FIG. 8 is a top plan view of closed polygonal shaped modules for use in an embodiment of the retaining wall;
[0028] FIG. 9 is a top plan view of an end or middle module of the modular retaining wall illustrating the open polygon shape; and
[0029] FIG. 10 is a top plan view of an end module of the retaining wall illustrating the closed polygon shape.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The invention is described with reference to the accompanying figures, which illustrate the best mode known to the inventor at the time of the filing of the application illustrating the modular retaining wall of the invention.
[0031] As better illustrated in FIG. 1 , retaining wall 10 consists of various modules which form a contiguous barrier wall across a length of the modules when in their assembled state. Some modules are essentially interlocking linear U-shaped channels, e.g., 12 a, 12 b, and 12 c whereas other interlocking modules, e.g., angled module 14 , are used to impart non-linearity to the wall. As illustrated in the figure, the imparted angle is approximately 45°, although this is but an example of any angle between 1° and 180°, the end-use application, which in an aqueous environment will be the shoreline defining the requisite angularity required for the non-linear modules. The combination of linear U-shaped modules with non-linear modules provides essentially limitless geometries for retaining wall 10 . At each end of the wall, is an end-cap 16 , 18 , with an appropriate geometry so as to interlock or mate with its adjacent module, whether that module is linear or angled.
[0032] As better illustrated in FIG. 2 , a combination of one linear U-shaped channel module 12 a with adjacent angled channel 14 with respective end caps 16 , 18 is shown in an unassembled state. Linear module 12 a is comprised of a pair of essentially parallel vertically-extending sides 20 in connected engagement with an essentially vertical third side 24 positioned normal to the vertical plane of sides 20 at one end of each side 20 forming an essentially open “U-shaped” channel 66 within module 12 a. Affixed to the exterior of third side 24 and positioned interiorly of each of the ends of the side, is a pair of outwardly facing “J-shaped” or “U-shaped” hook protrusions 26 defining an open longitudinal channel 28 . Affixed to each end of lateral sides 20 at the open end of U-shaped channel 66 are a pair of inwardly facing end wall segments 30 . Spaced apart from end wall segments 30 and penetrating inwardly and curvilinearly toward the open end of the channel are interior curvilinear wall segment protrusions 32 , the combination of end wall segments 30 and interior curvilinear wall segment protrusions 32 defining open vertically-extending longitudinal channel 34 . While curvilinear wall segments 32 are defined as curvilinear, in an alternative embodiment, these segments could be intersecting linear segments, the end-use application defining the need for a geometry which is either curvature-based or intersecting perpendicular line based in a manner similar to that defined for outwardly-facing J-shaped hooks 26 .
[0033] In constructing retaining wall 10 , either a second linear U-shaped channel module 12 b is attached to the first linear U-shaped channel module 12 a or a non-linear or angled module 14 is affixed through mating channels and protrusions. As illustrated in FIG. 2 , a non-linear module 12 b is shown adjacent to the closed end of linear U-shaped module 12 a. This angled module, shown to produce an angle of approximately 30°, although both larger and smaller angles are within the scope of this invention, ranging from 1° to 180° are envisioned. Angled module 14 is essentially J-shaped or hook-shaped in which side 44 and curvilinear or curved side 46 intersect, the degree of curvature defined by an angle α (shown to be approximately 45° in the Figure) formed by the intersection of the vertical plane of side 44 and the vertical plane of curvilinear side 46 . In a manner analogous to that discussed with vertical third side 24 of linear module 12 a, and affixed to the exterior of side 44 and positioned interiorly of each of the ends of this side, is a pair of outwardly facing “J-shaped” hook protrusions 52 defining an open longitudinal channel 62 . Affixed to non-intersecting end of side 44 at the open end of open triangular shaped channel 68 and to non-intersecting end of curvilinear side 46 at the same open end of channel 68 is a pair of inwardly facing end wall segments 48 . Spaced apart from end wall segments 48 and penetrating inwardly and curvilinearly toward the open end of the channel are interior curvilinear wall segment protrusions 50 , the combination of end wall segments 48 and interior curvilinear wall segment protrusions 50 defining open longitudinal channel 54 . While curvilinear wall segments 50 are defined as curvilinear, in an alternative embodiment, these segments could be intersecting linear segments, the end-use application defining the need for a geometry which is either curvature-based or intersecting perpendicular line based in a manner similar to that defined for outwardly-facing J-shaped hooks 26 .
[0034] Attachment of angled module 14 to a linear module, e.g., 12 a or 12 b or 12 c, is effected by mating engagement of male J-shaped hook protrusion 26 into open female longitudinal channel 54 formed by end wall segments 48 and curvilinear segments 50 . By having mating engagement occur with two channels simultaneously, the modules become self-aligning.
[0035] Retaining wall 10 is constructed by matingly securing linear U-shaped modules 12 and angled modules 14 in combination to meet the geometry required by the end-use application. It is recognized that since the modules are mirror images when dissected through a horizontal plane, that the direction of the turn of the retaining wall through the utilization of an angled module can be in either direction by simply turning the angled module upside-down. At either end of the retaining wall, is an end cap, the configuration of which is dictated by whether the end cap is designed to close an open U-shaped channel or to mate with a pair of outwardly facing J-shaped hooks. In FIG. 2 , channel closing end cap 16 is constructed with side 36 essentially parallel to third side 24 at the closed end of channel 66 . Spaced inwardly and interiorly of each opposed end 38 of the end cap is a pair of outwardly facing “J-shaped” hook protrusions 40 defining an open longitudinal channel 42 . Attachment of channel closing end cap 16 with linear module 12 a occurs via mating engagement of male J-shaped hook protrusion 40 into female longitudinal channel 34 formed by end wall segments 30 and curvilinear segments 32 . At the opposed end of retaining wall 10 from channel-closing end cap 16 is terminating cap 18 having a side 56 with a pair of inwardly facing J-shaped hooks 58 at each end with a pair of inwardly facing fingers 60 spaced apart and inward from the pair of J-shaped hooks. Attachment of terminating end cap 18 with angular module 14 occurs via mating engagement of male J-shaped hooks 52 into open female longitudinal channels 64 formed by J-shaped hooks 58 and inwardly facing fingers 60 thereby closing and simultaneously forming channel 70 between side 56 of terminating end cap 18 and side 44 of angled module 14 .
[0036] As illustrated in FIG. 3 , terminating end cap need not be affixed to angled module 14 , but rather could also terminate a linear U-shaped channel module 12 c. Attachment of terminating end cap 18 with linear module 12 c occurs via mating engagement of male J-shaped hooks 26 into open female longitudinal channels 64 formed by J-shaped hooks 58 and inwardly facing fingers 60 thereby capping retaining wall 10 .
[0037] As used in the field and in a preferred embodiment only, subsequent to driving the modules into the seabed using mechanized driving equipment, each closed cavity which is formed through mating engagement with a subsequent module, is filled with pea gravel or concrete or combinations thereof. The filling operation creates outward lateral pressure on each module. For those modules which have relatively small horizontal dimensions, the inherent structural strength of the walls of the module are sufficient to resist any lateral bowing of the module. However, for those modules which have a larger horizontal dimension, e.g., 12 a, 12 b, 12 c in the Figures, it is often desirable to include T-shaped (or other geometried) male anchors 72 positioned on opposing side walls 20 on the inside of cavity 66 , thereby forming two separate cavities, 66 a and 66 b. This lessens the tendency of the larger modules to lateral bowing when the male anchors 72 are in mating engagement with at least one rib 74 (better illustrated in FIGS. 5-7 ) which are in mating engagement with the male anchors. While a pair of T-shaped male anchors 72 are illustrated in FIGS. 4, 6 and shown to be in engagement with a rib 74 having a pair of open oval channels 76 a positioned at each end of the rib for mating engagement with the male anchors, there is no need to limit the invention to this geometry. As illustrated in FIGS. 5, 7 , reinforcing rib 74 can mate with male anchors 72 a (inwardly facing bent finger positioned normal to the vertical plane of wall 20 ) or 72 b (inwardly facing bent angular finger). When in either of these geometries, it is important that the geometry of the opposed ends 76 b of reinforcing rib 74 successfully mate or securely or lockingly engage with the male anchor.
[0038] As illustrated in FIGS. 4-7 , each of the modules can have mating attachment locking mechanisms which employ slightly different geometries, and the invention is not limited to any one geometry. For example, inwardly facing wall segments 30 may be geometried as inwardly facing J-shaped hooks 30 b which bend backwards 180°, or as inwardly facing J-shaped hooks 30 c which form an acute angle with wall 20 , said angle ranging from 1-90°, or as outwardly-facing J-shaped hooks 30 d. Additionally J-shaped hooks 26 may be geometries as outward-facing J-shaped hooks 26 a which form an acute angle to the initial normal projection from third end wall 24 , said angle ranging from 1-90°, or outward-facing J-shaped hooks 26 b which bend backwards 180°, or outward-facing J-shaped hooks 26 c or inward-facing hooks 26 d. Similarly, inwardly-facing wall segments 48 , namely 48 a, 48 b, 48 c or 48 d may be possessed of different geometries, the key being mating or secure or locking engagement with their corresponding J-shaped hooks 26 . Similar comments are pertinent to protrusions 52 , namely 52 a, 52 b, 52 c, and 52 d which would need to correspondingly securely or matingly engage with their associated next modular unit.
[0039] FIG. 8 illustrates a further embodiment of the modular retaining wall construction wherein each module is of a closed geometry for additional stability if required by the application. Module 12 a comprises a closed rectangular polygon having a pair of parallel sides 20 and a pair of connecting ends. End 24 a simply closes the polygon on one side and is used as a terminating end module to the retaining wall 10 . When used in this configuration, there is no need for end cap 36 as illustrated in FIG. 3 for example. Opposed end 24 has a pair of outwardly-facing male J-shaped hook protrusions 26 for engagement with inwardly-facing J-shaped hooks of inner module 12 b. This module is the building block module when the wall is constructed with closed polygon modules. Module 12 b comprises similar parallel sides 20 with opposed end walls, one end wall having a pair of inwardly-facing J-shaped hooks 30 while opposed end 24 has a pair of outwardly-facing J-shaped hooks. Construction of the retaining wall includes linking as many modules 12 b as is necessary until the wall either ends or is angled. When angularity is required to the construction of the wall, a closed triangular-shaped module is added to end 24 of module 12 b through gripping or securing engagement of outwardly-facing J-shaped hooks 26 with inwardly-facing J-shaped hooks. Completion of a modular retaining wall is effected by the attachment of module 12 c, a module similar to 12 a with the exception that the securing fingers are inwardly-projecting J-shaped hooks 30 in contrast to the outwardly-facing J-shaped hooks 26 of module 12 a.
[0040] While the invention has been described in terms of open U-shaped modules and closed rectangular modules for the essentially linearly oriented modules, there is no need to limit the shape of the modules to such. In fact, as illustrated in FIGS. 9-10 , both open and closed polygons are useful in the invention. As shown particularly in FIG. 9 , end 12 a or middle module 12 b which was illustrated to be an open U-shaped three-sided polygon, may be envisioned as an open seven-sided polygon, wherein side panel 20 has been modified by inwardly-positioned side panels 20 a and 20 b. It is noteworthy that the apex of side panels 20 a and 20 b need not be equally spaced between bottom side 24 and end cap 36 , but may be positioned off-center. It is also noted that the length of side panels 20 a and 20 b need not be equal. In a similar manner, this concept may be extended to the closed polygons which were originally shown to be rectangular in shape in FIG. 8 , but are illustrated to be polygonal in FIG. 10 . This concept may equally be extended to the non-linearly oriented modules, e.g., 14 .
[0041] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the Prior Art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
[0042] This invention has been described in detail with reference to specific embodiments thereof, including the respective best modes for carrying out each embodiment. It shall be understood that these illustrations are by way of example and not by way of limitation. | A modular retaining wall with improved features is illustrated and described. Open or closed polygonal modules having channels disposed therein are set at least partially below a surface, said surface either being land-based or aqueous-based, and interfaces therebetween, e.g., shoreline, and attached to each other by respective fastening means which provide engaging connectivity between the modules. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a soil compacting device.
2. Description of the Related Art
Vibratory tampers, vibrating plates or vibrating rollers are generally used for soil compaction. Whereas tampers are displacement-excited vibratory systems with a large amplitude, vibrations in the case of vibrating plates are produced by means of force excitation. For reasons connected with the excitation of vibrations in the soil particles, guideability and to protect the operator against unwanted body vibrations, vibrating plates are often designed in such a way that they have a relatively high frequency (40 to 80 Hz) and a small amplitude of the vibrating base plate. From the category of vibrating rollers, trench rollers are generally used for soil compaction, in which vibrations are produced by rotating unbalanced weights within the facings or on the chassis forming a lower mass.
When using vibrating plates, in particular, on moist soils (what are referred to as cohesive soils with a high water content or saturated soils), such as silts and clays, that is to say fine-particle soils with little tendency toward water permeability, there is the problem that the soils can only be compacted to a limited extent by the action of vibrations. This is due to the fact that the cohesion which is often typical of cohesive soils affects the adhesion of the individual particles to one another and hence prevents repositioning of the particles. In the case of vibrating plates, the small amplitude of the vibrating base plate in conjunction with the high frequency leads to a further supersaturation of the soil with water, making the latter softer and more plastic in terms of vibration and causing its adhesive effect on the vibrating plate to increase. As a result, the vibrating plate may sink into the soft earth and no longer be capable of being moved along. In practice, this has led to vibrating plates not being used in damp weather or on saturated cohesive soils even though the soil compaction and surface quality that can be achieved by means of vibrating plates are highly regarded.
In practice, however, there is frequently the problem that, although the vibrating plates are used primarily only on non-cohesive soils, it is necessary for them at certain points to cross supersaturated cohesive soils which are likewise situated in the area to be compacted. In this case, the vibrating plates run the risk of sinking in or digging themselves in due to their natural vibration as they cross these points.
DE-B 11 68 350 has disclosed a vibration device for compacting the construction site with a vibratory plate. The vibratory plate is attached by springs to a road roller, between the front roller drum and the rear wheels. To increase the contact pressure of the vibratory plate on the ground, hydraulic cylinders are provided, these hydraulic cylinders pressing the springs and the vibratory plate against the ground and thereby increasing the spring preload. The problem described of self-propelled vibrating plates on cohesive soils does not arise with this device since the roller ensures sufficient propulsion.
Similar vehicles with attached soil compacting devices are known from DE 43 40 699 A1 and DE-A 20 46 840, where a plurality of vibratory plates or tampers are attached to a heavy travel drive.
U.S. Pat. No. 5,387,370 has disclosed an electroviscous fluid for dampers with variable damping properties, the change in damping being brought about by subjecting the electroviscous fluid to a suitable electric voltage.
U.S. Pat. No. 5,547,049 describes a construction with a magnetorheological fluid in which the damping properties of the fluid can be adjusted by varying an applied magnetic field.
OBJECTS AND SUMMARY OF THE INVENTION
The object on which the invention is based is to specify a soil compacting device in which the abovementioned problem of the device sinking in when temporarily crossing cohesive soils is avoided.
A soil compacting device according to the invention with an upper mass, a lower mass for soil compaction, a spring system coupling the upper mass and the lower mass, and with a damper system, which is arranged between the upper mass and the lower mass and interacts with the spring system, is distinguished by the fact that the damping properties of the damper system can be varied during the operation of the device. This makes it possible to vary the vibration properties and vibration behavior of the device and, for example, to adjust them in such a way that the amplitude of vibration is increased in such a way when crossing cohesive soil, for example, that the upper mass is induced to perform a resonance-type vibratory movement in order thereby to exert larger amplitudes and forces on the lower mass. The lower mass in this context is generally the actual base plate including the exciter by means of which the soil is compacted, while the upper mass is formed by the drive and the control system for the device.
By virtue of the fact that the vibration behavior can be varied during the operation of the device by means of the damping properties of a damper system provided for the partial or complete coupling of springs, the operator can cross the cohesive soil without interrupting his work. The damping properties can be adjusted manually or automatically, as defined in a number of the subsequent subclaims.
The forces on the lower mass generated by appropriate variation of the vibration properties (frequency, amplitude, direction of vibration) of the lower and the upper mass make it possible to overcome the increased sticking at the base plate caused by moist soils and associated with vibration and adhesion. The large amplitudes with an appropriately forward-directed force vector allow the device to execute a jumping movement, even on soils which are of low elasticity and are predominantly plastic.
In a particularly preferred embodiment of the invention, at least one damper of the damper system has a damping material composed of an electroviscous fluid. In the case of electroviscous fluids, the viscosity of the fluid can be varied under the action of electric voltage. This means that, depending on how the fluid is acted upon by an electric voltage, almost any viscosities and hence damping constants can be set at the damper. Dampers incorporating an electroviscous fluid are therefore particularly suitable for enabling the damping properties of the damper to be changed quickly during its operation. The response time of typical electroviscous fluids is around 3 milliseconds.
The damping properties of the damper system provided for intermittent or continuous coupling of spring systems can therefore advantageously be adjusted by subjecting the electroviscous fluid to a suitable electric voltage.
It can be particularly expedient if the electric voltage is clocked. This is particularly recommended when the vibration properties are adjusted by means of an automatic control system.
The electric voltage can additionally be adjusted to different levels.
However, it is also possible to vary the clocking, i.e. to change the lengths of time for applying voltage.
In a preferred embodiment of the invention, the electric voltage or clocking can be adjusted by means of an automatic control system. It is advantageous if the automatic control system has at least one sensor system.
It is particularly preferred if the sensor system has at least one acceleration sensor. If, namely, the base plate of the vibrating plate sinks into a soft soil or comes into contact with a soft soil, the reaction forces exerted by the soil on the plate change relative to the forces exerted by a firm underlying surface. In addition, there is a change in the frequency, amplitude and length of the jump of the lower mass and this can be detected by the acceleration sensor. When presettable limiting values are undershot, the sensor can give the signal that the contact area of the plate with soft soil is increasing at this moment or that it is already moving on said soil. This knowledge will then cause the automatic control system to alter the spring stiffness of the vibratory system and hence the vibration behavior accordingly by means of the damping constant of the damper in order to achieve the effects described above.
Instead of electroviscous fluids, it is also possible to use magnetorheological fluids, the viscosity of which changes as a function of an applied magnetic field. The magnetic field is then controlled and varied in a manner similar to the variation or clocking of the voltage in the case of electroviscous fluids.
Preferably, at least one spring of the spring system is arranged in parallel with a damper of the damper system. It can also be expedient if at least one spring of the spring system is arranged in series with a damper of the damper system. By appropriate arrangement of springs and dampers in the overall spring/damper system of the vibrating plate, it is thereby possible to define suitable spring characteristic regions within which the vibration properties can be varied. The interacting springs can have the same or different spring characteristics.
It can be particularly advantageous if the spring stiffness of the overall system is adjusted in such a way, by varying the damping constants, that the upper mass enters into resonant vibration during the operation of the device. This allows a maximum force effect at a large amplitude to be exerted on the lower mass in order to overcome the static friction with the soft underlying surface.
In a particularly preferred embodiment of the invention, at least one spring can be connected up or disconnected by means of a damper connected in series. This is possible by virtue of the fact that, at maximum stiffness, the damper completely activates the spring, while, given a correspondingly soft setting, it eliminates the effect of the spring.
The resultant direction of vibration of the upper mass can advantageously be controlled by connecting up and disconnecting one or more springs. Thus, for example, a resonant vibration of the upper mass can take place in a predetermined or controllable direction and hence expediently align the resultant force vector on the lower mass.
It is expedient if the lower mass or the upper mass is coupled to a vibration exciter by means of which the overall system has imparted to it the vibration required for soil compaction and movement of the vibrating plate.
In another embodiment of the invention, the upper mass is connected to the lower mass at four points, in each case by means of a spring/damper combination, the damping properties of the dampers being adjustable asymmetrically. Asymmetrical means that the dampers can assume different damping coefficients at each of the four points, making it possible, for example, to achieve an advantageous jumping movement of the lower mass, i.e. the base plate, for cohesive soils.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in greater detail below with reference to the accompanying figures, in which:
FIG. 1 shows the basic structure of a soil compacting device according to the invention;
FIGS. 2 and 3 show suitable arrangements of spring and damper elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the basic structure of a vibrating plate according to the invention. The invention can, of course, also be employed with other soil compacting devices, e.g. with vibrating rollers or vibrating tampers.
An upper mass 1 , which essentially accommodates the drive, is coupled by a spring system 2 to a lower mass 3 representing the base plate. The lower mass 3 rests flat on the soil to be compacted.
The lower mass 3 carries one or more vibration exciters known per se (not shown), which can also be moved in opposite directions for the purpose of forming directional vibrations. Depending on the construction of the vibrating plate, the vibration exciter has one or two shafts with unbalanced weights, which are driven by the motor belonging to the upper mass 1 via V-belts or a hydraulic system, for example, and, in the process, generate centrifugal forces. These dynamic forces bring about both the forward motion of the plate and its compacting action. The centrifugal forces produced are always well above the deadweight of the vibrating plate, with the result that the entire unit is briefly raised a few millimeters above the ground and moved along every time the unbalanced weights rotate. The plate then reaccelerates back to the ground and acts with a brief, high surface pressure on the material to be compacted with the kinetic energy built up and the centrifugal force produced in the exciter.
Arranged between the upper mass 1 and the lower mass 3 there is furthermore a damper system 4 which interacts with the spring system 2 and forms an overall vibratory system with the masses 1 , 3 .
The spring system 2 comprises a plurality of springs connected in parallel or in series and composed, for example, of metal or rubber-metal elements, pneumatic springs or other flexible materials, which are connected to one another by dampers of the damper system 4 . Expedient arrangements of springs 2 and dampers 4 are illustrated in FIGS. 2 and 3.
Since the damping properties of the damper system 4 and hence of the individual dampers can be varied during the operation of the device, it is possible to set very different characteristic curves for the overall vibratory system. Assuming that the damper 4 in FIG. 2 is set so as to be extremely hard, it can be seen that the two springs 2 a, 2 b illustrated are connected in parallel and that their spring constants are added together. If, on the other hand, the damper 4 is set so as to be extremely soft, spring 2 b loses its effect in the overall vibratory system and the system is thus determined by spring 2 a alone.
Similar remarks can be made regarding the connection of spring elements in series in accordance with FIG. 3 .
The damper systems respond extremely rapidly to appropriate activation (within 3 milliseconds) and comprise reciprocating cylinders which are filled with electroviscous fluid and the damping constant of which can be varied over extremely wide ranges by clocking an applied high voltage which is, in addition, variable. The extreme states of these damper elements lie between no damping, i.e. rigid transmission of the forces introduced, to 100% damping, whereby the forces introduced are transmitted virtually not at all but instead are absorbed during the working displacement of the damper.
A sensor 5 which continuously measures the acceleration of the lower mass 3 is mounted on the lower mass 3 . When the vibrating plate is passed over a piece of ground with a tendency to adhesion or vibratory penetration, the vibration behavior changes as it approaches this piece of ground, i.e. the amplitude of the base plate, (lower mass 3 ) changes because the softer ground exerts different reaction forces on the plate than a hard underlying surface and the forward acceleration decreases. This change is detected by the acceleration sensor 5 and indicated to a control unit (not shown) which, in turn, adjusts the viscosity in the damper system 4 by suitable voltage control and/or clocking of high voltage. As a result, in accordance with the invention the resonant frequency of the vibratory system is adjusted to the range of the excitation frequency, thereby resulting in different modes of vibration, all characterized by high amplitudes, depending on the eigenform excited. The large-amplitude vibration which now results can be directed in such a way by appropriate choice of frequency and mounting of the spring and damper elements that it exerts maximum force vectors on the lower mass and thereby helps to release the lower mass 3 from the ground.
Depending on the embodiment, the automatic control system activates just one damper member in the overall system or a plurality of dampers. If a plurality of dampers are activated, they can be adjusted to the same damping constant or—if expedient in the given application—to different damping constants. The person skilled in the art can decide here what outlay is necessary and appropriate for the configuration of the automatic control system. It may be possible to achieve the desired effect according to the invention by activating just one damper.
In the control unit, the acceleration value for the base plate detected by the acceleration sensor 5 is compared with preset desired values. If it is found that the base plate does not achieve the required acceleration patterns, the control unit concludes that the vibrating plate is on a problematic underlying surface. The control unit then controls the viscosity in the connected damper elements of the damper system 4 in accordance with predetermined characteristics.
Instead of automatic control, it is possible for the operator to adjust the vibration behavior of the soil compacting device as a function of the underlying surface which is being crossed at that particular time, using control elements (not shown). Thus, for example, it is possible for a switch to be provided, which is to be actuated by the operator when he notices that the base plate is sticking on soft ground. When the switch is actuated, a corresponding damper system with electroviscous damper elements is then activated and the upper mass is adjusted to resonance of a suitable eigenform. Once the critical ground has been crossed, the operator switches the switch off again, whereupon the device reattains its normal operating state.
There is a significant advantage over the prior art in the control behavior of the vibrating plate since, previously, it was only possible to adapt or adjust the vibrating plate approximately to the ground to be compacted by configuration of the entire vibratory system of the vibrating plate and hence only by permanent presetting. In this arrangement, it was hitherto impossible to adjust the soil compacting device equally well to two different types of soil (noncohesive and moist/cohesive soils).
Examples of suitable electroviscous or electrorheological fluids are RHEOBAY® products. With these fluids, the shear stress that can be used for force transmission, and hence the dynamic viscosity, is raised within milliseconds by applying an electric field. When the voltage is switched off, the original viscosity is restored. The field strength to be applied is preferably between 0 and 3 kV/mm. Both D.C. and A.C. voltages can be applied. The voltage applied can be clocked and achieve pulse widths between 0 and 100%. | A soil compacting device has a damping system which couples an upper mass and a lower mass together with a spring system in a vibration system. The damping properties of the damping system can be modified while the device is in operation. Therefore, when the soil compacting device passes over soils having different properties, it can constantly be adjusted in an optimal manner to the ground underneath it by acting on the vibration properties of the overall vibration system. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device for opening and closing the discharge door of a bulk seed box and more particularly to a device which utilizes an electrically operated screw actuator or linear actuator to open and close the discharge door.
2. Description of the Related Art
Bulk seed systems have been in wide use for many years to eliminate the need for filling row planter boxes and grain drills with seed from individual bags. A popular type of bulk seed box is that which is manufactured by Buckhorn, Inc. of Milford, Ohio, who is the owner of U.S. Pat. Nos. 5,845,799 and 6,010,022 relating to bulk seed boxes. Pioneer Hi-Bred International, Inc. of Johnston, Iowa, markets agricultural seeds in large bulk seed boxes under the registered trademark PROBOX®. See also U.S. Pat. Nos. 5,094,356 and 7,086,342 which disclose bulk seed boxes having discharge doors or slide gates.
The bulk seed boxes of Buckhorn, Inc. and Pioneer have a sliding discharge door at the lower ends thereof through which the seed in the bulk seed box is dumped into a seed system, wagon, truck, etc. When the large bulk seed boxes are delivered to a farmer or the like, the bulk seed box is normally elevated above the ground by means of a forklift or a front end loader so that the contents of the bulk seed box may be dumped into a seed system/wagon/truck so that the seed may be conveyed therefrom into the planting devices. The fact that the bulk seed boxes are elevated above the truck or the like requires that a person climb upwardly on the truck or a ladder to manually open the discharge door. Further, the weight of the seed in the box sometimes causes the bulk seed box to slightly deform which makes it extremely difficult to manually open or close the discharge door. Applicant's invention described and shown in U.S. Pat. No. 8,137,043 issued Mar. 20, 2012 represents a vast improvement in the art. The instant invention represents a further improvement in the art.
SUMMARY OF THE INVENTION
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
A lightweight portable device for opening and closing the discharge door of a bulk seed box is disclosed which is removably secured to the lower end of the bulk seed box while the bulk seed box is on the ground or other suitable supporting surface. The inner end of the device of this invention is selectively removably inserted into openings in the lower end of the bulk seed box at opposite sides of the discharge door. The device includes an electrically operated screw actuator or linear actuator which has a generally C-shaped connector mounted on the outer end of the actuator rod thereof which is selectively removably connected to the discharge door and which will pull the discharge door from its closed position to its open position as the actuator rod of the screw actuator is retracted. The C-shaped connector may also be used to push the discharge door from its open position to its closed position upon the extension of the actuator rod of the screw actuator.
The device may be remotely controlled which eliminates the need for a person to climb up on a truck or ladder to manually operate the discharge door.
It is therefore a principal object of the invention to provide a device for opening and closing the discharge door of a bulk seed box.
A further object of the invention is to provide a device of the type described which includes an electrically operated screw actuator for moving the discharge door of the bulk seed box between its closed and open positions and vice versa.
Still another object of the invention is to provide a device for opening and closing the discharge door of a bulk seed box which may be remotely operated.
Yet another object of the invention is to provide a device for opening and closing the discharge door of a bulk seed box which is portable and lightweight.
These and other objects will be obvious to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
FIG. 1 is a perspective view of the device of this invention with the actuator rod of the screw actuator being in its retracted position;
FIG. 2 is another perspective view of the device of this invention with the actuator rod of the screw actuator being in its retracted position;
FIG. 3 is a side elevational view of the device of this invention with broken lines illustrating the screw actuator in its extended position and in its elevated position;
FIG. 4 is a partial perspective view illustrating the C-shaped connector of the device being connected to the discharge door of a bulk seed box; and
FIG. 5 is a partial sectional view illustrating the C-shaped connector of the device connected to the bulk seed box and the discharge door thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims.
The numeral 10 refers to the door opening and closing device of this invention which is designed to open and close the sliding discharge door 12 of a bulk seed box 14 such as disclosed in U.S. Pat. Nos. 6,010,022 and 5,845,799, the disclosures of which are incorporated by reference thereto. In the '022 patent, the sliding door is identified as a cutoff device 50 which selectively closes the outlet 60 in the bottom wall of the base. In the '799 patent, the sliding discharge door is referred to as a cutoff device or flow control valve 89 .
Device 10 includes a frame or support 18 which is shown to be L-shaped with a bottom plate 20 and an upstanding side plate 22 . It should be noted that the support 18 could have other shapes as well. A conventional battery receptacle 24 is mounted on the outer side of plate 22 and is adapted to selectively removably receive a rechargeable battery 26 which in this case of the particular device is an 18-volt rechargeable battery such as marketed by Black & Decker. When positioned in receptacle 24 , the battery 26 is electrically connected to the electrical circuitry of the receptacle 24 in conventional fashion. Electrical leads 27 extend from receptacle 24 which are connected to a terminal block 28 which may include a transformer if necessary.
Terminal block 28 is electrically connected to a controller 30 , by leads 31 , which includes an RF receiver. Terminal block 28 is electrically connected to an electrically driven screw actuator 32 or linear actuator, by leads 33 , the base of which is pivotally secured to bottom plate 20 , about a horizontal axis, at 34 . Screw actuator 32 includes an extendable and retractable actuator rod 35 .
An elongated support 36 has its rearward end secured to the underside of plate 20 and extends forwardly therefrom. Support 38 is secured to the forward end of support 36 so as to be transversely disposed with respect thereto.
The numeral 40 refers to a vertically disposed plate having a rearward end 42 and a forward end 44 . As seen, the upper end of plate 40 is curved at 46 . The upper forward end of plate 40 has a pair of hooks 48 and 50 provided thereon.
The numeral 52 refers to a vertically disposed plate having a rearward end 54 and a forward end 56 . As seen, the upper end of plate 52 is curved at 58 . The upper forward end of plate 52 and has a pair of hooks 60 and 62 extending upwardly therefrom. As seen, plates 40 and 52 are welded to the ends of support 38 .
A horizontally disposed C-shaped connector 64 is secured to the outer end of rod 35 of screw actuator 32 and has hooks 68 and 70 at the opposite ends thereof. As seen, the body 71 of screw actuator 32 extends through a handle 72 which includes side portions 74 and 76 and an upper portion 78 . The handle 72 not only provides a handle but also serves as a limit to the upward pivotal movement of the screw actuator 32 with respect to the support 36 .
The device 10 is used as follows. When the filled bulk seed box 14 is on the ground or other suitable supporting surface, the plates 40 and 52 are extended inwardly through openings in the bulk seed box 14 at opposite sides of the discharge door 12 . The rearward end of the device 10 is then moved downwardly, which is enhanced by the weight of the device 10 , so that the hooks 48 , 50 and 60 , 62 on the upper forward ends of the plates 40 and 52 respectively move upwardly into engagement with the bulk seed box 14 to hold the device 10 in place. At this time, the screw actuator 32 will usually be in its retracted position. The forward end of actuator 32 will then be pivotally moved upwardly to the uppermost dotted line position of FIG. 3 . The remote controller fob 80 , which is an RF transmitter, will then be actuated to extend the actuator rod 35 to the upper dashed line position of FIG. 3 to position the connector 64 over the central upstanding wall portion 82 of discharge door 12 . The connector 64 is then lowered to engage the wall portion 82 .
The bulk seed box 14 may then be raised upwardly by a front-end loader or the like. When the box 14 is properly positioned over a seed system wagon, truck, or the like, the fob 80 will be actuated to cause the actuator rod 35 of actuator 32 to be retracted which will cause the discharge door to be opened. When the seed has been discharged from the box 14 , the fob 80 may be again activated to cause the actuator rod 35 to be extended from actuator 32 which will cause the connector 64 to push the discharge door 12 to its closed position. The instant invention is lightweight, portable and easy to operate.
Although the device 10 has been described as being used to open and close the discharge door 12 of a bulk seed box 14 which is to be elevated above a seed system wagon, truck or the like, the device 10 may also be used to open and close the discharge door 12 of a bulk seed box which is positioned on a seed tender such as shown in U.S. Pat. Nos. 6,971,324 and 6,994,039.
Thus it can be seen that the invention accomplishes at least all of its stated objectives.
Although the invention has been described in language that is specific to certain structures and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A device is described for opening and closing the discharge door of a bulk seed box. The device comprises a portable lightweight structure which is attached to the box and which uses an electrically operated screw actuator or linear actuator to move the discharge door of the box from its closed position to its open position and vice versa. The device is preferably remotely controlled. |
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 to determining the level of a fluid in a well such as a gas well, an oil well, or water well.
[0003] 2. Description of the Art Practices
[0004] It is known that wells replenish fluids at different rates even in the same formation or well field. The rate of fluid flow into the well bore is maximized because the hydrostatic head driving the fluid is at a maximum. See for example Burris, et al., U.S. Pat. No. 6,085,836 issued Jul. 11, 2000. The Burris, et al., patent is incorporated herein by reference.
[0005] The preceding observation suggests that the well pump should run constantly to keep the level in the well bore as low as possible thus maximizing production. Of course, this is often unsatisfactory for several reasons.
[0006] First, running the pump constantly or at too great a speed is inefficient since, some of the time, the well bore is completely empty and there is nothing to pump. Thus, energy conservation becomes a cost consideration. Second, the equipment is subject to wear and damage resulting in costly repairs when pumps are run dry. Third, paraffin build up is more pronounced when a well is allowed to pump dry. In the dry pump condition gases are drawn into the bore. The gases in the bore then expand and cool. As the gases cool, paraffin build up is promoted as these high melting hydrocarbons begin to plate out on the surfaces of the bore. However, a well may be pumped continuously provided that the liquid level of the well is high enough to ensue the well sump has liquid therein, e.g. avoid pumping gas into the tubing.
[0007] Given the above considerations, control strategies aimed at optimizing well production have emerged. Notably, timers have been used to control the pump duty cycle. A timer may be programmed to run the well nearly perfectly if the one could determine the duration of the on cycle and off cycle which keeps the fluid level in the bore low but which does not pump the bore dry.
[0008] The pump on cycle and off cycle can be determined for a group of wells or for an entire well field. Savings in energy may be maximized by knowing which wells fill at what rate and then optimizing pumping to reduce or maintain a constant electric load below the maximum peak available.
[0009] Given fluid level information, deciding when or how fast to run the pump is very straightforward and production can be optimized. Fluid level determinations, particularly for deep down hole (bore) systems, have been implemented. Unfortunately, these deep down hole systems have been costly and complex to install, unreliable in operation, and costly to repair or service. Although the implementation details will not be discussed here, it is worth noting that these systems, when operating correctly, have proven that significant gains in well production are available when control strategies using fluid level measurement are applied.
[0010] One system that has been attempted is the use of one-shot measurements. The one-shot measurement will use a sonic event such as a shotgun shell to generate the event. Another system is based on a nitrogen tank being utilized to generate a sonic event. In either of the foregoing systems the production of the well must be shut down to implement the sonic event and the corresponding data evaluations. By contrast the present invention will permit continuous operation of the well as the sonic events are generated, the data collected, the well conditions read out, and changes in pumping implemented. Moreover, the system of the present invention is conducted utilizing fluid from the well thus avoiding the cost of the nitrogen and does not require opening of the well to the atmosphere.
[0011] Clearly, what is needed is a control system with the advantages of fluid level measurement which is cost effective to install and operate and which is reliable. Basic features for fluid level measurement should include applicability to oil, water, or other wells and should be applicable to rod, screw (such as by a frequency drive), or other pump types.
[0012] A fluid level measurement system should be simple and inexpensive to install in the T-Head and useful for well depths to 10,000 feet. Such a fluid level measurement system should be self calibrating for each installation and accurate to 10 feet (3.1 meters). The system should be robust to harsh environments within and around the well.
[0013] A fluid level measurement system is desirably able to provide fluid level measurements in well in which gas is produced under vacuum. That is, some wells do not have sufficient pressure in the well to permit the gas to flow to the T-Head. In such cases, the well is often one in which methane is derived from a coal seam in which progressive cavity pumps are employed.
SUMMARY OF THE INVENTION
[0014] The present invention describes a device for controlling pump conditions comprising:
a T-Head connector;
at least one microphone connected with said T-Head connector; a gas compression chamber connected with said T-Head connector; a first valve for controlling fluid communication between said gas compression
chamber and a wellhead; a computer controller; said computer controller connected with said first valve to open and close said first valve to permit fluid communication between said gas compression chamber and the wellhead; said computer controller to activate said gas compression chamber, for when in use, to compress gas from the wellhead to obtain a compressed gas at a greater pressure than that of the wellhead, and, said computer controller connected with said gas compression chamber, for when in use, to open a valve to release the compressed gas into the wellhead.
[0024] The present invention also describes a device for controlling pump comprising:
a T-Head connector; at least one microphone connected with said T-Head connector; a piston chamber connected with said T-Head connector; a piston located within said piston chamber; a first valve for controlling fluid communication between said piston chamber and a wellhead; a second valve for controlling fluid communication between said piston chamber and the wellhead; said first valve and said second valve located on opposite sides of said piston; a computer controller; said computer controller connected with at least one of said first valve or said second valve to open and close said first valve or said second valve to permit fluid communication between said piston chamber and the wellhead; and, said computer controller connected with said piston, for when in use, to drive said piston in said cylinder.
[0035] A further aspect of the present invention describes a method for comprising:
at least partially opening a first valve to permit fluid communication between a gas compression chamber and a wellhead; closing said first valve to prevent fluid communication between said gas compression chamber and the wellhead; activating said gas compression chamber to compress fluid in said gas compression chamber thereby obtaining a compressed fluid in said gas compression chamber; at least partially opening said first valve to release the compressed fluid into the wellhead thereby generating a sonic event; obtaining data from the sonic event; processing the data from the sonic event to determine the conditions for controlling the pump.
[0042] Yet another aspect of the present invention describes a method for controlling pump conditions for a well comprising:
closing a first valve to prevent fluid communication between a piston chamber and a wellhead; moving a piston in said piston chamber away from said valve; opening said valve to permit fluid from the wellhead into the piston chamber thereby generating a sonic event; obtaining data from the sonic event; processing the data from the sonic event to determine the conditions for controlling the pump.
[0048] Yet another aspect of the present invention describes a method for compressing a method for controlling pump conditions for a well comprising:
closing a first valve in a piston chamber to prevent fluid communication between said piston chamber and the wellhead; simultaneously closing a second valve in said piston chamber to prevent fluid communication between said piston chamber and the wellhead; moving a piston in said piston chamber away from said first valve so as to create a partial vacuum in the region between said first valve and said piston while compressing fluid in the region between said second valve and said piston; simultaneously opening said first valve and said second valve to create a first sonic event in the wellhead and a second sonic event in the wellhead; obtaining data from at least one of the sonic events; and, processing the data from the sonic event to determine the conditions for controlling the pump.
[0055] The present invention also describes a device for receiving audio signals comprising a method for controlling pump conditions for a well comprising:
at least partially opening a first valve to permit fluid communication between a piston chamber and a wellhead; said piston chamber having therein a piston; said piston having a front face and a rear face; said piston chamber having a second valve; closing said first valve to prevent fluid communication between said piston chamber and the wellhead; driving said piston within said piston chamber in the direction of said first valve such that the first face of said piston compresses fluid in said piston chamber thereby obtaining a compressed fluid in said piston chamber; at least partially opening said first valve to release the compressed fluid into the wellhead thereby generating a sonic event; obtaining data from the sonic event; processing the data from a sonic event to determine the conditions for controlling the pump
[0065] The present invention describes a device for receiving audio signals comprising a method for determining at least one of the amount of a liquid phase and/or a gaseous phase in a sealable container, for when in use the sealable container containing a liquid phase and a gaseous phase, the sealable container having located therein:
at least one microphone; a gas compression chamber; a piston located within the gas compression chamber; a first valve for controlling fluid communication between the gas compression chamber and said sealable container; means to open and close the first valve to permit fluid communication between the gas compression chamber and the sealable container; and, means to drive the piston in the gas compression chamber, closing the first valve to prevent fluid communication between the gas compression chamber and the sealable container; then causing at least one of:
moving the piston in the gas compression chamber away from the first valve to cause at least a partial vacuum in the gas compression chamber; opening the first valve to permit fluid communication between the sealable container and the gas compression chamber thereby generating a sonic event by fluid from the sealable container moving into the gas compression chamber, or compressing fluid within the gas compression chamber to obtain a compressed fluid with the first valve closed to prevent evacuation of the fluid from the gas compression chamber and opening the first valve to release the compressed fluid into the sealable container thereby generating a sonic event; and,
obtaining data from the generation of the sonic event with the microphone, correlating the data, and determining at least one of the amount of a liquid phase and/or a gaseous phase in the sealable container.
[0076] Yet another aspect of the present invention describes a device for receiving audio signals comprising
a microphone having microphone leads; said microphone and microphone leads encased in substantially hydrocarbon impervious flexible tubing; and, said microphone capped with a latex cover.
[0080] A further aspect of the present invention describes a device for receiving for receiving audio signals comprising
a microphone having microphone leads; said microphone and microphone leads encased in substantially hydrocarbon impervious flexible tubing; and,
a heating element is located within said flexible tubing.
[0083] A further aspect of the invention is a device for receiving audio signals comprising
a microphone having microphone leads; said microphone and microphone leads encased in substantially hydrocarbon impervious flexible tubing;
a heating element is located within said flexible tubing; and,
said microphone capped with a latex cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0087] Further features of the present invention will become apparent to those skilled in the art to which the present invention relates from reading the following specification with reference to the accompanying drawings, in which:
[0088] FIG. 1 is a partial sectional view of an aspect of the invention;
[0089] FIG. 2 is a partial sectional view of a well head system;
[0090] FIG. 3 is a view of a microphone according to the invention;
[0091] FIG. 4 is a partial sectional view of a second embodiment of the present invention; and,
[0092] FIG. 5 is sectional view of a propane storage tank.
DETAILED DESCRIPTION OF THE INVENTION
[0093] A pump controlling device 10 for controlling pump conditions in a well is shown in FIG. 1 . The pump controlling device 10 is connected with well 12 as seen in FIG. 2 . The pump controlling device 10 comprises a gas compression chamber shown herein as a piston chamber 14 . A piston 16 is located within the piston chamber 14 . The piston 16 has a piston front face 18 and a piston rear face 20 . The term compression chamber herein means any suitable means of compressing a gas.
[0094] The piston chamber 14 has a piston fore chamber 22 located on the side of the piston chamber 14 adjacent to the piston front face 18 . The piston 16 forms an airtight seal to prevent fluid communication between the piston front face 18 and the piston rear face 20 . The piston chamber 14 has a piston after chamber 24 located on the side of the piston chamber 14 adjacent to the piston rear face 20 .
[0095] The piston 16 has a piston stem 36 . The piston stem 36 extends axially in after chamber 24 and extends through an airtight opening 38 . The piston stem 36 is connected with a piston driver 40 . The piston driver 40 is conveniently operated by any source of power such as electricity or steam. The piston driver 40 may also be hydraulically operated.
[0096] The piston fore chamber 22 has an opening 48 . A conduit 52 forms an airtight seal at the opening 48 with the piston fore chamber 22 . The conduit 52 is thus in fluid communication with the piston fore chamber 22 .
[0097] The conduit 52 is connected with a pressure measuring device 58 . The pressure measuring device 58 is located so as to determine fluid pressure within the conduit 52 . The conduit 52 is also connected with a temperature measuring device 62 . The temperature measuring device 62 is located so as to determine fluid temperature within the conduit 52 .
[0098] A valve 68 provides for fluid flow and fluid shutoff to the conduit 52 . A second conduit 70 is connected to the valve 68 . The valve 68 controls fluid flow between the conduit 52 and the second conduit 70 .
[0099] A T-Head connector 80 is a generally cylindrical barrel having an air tight closure cap 82 at one end. The T-Head connector 80 has an opening 84 at the opposite end from the closure cap 82 . The second conduit 70 extends through the opening 84 into the T-Head connector 80 . The second conduit 70 makes an airtight connection with the T-Head connector 80 .
[0100] The second conduit 70 has a right angle bend 86 within the T-Head connector The right angle bend 86 provides a second segment 88 of the second conduit 70 .
[0101] The second segment 88 of the second conduit 70 has an opening 90 to provide fluid communication to the T-Head connector 80 of a well 12 . The opening 90 is at the opposite end from the closure cap 82 . Thus, when the valve 68 is in the open position there is fluid communication from the opening 90 to the piston fore chamber 22 .
[0102] A tube 92 extends between the piston after chamber 24 and the T-Head connector 80 . The tube 92 makes an airtight seal with the piston after chamber 24 at an opening 94 in the piston after chamber 24 . The opening 94 is located in the piston after chamber 24 such that the maximum stroke of the piston 16 by the piston stem 36 does not permit the piston front face 18 to be positioned such that there is fluid communication between the piston fore chamber 22 and the tube 92 .
[0103] An opening 96 is located in the T-Head connector 80 . The tube 92 makes an airtight seal with the T-Head connector 80 at the opening 96 . The tube 92 provides fluid communication between the piston after chamber 24 and the T-Head connector 80 .
[0104] A microphone opening 98 is located in the T-Head connector 80 . A microphone conduit 100 is adapted to form an airtight seal in the T-Head connector 80 at the microphone opening 98 . The microphone conduit 100 has an open end 102 in fluid communication the T-Head connector 80 .
[0105] The microphone 110 is preferably a condenser microphone. The microphone 110 is preferably unidirectional. The microphone 110 is connected with a computer 120 . The computer 120 is capable of processing the reception of sonic events by the microphone 110 . For convenience, the various leads to the computer 120 are not shown and labeled in the Figs. The computer 120 is also capable of providing a signal to drive the piston 16 in the piston chamber 14 .
[0106] The microphone is best seen in FIG. 3 . The microphone 110 is enclosed by a microphone sleeve 112 . The microphone sleeve 112 has a threaded screw 114 at one end. A microphone cap 116 fits over the microphone sleeve 112 to protect the microphone 110 from dust. A microphone heating element 118 is placed in the microphone sleeve 112 to protect the microphone 110 from condensation. The microphone sleeve 112 is conveniently bent at a 45 degree angle to permit easy insertion into the T-Head connector 80 at the microphone opening 98 .
[0107] As best seen in FIG. 2 , the well 12 comprises in part a wellhead 138 . A well casing 140 is located within the wellhead 138 and extends downward into the well 12 . The wellhead 138 may also be utilized for the underground storage of propane or other liquefied gas. In the later case there is no annulus but rather tubing in which the pump controlling device 10 is conveniently mounted.
[0108] Well tubing 142 is located within the well casing 140 . The well tubing 142 extends downward in the well casing 140 forming an annulus 146 between the outer surface of the well tubing 142 and the inner surface of the well casing 140 .
[0109] The well casing 140 and the well tubing 142 are fastened to a standard T-Head connection 150 . The well casing 140 and the well tubing 142 are not in fluid communication at the T-Head connection 150 .
[0110] The T-Head connection 150 has two pipes 152 and 154 . A T-head valve 158 and a T-head valve 160 respectively terminate the pipes 152 and 154 of the T-Head connection 150 .
[0111] The pipe 152 in the T-Head connection 150 is utilized to remove, in the case of an oil and gas well, the gas. The second pipe 154 is utilized as a backup. In the present invention the T-Head connector 80 is connected to the opposite side of the T-head valve 160 from the pipe 154 . The T-Head connector 80 is in fluid communication with the annulus 146 of the well when the T-head valve 160 is open.
[0112] In operation, the valve 68 is placed in the closed position to prevent fluid communication between the T-Head connector 80 and the piston fore chamber 22 . The T-head valve 160 is open such that the T-Head connector 80 is in fluid communication with the T-Head connection 150 . The T-Head connection 150 is then in fluid communication with the annulus 146 of a well as shown in FIG. 2 .
[0113] The pressure of the gas in the annulus 146 is determined by the pressure measuring device 58 with the valve 68 open. The pressure determined by the pressure measuring device 58 is reported to the computer 120 .
[0114] The temperature measuring device 62 may be used to measure the fluid temperature in the annulus 146 at this time. As the operation of the invention may be conducted in a dynamic manner the temperature of the fluid drawn through the T-Head connector 80 is effectively the temperature of the fluid in annulus 146 . The fluid temperature determined by temperature measuring device 62 is reported to the computer 120 .
[0115] The valve 68 is then placed in the closed position preventing further fluid communication between the annulus 146 and the piston fore chamber 22 . The piston 16 is moved away from the closed valve 68 causing an effective axial expansion of the piston fore chamber 22 with the result being a partial vacuum in the piston fore chamber 22 . There is no practical resistance to the movement of the piston 16 as the tube 92 is in fluid communication with the after chamber 24 .
[0116] The piston 16 is then driven toward the closed valve 68 . Driving of the piston 16 compresses the fluid in the piston fore chamber 22 thereby forming a compressed fluid having a greater pressure and temperature than the fluid in the annulus 146 . Typically, it is desirable that the pressure of the compressed fluid in the piston fore chamber 22 be at least 30 psi greater than the pressure of the fluid in the annulus 146 .
[0117] The pressure and the temperature of the compressed fluid in the piston fore chamber 22 may be measured by the pressure measuring device 58 temperature measuring device 62 and reported to the computer 120 .
[0118] The valve 68 is then opened releasing the compressed fluid through the second conduit 70 around the right angle bend 86 . The expanding compressed fluid moves around the right angle bend 86 through the second segment 88 exiting the opening 90 into the T-Head connector 80 .
[0119] The T-Head connector 80 volume is much greater than the regions that the compressed fluid has passed. The result of the larger volume is that the compressed fluid rapidly decompresses releasing mechanical energy in the form of a sonic event.
[0120] The sonic event is transmitted through the fluid in the T-Head connector 80 into the annulus 146 . The measurement of the level of liquid in annulus 146 is determined by the Doppler effect as received by the microphone 110 . The signal from the microphone is transmitted to the computer 120 .
[0121] When the computer 120 has correlated the data from the sonic events the computer 120 determines the amount of liquid 180 in the wellhead 138 . The computer then generates a signal to the pump (not shown) to order the pump to begin operation to remove liquid 180 from the wellhead 138 . Similarly, the computer 120 may generate a signal to the pump to discontinue the pumping operation to prevent an excess of liquid 180 from being removed from the well.
[0122] For continuous operation of a well, such as with a screw pump, the operating conditions may be varied to maximize production while minimizing electric consumption. That is, every time a well starts pumping a large voltage is required to overcome the pump inertia. If the pump is operated on a continuous basis electrical consumption may be minimized. Similarly, where it is desired to stop to start pumping, the optimum conditions for removing liquid 180 from the tubing 142 may be determined.
[0123] A second embodiment of the present invention is shown in FIG. 4 . The tube 92 is replaced with the following components.
[0124] The piston after chamber 24 has an opening 94 . A conduit 252 forms an airtight seal at the opening 94 with the piston after chamber 24 . The conduit 252 is thus in fluid communication with the piston after chamber 24 .
[0125] The conduit 252 is connected with a pressure measuring device 258 . The pressure measuring device 258 is located so as to determine fluid pressure within the conduit 252 . The conduit 252 is also connected with a temperature measuring device 262 . The temperature measuring device 262 is located so as to determine fluid temperature within the conduit 252 .
[0126] A valve 268 provides for fluid flow and fluid shutoff to the conduit 252 . A second conduit 270 is connected to the valve 268 . The valve 268 controls fluid flow between the conduit 252 and the second conduit 270 .
[0127] An opening 96 is located in the T-Head connector 80 . The second conduit 270 makes an airtight seal with the T-Head connector 80 at the opening 96 . The second conduit 270 provides fluid communication between the piston after chamber 24 and the T-Head connector 80 .
[0128] The second conduit 270 extends through the opening 96 into the T-Head connector 80 . The T-Head connector 80 has an opening 84 . The second conduit 270 makes an airtight connection with the T-Head connector 80 .
[0129] The second conduit 270 has a right angle bend 286 within the T-Head connector 80 . The right angle bend 286 provides a second segment 288 of the second conduit 270 .
[0130] The second segment 288 of the second conduit 270 has an opening 290 to provide fluid communication to the T-Head connector 80 of a well 12 . The opening 290 is at the opposite end from the closure cap 82 . Thus, when the valve 268 is in the open position there is fluid communication from the opening 290 to the piston after chamber 24 .
[0131] A microphone opening 298 is located in the T-Head connector 80 . A microphone conduit 300 is adapted to form an airtight seal in the T-Head connector 80 at the microphone opening 298 . The microphone conduit 300 has an open end 302 in fluid communication the T-Head connector 80 .
[0132] The microphone 310 is preferably a condenser microphone. The microphone 310 is preferably unidirectional. The microphone 310 is essentially the same as the microphone 110 seen in FIG. 3 . The microphone 310 is connected to the computer 120 . The computer 120 is capable of processing the reception of sonic events by the microphone 310 .
[0133] The second mode of operation is generally the same as the first mode of operation. In the second mode of operation, the valve 68 is placed in the closed position to prevent fluid communication between the T-Head connector 80 and the piston fore chamber 22 . The T-head valve 160 is open such that the T-Head connector 80 is in fluid communication with the T-Head connection 150 . The T-Head connection 150 is then in fluid communication with the annulus 146 of a well as shown in FIG. 2 .
[0134] The pressure of the gas in the annulus 146 is determined by the pressure measuring device 58 with the valve 68 open. The pressure determined by the pressure measuring device 58 is reported to the computer 120 .
[0135] The temperature measuring device 62 may be used to measure the fluid temperature in the annulus 146 at this time. As the operation of the invention may be conducted in a dynamic manner the temperature of the fluid drawn through the T-Head connector 80 is effectively the temperature of the fluid in annulus 146 . The fluid temperature determined by temperature measuring device 62 is reported to the computer 120 .
[0136] The valve 68 is then placed in the closed position preventing further fluid communication between the annulus 146 and the piston fore chamber 22 . The valve 268 is placed in the open position to reduce the effort needed to draw the piston 16 away from the valve 68 .
[0137] The piston 16 is moved away from the closed valve 68 causing an effective axial expansion of the piston fore chamber 22 with the result being a partial vacuum in the piston fore chamber 22 . The valve 68 is rapidly opened resulting in a sonic event (an implosion) as the fluid from the annulus 146 moving into the piston fore chamber 22 . The return echo from the sonic event is received by the microphone 110 and the data therefrom transmitted to the computer 120 .
[0138] The piston 16 is then driven toward the closed valve 68 . Simultaneously, the valve 268 is closed. The driving of the piston 16 compresses the fluid in the piston fore chamber 22 thereby forming a compressed fluid having a greater pressure and temperature than the fluid in the annulus 146 . Typically, it is desirable that the pressure of the compressed fluid in the piston fore chamber 22 be at least 30 psi greater than the pressure of the fluid in the annulus 146 .
[0139] The pressure and the temperature of the compressed fluid in the piston fore chamber 22 may be measured by the pressure measuring device 58 temperature measuring device 62 and reported to the computer 120 .
[0140] The valve 68 is then opened releasing the compressed fluid through the second conduit 70 around the right angle bend 86 . The expanding compressed fluid moves around the right angle bend 86 through the second segment 88 exiting the opening 90 into the T-Head connector 80 .
[0141] The T-Head connector 80 volume is much greater than the regions that the compressed fluid has passed. The result of the larger volume is that the compressed fluid rapidly decompresses releasing mechanical energy in the form of a sonic event.
[0142] The sonic event is transmitted through the fluid in the T-Head connector 80 into the annulus 146 . The measurement of the level of liquid in annulus 146 is determined by the Doppler effect as received by the microphone 110 . The signal from the microphone is transmitted to the computer 120 .
[0143] When the valve 68 is opened to release the compressed fluid the valve 268 is also opened causing a sonic event by the implosion of fluid into the piston after chamber 24 . The implosion caused by the valve 268 opening is received by the microphone 310 .
[0144] The operation of generating sonic events continues with valve 68 being closed while the piston 16 is withdrawn away from valve 68 . Simultaneously, the valve 268 is closed and the piston rear face 20 begins to compress fluid in the piston after chamber 24 . The compressed fluid in the piston after chamber 24 is then released when the valve 268 is opened thus generating another sonic event.
[0145] Four sonic events are generated by each piston cycle. By varying the degree that each of valve 68 and valve 268 are open as well as by varying the size of the piston fore chamber and the piston after chamber the tone of each sonic event may be varied to differentiate the echo received by the microphone 110 and microphone 310 .
[0146] When the computer 120 has correlated the data from the various sonic events the computer 120 determines the amount of liquid 180 in the wellhead 138 . The computer then generates a signal to the pump (not shown) to order the pump to begin operation to remove liquid 180 from the tubing 142 . Similarly, the computer 120 may generate a signal to the pump to discontinue the pumping operation to prevent an excess of liquid 180 from being removed from the well.
[0147] The device 10 may also be operated in a wellhead 138 to aid in pumping propane or other liquefied gas. The definition of pumping includes maintaining the static state of not removing any propane or other liquefied gas from underground storage but rather measuring the volume by determining the depth of the well to the point where the liquefied gas begins. In this manner not only can inventory of the propane or other liquefied gas in the well be determined but also the amount of propane or other liquefied gas that may be pumped into the well.
[0148] As best seen in FIG. 5 is a liquefiable gas storage tank 400 . The liquefiable gas storage tank 400 is an enclosed vessel having a liquefiable gas storage tank bottom 402 . The liquefiable gas storage tank 400 has a liquefiable gas storage tank top 404 . The liquefiable gas storage tank 400 is generally cylindrical in shape having a liquefiable gas storage tank sidewall 406 .
[0149] The liquefiable gas storage tank 400 has a gas withdrawal conduit 410 extending through the liquefiable gas storage tank top 404 . A gas flow control valve 412 controls fluid communication between the liquefiable gas storage tank 400 and the gas take off conduit 414 .
[0150] A microphone assembly 420 extends through the liquefiable gas storage tank top 404 of the liquefiable gas storage tank 400 . The microphone assembly 420 is sealed to the liquefiable gas storage tank top 404 to prevent leakage of gas from the liquefiable gas storage tank 400 .
[0151] A piston assembly 430 extends through the liquefiable gas storage tank top 404 of the liquefiable gas storage tank 400 . The piston assembly 430 is sealed to the liquefiable gas storage tank top 404 to prevent leakage of gas from the liquefiable gas storage tank 400 . The piston assembly 430 is similar in design and function to the components of the pump controlling device 10 .
[0152] In use, the piston assembly 430 has components corresponding to the piston chamber 14 and the piston 16 . A valve (not shown) is alternately opened and closed to provide fluid communication between the piston chamber 14 and gas 432 within the liquefiable gas storage tank 400 . The piston is driven forward against the closed valve to compress the gas within the piston chamber 14 . When the gas has been sufficiently compressed within the piston chamber 14 the valve is opened. As the compressed gas is under a greater pressure than the gas 432 within the liquefiable gas storage tank 400 the compressed gas decompresses and releases mechanical energy thereby generating a sonic event.
[0153] The sonic event (acoustic waves) travel through the gas 432 within the liquefiable gas storage tank 400 . The acoustic waves eventually reach the surface of the liquefied gas 434 that is gravitationally positioned at a level below the level of gas 432 . The acoustic waves are reflected from the surface of the liquefied gas 434 toward the microphone assembly 420 . The microphone assembly 420 receives the reflected acoustic wave. By knowing the shape and volume of the liquefiable gas storage tank 400 the Doppler effect may be utilized to the determine the amount of liquefied gas and gas within the liquefiable gas storage tank 400 .
[0154] The inventions embodied herein are merely exemplary and the suggested feature should be utilized to unduly limit the scope of the invention. | A device for employing sonic transmissions is utilized to determine fluid level in a well or a container. The device may be utilized while the well is operating. It is known that wells replenish fluid at different rates even in the same formation or well field. Increased well production at minimum pumping cost is achieved for a given well. |
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CROSS-REFERENCE TO RELATED APPLICATIONS:
The present invention relates to blowout preventer ram locks, as does co-pending U.S. patent application Ser. No. 605,857, filed Aug. 19, 1975, and assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
The present invention relates to locks for blowout preventer rams.
In ram blowout preventers, each closure of the ram causes a certain amount of wear of the ram sealing elements which move into the borehole of the preventer for sealing contact with a pipe or other object, such as another ram. During succeeding closures of the rams, the effectiveness of the seal was reduced when the ram was locked in sealing position due to such wear.
Certain prior art blowout preventer ram locks, such as in U.S. Pat. Nos. 3,242,826 and Re27,294, used snap rings or collets mounted with a ram piston for locking. When the piston reached a predetermined locking position defined by a groove in the ram piston cylinder, the snap ring moved into the groove to lock the ram and piston in place. However, with this structure, only one locking position of the ram, as defined by the relative position of the snap ring and groove, was obtained. Change of the locking position to compensate for sealing element wear required adjustment of the relative positions of the locking elements, requiring undesirable disassembly of the blowout preventer cylinders for such adjustments to be made.
Other blowout preventer ram locks, such as in U.S. Pat. No. 3,208,357, used a taper locking pin which moved into locking position behind the ram piston once the ram had been moved into sealing position. However, extra hydraulic operating and control lines, separate and distinct from those for causing ram piston movement, were required, increasing the complexity of the control system for those types of ram locks.
In the co-pending application referred to above, these shortcomings have been for the most part overcome. However, locking action in such co-pending application was based on frictional engagement of locking rings in locking position. For high loads, however, this frictional engagement could be subject to slippage. In certain instances, unlocking of the frictionally engaging locking structure could cause difficulties. Also, dirt or particles in the operating fluid could cause galling of the frictionally engaging locking surfaces.
SUMMARY OF THE INVENTION
Briefly, the present application provides a new and improved ram lock for blowout preventer rams which automatically locks the ram against outward movement during inward movement of the ram to a closed position in a bore of the blowout preventer, and further locks the ram at an adjustable closed position to achieve the desired degree of sealing contact with a well pipe or like object in the bore.
A ram carrier moves the ram through the blowout preventer to and from the desired closed position. The ram carrier moves in the preventer in response to opening and closing fluid pressures and has a threaded surface which continuously engages a similar threaded surface on a lock nut rotatably moving with respect to the ram carrier. The lock nut also includes a movable clutch plate, having ratchet teeth, which is mounted with and moves with the lock nut. A fixed clutch plate having ratchet teeth adapted to engage the ratchet teeth of the movable clutch plate is mounted with the blowout preventer. The ratchet teeth of the clutch plates, when engaged, permit unidirectional rotational movement of the lock nut during inward advance of the ram carrier to the closed position. The engaged ratchet teeth lock the ram carrier, however, against reverse movement, thereby automatically locking the ram. Further, the engaged ratchet teeth permit the ram carrier to be moved inwardly to an adjustable closed position, for example to compensate for ram elastomer wear, while the lock automatically locks the ram and ram carrier in this adjustable closed position.
An unlocking piston responds to opening fluid pressure by disengaging the ratchet teeth of the movable clutch plate from the ratchet teeth of the fixed clutch plate, unlocking the ram and ram carrier and permitting the ram to move from the closed position in response to the opening fluid pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of a ram blowout preventer according to the present invention;
FIG. 2 is a vertical sectional view of a ram blowout preventer and lock of the present invention in an open position;
FIG. 2A is a vertical sectional view of the blowout preventer of FIG. 2 in a partially open position;
FIG. 3 is a cross-sectional view along the lines 3--3 of FIG. 2; and
FIG. 4 is a cross-sectional view along the lines 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the letter B (FIG. 1) refers generally to a blowout preventer of this invention which is formed with a pair of rams R which are locked into place by a locking apparatus L of the present invention automatically and at adjustable closed positions for sealing contact with a well pipe or like object. The blowout preventer B is typically mounted in a stack of blowout preventers or in a string of well casing or pipe.
As is conventional, the rams R are disposed in a conventional blowout preventer body or housing 10 having a longitudinal well bore 10a formed therethrough, through which well pipe or other objects such as well tools may pass in normal operations conducted with the blowout preventer B in an open or retracted position (FIG. 1). In the open position, the rams R are mounted in conventional recesses in the body 10 adjacent the bore 10a. The rams R move in response to a motive or power means M from their respective recesses into an extended or closed position in the bore 10a for sealing contact of conventional sealing elements with a well pipe, well tool or another ram. The sealing elements of the ram are conventional and are carried by a conventional ram block of the ram R. Since the sealing elements and ram blocks are conventional, they are not shown in the drawings in order to more clearly show other structures.
The rams R may be any of several types of blowout preventer rams. For example, the rams R may be of the type known as a "blind" ram for sealing against another "blind" ram of similar structure; the type wherein the sealing inner portions of the rams are shaped for sealing about a pipe or well tool in the bore, as well as with one another on each side of the pipe or well tool; or the shear-seal ram type for shearing tubing or objects in the bore 10a in conjunction with a similar shear seal ram and thereafter sealing the bore 10a of the preventer B against well pressure.
A conventional head or bonnet 12 (FIG. 2) is connected to each side of the body or housing 10 and each of such heads or bonnets has a conventional recess aligned with the recesses in the housing or body 10 so that the rams R may be received in such recesses when they are in the retracted or open position (FIG. 1). A piston rod 14 (FIG. 2) extends through suitable sealing structure in an opening 12b of each head or bonnet 12. Each piston rod 14 extends to a piston or ram carrier 16 of conventional construction which is disposed in a ram piston cylinder 17 with O-rings 16a or other suitable seals therebetween. The piston 16 moves in response to the motive means M within the cylinder 17 in a manner to be set forth.
The ram piston 17 is mounted with the bonnet 12 by bolts 20 or other suitable fastening means. Similarly, a cylinder head cap or end closure 18 is mounted with the ram piston cylinder 17 by conventional bolts or other suitable fastening means.
For purposes of illustration in the preferred embodiment, the motive means M includes a fluid inlet line 24a (FIG. 2) shown for introducing air, hydraulic fluid or other operating fluid pressure into the cylinder 17 against an outer surface 16b of the piston 16 for moving the piston 16 inwardly (to the left as viewed in FIGS. 2 and 2A) to move the rams R toward the center of the bore 10a. An opening fluid conduit 24b is formed through the body of the bonnet 12 for introducing air, hydraulic fluid or other operating fluid pressure into the cylinder 17 against an inner surface 16c (FIG. 2) of the piston 16 for moving the piston 16 outwardly (to the right as viewed in FIGS. 2 and 2A) to retract the ram R from the closed position in the bore 10a.
It should be understood that various systems for providing operating or motive power to the blowout preventer B may be employed and the invention is not limited to the specific form illustrated in the drawings. It should also be understood that a similar power means is provided for the left-hand ram R as viewed at FIG. 1 in the same manner as the power means 91 illustrated for the right-hand ram R in FIG. 2.
Considering now the lock L, a piston tail rod 26 of the ram piston 16 extends rearwardly from the piston 16 and moves into and out of an opening 28 in the cylinder head 18, as the piston 16 (FIG. 2A) moves transversely inwardly and outwardly (as indicated by an arrow 29) with respect to the bonnet 12 in response to the power means M. The piston tail rod 26 has a threaded external surface 26a formed thereon which is continuously engaged with a threaded inner surface 30a of a lock nut 30 of the lock L.
The threaded surfaces 26a and 30a are in the form of multi-start helical threads, as indicated by phantom lines 31, to prevent binding therebetween in response to fluid pressure which might otherwise resist relative movement between the tail shaft 26 and lock nut 30. An eight-start thread may be used, if desired, although it should be understood that helical threads having other numbers of start may be used as well.
The threaded surfaces 26a of the tail shaft 26 and 30a of the lock nut 30 engage so that the lock nut rotates in a clockwise direction (as indicated by an arrow 32 in FIG. 3) in response to inward movement of the piston 16. As will be set forth below, the lock L restrains rearward movement of the piston 16 until unlocked, at which time the threaded surfaces 26a and 30a cause the lock nut 30 to move in a reverse or counter-clockwise direction in response to outward movement of the piston 16. Suitable bearings are provided between the lock nut 30 and cylinder 17 to reduce friction during relative movement therebetween.
It is to be noted that the piston 16 and tail shaft 26 do not rotate with respect to the cylinder 17 or bonnet 12 during inward or outward movement. When the lock L is disengaged, the lock nut 30 rotates with respect to the tail shaft 26 in the manner set forth above. When engaged, the lock L restrains rearward movement of the piston 16.
A fluid conduit 36 is formed in the piston tail rod 26 to provide fluid communication between the space in the cylinder 17 rearward of the surface 16b on the piston 16 and the opening 28 in the cylinder head 18 so that operating fluid introduced through the fluid inlet 24a may pass into the opening 28 to assist in inward movement of the ram piston 16.
The lock L further includes a movable clutch plate 38 mounted with the lock nut 30 by means of splined surfaces therebetween (FIG. 3) or other suitable connecting means so that the movable clutch plate 38 moves along with the lock nut 30 with respect to the tail shaft 26 during inward and outward movement of the ram R.
The movable clutch plate 38 has a plurality of mounting sockets 39 formed therein on an opposite surface 38d (FIG. 3) from the ratchet teeth 38a for receipt of the load springs 40 or other suitable resilient means in the sockets 39 (FIG. 3). The loading springs 40 extend outwardly from the sockets 39 in the clutch plate 38 into engagement with the lock nut 30 (FIG. 2) and urge the movable clutch plate 38 rearwardly away from the lock nut 30, into engagement with a fixed clutch plate 42 of the lock L.
The movable clutch plate 38 has ratchet teeth 38a (FIG. 4) formed on a rear surface thereof which are selectively engageable, in a manner to be set forth, with opposing ratchet teeth 42a of the fixed clutch plate 42. The clutch plate 42 is fixedly mounted by face bolts 44 or other suitable means with the cylinder head 18. The clutch plate might, if desired, be integrally formed with the cylinder head 18.
Each of the ratchet teeth 38a on the movable clutch plate 38 has a sloping ramp surface 38b (FIG. 4) formed thereon which contacts a conforming sloping ramp surface 42b of corresponding teeth 42a on the fixed clutch plate 42. Each of the ratchet teeth 38a and 42a further has a planar stop surface 38c and 42c, respectively, formed between their adjacent ramp surfaces 38b and 42b.
The clutch plate 38 is mounted with the lock nut 30, as has been set forth, and the engaged sloping ramp surfaces 38b and 42b of the ratchet teeth permit the movable clutch plate 38 to move clockwise therewith, as indicated by an arrow 32a (FIG. 4) when the piston 16 is moving inwardly.
During the inward movement of the piston 16, closing fluid pressure is admitted from inlet 24a into cylinder 17 against surface 16b of the piston 16. The clutch plate 38 and lock nut 30 are automatically moved rearwardly by the closing fluid pressure in cylinder 17, bringing the movable clutch plate 38 into engagement with fixed clutch plate 42. In this manner, the ram R is locked against rearward movement, which might be caused by forces such as well bore pressures and the like, causing the lock L to be activated and locked.
The lock L is activated by engagement of the ratchet teeth 38a and 42a of the engaged clutch plates 38 and 42 along planar surfaces 38c and 42c. The ratchet teeth 38a and 42a are maintained in engagement by the closing fluid pressure in the cylinder 17, as well as by the force of the load springs 40. In the locking position of lock L, the movable clutch plate 38 moves, as indicated by arrow 32a (FIG. 4) with the lock nut 30 during inward movement of the piston 16. The resilient load springs 40, however, yield sufficiently to permit relative ratcheting movement between the ratchet teeth 38a of moving clutch plate 38 and the ratchet teeth 42a of the fixed clutch plate 42 as the piston 16 moves inwardly.
A fluid conduit 50 is formed in the piston 16 to communicate closing fluid pressure from the inlet 24b rearwardly through the tail shaft 26. A tube or stinger 52 is mounted in the conduit 50 within the tail shaft 26 and suitable seals are provided therebetween. The stinger 52 is mounted at an outer end thereof with the cylinder head 18, with suitable seals therebetween, by a mounting plate 54 or other suitable means.
A conduit 56, formed extending through the stinger 52, is in fluid communication at an L-joint 57 of stinger 52 with an unlocking fluid conduit 58 formed in the cylinder head 18. The unlocking conduit 58 conveys unlocking fluid pressure from the conduit 56 to an annular unlocking chamber 60 formed between cylinder head 18 and cylinder 17.
An annular unlocking piston 62 is mounted in the unlocking chamber 60 in contact with the movable clutch plate 38 outwardly of the ratchet teeth 38a thereon through a bearing 64. Suitable seals are provided between unlocking piston 62, cylinder 17 and cylinder head 18 to seal the unlocking chamber 60. The unlocking piston 62 moves from the locking position (FIG. 2) to the unlocking position (FIG. 2A) in response to abatement of locking or closing fluid pressure on inlet 24a and introduction of opening or unlocking fluid pressure in the cylinder 17 from inlet conduit 24b through the conduit 50, stinger 52 and conduit 58, which convey such pressure to the unlocking chamber 60.
As the piston 62 moves to the unlocking position, the force of springs 40 is overcome and movable clutch plate 38 is moved inwardly to a position (FIG. 2A) where a gap 66 is present and there is no engagement between the ratchet teeth 38a and 42a. With the ratchet teeth 38a and 42a out of engagement with each other, locking action between the lock nut 30 and body of the blowout preventer is removed, and the threaded surface 26a of the tail shaft 26 is permitted to pass rearwardly through the surface of the lock nut 30, with the lock nut 30 and clutch plate 38 rotating in the reverse direction to the arrow 32 (FIG. 3).
It should be understood that a lock L is provided for the left-hand ram R as viewed in FIG. 1 in the same manner as the lock L discussed above for the right-hand ram R in FIG. 2.
In the operation of the blowout preventer B with the lock L, when it is desired to move the ram R inwardly from the open position (FIG. 1) to the closed position (FIG. 2), operating fluid pressure is provided through the fluid inlet 24a to act on the ram piston 16 and move the ram R inwardly. The operating fluid introduced into the cylinder 17 from the inlet 24a concurrently acts to move the clutch plate 38 to a position where the ratchet teeth 38a engage the ratchet teeth 42a of fixed clutch plate 42. Engagement of the ratchet teeth 38a and 42a in the locking position occurs during initial stages of inward movement of the piston 16 from the open position, for reasons to be set forth. Locking fluid pressure further passes from the cylinder 17 into the socket 28 in the cylinder head 18 through the conduit 36 in the tail shaft 26 of the piston 16, to assist in causing inward movement of the piston 16.
With the ratchet teeth 38a of clutch plate 38 moved into the locking position (FIG. 2) with the ratchet teeth 42a of the clutch plate 42 from the outset of inward movement of the piston 16, contact is maintained between the ratchet ring teeth 38a and 42a by the springs 40. In this manner, during all stages of inward advance of the piston 16 with respect to the bore 10a of the preventer B, the lock nut 30 freely rides and rotates with respect to the piston tail shaft 26 permitting continuous inward advance of the ram R due to the relative movement of the sloped ratchet teeth 38b and 42b permitted by the springs 40.
However, at substantially all positions of the ram R with respect to the bore 10a during such inward movement, the flat surfaces 38c and 42c of the ratchet teeth 38a and 42a are engaged and locked against any rearward force on the piston 16, locking so that the ram R is locked and restrained against such rearward movement. In this manner, the lock L automatically locks the ram piston 16 and the ram R against rearward movement at any position during inward movement thereof. It is to be noted that this automatic locking of the lock L occurs in response to the same fluid pressure which moves the piston 16 inwardly, since the lock L is continuously engaged with the piston 16, and thus without the need for a separate and distinct locking fluid control system from that of the moving fluid system.
Further, once the ram R has reached an initial sealing position contacting a well pipe or other object in the bore 10a of the preventer B, it is possible to compensate for wear of the blowout preventer sealing elements, typically elastomer or other sealing material. Once the initial closed position has been reached with the ram block forcing the ram sealing elements into an initial seal with the object in the bore 10a, increased pressure is introduced through the fluid inlet 24a to act on the ram piston 16 and move the piston 16 and ram R further inwardly. The ram R is moved further inwardly in this manner with the ram block forcing the sealing elements thereof into closer engagement with the object in the bore 10a increasing the feed of the sealing elements into contact with the object to compensate for any wear or loss of the sealing elements until the desired degree of sealing contact between the object in the bore and the ram R is obtained. It is to be noted that with the threaded contact between the tail shaft 26 of the piston 16 and the lock nut 30 the adjustable locking position obtained with the lock L may be selectively varied over a wide range of positions to achieve the desired seal in contrast to a number of discrete and fixed positions. It is further to be noted that automatic mechanical locking of the lock L is maintained during movement of the ram R to the adjustable closed position.
Once the ram R is in the desired sealing position, the pressure of the operating fluid in the fluid inlet 24a may be abated and the ram R remains locked in the sealed position automatically by the lock L due to the locking engagement of the ratchet teeth 38a and 42a, forming a locking connection between the ram R and the remainder of the blowout preventer B.
When it becomes desirable or necessary to unlock the ram R from the adjustable closed position, suitable unlocking fluid pressure is provided through the fluid inlet 24b. The fluid pressure through the inlet 24b acts on the inner surface 16b of the piston 16 to move such piston and the ram R rearwardly with respect to the blowout preventer B. Further, the fluid pressure is concurrently supplied through conduits 50, 56 and 58, in the manner set forth, to the unlocking chamber 60, moving the piston 62 into engagement with the movable clutch plate 38 and causing the ratchet teeth 38a and 42a to move out of engagement, unlocking the lock L in order to permit rearward movement of the piston 16.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof and various changes in the size, shape and materials as well as in the description of the preferred embodiment may be made without departing from the spirit of the invention. | A new and improved ram lock for blowout preventer rams which permits locking of the ram at multiple and adjustable positions to compensate for wear on sealing elements of blowout preventer rams and increase sealing action of the ram without requiring separate special control lines. Automatic locking of the ram at a desired position, such as in adjustable sealing positions to compensate for ram elastomer wear, is obtained. |
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REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a continuation-in-part of, and hereby claims priority to, U.S. Non-Provisional application Ser. No. 12/660,694, filed Mar. 2, 2010 entitled “Three Dimensional Connection System For Bed Frame”, which in turn, claims priority from U.S. Provisional Application Ser. No. 61/165,493 filed Mar. 31, 2009. The present application also hereby claims priority to U.S. Provisional Application Ser. No. 61/339,226, filed Mar. 2, 2010 entitled “Bed Frame Having Protective Plastic Coating”. Applicants claim the benefits of 35 U.S.C. §120 as to said Non-Provisional Application, and the benefits of 35 U.S.C. §119 as to said Provisional Applications, and the entire disclosures of all applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a bed frame for supporting a mattress or mattress set and, more particularly, to a bed frame that has a protective plastic casing that covers the structural components of the bed frame.
BACKGROUND OF THE INVENTION
[0003] There are currently in use conventional bed frame assemblies that are used for supporting a mattress or mattress set and such bed frame assemblies are normally made up of two side rails and at least one cross member. The bed frame supports the load of a mattress set by means of multiple support legs.
[0004] With many bed frames, the side rails and cross members are made of a metal, generally iron or steel, and the overall frame therefore has multiple sharp edges for the metal components. Further, the use of metal makes the bed frame a difficult platform on which the box spring and mattress are slid in assembling a bed. The metal material for bed frames is not particularly lubricious and therefore hampers the sliding of a box spring over the assembled frame and there is the possibility that one of the sharp edges of the bed frame will cause a tear in the box spring or mattress material.
[0005] Accordingly, it would be advantageous to provide a covering for a bed frame that is both protective of sharp edges as well as facilitate the sliding of a box spring over the bed frame in the assembly of a completed bed.
SUMMARY OF THE INVENTION
[0006] A feature of the present bed frame is that the metal frame is encased in plastic, thereby allowing the box spring and mattress to easily slide in place on top of the frame without contact with the metal, that is, along some portion or all of the length of a side rail or cross rail, the rail is totally surrounded by a plastic shield. The side rails and the cross rails are encased in a plastic shield and there are plastic injection molded end caps. With the present invention, therefore, the side and/or cross rail for a bed frame can be encased with plastic shields at the point of manufacture such that the rails are shipped with the plastic shields assembled thereto. As such, each step of the assembly of the bed frame using a plastic shielded component can have the advantage of the present invention since that assembly does not need to deal with hard steel components.
[0007] In an exemplary embodiment, the side rails are made from one or more rail steel angle iron pieces, however any structural metal beam can be used with the present invention including rolled tubing and folded strips. The plastic is a more lubricious surface than the steel and therefore the task is made simpler requiring less exertion and stress. Secondly, the plastic is not abrasive to the fabric of the bedding and so the material is protected from damage or wear. Thirdly, the plastic serves to make the frame quiet by inhibiting any metal on metal squeaking. The staples or tacks in the box spring can make sound on a metal bed frame. The plastic forms an entirely flat platform for supporting the bedding. In an exemplary embodiment, there may be grooves formed on the surface of the plastic that serve to further deaden any sounds and inhibit vibration.
[0008] In an exemplary embodiment, the bed frame has a double angle iron side rail encased in a plastic extrusion. This side rail is more rigid because it has a tall vertical proportion. The plastic serves to dress the frame and make it more like traditional finished furniture as well as to make the steel more comfortable and safer to handle because it is softer and has few edges.
[0009] The cross rails are preferred to also be made of two piece of angle iron covered by a plastic extrusion. This allows the cross rail to also present the appearance of a finished part. The ends of the cross rails are capped with an injection molded end caps. All metal rails, both assembled and unassembled, are encased by plastic. The plastic shield could be manufacture in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the shield. Ribs are utilized on the inside of the extrusion to support the shaping and hold the internal metal structure in place. These ribs can take a number of different configurations. The preferred rib configuration is to have two ribs hanging straight down from the curved surface to contact the metal structure. These would be positioned only about a 0.25 inch inboard of the outer edges of the metal. In this way, the ribs will not fall off the edge but are also as short as possible. This will help with the thickness and consistency during manufacture.
[0010] In a further embodiment, the side rail of the bed frame is constructed of a single L shaped angle iron completely encased in plastic. The vertical flange of the angle iron extends upwardly to form a ridge to retain the bedding from side to side movement. The plastic extends downward below the horizontal portion of the angle. In this way, the side rail has a larger visual impact on the appearance of the bedding. Also this serves the function of covering the cut end of the cross rails at the point they connect to the side rails.
[0011] In addition the plastic overhang allows for the addition of lighting where the wiring and the fixtures are shielded from view. This light serves as a safety feature but also makes the bed more visually exciting. The plastic shield could be manufactured in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the encasement. Ribs are required on the inside of the extrusion to support this shaping and hold the internal metal structure in place. These ribs can be provided in a number of different configurations.
[0012] In a further embodiment, the side rail of the bed frame is constructed of a single L shaped angle iron completely encased in plastic with the vertical flange of the angle iron extending downwardly such that the leg of the angle perpendicular to the floor is positioned below the bottom surface of the bedding. In this case, the plastic is extended above the vertical member of the angle iron to form a ridge that retains the bedding against side to side movement. In this way, the side rail has a larger visual impact on the appearance of the bedding.
[0013] Also the rail downward turned flange of the angle iron serves the function of covering the cut end of the cross rails at the point they connect to the side rails. In addition the plastic overhang allows for the addition of lighting where the wiring and the fixtures are shielded from view. As such, the geometry of the rail that allow for the rails rigidity is all below the bedding.
[0014] The upstanding rigid portion can be much abbreviated in height because it is only a retainer. This is critical when the box spring has pull out storage drawers that can be blocked by tall side rails. The plastic shield could be manufactured in many ways including injection molding, insert injection mold, and coating. A preferred method of manufacture is to extrude the encasement. The upstanding ridge of plastic could take many forms. The preferred embodiment would be a hollow loop within extending from the main body of the plastic shield. Within the upstanding loop there is a ribbed reinforcement to provide strength to the otherwise unsupported member.
[0015] As a still further exemplary embodiment, since the plastic shields are affixed to the bed frame component at the manufacturers location, the manufacturer can provide the bed shields in a variety of standard or custom colors so that the ultimate user may have a bed frame components that are of a particular color to match the room or to identify the component as applicable for a particular size or type of bed frame. Thus, the manufacturer can use a customer-selected color of plastic shield and that specific color bed frame components can be boxed up and shipped to the customer with the desired color.
[0016] These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an exploded view illustrating a cross rail bed frame member having a protective plastic end cap;
[0018] FIG. 2 is an exploded view illustrating a side rail bed frame member having a protective plastic end cap;
[0019] FIG. 3 is a cross sectional view of a side rail encased in plastic made with two angle irons;
[0020] FIG. 4 is a cross sectional view of a cross rail encased in plastic made with two angle irons;
[0021] FIGS. 5 and 5A are a cross sectional view and an enlarged cross sectional view of a side rail having a plastic shield with surface grooves;
[0022] FIGS. 6 and 6A are a cross sectional view and an enlarged cross sectional view of a cross rail having a plastic shield with surface grooves;
[0023] FIG. 7 is a schematic view illustrating a mattress/foundation sliding on an entirely plastic encased bed frame;
[0024] FIG. 8 is a cross sectional view of a side rail made with an angle iron encased in plastic having one upturned flange with a plastic shield blocking the end of a cross rail;
[0025] FIG. 9 is a perspective view illustrating the visual difference between a raw angle iron and the plastic encasement covering the angle iron;
[0026] FIG. 10 is a cross sectional view of a side rail of FIG. 8 with a lighting strip concealed behind the plastic shield;
[0027] FIG. 11 is a perspective view illustrating bed frame and mattress with the concealed light of FIG. 10 ;
[0028] FIG. 12 is a cross sectional view of a side rail made with an angle iron encased in plastic having one downturned flange with a plastic shield blocking the end of a cross rail with a plastic lip for retaining the bedding;
[0029] FIG. 13 is a cross sectional view of a side rail of FIG. 12 with a lighting strip concealed behind the downturned flange of the angle iron;
[0030] FIG. 14 is a cross sectional view of a side rail of FIG. 12 having standing ribs to support the outer portion of the plastic shield; and
[0031] FIG. 15 is a cross sectional view of a side rail of FIG. 12 having a different configuration of outer portion of the plastic shield than the embodiment of FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] Turning to FIG. 1 , there is shown an exploded view illustrating a bed frame cross rail 10 having a protective plastic end cap 12 that fits over the end of the cross rail 10 to cover the sharp edges that are present at the ends of the cross rail 10 . As can be seen, the cross rail 10 is comprised of two angle irons 14 , 16 secured together by means such a rivets 18 to form a T-shape. As is well known, the ends of such cross rails result in sharp edges of the angle irons 14 , 16 that can be hazardous to a person striking a sharp edge. The end cap 12 is also therefore a T-shape and fits over the ends of the cross rails 10 and may include an enlarged pocket 20 to enable the end cap 12 to slip over a rivet where necessary. Although only one end cap 12 is illustrated, both ends of the cross rails 10 may be protected by an end cap 12 .
[0033] Next, in FIG. 2 , there is an exploded view of a side rail 22 and a plastic end cap 24 that fits over the end of the side rail 22 . In this embodiment, again, there are two angle irons 26 , 28 that are secured together forming a combined vertical flange 30 and an overlapping inwardly directed horizontal flange 32 . There is also a plastic shield 34 that covers the external surface of the vertical flange 30 and abuts against the end cap 24 when the end cap 24 is slid onto the end of the side rail 22 , thereby fully covering the exterior surface of the vertical flange 30 . A fastener 36 can be used to secure the end cap 24 to the side rail 22 by passing though the end cap 24 and a hole 38 in the side rail 22 . The exterior surface 40 of the end cap 24 can be designed to be of the same curvature as the exterior surface 42 of the plastic shield 34 so that the two components meet in a smooth junction.
[0034] Turning next to FIG. 3 , there is shown a cross sectional view of a side rail 44 that, again, is constructed of two angle irons 46 , 48 secured together. As can be seen, the combined angle irons 46 , 48 forms an overlapping horizontal flange 50 and a combined adding vertical flange 52 that is twice the length of a vertical flange of the angle irons 46 , 48 . A plastic shield 54 fully surrounds the cross section of the side rail 44 such that the metal side rail 44 is completely covered and thus the cold steel or other metal is easier to handle and is more esthetically pleasing.
[0035] In the orientation of FIG. 3 , the plastic shield 54 has an exterior portion 56 that is held away or displaced from the vertical flange 52 by means of ribs 58 , 60 and which can be molded into the plastic shield 54 . Since the plastic shield 54 is, in the embodiment of FIG. 3 , unbroken, it can be slid along the longitudinal length of the side rail 44 in order to install the plastic shield 54 to the side rail 44 .
[0036] Turning next to FIG. 4 , there is a cross sectional view of a cross rail 62 that is, again, made up of two angle irons 64 , 66 that are secured together. In this embodiment, since the bed frame component is a cross rail, the cross rail 62 is oriented such that the upper, horizontal flange 68 is twice the length of a single flange of either of the angle irons 64 , 66 and the vertical flange 70 overlaps the flanges of the angle irons 64 , 66 . Again, however, there is a plastic shield 72 that surrounds the entire cross section of the cross rail 62 so as to fully cover the metal angle irons 64 , 66 .
[0037] It should be noted, that while the description of a cross rail or side rail component making up a bed frame may be described as being comprised of two angle irons secured together, the present invention is equally applicable to a side rail or cross rail being provided as a single, unitary construction.
[0038] In FIGS. 5 and 5A , there is cross sectional view of a side rail and an enlarged cross section of a side rail 44 with the plastic shield 54 as shown in the embodiment of FIG. 3 , however, the external surface 74 of the exterior portion 56 is curved outwardly and has surface grooves 76 formed thereon. The surface grooves 76 serve to further deaden any sounds and inhibit vibration. In addition, since the plastic shields may be extruded and have a shiny exterior finish, the use of the surface grooves 76 creates a finish that is less susceptible to marring or surface damage.
[0039] In FIGS. 6 and 6A , there is cross sectional view of the cross rail 62 and an enlarged cross section of the cross rail 62 with the plastic shield 72 as shown in the embodiment of FIG. 4 , however, the external surface 78 of the upper portion 80 of the plastic shield has surface grooves 82 formed thereon.
[0040] Next in FIG. 7 , there is a schematic view of a box spring 84 being slid onto a bed frame 86 . As can be seen, the box spring 84 slides in the direction of the arrow A along the side rails 88 . In accordance with the present invention, the side rails 88 are fully covered by a plastic shield 90 , including end caps 92 such that the box spring 84 can slide easily and in a more lubricious manner than if the box spring 84 were sliding along raw steel side rails. The protective plastic end caps 92 prevent the otherwise sharp edges of the side rails 88 from cutting into the box spring and the smooth sliding action along the plastic shields 90 of the side rails 88 also minimizes damage to the box spring.
[0041] Turning to FIG. 8 , there is shown a cross sectional view of a side rail 94 that is an L-shaped configuration, such as an angle iron, with a horizontal flange 96 positioned to underlie a box spring (not shown) and a vertical flange 98 extending upwardly from the horizontal flange 96 and adapted to be positioned proximate to, and run along, the outside edge of a box spring. Again, there is a plastic shield 100 that fully encases the side rail 94 so as to enclose the side rail 94 entirely. FIG. 8 also shows a cross rail 102 of a bed frame and, as can be seen, there is a downwardly directed portion 104 of the plastic shield 100 that extends below the horizontal flange 96 and which covers the outer end 106 of the cross rail 102 to provide protection again a person inadvertently encountering that outer end 106 and being injured.
[0042] As such, the plastic shield 100 not only encases the side rail 94 for protection to make the side rail 94 easier to handle and maneuver, but when the side rail 94 is assembled in constructing a bed frame, the same plastic shield 100 affords protection for persons by covering the outer end 106 of a cross rail 102 .
[0043] In the embodiment of FIG. 8 , there can also be seen a rib 108 that contacts the vertical flange 98 to position the exterior portion 110 of the plastic shield 100 outwardly from the vertical flange 98 and also a reinforcing rib 112 that adds strength and rigidity to the downwardly directed portion 104 .
[0044] Turning then to FIG. 9 , then is shown a perspective view of the side rail 94 of FIG. 8 with a portion of the plastic shield 100 removed so that a distinction can be seen between the easily handled and protected portion of the side rail 94 protected by the plastic shield 100 and the bare portion of the side rail 94 where there is no such protection.
[0045] Turning to FIG. 10 , there is a cross sectional view of a further exemplary embodiment of the side rail 94 of FIG. 8 . In FIG. 10 , a light 114 , such as a fluorescent light, is located underneath the horizontal flange 96 and thus is underneath the box spring and mattress and is located interior of the downwardly directed portion 104 and is therefore in a protective location where the light 114 cannot be easily kicked or otherwise struck by a person or objects nearing the bed frame.
[0046] In FIG. 11 , taken along with FIG. 10 , there is a perspective view of a box spring 116 and showing the side rail 94 having a plastic shield 100 and illustrating the effect of the indirect lighting where the light rays 118 are directed downwardly and inwardly by the downwardly directed portion 104 of the plastic shield 100 thereby creating a desirable lighting effect.
[0047] Turning next to FIG. 12 , there is shown a cross sectional view of an alternative embodiment of a side rail 120 that is an L-shaped configuration, such as an angle iron, with a horizontal flange 122 positioned to underlie a box spring 124 and a vertical flange 126 extending downwardly from the horizontal flange 122 , that is, the vertical flange 126 extends beneath the box spring 124 and is adapted to be positioned proximate to, and run along, the outside edge of the box spring 124 .
[0048] Again, there is a plastic shield 128 that fully encases the side rail 120 so as to enclose the side rail 120 entirely. FIG. 12 also shows a cross rail 130 of a bed frame and, as can be seen, there is a upwardly directed portion 132 of the plastic shield 128 that extends above the horizontal flange 122 and which is located proximate to the box spring 124 and prevents the box spring 124 from movement in a lateral direction.
[0049] As such, the plastic shield 128 not only encases the side rail 120 for protection to make the side rail 120 easier to handle and maneuver, but when the side rail 120 is assembled in constructing a bed frame, the same plastic shield 128 affords stability against lateral movement of the box spring 124 as well as protection against persons contacting the sharp outer end 134 of the cross rail 130 .
[0050] In the embodiment of FIG. 12 , there can also be seen a rib 136 that contacts the vertical flange 126 to position the exterior portion 138 of the plastic shield 128 outwardly of the vertical flange 126 and also a reinforcing rib 140 that adds strength and rigidity to the upwardly directed portion 132 .
[0051] Turning then to FIG. 13 , there is shown a cross sectional view of the side rail 120 of FIG. 12 further including a light 142 that can be positioned beneath the horizontal flange 122 and behind the vertical flange 126 so as to protect the light 142 from damage by persons or objects striking the light 142 .
[0052] In FIG. 14 , there is a side rail 120 that is constructed the same as in the FIG. 12 embodiment, that is, the side rail 120 is an L-shaped configuration, such as an angle iron, with the horizontal flange 122 positioned to underlie a box spring and the vertical flange 126 extending downwardly from the horizontal flange 122 .
[0053] With the FIG. 14 embodiment, however the plastic shield 144 is of a slightly different configuration, that is, the upwardly directed portion 146 is more circular in appearance and the exterior portion 148 of the plastic shield 144 is concave inwardly in design and there are two ribs 148 that extend inwardly from the exterior portion 148 and contact the vertical flange 126 to add strength and rigidity to the plastic shield 144 .
[0054] Finally, in FIG. 15 , there is a further embodiment wherein the plastic shield 152 has an outer portion 154 with a lower section 156 that is generally parallel to the vertical flange 126 with an upper section 158 that curves inwardly toward the vertical flange 126 , such that an upper rib 160 is shorter that a lower rib 162 .
[0055] While the present invention has been set forth in terms of a specific embodiment of embodiments, it will be understood that the present plastic shielding system for a bed frame herein disclosed may be modified or altered by those skilled in the art to other configurations. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims appended hereto. | A bed frame wherein the side rail and/or cross rails are fully encased in plastic shields. A plastic shield or shields cover the entire cross sectional area of the side and cross rails so that the side rail and cross rails are easy to handle and esthetically pleasing. The system avoids the need for a person to handle cold, sometimes dirty, steel and the cross and side rails may be T-shaped or L-shaped angle irons, or other configurations and covered with plastic shields. With the plastic shields, the steel members need not be finished since the outer appearance of the steel is encased by the plastic shields and not seen by persons. |
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This application is a continuation of application Ser. No. 12/975,758, filed Dec. 22, 2010, which issued as U.S. Pat. No. 8,813,841.
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 dose-up in FIG. IB. 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, a-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 4 I, which is created by the bottom of solenoid valve base 30 , inflow housing 40 , and piston 42 . Check valve 35 prevents flow of fluid from head space 4 I through the check valve to the side opening.
Passageway 36 connects head space 4 I with solenoid valve 32 . When solenoid valve actuator 3 I (see FIG. 1A ) is energized, the solenoid valve 32 opens, allowing fluid to flow from head space 4 I 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 4 I 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 5 I 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 4 I 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 seal 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 pulse 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 sub 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-sub 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 space 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 54 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 215 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 pressure pulse 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 space 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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BACKGROUND
The present invention relates to keyed locks. More particularly, it concerns locks wherein the key can neither be turned nor removed with the lock open, thus providing an extra measure of protection against accidental lockout.
SUMMARY OF THE INVENTION
The present invention is directed to a lock body which is formed from two identical molded sections having a number of integrally formed features. These features facilitate assembly of the lock and also help hold the lock's moving parts in place. Each section is formed from a plastic material, resulting in a strong, light weight device. Among the features belonging to each section are a recessed area on which labels can be placed, projections and holes for aligning two sections during assembly and a number of upstanding support structures, depressions and other formations for immobilizing, supporting and orienting the various moving parts. The lock body is also provided with a restricted key hole to resist tampering.
In a lock of the present invention, a lock shackle is provided with a first notch on the inside of its long leg, a neck near the end of the long leg, and a recessed inner surface between the notch and the neck. The neck is formed by a circumferential indentation which is shallower than the notch.
When the shackle is in the locked position, a lock bearing engages the notch and is held in place by a retaining member which is turned by the key. Thus, the lock bearing prevents the shackle from being retracted. Turning the key moves the retaining member, allowing the lock bearing to move out of the notch. With the lock bearing no longer held in place by the retaining member, an upward force on the shackle allows the shackle to be retracted, thus opening the lock.
With the shackle retracted, the lock bearing formerly engaging the notch on the shackle's long leg prevents the key from turning. This is because the lock bearing partially obstructs, and thus prevents, the retaining member from moving as the key is turned. When the short leg of the shackle is reinserted, the lock bearing reenters the notch of shackle's long leg and no longer prevents the retaining member from rotating as the key is turned.
An additional notch may be formed on the inside of the shackle's short leg, across from the first notch. In such case, a second lock bearing is used to engage the second notch, thus providing added strength to the lock's shackle retaining mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood through the following figures in which:
FIG. 1 is a perspective view of the lock shown in the locked position;
FIG. 2 is a perspective view of the interior of one section from which the lock body is formed;
FIG. 3 is a top view of the movable parts shown in the locked position;
FIG. 4 is a top view of the movable part shown in the unlocked position;
FIG. 5 is a view of the extension;
FIG. 6 is a view of the lock cylinder; and
FIG. 7 is a view of the lock shackle.
FIG. 8 shows a detailed view of a groove member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The lock 200 of the present invention has a lock body 10 which preferably is formed from a light weight plastic resin having good impact and chemical resistance. Plastic resins are both lighter and less expensive than steel. They are also well suited for prolonged use in hostile weather environments and can withstand large temperature variations. Furthermore, unlike most metals from which lock bodies are typically formed, plastic resins are nonconductive.
In the preferred embodiment, the lock body 10 is formed from XENOY™ made by General Electric, Co. This material has been selected for its strength, impact and chemical resistance and its low density. Other plastics may also be used for a lock body in accordance with the present invention.
The exterior of the lock body 10 is provided with a slightly recessed rectangular area 12. This area is suitable for placing a label or sticker carrying identifying information, instructions, and the like. The recessed area could, instead, be circular, triangular or square. Virtually any two-dimensional shape will suffice.
The lock body is further provided with a butterfly-shaped key hole 14 on its bottom face 16. The key hole is provided with a first and a second pair of abutments 18, 20 built into the lock body 10. These abutments, or key stops, restrict the rotation of the key. In the preferred embodiment, the key can only be rotated about 90° between the locked and unlocked positions until the haft of the key abuts one or the other pair of key stops 18, 20.
The lock body 10 is approximately 1/8 thick at its bottom where the key hole 14 is situated. This means that the entrance to the lock cylinder 22 is recessed by at least this distance with respect to the bottom face 16 of the lock body 10. The recessed, contoured key hole 14 provides an added measure of protection against picking and tampering with the lock.
Within the lock body is a lock cavity in which the lock's moving parts are housed. The moving parts include the lock cylinder 22, the lock shackle 24, spherical lock bearings 26, 28 and an extension member 30. The moving parts are held in place by the contoured inner surface 38 of the lock body 10.
The lock body 10 is formed from two identical halves, or sections 34, 36 formed from the aforementioned XENOY™ alloy. Each section is a single molded piece having a longitudinal axis A dividing the section into a left side and a right side, an inner surface 38 and an outer surface 40. The inner surface 38 is surrounded by a pair of side walls 42 and 44 and also a top 46 and a bottom wall 48.
The inner surface 38 comprises a number of integrally formed features. These features facilitate assembly of the lock, help in joining one section to another, and/or hold the moving members in place once the lock is assembled. Using two identical sections simplifies manufacturing as items of only one kind need be manufactured and kept on hand for assembly.
Each section is provided with integrally formed locator posts 50, 52 and receiving holes 54, 56. The posts on one section mate with holes on an opposing section. The posts and holes help align the two sections during assembly. The first 50 of the two locator posts is formed on the edge 58 of the section's top wall 46, about midway between the longitudinal axis A and the side wall 42. The first locator post 50 mates with a first hole (on an opposing section) which is situated on the edge 58, about midway between the longitudinal axis A and the other side wall 44 of the section. The second locator post 52 is situated near the bottom wall 48 of the section close to the side wall 42 and mates with a complementary receiving hole 56 near the bottom wall 48 close to an opposing sections' other side wall 44.
Two pairs of tongue-and-groove members are also formed in each section to aid in the assembly of the lock body. The tongue-and-groove members also serve as energy directors when the two sections are ultrasonically welded together.
The groove member 60 of the first of these pairs is L-shaped, with one leg 62 extending along a one side edge 64 of the lock section and a second leg 66 running along one side of the bottom edge 68. This groove's complementary tongue member 70 has a first leg 72 which extends along the other side edge 74 and a second leg 76 extending along the other side of the bottom edge 68.
The second pair of tongue-and-groove members is found in a central area of the top edge 58. In this second pair, the groove 78 extends from the middle of the top edge 58 part way in the direction of the side edge 64. The tongue member 80 similarly extends from the middle of the top edge 58 part way towards the other side edge 74. Thus, tongue-and-groove members are present on all four edges of the section.
As shown in FIG. 8, each of the groove members has a pair of groove side walls 82, 84 and a base portion 86. The base portions of the groove members are provided with serrations 88. Preferably, the lock body is formed by ultrasonically welding together two opposing sections. During this process, the tongue members and the groove members fuse together as at least a portion of the tongue members melt. The serrations in the groove members accommodate plastic resin when it softens and flows during welding operations. The serrations can, alternatively, accommodate excess adhesive, when used either in place of, or to supplement, the ultrasonic welding.
It should be noted that in the preferred embodiment, the posts 50, 52 which help align the two sections during assembly, are taller than the tongue members 70, 80, which aid in sealing the lock body.
Each section is provided with two spaced apart semi-circular shackle cutouts 90, 92 at its top edge 58, proximate to the side edges. These cutouts are symmetrically disposed about the longitudinal axis A of the section. In an assembled lock body, opposing pairs of cutouts form shackle opening which are occupied by the legs of the "J"-shaped lock shackle 24 when the shackle is in the locked position. As shown in FIG. 2, the shackle cutouts in the section 34 border the tongue-and-groove members situated on the top edge 58.
Each section is also provided with a central cutout 94 on its bottom edge. The central cutout forms one-half of the butterfly-shaped key hole 14. When the lock is assembled, one central cutout is mated with its reversed image on an opposing section to form a single butterfly-shaped key hole 14 having the aforementioned pair of key stops.
The inner surface of each section is formed with a number of upstanding support structures 96 which help support, immobilize and orient various lock components. Included among these structures are two rows of small support ribs 98, each row aligned with one of the semi-circular shackle cutouts 90, 92 formed on the top edge. Each row runs parallel to adjacent side edges of the section and is shaped to receive one leg of the lock shackle. The second locator post 52 is situated at the end of one of the two rows, away from the semi-circular shackle cutout. This locator post 52 serves as a stop for the long leg 132 of the lock shackle 24, ensuring that the latter does not descend too far into the lock body 10.
Each section is also provided with a single central row of large support ribs 100. The row of large support ribs runs from the bottom edge of the section interior near the central cutout for the key hole 14, to about two-thirds of the way up. The central row of large support ribs 100 is shaped and sized to accommodate the lock cylinder 22. The cylinder rests on this row and against the inside surface of the central cutout. A pair of housing stops 102 integrally formed with the section prevents the cylinder body from shifting upwards.
Also formed integrally with each section, is a concave formation 104 arranged to receive and hold in place a cylindrical extension to the lock cylinder. As shown in FIG. 2, the concave formation is in the form of a first channel extending along a portion of the longitudinal axis A. It extends from the abutments 110, 112 formed on the inner surface 38 to the upper wall 46 of the section 34.
On either side of the curved formation are two shallow bowl-shaped depressions 106, 108, also situated above the roof member in the upper portion of the section interior. These depressions are formed from a second channel which is arranged transversely with respect to the first channel and cuts across the longitudinal axis A. These depressions are sized to accommodate the lock bearings 26, 28 which engage the notches in the lock shackle. With the lock assembled and in the locked position, the lock bearings are held in support areas between opposing pairs of depressions, bounded on one side by the extension 30, and on the other by the lock shackle 34, as shown in FIG. 3.
A further feature of each section is a pair of L-shaped welding abutments 110, 112 just below each bowl-shaped depression. The welding abutments are taller than any of the rows of support ribs. However, the welding abutments do not extend as far up from the section as do either the tongue members or the locator posts. The welding abutments are positioned in a central area of the section, away from the section's edges and thus, the tongue-and-groove members. The welding abutments abut one another when the two sections are brought together and the tongue-and-groove members are fused during ultrasonic welding operations. Thus, the welding abutments prevent the two sections from being forced too close to one another and interfering with normal locking and unlocking operations. In effect, the welding abutments serve to keep opposing ribs separated by a minimum predetermined distance.
FIG. 3 shows the moving parts of the lock in a section as they appear when the lock is locked. As shown in FIG. 6, the lock cylinder has a shell 114 having an integrally formed pin housing 116. The cylinder also has plug 118 which has a keyway 120 at one end for receiving a key. At least a portion of the plug is housed within the shell 114. At the other end of the plug, away from the keyway, is an integrally formed plug projection 122. The plug and plug projection turn with the key.
Shown above the cylinder in FIG. 3 is an extension 30 which lays in the formation between the two depressions 106, 108. In an assembled lock, the extension 30 is positioned in an extension cavity formed by opposing formations. As shown in FIG. 5, the extension 30 is substantially cylindrical and is formed with an extension projection 124 at one end. The extension projection complements the plug projection 122 formed on the cylinder plug 118. When a key turns the cylinder plug, the plug and plug projection rotate along the longitudinal axis A. During this motion, the plug projection abuts and then turns the extension 30.
As is known to those skilled in the art, the complementary abutting projections on the plug and extension can be replaced, for instance, by complementary male and female members formed on these components. The plug and extension could, instead, be formed as a single piece which performs the functions of both. Alternatively, they could comprise a number of operatively engaged elements which collectively perform these same functions.
The extension is also formed with a pair of arc-shaped undercuts 126, 128 on its cylindrical side wall 130. The undercuts are preferably sized and shaped so as conform to the lock bearings 26, 28. With the lock in the locked position, the undercuts are at right angles to the lock bearings. In this position, one side of each lock bearing occupies a shackle notch 136, 138 while the other side is held in place by the cylindrical wall 130 of the extension. With the lock bearings held in this position, the shackle 24, cannot be retracted.
The shackle is formed with a long leg 132 and a short leg 134. In the preferred embodiment, each leg is provided with a notch 136, 138 formed on the inner leg's surface. The curve of each notch 136, 138 is similar to the curve of the extension's undercuts 126, 128. Near its end, the shackle's long leg 132 is also provided with a radially symmetric neck portion 140 having a circumferential indent. Extending between the notch and the neck on the long leg is a recessed, flat area 142 on the long leg's inner surface. This area is recessed relative to the cylindrical contour of the long leg 132. The long leg's notch 136, however, is deeper than either the recessed flat area 142 or the neck's 140 circumferential indent.
The lock bearings 26, 28 are spherical metallic balls, which also could be plastic or ceramic, sized to fit the contour of the extension's undercuts as well as the shackle's notches. With the shackle 24 in the locked position, the bearings are held between the shackle notches and the cylindrical wall 130 of the extension 30. With the shackle retracted, the lock bearings remain close to the aforementioned depressions in the section, but are able to move around somewhat.
To unlock the lock, the key is inserted into the plug 118 of the cylinder 22 through the restricted key hole 14. Once the notches of key match with the corresponding tumbler pins in the cylinder, the proper shear line between the plug 118 and shell 114 of the cylinder is achieved. This allows the key, cylinder plug 118 and extension 30 to rotate to key stops 20. Preferably the key is rotated about 90° to effect the unlocking.
When the key is turned to unlock the lock, the plug 118 and the extension 30 also make a quarter turn. This causes the undercuts 126, 128 to become aligned with the lock bearings. When the extension and undercuts are in this position and a force is applied to retract the shackle out of the lock body, the lock bearings 26, 28 are cammed out of the notches 136, 138 of the shackle 24 and engage the undercuts of the extension. This allows clear passage of the short leg 134 from the lock body. Once unlocked as shown in FIG. 4, the shackle can be rotated 360° about the shackle's long leg, which is still retained in the lock body 10.
With the shackle 24 retracted, the lock bearing 26 abuts either the recessed area 142 or the neck 140 of the long leg. As these two features are not as deep as the notch 136, the lock bearing 26 at least partially enters the undercut 128. If one were now to turn the key, the lock bearing 26 would become wedged between an inner wall of the undercut 128 and the flat surface 142 of the long leg 132 of the shackle. This prevents the key from being turned.
To lock the lock, the short leg 134 of the shackle 24 must be inserted into the lock body. This allows the lock bearing 26 to enter the long leg's notch so that it no longer occupies the undercut 128. Under these conditions, the extension 30, and thus, the key, may be turned without interference from the lock bearing 26.
While it is preferable to have notches on both shackle legs, the notch 138 on the short leg 134 is not absolutely critical to practice the invention. One may eliminate the notch 138 on the short leg, its corresponding lock bearing 28 and corresponding undercut 126 on the extension 30. Then, only the long leg 132 will have a notch 136 and there will be a single lock bearing 26 and a single undercut 128 formed in the extension. And, as stated above, the extension could be integrally formed with the cylinder plug, reducing the number of moving components.
Assembly of a lock is fairly straightforward. A first section 36 is laid on a flat surface, the section's inner surface facing 38 up. The shackle 24, lock cylinder 22 and extension 30 are then placed on those interior features shaped to accommodate them, the shackle being in the inserted position. With the shackle inserted, the cylinder 22 can only be placed in one way, the pin housing 116 being situated under the short leg 134 of the shackle 24, as shown in FIG. 3. Next, the lock bearings 26, 28 are placed between the extension 30 and the shackle notches 136, 138. Then, a second section 34 is laid over the moving parts and aligned with the first section 36. The two sections are then ultrasonically welded, forming the lock 200. This assembly process contrasts with prior art techniques in which one takes a lock body already having a shackle and lock cylinder in place, drilling holes into the body, placing lock bearings or the like in predetermined locations, and then sealing the drilled holes.
While there has been described what is at present considered to be a preferred embodiment of this invention, it will be clear to those skilled in art that various changes and modifications may be made without departing from the invention which is intended to cover all such changes and modifications as fall within the true spirit and scope of the claims set forth hereunder. | A lock in which a key can neither be turned nor removed with the lock is open, is disclosed. The lock body is formed from two identical sections, the inner surface of each being provided with formations which accommodate the moving parts of the lock. The lock cylinder is provided with a plug which is operatively engaged to an extension. The lock shackle is engaged by a lock bearing which is held in place by the extension. Turning the key turns the plug and thus, the extension. This disengages the lock shackle as the lock bearing is no longer held in place. After it has been retracted, the contour of the lock shackle abuts the lock bearing, causing it to engage the extension, thus preventing the extension, the plug and the key from being turned. |
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FIELD OF THE INVENTION
This invention relates generally to track hoes and like machinery, and, in particular, to systems and methods for transporting bulk amounts of material using such machinery.
BACKGROUND OF THE INVENTION
Track hoes and like machinery are often used for digging through hard soil, pavement, and the like. As a result, shovels are sized such that the hydraulics powering the shovel can apply sufficient force to drive a relatively small shovel through the soil or pavement. The articulated arm and hydraulics of the arm are therefore capable of carrying much more material than can be lifted with the shovel. In use, great inefficiencies arise as a shovel sized for penetrating soil is used to transport soil, broken pavement, and other materials into a container such as a dump truck or dumpster. The steps of scooping, lifting, and dumping the undersized shovel must be repeated an excessive number of times in order to load materials broken up by the shovel.
It would therefore be an advancement in the art to provide a system and method for loading, lifting, and dumping large amounts of loose material using a track hoe that took greater advantage of the power and capability of the articulated arm and associated hydraulics of the track hoe.
SUMMARY OF THE INVENTION
A hopper enabling a track hoe to scoop, transport, and unload large volumes of materials is disclosed. The hopper includes a tray defining a full-tray center of gravity. A lift handle and a dump handle are secured to the tray. The lift handle is connected to the tray closer to the full-tray center of gravity than the dump handle, with the full-tray center of gravity between the point of securement of the lift handle and the dump handle. The lift handle pivotally mounts to the tray and includes a cross bar extending transversely across the tray for gripping by the shovel and thumb of a track hoe. Stops engaged the lift handle and the tray to maintain the cross bar a minimum distance above the tray to facilitate gripping by the track hoe.
In one embodiment, the tray includes a floor, first and second lateral walls and a rear wall. The lift handle pivotally secured to the first and second lateral walls by means of U-shaped members pinned to the lateral walls. Portions of the U-shaped members interfering with the first and second lateral walls serve as the stops.
The hopper is filled by various methods, including pushing the hopper into a mound of material or scraping material onto the tray. The hopper is dumped by various methods including lifting upwardly on the dump handle, resting the tray on a wall or a portion of the track hoe such that it tips, or driving a front edge of the tray into a mound of material or other structure to cause tipping.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is a perspective view of a hopper, in accordance with an embodiment of the present invention;
FIG. 2 is a side view of a hopper, in accordance with an embodiment of the present invention;
FIG. 3A is a rear view of a hopper, in accordance with an embodiment of the present invention;
FIG. 3B is a front view of a hopper, in accordance with an embodiment of the present invention;
FIG. 4A is a top view of a hopper, in accordance with an embodiment of the present invention;
FIG. 4B is a bottom view of a hopper, in accordance with an embodiment of the present invention;
FIG. 5 is a side view of a track hoe and hopper illustrating a method of loading the hopper, in accordance with an embodiment of the present invention;
FIG. 6 is a side view of a track hoe and hopper illustrating an alternate method of loading the hopper, in accordance with an embodiment of the present invention;
FIG. 7 is a side view of a track hoe and hopper illustrating a method of carrying a loaded hopper, in accordance with an embodiment of the present invention;
FIG. 8 is a side view of a track hoe and hopper illustrating a method of dumping the hopper, in accordance with an embodiment of the present invention;
FIG. 9 is a side view of a track hoe and hopper illustrating an alternate method of dumping the hopper, in accordance with an embodiment of the present invention; and
FIG. 10 is a side view of a track hoe and hopper illustrating another alternate method of dumping the hopper, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 4B , a hopper 10 includes a tray 12 , a lift handle 14 , and a dump handle 16 . The lift handle 14 is gripped by the shovel and thumb of a track hoe in order to lift a filled hopper 10 . The dump handle 16 is also gripped by the shove and thumb of a track hoe in order to dump the hopper 10 .
The lift handle 14 is typically pivotally mounted to the tray 12 . In the illustrated embodiment, the lift handle 14 includes a cross bar 18 and two side bars 20 a , 20 b . The side bars 20 a , 20 b mount to the tray 12 by means of U-shaped members 22 a , 22 b . The legs of the U-shaped members 22 a , 22 b are pinned to side walls 24 a , 24 b forming part of the tray 12 . In use, the U-shaped members 22 a , 22 b function as stops, interfering with the pivoting of the lift handle 14 such that the cross bar 18 is distanced from the tray 12 such that a portion of the shovel or thumb of a track hoe can be inserted between the cross bar and tray 12 in order to grip the cross bar 18 . One or more tethers 26 a , 26 b attach to either the cross bar 18 or side bars 20 a , 20 b to limit the rotation of the lift handle 14 away from the tray 12 . The tethers 26 a , 26 b may secure to a portion of the tray such as the lateral walls 24 a , 24 b or a rear wall 28 . The tethers 26 a , 26 b may be embodied as chains extending from the rear wall 28 .
The dump handle 16 typically secures to the rear wall 28 of the tray 12 . In the illustrated embodiment the dump handle 16 is embodied as a flexible cable 30 secured at its ends to the rear wall 28 . Laterally extending knobs 32 may be formed on the tray 12 to facilitate manipulation of the tray 12 as it lays on the ground or other support surface. The knobs 32 may be part of a single bar extending along the entire rear wall 28 . The shovel of a track hoe is used to push or pull on the knobs 32 to rotate the tray 12 . Cap plates 34 may be formed on the knobs 32 . The cap plates 34 may be caught by the shovel of a track hoe to drag the tray 12 laterally.
The tray 12 may have reinforcing members 36 positioned along the upper edges of the lateral walls 24 a , 24 b to stiffen the tray and prevent damage from impact with the track hoe or the contents of the hopper 10 . A plate 38 may also secure along the exposed edge of a floor 40 extending between the side walls 24 a , 24 b and the rear wall 28 to facilitated scraping up material and to resist deformation of the leading edge of the floor 40 .
The lateral walls 24 a , 24 b taper from a maximum height near the rear wall 28 to a minimum height near the front edge of the floor 40 . The floor 40 is typically narrowest near the rear wall 28 and grows wider toward the front edge.
A filled tray 12 has a filled center of gravity 42 . In one embodiment the lift handle 14 is pivotable such that the cross bar 18 is substantially directly above the filled center of gravity 42 . The lift handle 14 typically secures to the tray 12 at a point of securement 44 such that the filled center of gravity 42 is positioned between the point of securement 44 and the point of securement of the tethers 26 a , 26 b to the tray 12 , such as the rear wall 28 .
Referring to FIG. 5 , in one method of loading the hopper 10 , the hopper 10 is placed in front of a mound 46 of material. A track hoe 48 then pushes the hopper 10 into the mound 46 . Many track hoes are provided with a long blade 50 extending along the front of the track hoe near the ground. The blade 50 may therefore be used to drive the hopper 10 into the mound 46 . Referring to FIG. 6 , in an alternative method of use, the hopper 10 is placed near the mound 46 and the articulated shovel 52 is used to scrape material into the hopper 10 . The hopper 10 may be held in place by the blade 50 when using such a method.
The methods of FIG. 5 and 6 made possible by the hopper 10 decreases the amount of movement required by the articulated shovel 52 to scoop up material. Both hopper 10 and material may be located at ground level near one another. Only a single step of lifting and dumping is required to dump the filled hopper, rather than the repeated scooping, lifting, and dumping steps required to load an equivalent volume using the articulated shovel 52 alone.
Referring to FIG. 7 , to lift the hopper 10 , the lift handle 14 is gripped by capturing the cross bar 18 between the shovel 52 and thumb 54 of the track hoe 48 . The hopper 10 is then transported to a different location and dumped. In the method of FIG. 8 , the shovel 52 and thumb 54 grip the dump handle 16 and lift upwardly to dump the hopper 10 . In the method of FIG. 8 , the underside of the tray 12 proximate the rear wall 28 is lowered onto a structure, such as a side wall 56 of a truck. As the hopper 10 is lowered further it tips and dumps its contents. In a specific embodiment of this method shown in FIG. 9 , the tray 12 is rested on the top of the blade 50 to cause the hopper 10 to tip. The track hoe 48 may be driven forward or back during dumping according to this method in order to distribute the contents of the hopper 10 . Gravel or other paving material may be distributed as it is driven over by the track hoe 48 in order to pave a road. The blade 50 may be used in this method to simultaneously distribute the contents of the hopper 10 evenly over the road. Other methods may also be used to tip the hopper 10 , including driving the front edge of the tray against a mound of already dumped material or other structure to cause tipping.
While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow. | A hopper includes a tray having a floor, first and second lateral walls, and a rear wall. A lift handle pivotally secures to the lateral walls. A dump handle secures to the rear wall. The lift handle includes a cross bar extending transversely across the tray for gripping by the shovel and thumb of a track hoe. Stops engage the lift handle and the tray to maintain the cross bar a minimum distance above the tray to facilitate gripping by the track hoe. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/294,451 filed on 2010 Jan. 12 by the present inventor, which is incorporated herein by reference.
TECHNICAL FIELD
[0002] Disclosed embodiments relate to ladder leveler and stabilizer apparatuses.
BACKGROUND
[0003] Ladder falls are a leading industrial safety issue. There are approximately 200,000 ladder related accidents in the United States each year. Standard commercial ladders are inherently unstable due to their narrow base width as well as ladder feet designed for level placement. Often users of these ladders need to lean or carry awkward loads while on ladders placed on uneven ground and this combination can result in the center of gravity of the ladder load extending beyond the ladder feet, thereby placing the user at high risk of a ladder fall.
[0004] Numerous ladder leveler designs (e.g. U.S. Pat. No. 5,542,497) disclose extendable ladder feet in order to keep the ladder rails vertical when placed on inclined ground. However, these designs do not significantly widen the ladder base and therefore the ladder remains prone to tipping.
[0005] Numerous ladder stabilizer designs (e.g. U.S. Pat. No. 6,527,084) disclose telescoping support feet attached to the ladder rails on one end and in contact with the ground at a distance from the ladder on the other end for stabilization against lateral movement of the ladder. However, these designs are not suitable for stabilization in the case where one of the ladder feet is not in contact with the ground or the ladder rails are not vertical.
[0006] U.S. Pat. No. 6,336,521 discloses a ladder leveling device with an arch structure that fails the ANSI/OSHA requirements that the first rung, in this case the arch, is flat and that rung-spacing is twelve inches. Furthermore, since the height of the arch is related to the arch base width and ANSI/OSHA standards require that the first rung is no higher than fourteen inches off the ground, the permissible arch base width is restricted by this constraint, and consequently the stability of the ladder leveling device limited.
[0007] U.S. Pat. No. 1,424,934 discloses a ladder leveler for use on hillsides. The aforementioned disclosure reveals a typical application on sloping ground where one of the ladder leveler feet does not extend beyond the ladder rails, and therefore does not add stability to the ladder during normal use. In addition, the ladder leveler is not separable from the ladder, and therefore lacks flexibility in use and transportation.
[0008] Most ladder leveler and/or stabilizer designs require permanent ladder modifications (such as drilling of holes) or if designed to retrofit without modification are not readily installed/removed, and additionally their usage often requires that each support leg is adjusted separately, which can be challenging for one person to manage alone.
SUMMARY
[0009] Clearly, there is a need for a combined ladder leveler and stabilizer that levels a ladder on sloping or uneven ground, significantly broadens the ladder base for stability, retrofits to existing ladders without ladder modification, and furthermore is fast to attach/remove, easy to adjust by a single user, readily portable, and compliant with ANSI/OSHA ladder design standards.
[0010] Disclosed embodiments of the leveler and stabilizer for a ladder include: a) a base assembly with feet extending beyond the ladder's rails, the feet adapted to stand on a variety of ground surfaces and inclines; b) a ladder harness assembly adapted on one side to attach to the ladder and adapted on the other side to attach to the base assembly by both a ladder harness pivot and a base assembly retainer, the ladder harness pivot for permitting rotation of the ladder harness assembly relative to the base assembly, and the base assembly retainer for preventing separation of the ladder harness assembly from the base assembly; and c) a ladder harness locking mechanism for preventing rotation of the ladder harness assembly relative to the base assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Disclosed embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings.
[0012] FIG. 1 illustrates a front elevation of an embodiment of the ladder leveler and stabilizer with attached ladder on inclined ground surface.
[0013] FIG. 2 illustrates a side elevation of an embodiment of the ladder leveler and stabilizer with attached ladder.
[0014] FIG. 3 illustrates a front elevation of an embodiment of the ladder leveler and stabilizer with attached ladder.
[0015] FIG. 4 illustrates a rear elevation of an embodiment of the ladder leveler and stabilizer with attached ladder.
[0016] FIG. 5 illustrates a front perspective exploded view of an embodiment of the ladder leveler and stabilizer.
[0017] FIG. 6 illustrates a rear perspective exploded view of an embodiment of the ladder leveler and stabilizer.
DETAILED DESCRIPTION
[0018] According to one particular embodiment of the ladder leveler and stabilizer ( 100 ), shown in FIGS. 1-6 , the width of the base assembly ( 110 ) is twice the ladder ( 200 ) width, which means that the center of gravity of the ladder load must extend beyond the feet ( 134 ) before the ladder ( 200 ) can fall, and consequently provides a high degree of stability to the ladder ( 200 ).
[0019] The ladder harness assembly ( 170 ), which is attached to the base assembly ( 110 ) by the ladder harness pivot ( 186 ) and base assembly retainer ( 174 ), does not contact the ground and is capable of rotating about the ladder harness pivot ( 186 ). The rotatable ladder harness assembly ( 170 ), to which the ladder ( 200 ) is attached, permits rapid leveling of the ladder ( 200 ) on various ground inclines. The ladder harness locking mechanism ( 180 , 114 ) is designed to allow the ladder harness assembly ( 170 ) to lock at specific angles in order to hold the ladder ( 200 ) rails vertical. Further, the ladder harness locking mechanism ( 180 , 114 ) can be engaged and disengaged rapidly without the aid of tools, permitting rapid leveling of the ladder ( 200 ) by a single user.
[0020] The ladder ( 200 ) is securely attached to the ladder harness assembly ( 170 ) by the lower rung retainer assembly ( 178 , 176 , 192 , 193 , 195 ) and the upper rung retainer ( 199 ), which attach to the first and second rung of the ladder ( 200 ) respectively. Together the lower and upper rung retainers constitute a quick release mechanism for fast attachment/removal of the ladder ( 200 ), thus allowing the ladder leveler and stabilizer ( 100 ) to be readily used with different ladders as the need arises. Furthermore, ease of separation of the ladder ( 200 ) from the ladder leveler and stabilizer ( 100 ) facilitates portability of both the ladder ( 200 ) and ladder leveler and stabilizer ( 100 ).
[0021] Ladder stability and vertical rail orientation can be achieved on a variety of ground surfaces and inclines by placing the base assembly ( 110 ) on a ground surface, mounting the ladder ( 200 ) onto the ladder harness assembly ( 170 ), rotating the ladder harness assembly ( 170 ) to achieve vertical ladder rail orientation, and locking the ladder harness assembly ( 170 ) to maintain vertical ladder rail orientation.
[0022] The overlapping central cutout in the base assembly ( 110 ) and ladder harness assembly ( 170 ) permits a ladder user's foot to be placed onto the first rung of the ladder ( 200 ) without obstruction. The second rung of the ladder ( 200 ) clears the top of the upper rung retainer ( 199 ) and placement of a user's foot on that rung is unimpeded. Consequently, this design does not alter the distance between the first and second ladder ( 200 ) rungs and thus complies with ANSI/OSHA ladder requirements regarding ladder rung spacing. Further, the height of the first rung of the ladder ( 200 ) above level ground is no higher than fourteen inches and thus complies with ANSI/OSHA ladder requirements regarding ladder first rung height. Indeed, the ladder leveler and stabilizer ( 100 ) meets or exceeds all relevant ANSI A14 ladder requirements for ladders type III through IA.
[0023] According to the embodiment shown in FIGS. 1-6 , the leg assemblies ( 130 , 150 ) include leg struts ( 132 ), leg strut fasteners ( 146 , 148 ) for attachment of the leg assemblies ( 130 , 150 ) to the base assembly ( 110 ), feet ( 134 ), feet pivots ( 140 ), feet pivot retainers ( 142 ), foot pads ( 136 ), and foot pad fasteners ( 138 ). The feet ( 134 ) have a serrated edge ( 144 ) to provide additional grip when the ladder leveler and stabilizer ( 100 ) is mounted on soft surfaces.
[0024] The upper rung retainer ( 199 ) is a support bracket for supporting the ladder load and laterally retaining the second rung of the ladder. The upper rung retainer ( 199 ) is braced by the base assembly retainer ( 174 ) and the ladder harness assembly ( 170 ) to which it attaches. The lower rung retainer assembly ( 178 , 176 , 192 , 193 , 195 ) comprises the lower rung retainer wire clip ( 178 ) in order to laterally retain the first rung of the ladder ( 200 ), the lower rung retainer channel ( 176 ), the lower rung retainer cotter pins ( 192 ) to retain the lower rung retainer wire clip ( 178 ) in the lower rung retainer channel ( 176 ), the lower rung retainer cables ( 193 ) for attachment to lower rung retainer cotter pins ( 192 ), the lower rung retainer wire clip fasteners ( 194 ) for securing the ends of the lower rung retainer wire clip ( 178 ), and the lower rung retainer fasteners ( 195 ) for attachment of the lower rung retainer channel ( 176 ) to the ladder harness assembly ( 170 ).
[0025] The base assembly retainer ( 174 ) allows the ladder harness assembly ( 170 ) to rotate about the ladder harness pivot ( 186 ) without the top portion of the ladder harness assembly ( 170 ) separating from the base assembly ( 110 ), thus relieving rotational stress on the ladder harness pivot ( 186 ). Base assembly retainer fasteners ( 196 , 198 ) attach the base assembly retainer ( 174 ) to the ladder harness assembly ( 170 ).
[0026] The ladder harness locking mechanism ( 180 , 114 ) comprises the spring-loaded plunger ( 180 ) that affixes to the base assembly retainer ( 174 ), and a locking plate ( 114 ) that affixes to the base assembly ( 110 ) with locking plate fasteners ( 126 , 128 ). The locking plate ( 114 ) has multiple slots for capturing the retractable end of the spring-loaded plunger ( 180 ). The ladder harness locking mechanism ( 180 , 114 ) is designed to permit ladder ( 200 ) leveling on ground inclinations up to 30 degrees.
[0027] The ladder harness pivot ( 186 ) and ladder harness pivot fasteners ( 182 , 184 , 124 , 122 , 118 , 120 , 116 ) attach the ladder harness assembly ( 170 ) and base assembly ( 110 ) and permit the ladder harness assembly ( 170 ) to rotate relative to the base assembly ( 110 ).
[0028] The bubble level ( 188 ), which serves as a user aid for leveling the ladder ( 200 ), is retained between the bubble level plates ( 190 ) and secured with bubble level fasteners ( 191 ).
[0029] According to the embodiment shown in the FIGS. 1-6 the ladder leveler and stabilizer ( 100 ) is constructed of lightweight aluminum with the exception of the high stress components and the rubber foot pads ( 136 ). Steel components include the locking mechanism ( 180 , 114 ), ladder harness pivot ( 186 ), leg assemblies ( 130 , 150 ), base assembly retainer ( 174 ), lower rung retainer wire clip ( 178 ), and fasteners.
[0030] The ladder leveler and stabilizer ( 100 ) of the aforementioned embodiment fits aluminum and fiberglass extension ladders of lengths up to 32 feet, encompassing approximately ninety percent of commercial extension ladders.
[0031] Alternate embodiments of the base assembly ( 110 ) include base assemblies of different widths to accommodate different applications.
[0032] Alternative embodiments of the leg assemblies ( 130 , 150 ) include telescoping leg struts in order to provide ladder stability and leveling on steps.
[0033] Alternative embodiments of the feet ( 134 ) include feet with holes to permit the feet ( 134 ) to be easily staked into soft, slippery, or inclined ground for additional safety.
[0034] While particular embodiments have been described, it is understood that, after learning the teachings contained in this disclosure, modifications and generalizations will be apparent to those skilled in the art without departing from the spirit of the disclosed embodiments. It is noted that the foregoing embodiments and examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting. While the apparatus has been described with reference to various embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Further, although the system has been described herein with reference to particular means, materials and embodiments, the actual embodiments are not intended to be limited to the particulars disclosed herein; rather, the system extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may effect numerous modifications thereto and changes may be made without departing from the scope and spirit of the disclosed embodiments in its aspects. | A ladder leveler and stabilizer that combines both ladder leveling and ladder stabilization. In particular, the ladder leveler and stabilizer levels a ladder on sloping or uneven ground, significantly broadens the ladder base for stability, retrofits to existing ladders without ladder modification, and furthermore is fast to attach/remove, easy to adjust by a single user, readily portable, and compliant with ANSI ladder design standards. |
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FIELD OF THE INVENTION
The present invention relates to a guide device for a connection element.
BACKGROUND OF THE INVENTION
A device of this general type is known from the European Patent Application No. EP-A2-0 297 033.
SUMMARY OF THE INVENTION
It is the object of the invention to create a different type of guide device than the device disclosed in the above-mentioned European Patent Application.
The present invention provides a guide device for a connection element including a bolt which by means of a sleeve insert, can be rotatably fastened to an end of a rod. The bolt is connected slidably axially to the front part of a guide sleeve so that rotary movement of the guide sleeve can be transmitted to the bolt. A bell-shaped flange is at a rear part of the guide sleeve which serves to define an inside space which is dimensioned as that a head of the sleeve insert can be disposed therein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail by a description of exemplified embodiments with reference to the drawings; wherein:
FIGS. 1 to 3 show diagrammatic sectional views of various connection elements with various variants of the device according to the invention, and
FIGS. 4 and 5 show views of a guide insert for the guide sleeve according to FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The connection element according to FIG. 1 comprises a sleeve insert 3 consisting of a flange-shaped sleeve head 1 and a tubular part 2, wherein the tubular part 2 is provided with an external thread 4 for fastening it to one end of a rod of a three-dimensional framework. A bolt 5 is guided through a through-bore of the sleeve insert 3, the head 6 of the bolt 5 resting on the end wall of the tubular part 2.
The bolt 5 has an elongated, round, smooth part 7 and an end part 8 which is provided with an external thread 9 for fastening the bolt to a guide insert 10 (FIG. 4).
FIG. 4 shows a side sectional view transversely to the longitudinal axis of the guide insert 10 with a threaded part 11 which serves to screw it onto a junction part.
The guide insert 10 has on one side thereof a hexagonal part 12 (FIG. 5) with a threaded bore 13, into which the threaded bolt can be screwed. Approximately in the middle of the shell of the guide part 12, a perpendicular threaded hole 14 is provided, through which a threaded pin 15 shown in FIG. 1, e.g. a hegaxonal socket pin, can be screwed on to guide the guide insert 10 in the assembled state.
The bolt 5 is guided through the through-bore of a guide device or guide sleeve 16, from which the threaded part 11 of the guide insert 10 projects. At the front part of the guide sleeve 16 this through-bore is shaped complementally to the guide part 12, so that a rotary movement of the guide sleeve 16 can be transmitted to the threaded part 11 with as little play as possible.
The through-bore of the front part of the guide sleeve 16 can, therefore, also be polygonal, the same as the guided part of the guide insert. However, these cross-sections are preferably hexagonal, as illustrated in FIGS. 4 and 5. In contrast thereto the guide sleeve 16 is, in its rear part, made flange-shaped towards the outside and rear, to form an approximately bell-shaped flange 17, in the inside space 18 of which the sleeve head 1 can be accommodated. As shown in FIG. 1, the flange 17 includes a bevel 17', and a height h is more than half (50%) of the total height H. In addition, the guide sleeve 16 has in its rear part a radially arranged ring-shaped wall 19, wherein in the inside space of the guide sleeve 16 between the wall 19 and the guide insert 10 a coil spring 20 is arranged around the bolt 5, which spring 20 presses the guide insert 10 and the bolt 5 connected thereto forwards. Further, guide sleeve 16 includes an inside space 18'.
The maximum outside diameter of the flange 17 is preferably the same as the outside diameter of the rod 21 to be connected by the connection element, so as to obtain a pleasing aesthetic effect, and the minimum inside diameter of the flange 17 in the bell-shaped space is greater than the maximum cross-section of the sleeve head 1, which preferably is not round, so that it can be screwed onto the rod 21 by means of a spanner. The diameter of the bore of the ring-shaped wall 19 is larger than the diameter of the bolt 5 and smaller than the diameter of the coil spring 20. The sleeve 16 according to FIG. 1 has an opening 22, through which the pin 15 is guided.
The mode of operation of the element according to FIG. 1 is basically known from the European Patent Application No. 297.033 with the difference that according to the present invention in its rear part, the guide sleeve 16 is constructed differently. The flange-shaped construction has the advantage that the transition between the end of the rod 21 and the sleeve 16 can be realized harmonically, and this in various variants, as, for example, on the outside the front part of the guide sleeve 16 may be hexagonal and the flange 17 round.
The connection element according to FIG. 2 corresponds essentially to the embodiment of FIG. 1, wherein for identical parts the same reference numerals are used. However, with this embodiment the guide device or sleeve 16' does not have an opening in its shell.
The connection element according to FIG. 3 has a few characteristics in common with the embodiment of FIG. 1, and also here the same reference numerals are used for identical parts. The connection element according to FIG. 3 comprises, in particular, also a sleeve insert 3 consisting of a sleeve head 1 and a tubular part 2, wherein the tubular part 2 is provided with an external thread 4. Through a through-bore of the sleeve insert 3 a bolt 5' is guided, the head 6 of which rests on the end face of the tubular part 2.
The bolt 5' has an elongated, round, smooth part 7', a guide part 23, the cross-section of which may be polygonal, and an end part 9' which is provided with an external thread 9". To simplify the drawing, the junction part 24 and the rod 25 are indicated only by broken lines.
The bolt 5' is guided through the through-bore of a guide sleeve 26, from which the end part 9' projects. In the front part of the guide sleeve 26 this through-bore is shaped complementally to the guide part 23 of the threaded bolt 5', so that a rotary movement of the guide sleeve 26 can be transmitted to the bolt 5' with as little play as possible.
The through-bore of the front part of the guide sleeve 26 can, therefore, also be polygonal, the same as the guided part of the bolt 5'. However, preferably these cross-sections are hexagonal. In contrast thereto the through-bore has in the rear part of the guide sleeve 26 a preferably round cross-section, in which case there occurs between the round part 7' of the bolt 5' and the preferably cylindrical inside wall of the guide sleeve 26 a relatively large gap, to form an open space in which a coil spring 27 can be accommodated.
In the shell of the guide sleeve 26 an elongated opening 22 may be provided through which a pin 15 can be loosely inserted and connected to the bolt 5', preferably radially in its guide part 8.
The spring 27 is arranged in the gap in such a way that at its end on the right it rests on a bush 28 having a cylinder part 28' and a flange part 28" and at its end on the left it rests on the pin 15 to press it forward and with this push the end part 9' out of the guide sleeve 26, when it is, for example, pushed by hand into the guide sleeve 26. The transmitting of the rotary movement is ensured by the shape of the front part of the guide sleeve 26. On the other hand the pin 15 is provided so that the bolt 5' can be pushed with the fingers along the elongated opening 22 against the action of the spring 27.
With this embodiment the bell-shaped flange 29 is separate from the actual guide sleeve 26, and the bush 28 is provided to fasten the flange 29 to the guide sleeve 26, e.g. by screwing or by a bayonet connection. In this case the flange 29, the bush 28 and the guide sleeve 26 form the guide device for the connection element.
The embodiment according to FIG. 3 has the property that the spring 27 no longer remains constantly clamped-in in the sleeve 26 if this is closed off, e.g. by screwing on the bush 28. The spring 27 can, therefore, easily be removed from the sleeve 26. This property is often desirable so that the spring 27 can be replaced more easily. In addition to this advantage, the connection element of FIG. 3 has the further advantage that due to the bell-shaped flange 29 a well matching transition can be realized between the rod 25 and the guide sleeve 26. This embodiment can be made without any opening 22 whatsoever in the shell of the guide sleeve 26, as it can be dismantled very easily. Instead of the pin, a projection of the bolt in the parts 7 and/or 23 could be provided, in which case the opening 22 could also be provided right up to the rear end of the guide sleeve 26.
In a further development of the invention, the flange 29 could form an integral part with the rear end of the guide sleeve 26.
In a further development of the invention, the flange 29 could form an integral part with the bush 28.
Finally, it must still be pointed out that instead of a coil spring it is also possible to use a spring that is put on from the side, e.g. a meander-shaped spring, and that with a view to maintaining the tolerances the flange ring and/or the sleeve may also be made from die cast metal, e.g. as bronze or zinc die castings. | A guide device including a bolt (5) which through a sleeve insert can be fastened rotatably to one end of a rod (21), which bolt is connected, sliding axially, to the front part of a guide sleeve (16') in such a way that a rotary movement of the guide sleeve (16') can be transmitted to the bolt (5). A spring (20) pushes the bolt (15) out of the guide sleeve (16'), and the rear end of the guide sleeve (16') an approximately bell-shaped flange (17) is provided, which delimits an inside space which is dimensioned such that the head (1) of the sleeve insert can be accommodated therein. |
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present disclosure relates in general to a system and method for compressing gas from a hydrocarbon producing well, where the gas is compressed in multiple stages, and conditioned between stages.
Description of the Prior Art
[0002] Hydrocarbons produced from subterranean formations are often multiphase fluid mixtures of gases and liquids. The liquids from these multiphase mixtures are usually collected and transported to processing facilities for further refinement. However, as it is not always economical to store or transmit the produced gases, they are sometimes sent directly to flare instead of being captured. When the gases are captured they are often processed to remove moisture and other undesirable compounds. Hydrate inhibitors, such as methanol, are occasionally used to prevent hydrate formation within the gas. However, the hydrate inhibitors can be difficult to separate from the gas and thus introduce added complexities when trying to obtain a marketable gas product.
SUMMARY OF THE INVENTION
[0003] Described herein is an example method of producing compressed natural gas which includes obtaining fluid from a wellbore; where the fluid contains liquid and gas, and also includes a mixture of higher molecular weight hydrocarbons and lower molecular weight hydrocarbons. The gas from the wellbore is pressurized to an interstage pressure, and moisture is removed from the gas while the gas is at the interstage pressure to form a dry gas. Higher molecular weight hydrocarbons are removed from the gas while the gas is at the interstage pressure to isolate natural gas, and the processed natural gas is pressurized to form compressed natural gas. Removing moisture from the gas can involve contacting the gas with a hygroscopic agent that couples with the moisture, and separating the moisture and hygroscopic agent from the gas. The step of separating the higher molecular weight hydrocarbons from the gas can include cooling the gas, flashing the gas across a flow restriction so that the higher molecular weight hydrocarbons condense to from a liquid, and separating the liquid from the gas. In this example, during the step of cooling heat from the liquid is transferred to the gas. Alternatively, the step of cooling includes directing the gas through a chiller. The liquid can be transferred to an offsite location that is remote from the wellbore. The step of removing moisture from the gas can include contacting the gas with a molecular sieve. The compressed natural gas can be transferred to a container, where the container is transported to a location remote from the wellbore. The steps of pressurizing the gas can take place proximate the wellbore. Moisture can be removed from the gas prior to the step of pressurizing the gas to the interstage pressure.
[0004] Another example method of producing compressed natural gas involves receiving an amount of gas directly from a wellbore, pressurizing the gas to an interstage pressure, dehumidifying the gas at the interstage pressure to form a dry gas, and compressing the dry gas to form compressed natural gas. The dry gas can include a mixture of higher molecular weight hydrocarbons and lower molecular weight hydrocarbons, the method may further involve separating the higher molecular weight hydrocarbons from the dry gas at the interstage pressure. In this example, the step of separating the higher molecular weight hydrocarbons includes cooling the dry gas with a lower temperature fluid selected from the group consisting of liquid comprising the higher molecular weight hydrocarbons, a chilled fluid, and combinations thereof. The step of dehumidifying the gas at the interstage pressure may include contacting the gas with a hygroscopic agent.
[0005] Also disclosed herein is an example of a system for producing compressed natural gas which is made up an interstage conditioning system with a dehumidifying system for removing moisture from gas from a wellbore, a booster compressor having a suction line in communication with the gas from the wellbore and a discharge line in communication with the interstage conditioning system, and a compressor having a suction line in communication with an exit of the dehumidifying system and a discharge line having compressed natural gas. The system can also have a separation tank in the interstage conditioning system for separating higher molecular weight hydrocarbons from the gas. The dehumidifying system optionally has a tank with an injection system for a hygroscopic agent. The dehumidifying system optionally includes a tank having a molecular sieve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 is a schematic view of an example of a system for processing fluid from a wellbore.
[0008] While the invention will be described in connection with embodiments, it will be understood that it is not intended to limit the invention to the embodiments. 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
[0009] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes +/−5% of the cited magnitude. In an embodiment, usage of the term “substantially” includes +/−5% of the cited magnitude.
[0010] 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.
[0011] An example of a compressed natural gas (CNG) system 10 is schematically illustrated in FIG. 1 . The CNG system 10 is downstream of a wellhead assembly 12 shown mounted over a wellbore 14 that intersects a formation 16 . Hydrocarbons, both liquid and gas, from the wellbore 14 are produced through the wellhead assembly 12 and transmitted from wellhead assembly 12 via a connected production line 18 . Production line 18 terminates in a header 20 . The header 20 may optionally be the destination for other production lines 22 , 24 , 26 that also transmit production fluid from other wellhead assemblies (not shown). A feed line 28 provides a communication means between the header 20 and CNG system 10 . The end of feed line 28 distal from header 20 terminates in a knockout drum 30 and which optionally provides a way of separating water and other liquids from the feedline 28 . A drain line 32 connects to a bottom of knockout drum 30 and directs liquids separated out from the fluid flow in feed line 28 . The gas portion of the fluid in feed line 28 directed into knockout drum 30 exits knockout drum 30 through an overhead line 34 shown extending from an upper end of knockout drum 30 . The end of overhead line 34 distal from knockout drum 30 connects to a suction line of a compressor 36 . In the example of FIG. 1 , compressor 36 includes a booster compressor 34 and a CNG compressor 40 . In this example, overhead line 34 terminates at a suction end of booster compressor 38 so that the gas in line 34 can be pressurized to an interstage pressure.
[0012] The interstage gas discharged from booster compressor 38 is treated in an interstage conditioning system 42 . More specifically, a discharge line 46 provides communication between a discharge side of booster compressor 38 to a dehydration unit 48 . In one alternative, an injection line 50 for injecting hygroscopic agent into the intermediate stage gas flow stream is shown connected to dehydration unit 48 . In one example the hygroscopic agent includes triethylene glycol (TEG), and extracts moisture contained within the interstage gas. A discharge line 52 is shown connected to dehydration unit 48 , and provides a means for moisture removal from the intermediate stage gas. Overhead line 54 is shown connected to an upper end of unit 48 and which is directed to a heat exchanger 56 . Within heat exchanger 56 , fluid from within overhead line is in thermal communication with fluid flowing through a bottoms line 58 ; where bottoms line 58 connects to a lower end of natural gas liquid (NGL) tank 60 . Downstream of heat exchanger 56 , overhead line 54 connects to a heat exchanger 62 . Flowing through another side of heat exchanger 62 is fluid from an overhead line 64 , where as shown overhead line 64 attaches to an upper end of NGL tank 60 . An optional chiller 66 is shown downstream of heat exchanger 62 in line with overhead line 54 . Further in the example of FIG. 1 is a control valve 68 illustrated in overhead line 54 and just upstream of where line 54 intersects with NGL tank 60 . Liquid within line 58 is transmitted to offsite 70 , and is controlled to offsite 70 via a valve 72 also shown set within line 58 . Valve 72 can be motor or manually operated.
[0013] Overhead line 64 is shown connected to a suction end of CNG compressor 40 and where the gas within overhead line 64 is compressed to a CNG pressure. A discharge line 74 connects to a discharge side of CNG compressor 40 and provides a conveyance means for directing the compressed natural gas from CNG compressor 40 to a tube trailer 76 . Optionally, a valve 78 is provided in discharge line 74 and for regulating flow through discharge line 74 , and to selectively fill tube trailer 76 . Alternatively, each booster compressor 38 may include a first stage 80 and second stage 82 . In this example, discharge from first stage 80 flows through suction of second stage 82 for additional pressurization. Similarly, CNG compressor 40 contains a first stage 84 and second stage 86 , wherein gas within first stage 84 is transmitted to a suction side of second stage 86 for additional compression. Examples exist wherein the booster compressor 38 and CNG compressor 40 are reciprocating compressors and wherein each have a number of throws, wherein some of these throws may be what is commonly referred to as tandem throws.
[0014] In one example of operation, a multiphase fluid from well 14 flows through lines 18 , 20 , 28 and is directed to knockout drum 30 . Embodiments exist where the fluid flowing through these lines contains at least an amount of flare gas, which might commonly be sent to a flare and combusted onsite. An advantage of the present disclosure is the ability to economically and efficiently produce an amount of compressed natural gas that may be captured and ultimately marketed for sale. Liquid within the fluid in line 28 out flows to a bottom portion of knockout drum 30 and is separated from gas within the fluid. From within drum 30 , the gas is directed into overhead line 34 . Line 34 delivers the gas to the suction of booster compressor 38 , where in one example the gas is pressurized from an expected pressure between 50 to 100 psig to a pressure of 400 psig, and which forms the interstage gas. Gas, which may include hydrocarbons, is directed through line 46 into dehydration unit 48 . For the purposes of discussion herein, lower molecular weight hydrocarbons are referred to those having up to two carbon atoms, wherein higher molecular weight hydrocarbons include those having three or more carbon atoms. To remove moisture from within the interstage gas in line 46 , hygroscopic agent is directed from injection line 50 into dehydration unit 48 and allowed to contact the gas within dehydration unit 48 . Alternatively, a molecular sieve 88 may be provided within dehydration unit 48 .
[0015] Hygroscopic agent, or sieve 88 , can then absorb moisture within the interstage gas. Sieve 88 may be regenerated after a period of time (by pressure swing adsorption or temperature swing adsorption) to remove the moisture captured within spatial interstices in the sieve 88 .
[0016] To remove higher molecular weight hydrocarbons from the interstage gaseous mixture in line 54 , the fluid making up the mixture is cooled within exchangers 56 and 62 and flashed across valve 68 . Cooling the fluid stream, and then lowering the pressure across valve 68 , is an example of a Joule-Thompson method of separation and can condense higher molecular weight hydrocarbons out of solution and into tank 60 . The resulting condensate can be gravity fed from within tank 60 and to offsite 70 . An optional flare 90 is schematically illustrated in communication with fluid from the wellbore 14 via an end of header 20 . Fluid in header 20 can be routed to flare 90 when system 10 is being maintained or otherwise out of service.
[0017] In alternatives employing the optional chiller 66 , the higher molecular weight hydrocarbons are separated from the fluid stream by a mechanical refrigeration unit instead of the Joule-Thompson method of gas conditioning. In examples where the Joule-Thompson method is employed, the discharge from the booster compressor 38 can be at about 1,000 psig. In examples using the mechanical refrigeration method, the discharge from the booster compressor 38 can be at a pressure of around 400 psig. An advantage of treating the gas at the interstage pressure is the ability to remove additional moisture from the gas as well as to optimize the separation of the higher molecular weight hydrocarbons. As such, a higher quality of compressed natural gas can be obtained and delivered via line 74 into the tube trailer 76 . Moreover, a higher quality of NGL can be delivered to offsite 70 . In currently known processes, methanol is sometimes added to the gas mixture to prevent the formation of hydrates during the gas treatment process. However, the addition of methanol is not only costly, but also reduces the quality and marketability of the end products.
[0018] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While embodiments of the invention 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 invention disclosed herein and the scope of the appended claims. | A system and method captures and processes flare gas so that the gas is usable as compressed natural gas (“CNG”). The flare gas is pressurized by a combination of a booster compressor and a CNG compressor. While interstage and between the booster compressor and the CNG compressor, the gas is treated to remove moisture and to separate out higher molecular weight hydrocarbons. The moisture is removed by contacting the interstage gas with a hygroscopic agent within a dehydration unit. The moisture free hydrocarbon fluid is expanded, and/or externally cooled and directed to a knock out drum. Higher molecular weight hydrocarbons are separated from the fluid in the knock out drum. Gas from the knock out drum is compressed in the CNG compressor. |
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BACKGROUND OF THE INVENTION
This invention relates to exterior pavements and in more particular to exterior architectural pavements or paving systems which are decorative as well as functional.
Architectural exterior pavements or paving systems are, generally speaking, those which are intended to present a pleasing and/or decorative visible surface. Architectural pavements are expected to carry pedestrian traffic and light vehicular traffic and, on occasion, have to support heavier vehicular traffic as well as endure or survive other forces ranging from freezing and thawing to earthquakes and tremors. Examples of such pavements have been used as walkways, courtyards, malls, streets, gardens, patios and/or the wearing or decorative surfaces of a building roof or deck. The decorative appearance of known architectural pavement is provided by the topmost layer of paving elements (hereinafter, pavers) which are usually rectangular or polygonal blocks such as clay tile, concrete, slate, stone, impregnated wood or other materials that provide a decorative but sturdy wearing surface and can be arranged in a decorative or aesthetically pleasing pattern.
Pavers are usually supported at the bottom by, variously, a sub-base of natural earth or compacted earth, a base which usually rests upon a sub-base and may be either rigid or somewhat yielding compared with the sub-base, and a setting bed laid on the base and supporting the pavers. A base usually comprises compacted stone or gravel, or compacted sand or compacted sand and gravel, asphalt, concrete, prior pavement or the load bearing aspect of a roof deck.
Two prior methods have been commonly employed for laying pavers on a base. The first is to lay desirably thin pavers and a setting bed on a rigid base, such as reinforced concrete, and then grout the joints between pavers so that the entire system is rigid. Problems with this arrangement arise, however, due to forces exerted from above, such as heavy vehicles, or exerted vertically from below as by sub-base instability, quakes or tremors, or horizontally by movement due to thermal or moisture expansion and contraction, which tends to cause the pavers, setting bed and/or the base to crack at random and monolithically.
A second procedure requires the use of relatively thick pavers (1-1/4 to about 4-1/2 inches thick) which are placed on or laid on a bed or base of sand, asphalt or the like which permits each individual paver to "float". Movement will then occur between pavers rather than through them. This method, however, requires the use of relatively thick pavers which have the necessary strength to prevent breaking under foot, under vehicular loading or other adverse forces mentioned above. Thick paver systems are, however, relatively expensive compared with so-called "thin" systems which employ pavers from about 1/8 inch thick for metal and from about 3/8 inch thick for other strong pavers, to about 1-1/4 inches thick for weak pavers made of asphalt or limestone, for example. With such prior thin pavers, setting beds of slightly less than one inch to about two inches in thickness have been employed. Thick paver systems offer no decorative advantage over thin paver systems.
SUMMARY OF THE INVENTION
A general object of this invention is to provide an architectural paving system and a method of architectural paving which overcomes the disadvantages, noted above, of prior systems and methods.
A more particular object is to provide a novel paving system and method wherein thin pavers may be employed and preserved against cracking where used over a base or sub-base that is somewhat yielding and/or caused to yield under adverse forces.
Another object is to minimize or eliminate the need for expansion joints when using thin pavers.
Another object is to gain the advantages of the use of thick pavers by and with the use of thin pavers.
Another object is to provide a paving system and method which permits the use of thinner paving sections of relatively light weight for a decorative roof deck without increasing the danger of cracking of the decorative surface.
Another object is to provide a paving system employing thin pavers, especially useful for a roof deck or the like, which can facilitate removal and/or replacement and repair of a leak in a roof membrane.
Another object is to provide a paving system with thin pavers which can facilitate removal and/or replacement and repair of underlying pipes, conduits and the like.
Another object is to provide a thin paver, paving system of pleasing appearance with straight joint alignment and useful spacing between pavers suitably filled.
Other objects and advantages of the invention will appear from the following description of preferred and modified forms and embodiments of my invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary isometric view of newly made pavement embodying my invention taken in a vertical plane proximate the near ends of pavers supported on the sectioned subjacent structure.
FIG. 2 is a fragmentary vertical cross-section of both the pavers and subjacent structure shown in FIG. 1 after the pavement has been used and after the setting bed has been cracked; the middle paver and the middle "integral" subjacent part of the setting bed having been displaced relative to adjacent corresponding portions of the pavement.
FIG. 3 is an enlarged fragmentary vertical section similar to FIG. 1 showing the cut made through and below the gap between pavers, through the bond coat and into the green setting bed.
FIG. 4 is an isometric view of the monolithic block of paver bonded to the fractured-out subjacent part of a setting bed seen as if detached from a fractured pavement such as the middle of FIG. 2
FIG. 5 is a fragmentary section taken through pavers, and newly laid pavement similar to FIG. 1, showing a form of my invention in which the base comprises strong, solid concrete, as in a prior highway with a bond preventing sheet or element interposed between the base and the setting bed.
FIG. 6 is a view similar to FIG. 5 taken however after the base has been stressed to the point of fracture and the pavers and subjacent parts of the setting bed fractured out into separate monolithic paving blocks as shown in FIG. 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, and initially to FIGS. 1 and 2, an architectural pavement embodying my invention is shown applied over a somewhat yielding, compacted sand and compacted stone or gravel, or the like, base 10. It should be noted that an architectural pavement embodying my invention may also be applied over substantially any base incuding reinforced or unreinforced concrete, asphalt, sand, compacted sand or gravel and roofing membrane or substantially any known or convenient material commonly employed as a base for architectural paving. The sub-base 11 as I refer to it herein, may comprise earth or compacted earth when speaking of pavements on earth, assuming no sub-base as such will be present in a roof structure to support a roofing membrane.
The architectural pavement of FIGS. 1 and 2 includes a sand-cement setting bed 12 which is laid over base 10. The base has a thickness and strength appropriate for the load, environment and use of any particular installation. The setting bed 12 may be a conventional Portland 3 to 1 sand-cement mixture and may include latex when appropriate as is understood in the art. Pavers 14 are placed on setting bed 12 while it is green, i.e., before it takes its initial set, and the pavers are bonded thereto by means of a bond coat 15. Bond coat 15 may be a rich 1 to 1 sand-cement plus latex, mixture or a suitable commercial thin-set bonding material. The bond coat 15 may be applied to the top surface of the setting bed 12 before it takes its initial set. Alternatively and preferably, the bond coat 15 is applied to the paver just prior to placing the paver on the green bed. Adjacent pavers are spaced apart by gaps 16.
Before setting bed 12 takes its initial set, I cause cuts 17 to be made between adjacent pavers 14 into the setting bed 12 to a depth A, FIGS. 1 and 3 measured from the top surface of the pavers to the bottoms of the cuts. FIG. 3 is an enlarged view of cut 17 wherein the effect of cutting through bond coat 15 is also shown. The material of the bond coat is severed, forced aside and upwardly as at 18 and improves the bond and seal at the lower opposite edges 14a of the pavers.
The combined depth A of the pavers, bond coat and cut is preferably not less than about one-third of the depth C from the top surface of the paver to the bottom of the bed 12. Should the thickness of the paver alone equal or exceed about 1/3 of the depth C in any instance, I prefer to make a significant cut through the bond coat and into the setting bed in any event. This insures that the gap 16 between adjacent vertical paver faces is not wholly or partially filled with bond coat material, on the one hand, and that the upper part of the setting bed is cut or scored to an appreciable depth below the bottom of the pavers and bond coat, even down to the bottom of the setting bed 12, on the other hand.
The function and accomplishment of the cuts 17 is to prevent cracking of the pavers by confining cracking and fractures to cracks 19 in the setting bed, FIGS. 2 and 6. Cracks 19 comprise downward extensions of parametric continuities of cuts 17 below gaps 16 all around the downward projections of the side edges of each paver and from the lower side faces of fractured-out blocks 13, FIGS. 2, 4 and 6. Otherwise cracking stress tends to fracture the pavers and the subjacent setting bed indiscriminately.
As suggested in FIGS. 2, 4 and 6, the preservation of the thin pavers 14 is done by integration of respective subjacent parts 12a of the setting bed and respective subjacent parts 15a of the bond coat with each paver 14 to form thick, strong, composite monolithic blocks 13. These blocks after being fractured in situ and from the bed or beds 12 are supported from below in the then altered base, sub-base or roof or deck structure or element upon which the green setting bed was originally placed and leveled. The fractured-out blocks 13 also have mutual lateral support with tight mechanical and frictional engagement with laterally adjacent blocks, or the adjacent up-and-down face or faces of the original unfractured and therefore originally unstressed aspect of setting bed 12 as suggested at 20 in FIGS. 2 and 6. The preserved pavers on the fractured-out blocks 13 supported as mentioned above, tend to be displaced so little from their original pattern and disposition as to fairly preserve the pattern and pleasing effect of the original paved surface.
Referring back to FIG. 3 and the depth of the cut 17, the foregoing will reflect my present experience and understanding: When the cut is significantly deeper than my preference about A in reference to C, FIGS. 1 and 3, the excessive depth may be more costly in time and effort without commensurate advantage. Should the cut by virture of depth and/or width cause the fractured-out blocks 13 to lack mutually beneficent lateral support, the strength, firmness or appearance of the whole fractured pavement many tend to be impaired.
In FIG. 4, the not necessarily sharp line L suggests that the parametric exterior surface of the block 13 above the line is smoother than that below the line because the former was smoothed by the cutting tool while the latter resulted from the fracture which created the block. I have found that knives similar to linoleum knives, having points curved at about right angles to the shank and with an arcuate cutting edge facing the handle, facilitate making a full cut where the groove through which the blade is drawn terminates opposite the side of an adjacent paver as when pavers are laid in an overlapping pattern or "running bond" not as shown in FIG. 1. Cutters with rotatable blades similar to the familiar lawn edging tools have advantage when the gaps 16 between adjacent pavers are aligned as shown in FIG. 1 to form continuous elongated grooves through which the cuts 17 are made. The width of the gaps 16 are preferably no smaller than 1/4 inch as with 8 × 8 inches or smaller pavers of 1/8 to 1 inch thickness. Greater gaps with larger and/or thicker pavers or non-rectangular patterns function within the teachings of my invention.
The size and/or the maximum horizontal dimension of a preferred form of a paver used in my invention depends on a number of interrelated factors.
Aesthetic values suggest that the size of a paver and/or the relative sizes, shapes and arrangement of different pavers, relate pleasantly to the size and shape of the paved area where it is employed and to the design or pattern of the pavement. In a curved walkway three feet wide, pavers one foot square would in my present view be less desirable than 6 × 6 inches or 4 × 8 inches pavers, for example. Large open areas invite patterns involving pavers of different sizes and shapes to break the monotony of repetition.
Economy pertaining to the cost of making and laying the pavers is important. A paver is related to the size of a human hand much as a common or decorative brick is so related. The brick is held in one hand while mortar is applied by trowel with the other. I prefer that my pavers be grooved or scored on their bottom sides to receive a bonding coat before being laid on a setting bed. Holding the paver in one hand facilitates applying the bond coat with the other. Thin pavers 4 × 8 inches, 6 × 6 inches, 8 × 8 inches, 8 × 16 inches, even 12 × 12 inches are easily handled. Smaller pavers while more easily handled, require more bonding and setting motions and alignments and may take more time to select and lay per unit of area than larger and more uniform pavers. Generally, small pavers cost more to make, as well as lay, per unit of area.
While square and rectangular pavers are suggested in the drawings herein, hexagonal and octagonal shapes in well known patterns are well adapted to use with my invention.
Transporting pavers from their place of manufacture to the place of use suggests that "thin" pavers of my preference made of frangible material will survive if small, better than large.
My invention facilitates a wide choice of pavers as to material, size of surface area and as to thickness. Pavers between about 1/8 to 1-1/4 inches are called thin pavers herein. My invention in its preferred form so integrates and isolates each paver with its subjacent coextensive part of the setting bed, that thin, large-in-area and structurally weak pavers may be employed with little or no hazard of cracking the pavers or the showing of unsightly cracks in the whole paved area. For example, my thin pavers may be made or selected from known material such as cast, wrought or extruded metal, slate, granite, fired clay, concrete, precast terrazzo tile, impregnated wood and/or asphalt tile.
Generally speaking the stronger materials such as metal, granite, fired clay and impregnated wood may be employed advantageously in pieces as thin as 1/8 to 3/16 inch for metal and 1/2 inch for other strong pavers in area-size up to about 8 × 8 inches. In area size of about 12 × 12 inches or 8 × 16 inches a thickness about 3/16 to 1/4 inch for metal and 5/8 to 3/4 inch for other strong materials is presently preferred. Weaker materials such as limestone, concrete, terrazzo tile and asphalt tile should, as I presently prefer, be made in area sizes up to about 8 × 8 inches by about 3/4 inch in thickness. In area sizes of about 12 × 12 inches or 8 × 16 inches, I prefer the thickness be about 1 to 1-1/4 inches for the satisfactory practice of my invention. Impregnated wood is a known commercial product of enhanced strength formed, as I believe, by treating wood to near vacuum pressure, then impregnating it with methylmethacrylate and finally subjecting the impregnated wood to cobalt radiation.
The form of my invention shown in FIGS. 5 and 6 employs the same or substantially the same pavers 14, setting bed 12, bond 15 therebetween, gaps 16 and cuts 17 which have the same or substantially and essentially the same functions, modes of operation and results as described in reference to FIG. 1. This paver and cut-setting bed combination is related to the rigid concrete base 26 somewhat differently than is the same paver-setting bed related to the base 10 in FIGS. 1 and 2.
In the FIGS. 5-6 form, a slip sheet 25 is placed on the base 26 and the setting bed is laid on the sheet 25 and supported on the base through the sheet. The office and function of the slip sheet is to prevent the bed 12 from bonding with or adhering to the rigid base 26. Otherwise, as I am presently advised, the function and operation of the cuts 17 and the controlled fracture-out of blocks 13, FIG. 4, would be lost or impaired. The sheets or slip sheets 25 may comprise tar paper, roofing paper or polyethylene film, for example; the sheets being tough and rugged enough to prevent adherence or bonding between the setting bed and the base. That is to say the sheet 25 will permit bed 12 and/or fractured-out blocks 13 to slip with respect to the base 26 when adverse forces and stresses buckle or break the base as at 27 and induce cracks 19 in the setting bed as suggested in FIG. 6. In FIG. 6, two fractured-out blocks 13 with portions 12a of the bed 12 are shown.
A few more examples of particular types of paving systems and pavements using and embodying my invention may help show its scope, utility and adaptability. In all instances, as above, the combination of pavers bonded to the setting bed, and/or to portions of the bed embraced, or to be embraced in fractured-out blocks persists. Variations between examples and the reasons therefore will be understood without additional drawings. In the following examples, all the pavers may be assumed to have about an 8 inches maximum horizontal dimension and may be square, rectangular, hexagonal or octagonal; the latter employing conventional, smaller, square pavers in the areas where the edges of contiguous octagons are not parallel or proximate.
Example 1
A residential backyard patio built on a compacted earth sub-base, a 4 inch base of sand compacted upon the sub-base, a setting bed laid on the base with exposed-aggregate decorative pavers 5/8 inch thick bonded to the bed. In this instance the total depth C of paver, bond and bed is about 2 inches, and the depth A of the cut between pavers measured from the top surface of the pavers is about 1 to 1-1/4 inches.
EXAMPLE 2
A paving system over an existing asphalt street as one finds in downtown metropolitan areas being converted to malls for pedestrian and limited vehicular use. Here the sub-base may be original concrete or brick pavement, the base, a superposed asphalt pavement which carried my 1/2 inch thick granite paver bonded onto the top of a setting bed with a depth C of 2-1/2 to 3 inches and the depth A from the top of the paver to the bottom of the cut not less than about 1-1/4 inches.
Example 3
A decorative paving improvement for a worn and/or seedy looking concrete or similar sidewalk essentially for pedestrian traffic. Here a 4 mill polyethylene slip sheet, or a single layer tar paper sheet, is placed over the sidewalk, my setting bed laid on the sheet and 1/2 inch thick impregnated wood pavers bonded to the bed. Here my preferred depth C of bed, bond and paver is 1-1/4 inches and the preferred depth A to the bottom of of the cuts is 5/8 inch.
Example 4
A roof deck having a decorative and durable surface of slate pavers about 3/8 inch thick upon which people and outdoor furniture comprise a normal minimum load. In this case a load bearing structural slab underlies and provides support for the superposed parts and elements up to and including the pavers. Insulation may be laid upon the structural slab and built-up roofing including the roof membrane is disposed on and/or above the insulation. Over the built-up roof I prefer to lay protective hard protective board about 1/4 inch thick to minimize danger of puncturing the built-up roofing during installation of my paver system. My setting bed is then laid on the protective board to a minimum depth of about 1-1/2 inches and to such greater reasonable depths as are advisable to effect a level paver surface over a sloping or uneven deck or roofing. My pavers are bonded to the green bed and cuts are made around the pavers according to my teaching above. The minimum depth C will be about 2 inches and the depth A from the top surface of the pavers to the bottom of the cuts will be no less than about 5/8 inch.
In the several forms of my invention illustrated and disclosed above, I prefer to "finish" the decorative surface after the setting bed has set and cured for 24 to 72 hours by spreading a dry joint filler 21, preferably comprising 10 parts bagged silica sand well mixed with 1 part cement colored in appropriate contrast or harmony with the pavers, over the whole paved surface and gaps 16, and then brushing the filler over the pavers and gaps until all the gaps 16 and cuts 17 are filled. Thereafter the dry filler mixture is brushed off the surface by brushing at about 45° to the line of the gaps until the level of filler in the gaps is lowered to about 1/4 inch below the surface of the pavers.
After the surplus filler has been brushed aside as aforesaid, a fine water mist is sprayed evenly over the entire paved surface just sufficiently to wet the joint filler in the gaps. Excess water, and puddles, if any, is/are squeegeed off the pavement and the job allowed to dry overnight. A day or so later the whole surface is dressed with boiled linseed oil taking care to saturate the filler, sometimes called joint filler, in the gaps. Excess dressing is wiped off after 20-30 minutes.
In the finished pavement the gaps 16 and cuts 17 are filled with discrete particles in gentle mutual adhesion and filled in the sense that foreign matter is excluded albeit the filler has no significant structural strength capable of transmitting deleterious force from one paver to another. The filler may also perform a structural function in the event of a fracture in the setting bed which opens one or more of the cracks 19 enough to permit and invite grains of filler to fall and/or flow down into the crack. Grains of filler, whether few or many tend to enhance the bond or grip between fractured-out blocks 13 and between such blocks and adjacent unbroken parts of the setting bed.
While I have illustrated and described preferred and modified forms and practices of my invention, changes, and improvements will occur to those skilled in the art which are within the essential principles and teachings hereof. Therefore I do not want my patent to be limited to the specific forms and examples stated herein nor in any manner inconsistent with the progress in the art which has been promoted by my invention. | Architectural or decorative pavement having thin decorative pavers or "tiles" made of or selected from known materials, from metal and impregnated wood to natural stone to clay or cementitious tiles, are bonded to the upper surface of a sand and cement (and latex, if desired) setting bed before the bed takes its initial set. "Thin" pavers are less than 1/4 inches thick. Stronger materials in these pavers lend themselves to minimum thickness in small to medium sizes. Thin pavers of weaker materials require maximum thickness in large to medium sizes.
The pavers are placed in rows and designs as may be pleasing with adjacent side edges spaced apart and forming gaps all around the perimeter of each paver.
While the bed and bond are both green, vertical cuts are made through and below the gaps and through the bond coat and appreciably into the setting bed all around the whole perimeter of each paver. The setting beds are supported on appropriate bases or other supporting means.
After the paving is cured the cuts in the setting bed create a stress line below which destructive forces exerted on the finished pavement are concentrated to vertical downward extensions of the cuts to the full depth of the bed, and form, in effect, whole, separate, monolithic fractured-out pavement blocks which may suffer bodily displacement while preserving the integrated pavers whole and intact.
The cuts into the setting bed, or the cuts and subjacent cracks, comprise by their numbers and proximity, expansion and control joints. |
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TECHNICAL FIELD
The present invention relates in general to a system for analyzing drilling mud circulated through a borehole during drilling. More particularly, this invention involves a system for continuously sensing and recording the relative concentration of hydrocarbon gases associated with cutings carried by the drilling mud.
BACKGROUND ART
In drilling oil or gas wells, mud-laden fluid or "drilling mud" is typically circulated through the borehole to cool and lubricate the drill bit, and to remove cuttings from the hole. The drilling mud is pumped into the hole from a nearby surface pond or pit, and is returned to the pit to deposit the various cuttings carried by the mud before recirculation through the hole.
The drilling mud provides a means of communicating with the bottom of the hole and with the geological formations penetrated by the drill bit. By appropriate measurements at the surface, before the mud is returned to the pit, useful data such as the concentration of oil, gas, water or sulfur in the drilling mud and cuttings, rate of drilling penetration, etc. can be determined through mud analysis. Such data can then be correlated with drilling depth to provide a log of useful information.
Examination of drilling mud and the cuttings carried thereby is known as mud logging. Although batch samples of drilling mud can be collected and analyzed, it is preferable to conduct sampling on a continuous basis. Continuous sampling is generally faster and more accurate than batch sampling. The control and amount of information afforded by continuous mud logging is particularly desirable when drilling exploratory holes, for instance, or when the stratigraphy is complicated.
While mud logging systems have been developed heretofore, the systems of the prior art have tended to be complex, expensive and difficult to operate. Most if not all of the prior systems for logging drilling mud on a continuous basis have required the attention of at least one operator. For example, one system of the prior art is truck-mounted and operator-attended, and consumes a large amount of power. The drilling mud is sampled inside the truck, which is usually parked a substantial distance away from the borehole due to the various drilling equipment which must be located around the hole. By the time the drilling mud reaches the truck, it may have become stale by percolation of gases out of solution, thereby reducing reliability and accuracy of the sampling. In addition, the expense of operating and maintaining such mud logging systems has made it infeasible to drill some exploratory holes that otherwise might have been drilled.
A need has thus arisen for a simplified mud logging system for analyzing the hydrocarbon content of drilling mud on a continuous basis with very little operator attention, except to activate the system and change the disk of a chart recorder at periodic intervals.
SUMMARY OF THE INVENTION
The present invention comprises a mud logging system which overcomes the foregoing and other difficulties associated with the prior art. In accordance with the invention, there is provided a mud logging system of simplified and inexpensive construction. The system herein utilizes a clock-driven, chart recorder to log the relative concentrations of hydrocarbons detected in drilling and returning from the borehole over an extended period without operator attention.
More particularly, the mud logging system herein comprises a sampling chamber, a hydrocarbon sensor mounted in the sampling chamber, and a recorder connected to the sensor through appropriate circuitry. The sampling chamber is adapted for connection to the drilling mud return line between the borehole and mud pit. As the drilling mud flows through the sampling chamber, any hydrocarbon gases associated with the cuttings carried by the mud separate from the mud for detection by the sensor. The recorder provides a continuous log of the relative concentration of hydrocarbons in the drilling mud over a predetermined period, such as twenty four hours, for correlation with drilling depth to locate production zones.
BRIEF DESCRIPTION OF DRAWINGS
A more complete understanding of the invention can be had by reference to the following Detailed Description together with the accompanying Drawings, wherein:
FIG. 1 is a schematic diagram of a mud logging system incorporating the invention;
FIG. 2 is a side view (partially cutaway) of the sampling chamber of the system;
FIG. 3 is a schematic diagram of the sensor circuitry utilized in the invention;
FIG. 4 is a schematic diagram of the control circuitry utilized in the invention; and
FIG. 5 is an enlarged view of a portion of a chart recorded with the system.
DETAILED DESCRIPTION
Referring now to the Drawings, wherein like reference numerals designate like or corresponding parts throughout the views, and particularly referring to FIG. 1, there is shown a mud logging system 10 incorporating the invention. System 10 includes a flow or sampling chamber 12 connected via pipe 14 to the return line of a mud circulation system (not shown) for a borehole. Drilling mud and borehole cuttings carried thereby pass through chamber 12 before return to the mud pit, from which the drilling mud is continuously circulated through the borehole during drilling. Chamber 12 defines a separation chamber within which any hydrocarbons associated with the cuttings in the drilling mud can be detected by a sensor 16 mounted in the top of the chamber. A line 18 connects sensor 16 with a control panel 20 situated in the doghouse or at some other location remote from sampling chamber 12. Control panel 20 includes a power on/off switch 22, an on/off lamp 24, a voltmeter 26, and a warning lamp 28. Power for system 10 is provided by a cord 30 which includes a plug for connection to a 110 volt AC outlet. Control panel 20 is connected by line 32 to a recorder 34 which includes a clock-driven chart 36 and a movable pen 38. In the preferred construction, control panel 20 and recorder 34 are housed in a common case.
Recorder 34 is responsive to a voltage signal via the circuitry within control panel 20 in accordance with the relative concentration of hydrocarbons detected by sensor 16. As the drilling mud flows through sampling chamber 12, any hydrocarbons which percolate out of solution within the chamber are continuously detected by sensor 16 and charted on recorder 34, as will be more fully explained hereinafter.
FIG. 2 illustrates sensor 16 mounted in the top wall of sampling chamber 12. Any sampling chamber of suitable construction can be utilized with system 10; however, in accordance with the preferred embodiment, sampling chamber 12 corresponds to the chamber disclosed and claimed in copending application Ser. No. 115,002, filed Jan. 24, 1980, and assigned to Energy Detection Company. Chamber 12 is preferably generally triangular in longitudinal cross section, and generally rectangular in lateral cross section. The back wall of chamber 12 includes a fitting for connection to pipe 14, while the front wall of the chamber includes an outlet 40 with a hinged trap door 42 thereon located below the inlet. Drilling mud entering chamber 12 slides down the declined bottom wall of the chamber and through outlet 40 for return to the mud pit. Any gas associated with cuttings carried within the drilling mud is thus allowed to percolate out of solution and collect within the upper portion of sampling chamber 12 for detection by sensor 16.
The details of sensor 16 are best shown in FIG. 3. Sensor 16 comprises a conventional pass-through ionic sensor of the type utilized in smoke alarm systems. For example, the Figaro TGS-109 sensor has been found satisfactory for use as sensor 16. Sensor 16 is connected to a five pin plug 44 to which line 18 leading to control panel 20 is connected. Pins B and D of plug 44 are connected to the heated cathode 16a of sensor 16. Pins A and C of plug 44 are connected to the anode 16b of sensor 16. When a hydrogen-rich gas passes through the filament of sensor 16, the current flow from cathode 16a to anode 16b increases in accordance with the concentration of hydrogen in the gas to provide an indication of hydrocarbons.
Referring now to FIG. 4, there is shown the circuitry contained in control panel 20. Line 18, which is shown in FIG. 1, connects plug 44 on sampling chamber 12 to a five pin plug 46 on control panel 20. The pins of plug 44 are connected to their counterparts on plug 46. Pins A and C of plug 46 are connected to pin 6 of terminal board 48, while pin B of the plug is connected to pin 7 of the terminal board and pin D of the plug is connected to pin 8 of the terminal board. It will be understood that the pins located on either side of each of the numerals 1-8 on terminal board 48 are connected together, but have been shown as separate pins for purposes of clarity.
The two leads of AC power cord 30 are connected to pins 1 and 3 of terminal board 48, while on/off switch 22 and fuse 52 are wired in series between pins 1 and 2. The on/off lamp 24 together with a resistor 54 are wired in series between pins 2 and 3 of terminal board 48. When switch 22 is closed, lamp 24 is energized to indicate that system 10 is on.
A transformer 56 is provided for converting 110 volt alternating current to two levels of direct current for use by sensor 16 and recorder 34. The primary terminals 56a of transformer 56 are connected to pins 2 and 3 of terminal board 48.
Transformer 56 includes a first set of secondary terminals 56b for providing a relatively low direct current voltage to sensor 16, and a second set of secondary terminals 56c for providing a relatively higher direct current voltage to recorder 34. A pair of resistors 58 and 60 are connected in parallel between the upper lead of first secondary terminal 56b and pin 8. The lower lead of first secondary terminal 56b is connected to pin 7. Pins 7 and 8 of terminal board 48, of course, are connected to cathode 16a of sensor 16.
A diode 62 and resistor 64 are connected in series between the upper lead of the second set of secondary terminals 56c and ground. Another diode 66 is connected between the lower lead of the second set of secondary terminals 56c and the junction between diode 62 and resistor 64. A zener diode 68 is connected between ground and the center tap of terminals 56c, which is also connected to the lower lead of the first set of secondary terminals 56b. A variable resistor 74 is connected between the center tap of secondary terminals 56c and ground. A resistor 70 is connected between pin 4 and ground and a resistor 72 is connected between the wiper of variable resistor 74 and pin 4. The variable resistor 74 provides for adjustment of the current flow to sensor 16 to vary the temperature thereof. A resistor 76 is connected between pin 5 and ground. Variable resistor 78 and resistor 80 are connected in series between pins 5 and 6. Resistors 82 and 84 are connected in series between pin 6 and ground. Resistors 78-84 provide signal conditioning and adjustment for the sensor signal which is transmitted to recorder 34.
Looking now at the left side of FIG. 4, line 32 interconnecting control panel 20 and recorder 34 is comprised of five leads 86, 88, 90, 92 and 94. Leads 86 and 88 which carry the alternating current to power recorder 34 are connected to pins 2 and 3, respectively, of terminal board 48. Lead 90, which carries the negative reference voltage for the sensor signal to ride on, is connected to pin 4. Lead 92 connected to pin 5 carries the conditioned signal from sensor 16. Lead 94 is connected to an internal threshold detector within recorder 34, which applies a voltage to energize the warning lamp 28 when a predetermined threshold, as set by arm 95 (FIG. 1) on recorder 34. has been exceeded. Diode 96, resistor 98 and capacitor 100 comprise a relaxation oscillator network causing lamp 28 to flash when a voltage is applied to lead 94.
Referring now to FIG. 5 in conjunction with FIG. 1, recorder 34 is preferably a twenty four hour, clock-driven unit. Any suitable recorder can be utilized, such as the Model ET recorder available from Partlow Corporation of New Hartford, N.Y. FIG. 5 illustrates a portion of a mud log recorded on chart 36 of recorder 34. Between the times of 1:00 p.m. and 4:00 a.m., it will be noted that the tracing on chart 36 is relatively close to the center of the chart, thus indicating little or no hydrocarbons in the formations penetrated by the drill bit at that time. On the other hand, a high concentration of hydrocarbons would appear to be present in the particular formations traversed between the times of 5:30-6:30 a.m. and 7:30-8:30 a.m. as indicated by the large deflections in the tracing made by pen 38. In correlating the information on chart 36 with drilling depth, of course, it will be necessary to allow for the lag time required for the drilling mud to travel from the bottom of the borehole to sampling chamber 12.
In view of the foregoing, it will be apparent that the present invention comprises a new and improved mud logging system having several advantages over the prior art. The system herein features simplified construction and requires no operator attention other than to turn on and adjust the system, and to periodically change the chart of the recorder. With the system herein, it becomes economically feasible to drill and log some exploratory holes which would be too costly with the complicated systems of the prior art. Other advantages will be apparent to those skilled in the art.
Although particular embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the specific embodiments disclosed, but is intended to embrace any alternatives, equivalents, modifications, and rearrangements of elements as fall within the scope of the invention as defined by the following Claims. | A system (10) for continuously analyzing drilling mud circulating through a borehole comprises a sampling chamber (12) through which flows the return mud, a sensor (16) mounted in the sampling chamber for detecting hydrogen gas percolating out of the drilling mud and for producing a signal representative of the concentration of hydrogen, and a recorder (34) for recording the signal from the sensor over a period of time. Appropriate circuitry within a control panel (20) is connected between the sensor (16) and recorder (34). In the preferred embodiment of the invention, the recorder (34) comprises a clock driven disk recorder. |
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CROSS REFERENCE TO OTHER APPLICATION
This is a Continuation-in-Part Application of application Ser. No. 198,830, filed Oct. 20, 1980 now abandoned.
BACKGROUND OF INVENTION
It is known in the construction industry, particularly the building of dwelling houses and other buildings, to erect a rain gutter at roof edges. Such gutters usually have associated downpipes. By these means, water coming off the roof may be intercepted, collected, and diverted into desired locations. This avoids splashing, "trenching", flooding, and other undesired effects. A persistent problem with such gutters is that they collect leaves, sticks, roof granules, pine needles, and other debris as well. This causes the gutters and/or down-pipes to become blocked. As a result, water backs up, causing it to flood over the gutter edges and sometimes down the side of the building, and permitting freezing in the gutter to occur. It may also or alternatively cause the gutter to accumulate pools of water which do not drain off rapidly or readily, and cause weeping and/or rusting of joint areas and sometimes freeze into ice in cold weather. Additionally, gutters may become broken by snow and/or ice sliding off the associated roof.
In an attempt to overcome the necessity for manually clearing the gutters and/or down pipes periodically, usually by ascending a ladder, various proposals have been made. They range from applying screens to cover the gutter openings, to deflector means. The general experience has been that the installation of screens basically does little more than relocate the problem of debris blocking from the gutter to the screen, necessitating periodic manual removal anyway. From time to time, it has been proposed to use "deflector" type devices, by which it was contended it would be possible to redirect the flow of rainwater coming off of the top surface of a roof into a gutter, free of debris which will, in the meantime have been ejected off of the roof onto the ground. Some of such deflector type devices include a lower arcuate surface by which, theoretically, water coming down the roof will, by the effect of surface tension, be forced to follow around the arcuate surface. By this means, it was postulated that the water may be deposited in the gutter which is positioned inside and below the arcuate surface, while debris carried by the water is jettisoned off, more or less tangentially to the curved surface, and falls to the ground. In this connection, reference is made to the following U.S. Pat. Nos.: Van Horn 546,042; Nye 603,611; Cassen 836,012; Cassens 891,405; Yates 1,101,047, Goetz 2,672,832, Bartholomew 2,669,950; Heier 2,873,700; Natthews et al 2,935,954; Foster 3,388,555; Homa 3,507,396; and Zukauskas 3,950,951.
A remarkable thing about devices such as the foregoing is that although the basic theory has been available for some time, as far as is now known, it has never actually been adopted or used in what might reasonably be described as a commercial embodiment. In part, this may be because there is little to impell builder-contractors to incur whatever extra cost or expense involved in making such installation initially. Once a conventional system has been installed, to "retrofit" an existing installation involves troublesome, time-consuming, costly, basic and/or aesthetically undesirable structural alterations to the existing gutter installation and, in many cases, to the building with which it is associated. It also appears that a reason why the concept has not found significant or widespread use is because, as disclosed to date, it didn't work with a sufficient degree of reliability or effectiveness to make it practically feasible. That is, practicing the extant disclosures as taught, it has been found that surface tension of the water often is not sufficient to contain the water through an arcuate travel path against counter-forces typically encountered from factors such as a large volume of water, steep slopes, "rivuletting", etc. Whatever the particular reasons, the impressive fact is the lack of their adoption and use to date, in spite of the obvious advantages which might occur if they could be used, in light of the costs and difficulty of obtaining maintenance labor, particularly in recent times.
Accordingly, it is an object of the present invention to provide means for accomodating roof-water while segregating debris therefrom.
Another object of this invention is to provide such means in a form which is substantially maintenance free.
Still another object of this invention is to provide means for accomplishing some or all of the foregoing objectives in a form which is structurally simple and easy to install.
Yet another object of this invention is to provide means for accomplishing some or all of the foregoing objectives which is adapted for retrofitting existing installations.
SUMMARY OF INVENTION
Desired objectives may be achieved through practice of the present invention, embodiments of which include a rain gutter debris deflector for disassociating rain water from debris and depositing the rain water in an associated rain gutter while ejecting debris so that it does not pass into the rain gutter, characterized by having an upper sloped portion, a lower arcuate deflector portion for re-directing water through operation of surface tension, and means for controlling the normal flow of water through the arcuate portion so that centripetal forces thereon substantially throughout will not exceed the surface tension of the water.
DESCRIPTION OF DRAWINGS
This invention may be understood from the descriptions herein set forth and from the accompanying drawings in which:
FIG. 1 illustrates a prior art device,
FIG. 2 illustrates another prior art device,
FIG. 3 is a cross-sectional view of an embodiment of the present invention,
FIG. 4 is a plan view of the embodiment of this invention illustrated in FIG. 3,
FIG. 5a through 5d illustrate various geometric patterns of embodiments of this invention,
FIG. 6 is a side elevation view of a rain deflector device,
FIG. 7 is a side elevation view of another embodiment of this invention,
FIG. 8 illustrates an embodiment of this invention, and
FIG. 9 illustrates details of an embodiment of this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, there is depicted a prior art device 10, for use in connection with a known per se rain gutter 12, which has an outer edge lip 14. Normally, such rain gutters are positioned higher up on the fascia 17 of the building 19 than as shown in FIG. 1, so that the plane of the shingles 15 is intercepted by the lip 14 of the gutter 12, so that rain coming off the roof shingles 15 will be caught by the gutter 12.
It will be obvious from FIG. 1 that installation of the water deflection device 10 has made it necessary to lower the gutter 12. Even with a new installation, this presents some difficulties because the positioning of the gutter 12 and the device 10 must be carefully regulated with respect to the amount of overhang and angle of the roof 15. In a "retrofit", or installation of a water deflector 10 to an existing installation, the problem is even more difficult, because it involves the added problem of having to move and relocate installed gutters and downspouts. According to the prior art, a water deflection device 10 may be installed contiguous with the edge of the roof. It includes a flat main portion 16 and a curved or arcuate portion 18 between the main portion 16 and the lower edge 20. The device 10 is so positioned that the lower edge 20 is between the front edge 14 and the rear wall of the gutter 12, and the curved portion is of sufficiently large radius as to extend beyond the trough 11 portion of the gutter 12, and to cause water 22 traversing the device 10 to be caused, by surface tension, to follow around the curved portion 18 and leave the device 10 at the lower edge 20. While this is going on, leaves and other debris 24 being impelled along by the water 22, if not being subject to the same surface tension forces will tend to generate sufficient centripetal force to fly free of the water and jettison free of the device 10 without ending up in the gutter 12. FIG. 2 illustrates a result which occurs when the prior art teachings, without more, are followed. As illustrated, substantial quantities of water 22, as well as unwanted debris, may break loose from the deflecting forces induced by the arcuate surface 18, causing water 22 to spill free of the gutter 12 without being caught by it. Without intending to be bound by any theory, it is believed that this occurs when the kinetic forces acting on the water are sufficient to overcome the surface tension, as a result of which the surface tension is inadequate to deflect the water into a reversing path and into the gutter 12. Such kinetic forces may so become excessive through any or a combination of a number of causes. Included among them are a steep slope of the roof 15 and or the main section 16 by which gravity induced forces become excessive, a high volume of water by which the total force becomes excessive; and "rivuletting" by which the thickness of the sheet of water traversing the device is not uniform but, instead, accumulates into more or less discrete streams with dry voids inbetween, so that excessive volumes of water are localized intermittantly across the face of the device 10 with consequent excessive forces in the rivulet areas sufficient to cause the water stream to break away at one or more places. One way, it was thought, that this adverse result might be remedied, is by increasing the radius of the arcuate portion. However, this induces other difficulties. For example, lowering the gutter to accomodate the consequent lowering of the bottom edge of the deflector is time consuming, difficult, expensive, and disruptive of the aesthetics of the building. These factors, in which the lack of acceptance and use of such devices may lie, are avoided through practice of the present invention.
FIGS. 3 and 8 illustrate embodiments of the present invention. Each includes a main body 16, a curved portion 18, and a lower edge 20, and is positioned with respect to an associated gutter 12 so that its arcuate section 18 is outside the trough 11 and the lower edge 20 is between the front and back walls of the gutter 12. Unlike prior art devices, however, these embodiments of this invention include ridges 30, arrayed substantially parallel to the axis of the arcuate portion 18. Three ribs are shown. Although it is within the contemplation of this invention that any number of such ribs may be used, it has been found that a single such rib is of minimal effectiveness for the purposes herein described, that two work well, and that excellent results are obtained with three or more. Generally speaking, it may be postulated that the number of ribs should be increased correspondingly to increases in the maximum quantity of water it is desired to accomodate, particularly where, through the operation of such material as an oil film, the surface wetting characteristics are more or less inhibited. It will be clear that such ribs may easily be incorporated into the sheet metal, plastic or other material from which the device 10 is made by initial casting, rolling, including them as an added part of the cross-section, or other known per se means, and that usually the ribs will have the added feature of strengthening the device against deflection in the longitudinal direction. As will be apparent from FIGS. 3, 8 and 9, the effect of the ribs 30 is to form longitudinal weirs and ponds 33 down the length of the device. As a result, water traversing the device has its velocity interrupted as it collides with the upper surfaces of the ribs and is distributed more or less uniformly across the face of the device. This effect is further enhanced when a second rib is added, and more so with a third. Past a certain number, further enhancement may occur in decreasing amount but not significantly so. In practice, it has been found advantageous to have the plane of the top surface of the deflector intersected by the upstream surface of the uppermost ridge at least (and preferably the other ribs as well) at a pronounced angle, rather than a gentle slope. This causes water moving across the deflector to be confronted by a relatively abrupt barrier at each such intersection, rather than a ramp over which the moving water will shoot, instead of cascading substantially evenly after having first collided with the rib and become more or less co-mingled with the pool of water formed above the ridge. This is emphasized in FIG. 9 where the intersection angle ρ is shown to be steep; i.e. in the range of 55°-85°. Obviously, the intersection angle may be made greater for ribs of semi-circular cross-section by raising the center, or shallower by lowering it. Further, other cross-sectional shapes may be utilized to exploit the phenomenon more effectively. For example, sectors of ellipses can be made to combine lower crowns of the ribs with steeper top and bottom intersections than circular cross-sections, while tear drop shapes can produce regulated crown heights with abrupt "up-stream" intersections while having tapered or shallow sloped "down-stream" intersections. It should also be clear that the upper surfaces of the ribs need not necessarily be arcuate in cross-section. For example, ribs which are merely linear, are quadrilateral, or are "saw-tooth" in cross-section will also function effectively.
As this implies, the height of the crown, or top-most point on the rib with respect to the plane of the upper deflector surface, can also have an affect on achieving the desired "pooling" and cascading attenuation, rather than overshooting with consequent rivuletting and disruption of the desired surface tension phenomenon. These parameters may be individually or collectively manipulated by those skilled in the cognizant arts in light of the particular roof slope-angle, deflector angle, anticipated water flow volume and other determinative factors.
The effectiveness of such ribs may also be enhanced by having the lowest (i.e., most "down-stream") of them in close proximity to the top of the curved portion, since this gives the water less opportunity to accelerate beyond desired limits after passing over the lowest rib. It has been found advantageous in certain installations for this spacing to be about 11/2 inches. The effect of such velocity attenuations and lateral re-distributions is to reduce the kinetic forces which tend to cause water traversing the device to break free in the course of traversing the arcuate portion 18 of the device, thereby permitting the surface tension forces to dominate the behavior of the water and to cause the water to follow the device around and into the gutter 12; all as shown in FIGS. 3 and 4. They also tend to break up "rivuletting". Note particularly that with the present invention, a smaller radius arcuate section 18 and/or positioning the deflector so that its upper flat surface is at a shallower angle than that of the roof surface, as hereinafter described, can obviate the necessity of relocating the gutter lower on the fascia board, particularly in "retrofit" installations.
Optionally, raised crowns 31 may be formed on the top surface of the main body 16, more or less throughout, or in isolated areas to hold leaves and debris up away from the principal water paths. This has the effect of keeping the water paths unblocked and of making leaves particularly easier to remove because they are less likely to stick down than on a flat surface. Such crowns may be of any suitable geometric shape in plan view, such as squares, circles, ellipses, trapezoids, and the like. Such crowns, which also facilitate removal of debris by the wind by keeping the debris raised above the deflector, may also or alternatively be positioned between the ribs hereinbefore described.
The embodiments illustrated in FIGS. 3, 4 and 8 are shown as having a plurality of continuous ribs 30. Although this is a desired configuration, as shown in FIG. 5, other configurations, such as the continuous and intermittent patterns shown in 5a, 5b, 5c, and 5d, may also be effectively used. Further, although linear ribbings are shown, they may be in other forms, such as broader bands, depressions, or other geometric configurations which will produce the desired barrier and/or redistribution effects. Note particularly that as shown in FIG. 5d, it is also within the contemplation of this invention that a multiplicity of staggered arcuate ribs might also be used. In this connection, the reference herein to the "long dimension" of such an arcuate rib means the general orientation indicated by a fictitious line joining its ends a-a 1 .
FIG. 6 illustrates the previously referred to "rivuletting" phenomenon. Here, because of uneven distribution of the water and/or incapacity for ready and uniform "wetting" of the surface of the device, the water 22 tends to concentrate in some areas 25, while being less concentrated, thinner, or even totally lacking in other areas 23. As a result, the concentrations of mass in the increased volume areas 25, reacting to the pull of gravity, may set up kinetic forces in the areas of concentration in excess of the surface tension forces, causing water not to follow the contour of the arcuate portion 18 of the device but rather to spill over the outside of the front wall of the gutter 12.
As shown in FIG. 7, this "rivuletting" effect may be controlled within tolerable limits or even eliminated by improving the "sheeting" of the water or otherwise rendering it so that it is substantially of uniform thickness across the face of the device. This is analagous to the lateral redistribution effect of the ribs 30 shown in FIGS. 3, 4, and 5, but may be produced by other means. One such means is in the choice of finish applied to the exposed upper surface of the device. For example, acrylic-latex paints generally are very wettable, while surfaces painted with certain polyester based paints are not. The latter, tending to exhibit a much greater tendency to "rivuletting" of the type shown in FIG. 6 than the former, therefore exhibit a greater tendency to "spillover" with devices of the type herein discussed than do the former. The more unified "sheeting" of the water 22 attainable through utilization of "wettable" surfaces is illustrated in FIG. 7 where a sheet of water 22 is shown to have traversed the main portion 16 and to have followed the arcuate contour 18 into the gutter 12. Such surface treatment may be used alone or in combination with the aforementioned ribs and/or other flow interruption devices.
As shown in FIG. 8, devices made in accordance with this invention may be affixed to the eave of a building in appropriate relationship to an associated rain gutter according to known per se means. The upper end of the main portion may be slid under a course of shingles or affixed thereto, or even merely placed in contact with the upper surface thereof as shown in FIG. 3, since, even if there is water leakage between its lower surface and the upper surface of the shingles, debris is not thereby admitted to the gutter and the roof continues to pass water to the gutter merely in the fashion that it was originally intended to do. An additional advantage of such devices is that they also facilitate avoiding the accumulation of ice and or snow at the roof edge both because they present a relatively smooth, adhesionless surface to such materials, and because they cover the gutters themselves which otherwise present "pockets" in which such ice or snow may deposit. It should be noted in particular that devices made in accordance with this invention will function effectively whether the underside of the upper region is substantially flush throughout with the upper surface of the associated roof as shown in FIG. 3, or whether there is an angular displacement therebetween as shown in FIG. 8. Furthermore, in practice, it has been found that it doesn't matter significantly even if the upper edge of devices made in accordance with this invention are not overlayed by a course of shingles since, in any event, the upper edge region will be more or less tight to the upper surface of the roof anyway, and any leakage of water at that point will filter out the significant portion of debris and the water so leaking will merely be handled by the lower edge of the roof and into the associated gutter, functioning entirely in the manner for which they were intended and constructed. In fact, advantages may be realized by positioning the deflector device at a more shallow angle (i.e., more nearly horizontal) than that of the plane of the roof as shown in FIG. 8 since, as will be apparent from the foregoing explanations, this will have the effect, beneficial in terms of operability of the arcuate portion as a debris-water segregator, of reducing the gravity-induced kinetic energy of water coming off the roof and of being aesthetically more pleasing. FIG. 8 also illustrates that it is not necessary to relocate the gutter 12 downward from the location in which traditionally it is placed; i.e., high up on the facia board 17 with its back wall under the overhang of the roof shingles. With the deflector at a shallower angle "β" than the angle "α" of the slope of the roof (with respect to horizontal), the curved portion 18 of the deflector may be of comparatively large radius, thus enhancing the effectiveness of the surface tension phenomenon. By this means, not only is considerable bother and expense avoided in retro-fitting an existing installation, but the final result in a new or retro-fit installation looks better and does not derogate materially from the appearance of the structure as a whole.
It should be noted that the embodiment shown in FIG. 3, where the uppermost edge of the top section of the deflector is not positioned under a course of shingles, may also be oriented at an angle shallower than that of the roof, by raising its curved portion and causing the entire structure to raise upward as it pivots along its upper edge. It has been found advantageous to adapt the upper edge region of deflectors embodying this invention for substantially continuous contact with the upper surface of the roof. This may be done by a variety of means, such as inserting the upper edge region as shown at "c" in FIG. 8, or simply having the upper edge rest on the roof as shown in FIG. 3 with the upper edge region of the deflector having some downward bias to hold it in contact with the roof, or with a strip of tape bridging the top edge region and the top of the roof, or with nails, adhesives, asphalt "spots" or other known per se means. Thus, the top region might be made to end with its top edge abutting the lower edge of a course of shingles, (shown as position "b" in FIG. 8), or with it ending (as shown at position "a" in FIG. 8) partway along the top surface of a shingle so as to afford a flat surface contiguous with the top of the roof, or with its top edge in "line" contact with the top of the roof.
As previously noted, substantial continuity is sufficient, since some water leakage under the deflector is usually of no significant moment to the utilization of such embodiments of this invention. If it is desired, however, as where the debris to be excluded from the gutter includes materials which are smaller than the gap between the deflector and the roof, the interface may be substantially totally sealed off. To enhance such continuity, particularly with the use of adhesives, it may be desirable to introduce an angulation to bring the top region into planar abuttment with the top surface of the roof while the mid-region of the deflector is at a comparatively shallower angle, all as shown in FIG. 8, but this is not critical to operability of this invention.
FIG. 8 also illustrates a support hanger 35 which is particularly adapted for such shallower angle deflectors when used with metal gutters of current design. The hanger may be made from any suitable material, such as metal or plastic, and may be fastened to the deflector by any of a number of known per se fastening means such as sheet metal screws, clips, rivets, welds or brazes, bolts and nuts, adhesives, or the like. As shown, it does not extend all the way along the underside of the top portion of the deflector to the roof, but it may do so and thus provide some added support. The outermost end 37 of the support 35 is formed in a "V" shape at the end of a horizontal span. Thus, the "V" shape may be inserted inside the closure forming the lip 14 of the gutter while the support is attached to the deflector and the deflector is oriented more or less vertical. The support-deflector combination may then be swung pivotally downward to position atop the roof. This hanger provides a structurally simple, effective, and inexpensive support means which is also adapted for facilitating maintenance.
Example
An embodiment of the present invention utilizing a deflector of design substantially like the deflectors shown in FIGS. 3 and 8 was installed at an angle of about 11° on a residence in Raleigh, N.C., the roof of which is at about 221/2°. The deflector was made from 0.019" aluminum with a painted finish. The length of the curve through the curved portion was about 21/2" and the length of the rest from the curved portion to the topmost edge was about 91/2". The radius of the curved portion was about 3/4". It had, each 0.15" high and 0.175" wide at the base, of arcuate cross section. The ridges were spaced about 11/2 apart, with the bottom-most ridge about 13/8" back from the top of the curved section. The device was found to work well, delivering virtually all of the water and virtually none of the debris crossing it to the associated gutter throughout the rainy seasons, sometimes during rainstorms which were considered heavy for the region.
Variants of the present invention may include modifications to accomodate the particular roof slope, edge contours and configurations, and/or building materials which characterize any specific structure. Additionally, local or regional climatic conditions may also be accomodated. For example, the National Weather Service publishes various data showing the maximum amounts of rainfall which occur for a range of time intervals (e.g., 5 minutes, 15 minutes, 60 minutes, etc.) over several spans of time (e.g., 2 years, 100 years, etc.). Data such as these may be utilized in varying the exact design configuration of a given deflector, for example, as to the number, nature, configurations, and/or dimensions and comparative proportions of the various elements, the radius and cross-sectional configuration of the curved portion, the surface textures and/or wetability, the angular disposition of the various elements with respect to each other and to the roof, etc., all as will be apparent to those ordinarily skilled in the cognizant arts in view of the present invention. Additionally, a wide variety of materials may be utilized to produce devices according to the present invention. Galvanized steel, aluminum, and other metals, as well as various plastics may also be used to particular advantage since they are easily formed according to technology which is known per se into complex and intricate shapes and configurations, are durable and weather resistant with minimum maintenance requirements, and may be made inherently to have desired surface characteristics such as improved wettability. All of the foregoing are within the skills, competence and knowledge of the person with ordinary skills in the cognizant arts.
Accordingly, it is to be understood that the embodiments of this invention herein described are by way of illustration and not of limitation, and that a wide variety of embodiments may be made without departing from the spirit or scope of this invention. | Embodiments useful as means for inhibiting the accumulation of leaves and other debris in household rain gutters. Embodiments include structures which comprise a deflector having a sloped portion, the top edge region of which is adapted for juxtapositioning to the roof shingles, and the bottom edge region of which is arcuate through a large radius cross-section. In such embodiments, the farthest outward extension is outside the outermost edge of the associated rain gutter and the lower edge is positioned between the edges of the rain gutter. Embodiments include means for attenuating the force of water and reducing the localized concentrating of water flowing thereover, such as longitudinal ridges and/or means for improving the surface wettability. Through practice of this device, kinetic gravity-induced forces on up to normal volumes of water flowing down the sloped portion may be kept, through the arcuate portion, below the forces acting counter-directionally thereto due to surface tension of the water normally to prevent substantially centripetal ejection of water as its direction of travel is changed to deposit it in the gutter while ejecting water carried debris carried outside the gutter. |
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FIELD OF THE INVENTION
[0001] The present invention relates generally to trailers and in one aspect relates to a towable accommodation or storage assembly including an expandable portion.
BACKGROUND OF THE INVENTION
[0002] There are numerous configurations of trailers and caravans current on the market that provide portable accommodation or that provide the means for transporting equipment, such as tents, recreation vehicles and boats. Towable accommodation in the form of camper trailers, caravans, campers, towable RVs and tent trailers are widely used in Australia and the USA.
[0003] There are also trailers that allow for the transportation of recreational vehicles, such as quad bikes, which also include a sleeping cubicle or sealed compartment for storing bedding.
[0004] All of these types of trailers or mobile accommodation units, typically comprise a chassis supported on wheels connected to a respective axle or independent suspension, a drawbar connectable to a towing vehicle and a body fixedly attached to the chassis.
[0005] Many of the trailers and caravans currently on the market include awnings that are configured to provide additional covered living space. Furthermore, there are a number of caravans and campers that include expandable body portions to provide an enlargeable internal living space such as the units disclosed in U.S. Pat. No. 5,090,749 to Counsel, and U.S. Pat. No. 9,597,993 to Pellicer. These expandable body portions typically include a slidable portion that can be slid outwardly when on site and then stored away during transport.
[0006] Existing expandable body portions are however typically configured to retract into the internal space of the caravan or camper trailers, which means that they can impinge upon the existing structures within the caravan or can make packing of the trailer or caravan problematic.
[0007] En-suite caravans have become popular in recent times. However, such caravans are typically larger in length thereby affecting off-road ability and requiring the towing vehicle to have sufficient towing capacity. Alternatively, an en-suite tent can be attached to a side of a camper trailer or caravan, however these typically cannot be accessed from the interior of the tailer or caravan and accordingly lack privacy. Furthermore, such en-suite tents cannot be used at many caravan or trailer park sites since they do not capture or at least direct the grey water in a controlled fashion.
[0008] The phase ‘towable accommodation or storage assembly’ used throughout the specification should be understood to include any type of towable vehicle including, but not limited to, on-road camper trailers, on-road caravans, off-road camper trailers, off-road caravans, tent trailers, RV's, motorhomes, haulage trailers, mobile homes, caravanettes, goods trailers, flatbed trailers, tradesman trailers, storage trailers, car carriers, boat trailer, horse floats or any other type of towable vehicle having a drawbar.
[0009] It should be appreciated that any discussion of the prior art throughout the specification is included solely for the purpose of providing a context for the present invention and should in no way be considered as an admission that such prior art was widely known or formed part of the common general knowledge in the field as it existed before the priority date of the application.
SUMMARY OF THE INVENTION
[0010] It could be broadly understood that the invention resides in a towable accommodation or storage assembly that includes a floor portion that is affixed to or supported on a drawbar, wherein an expansion portion is configured to be pivoted to one side of said floor portion to form at least one wall when said assembly is being used for the purpose of accommodation or utility.
[0011] In one aspect of the invention, but not the broadest or only aspect there is proposed a towable accommodation or storage assembly including, a chassis supported on at least two wheels connected to a respective axle or independent suspension, a drawbar, and a body generally rigidly mounted to said chassis, the towable accommodation or storage assembly being towable behind a towing vehicle, the body having spaced apart first and second sidewalls, a rear wall extending therebetween, a roof attached to upper parts of said sidewalls and rear wall, and a main floor attached to lower parts of said sidewalls and rear wall, an expansion portion, pivotably mounted to, or adjacent a generally vertical front edge of the first sidewall and pivotable to abut a generally vertical front edge of said second sidewall, a fixed first floor portion adjoining or extending outwardly of said main floor, and a movable second floor portion attached to or adjacent the first floor portion and supportable on or above said drawbar, wherein said expansion portion is configured to pivot about a generally vertical axis from a first position wherein the expansion portion abuts or is positioned adjacent said vertical front edge of the second sidewall and covers at least a part of the first floor portion, and a second position wherein at least a part of the first floor portion is exposed and said second floor portion is supported in a generally horizontal orientation on or above the drawbar to thereby provide at least a part of an expanded floor for an expanded living space and the expansion portion forms at least a first side wall of said expanded living space.
[0012] In one form the expanded floor of the expanded living space comprises the first floor portion that is fixed to the chassis or drawbar, and the second floor portion that is hingedly attached to a front edge of the first floor portion and pivotable about a horizontal axis between a generally vertical or oblique orientation and a generally horizontal orientation wherein it is configured to be supported on an upper surface of said drawbar.
[0013] Preferably the expansion portion completely overlays the first floor portion when in said first position, to seal the first floor portion from the ingress of dust. An underside of the expansion portion may include seals to inhibit the ingress of dust and sliders, rollers or wheels to assist in the movement of the expansion portion over said first and/or second floor portions.
[0014] In one form the body may include a front wall that encloses the body to define an internal living or storage space. The front wall may include a door to permit access to the internal living or storage space. In another form the body may include an open front or a movable partition wall. Alternatively, the body may include or comprise a rear flatbed or box tray, or the rear wall of the body may include or comprise a door for accessing the internal living or storage space
[0015] The towable accommodation or storage assembly could therefore be broadly understood to comprise an internal living or storage space at least partially delineated by the body, and an expanded living space that is at least partially delineated by the expansion portion and the expanded floor.
[0016] The front wall of the body or a portion thereof may be movable when the expansion portion is in said second position or between the first and second positions, to permit access between the expanded living space and the internal living or storage space.
[0017] In one form, generally rigid panels are used to form a roof, front wall and second side wall of the expanded living space. The panels are secured in place by relevant clamps, clips or temporary fixing means. The panels that form the roof and walls may be hingedly or slidably attached to the body. In one form the roof panel slidably engages the roof of the body wherein it can be extended when the expansion portion is in the second position.
[0018] In another form, at least some of the walls and/or roof of the expanded living space are constructed from a flexible material, such as but not limited to canvas, PVC or ripstop nylon, wherein zips, elastic cords, press studs, or strips of hook and loop fasters are used to hold the flexible material in place.
[0019] In another form an awning, tunnel tent or gusset may be used to connect the expanded living space to a rear internal space of said towing vehicle. The awning, tunnel tent or gusset may be connected to, or extends over, a rear of said towing vehicle.
[0020] The walls and/or roof of the expanded living space may include a foldable frame wherein as the expansion portion is opening the frame folds out from a storage position to form the walls and/or roof. This automatic deployment of the walls and/or roof may be used to reduce the time of setup. Alternatively, the flexible walls and/or roof may be manually retrieved from a storage cavity and may be clipped or otherwise secured in place. A removable pole/s or frame can be manually located in position in a similar fashion to the tent of some tent trailers.
[0021] The opening and closing of the expansion portion to provide the expanded living space may be undertaken by way of electric or mechanical assistance and include actuators, levers, pulleys, cables or any other necessary apparatus that are required to assist the user in moving the expansion portion. In one form the movement of the expansion portion may be completely automated with appropriate stops and override mechanisms to inhibit damage to any opening/closing apparatus.
[0022] The roof and walls of the expanded living space are configured to interconnect with each other and the expanded floor to thereby provide a generally enclosed expanded living space. The connection devices used to connect the roof and walls preferably provide a barrier to the ingress of water and dust, but in some forms may simply provide connection between the roof, walls and expanded floor without a weather seal to the surrounding environment.
[0023] In one form the fixed first floor portion and hinged second floor portion are generally planar and configured to be positioned on generally the same horizontal plane when being used for accommodation or utility purposes, i.e. kitchen, en-suite.
[0024] In another form the first and/or second floor portions includes at least one part that is sloped to permit drainage. Alternatively, the first and/or second floor portions may be slatted to permit movement of water therethrough into a sump or drain. In the immediately preceding forms the first and/or second floor portions are configured to act as shower base and includes a drainage hole or holes to be used to direct grey water into a detachable hose or a grey water tank.
[0025] The first and/or second floor portions may be rectangular or may conform to the shape of the drawbar and be generally triangular shaped. In the triangular configuration, the expansion portion will be configured to open to around 60° relative to a front vertical plane of the body, or any other suitable angle.
[0026] A movable internal panel attached to the expansion portion or a front portion of the body may be used to provide an internal sidewall for an ablutions cubicle containing a toilet and/or shower and/or basin.
[0027] In another form the internal panel is a bi-fold partition that includes two pivotable parts that are vertically connected and are positionable to form two walls of said ablutions cubicle.
[0028] Preferably the expansion portion includes storage compartments or facilities that can only be accessed from within the expanded living space. In one form the facilities may comprise a toilet, shower or sink with appropriate plumbing. The plumbing may include couplings for connection to a water source or dumping point. The couplings are preferably accessible from an exterior of the expansion portion and may include covers or caps to protect them when not in use.
[0029] In one form when the second floor portion is in a generally upright position it covers the external access points or couplings for the services i.e. power, gas or water couplings. The second floor portion may also be configured to cover a hot water system and/or water filtration system and/or storage area when in the upright position.
[0030] Preferably a door is located in at least one of said walls of the expanded living space to allow access thereto.
[0031] In one form a partition wall may be located between the expanded living space and the internal living or storage space of the body. The partition wall may be movable to fold out from an edge of the body or expansion portion. The partition wall may include a door therethrough or a void or voids to permit access between the expanded living space and the internal living or storage space of the body.
[0032] In another form, there is no barrier between the expanded living space and the internal living or storage space of the body, whereby the expanded living space provides an extension of the internal living or storage space of the body.
[0033] The body may provide a living space including at least one sleeping structure and the expansion portion may provide an expandable en-suite and/or kitchen space. An internal door is preferably used to separate the expandable en-suite from the living space.
[0034] The ablutions cubicle or en-suite may include movable walls wherein the size of the ablutions cubicle may be reduced by moving a wall or walls to access a part of the kitchen space or a storage area.
[0035] In another form, the expandable en-suite may be accessible from an exterior of the towable accommodation or storage assembly through an external door.
[0036] The expansion portion may provide cooking, preparation, eating, storage, sleeping and/or ablutions areas.
[0037] Preferably the hinged second floor portion acts as a stone guard when the towable accommodation or storage assembly is being towed and as a part of the expanded floor of the expanded living space when in an expanded arrangement.
[0038] The second floor portion is hingedly attached to or adjacent a forward edge of the fixed first floor portion. The hinged second floor portion is configured to hinge about a generally horizontal axis between an upright or angled position wherein it protects the expandable accommodation unit from damage by stones, and a lowered position wherein it is configured to rest generally horizontally on, or parallel with, the drawbar to thereby form part of the base of the expanded living space.
[0039] In another form, the second floor portion is slidably connected to or adjacent the first floor portion whereby it can be slid out of a stored position to be supported on or above the drawbar when the expansion portion is in the second position.
[0040] The expansion portion may be generally rectangular in its horizontal cross-sectional profile to thereby limit its footprint when in the first or folded position, whilst maximising the size of the expanded living space when the expansion portion is in the second or extended position.
[0041] Stabilising legs or struts may be used to support the hinged floor portion. Stabilising legs or struts may also support the expansion portion when in the first or open position. The legs or struts are preferably connected to the expansion portion and second floor portion, and can be pivoted or slid into place to support the respective structures. In another form, they may be reversibly attachable thereto.
[0042] Preferably the legs or struts are configured to engage a ground surface and may include feet or the legs, or the struts may be configured to engage receiving brackets on the chassis or drawbar.
[0043] Alternatively, the second floor portion may be supported completely on the drawbar and the expansion portion is supported on the first and/or second floor portions.
[0044] In another aspect of the invention there is proposed a method of providing an expandable portable living space, including the steps of: providing a towable accommodation or storage assembly including a chassis supported on at least two wheels connected to a respective axle or independent suspension, a drawbar for coupling to a towing vehicle for transportation thereof, a body generally rigidly mounted to said chassis, an expansion portion pivotably mounted to, or adjacent said body, and a floor portion or portions mounted to, or supported on, an upper surface of said drawbar; towing said towable accommodation or storage assembly with the expansion portion in a retracted position, to a lodging site; pivoting said expansion portion about a generally vertical axis into an extended position thereby exposing or positioning said floor portion or portions to provide an expanded floor for an expanded living space, the expansion portion forming at least one wall of said expanded living space; and attached or positioning a roof and walls in place to thereby at least partially enclose said expanded living space.
[0045] Preferably when in said retracted position the expansion portion abuts or is at least positioned adjacent a front of said body. The expansion portion may overlay a part of said floor portion or portions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description and claims, serve to explain the advantages and principles of the invention. In the drawings,
[0047] FIG. 1 is a perspective view of a first embodiment of the towable accommodation or storage assembly illustrating an expansion portion in a retracted or closed position;
[0048] FIG. 2 is a perspective view of the towable accommodation or storage assembly of FIG. 1 illustrating the expansion portion in an intermediate position;
[0049] FIG. 3 is a perspective view of the towable accommodation or storage assembly of FIG. 1 in an extended or open position;
[0050] FIG. 4 is a perspective view of a second embodiment of the towable accommodation or storage assembly illustrating in doted lines the walls and roof of the expanded living space;
[0051] FIG. 5 a is a top view of the towable accommodation or storage assembly of FIG. 1 , illustrating the expansion portion in the retracted or closed position;
[0052] FIG. 5 b is a top view of the towable accommodation or storage assembly of FIG. 2 , illustrating the expansion portion in the intermediate position;
[0053] FIG. 5 c is a top view of the towable accommodation or storage assembly of FIG. 3 , illustrating the expansion portion in the extended or open position;
[0054] FIG. 6 is a side view of the towable accommodation or storage assembly illustrating the locking brackets;
[0055] FIG. 7 is a perspective view of a third embodiment of the towable accommodation or storage assembly illustrating a wet area, internal partition wall and internal door;
[0056] FIG. 8 is an underside view of the towable accommodation or storage assembly of FIG. 7 ;
[0057] FIG. 9 is a perspective view of the towable accommodation or storage assembly of FIG. 7 in the fully expanded arrangement with the walls and roof attached;
[0058] FIG. 10 is a perspective view of a fourth embodiment of the towable accommodation or storage assembly illustrating a front boot;
[0059] FIG. 11 is a perspective view of the towable accommodation or storage assembly of FIG. 10 , illustrating the front boot open and the stone guard/second floor portion lowered to reveal a lower storage/couplings/services area;
[0060] FIG. 12 is a side view of a fifth embodiment of the towable accommodation or storage assembly having dual axles;
[0061] FIG. 13 is a perspective view of a sixth embodiment of the towable accommodation or storage assembly illustrating a foldable roof;
[0062] FIG. 14 is a perspective view of a seventh embodiment of the towable accommodation or storage assembly illustrating movable partitions;
[0063] FIG. 15 is a side view of the towable accommodation or storage assembly of FIG. 14 with the roof lifted and a tent attached to encloses the expanded living area;
[0064] FIG. 16 a is a top schematic view of the towable accommodation or storage assembly of FIG. 14 illustrating the partitions in a first position to thereby access the ablutions cubicle;
[0065] FIG. 16 b is a top schematic view of the towable accommodation or storage assembly of FIG. 14 illustrating the partitions in a second position to thereby access the kitchen sink;
[0066] FIG. 17 is a side view of a seventh embodiment of the towable accommodation or storage assembly having a tear-drop shape;
[0067] FIG. 18 is a side view of the towable accommodation or storage assembly of FIG. 17 with part of the roof lifted and tent attached; and
[0068] FIG. 19 is a side schematic view of the towable accommodation or storage assembly of FIG. 17 illustrating the use of an awning to connect the rear of the tow vehicle to the extended living space of the towable accommodation or storage assembly.
DETAILED DESCRIPTION
[0069] Similar reference characters indicate corresponding parts throughout the drawings. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.
[0070] Referring to the drawings for a more detailed description, there is illustrated a towable accommodation or storage assembly 10 , demonstrating by way of examples, arrangements in which the principles of the present invention may be employed.
[0071] FIG. 1 illustrates the towable accommodation or storage assembly 10 including a chassis 12 supported on at least one wheeled axle 14 , a drawbar 16 , and a body 18 rigidly mounted to the chassis 12 . The drawbar 16 includes a hitch 20 for connection to a tow ball 22 of a towing vehicle 24 . The drawbar 16 further includes a jockey wheel 26 . The reader will appreciate that the wheeled axle may alternatively be independent suspension.
[0072] The body 18 includes a main floor 28 spaced apart from a main roof 30 with a rear wall 32 and opposing sidewalls 34 , 36 extending therebetween.
[0073] The towable accommodation or storage assembly 10 further includes an expansion portion 38 that in the present embodiment is pivotably mounted to sidewall 36 by way of a vertically extending hinge 40 . When in the closed of retracted position as illustrated in FIG. 1 the expansion portion 38 is positioned over a fixed first floor portion 42 . It should be appreciated that the fixed first floor portion 42 may be integral with the main floor 28 , as illustrated in FIG. 3 , or may be separate to and abutting a front edge of the main floor 28 .
[0074] The expansion portion 38 is configured to pivot about a generally vertical axis from a first or retracted position as illustrated in FIG. 1 , through an intermediate position, as illustrated in FIG. 2 , to a second or extended position, as illustrated in FIG. 3 , to thereby provide an expanded living space 44 as illustrated in FIG. 4 .
[0075] The towable accommodation or storage assembly 10 includes a hinged second floor portion 46 that in an upright or slanted position may act as a stone guard. The second floor portion 46 is pivotable between an inclined position as illustrated in FIG. 1 wherein it protects the front of the towable accommodation or storage assembly 10 from damage by rocks and debris when being towed, and a generally horizontal position as illustrated in FIGS. 2 to 4 . In the horizontal position the second floor portion 46 rests upon the drawbar 16 and an upper surface forms at least a part of the expanded floor 48 of the expanded living space 44 .
[0076] The reader will now appreciate that the fixed first floor portion 42 and hinged second floor portion/stone guard 46 forms the expanded floor 48 of the expanded living space 44 .
[0077] In the present embodiment, the second floor portion 46 is attached to a front edge of the first floor portion 42 by a horizontally extending hinge 50 .
[0078] As illustrated in FIG. 4 the second floor portion 46 is supported on legs 52 . These support legs 52 may be attached to or deployed from the second floor portion 46 to stabilise the towable accommodation or storage assembly 10 at the front outer corners. The reader should however appreciate that struts (not shown) that engage the drawbar may alternatively be used, or the second floor portion 46 may be sufficiently supported on the drawbar to not require legs or struts.
[0079] As further illustrated in FIG. 4 , the main floor 28 , main roof 30 , rear wall 32 and opposing sidewalls 34 , 36 of the body 18 define an internal living or storage space 54 . This internal living or storage space 54 may include fixed structures, such as a bed 56 , storage draws 58 or other structures typically found in caravans or campers.
[0080] The expanded living space 44 is enclosed by a roof 60 , front wall 62 and sidewall 64 , shown as transparent in FIG. 4 to illustrate the boundaries of the expanded living space 44 .
[0081] The expansion portion 38 also includes fixed structures, such as shelves 66 and a window 68 .
[0082] FIGS. 5 a to 5 c illustrate the expansion portion 38 being pivoted about a generally vertical axis into the expanded or open position. As shown in FIG. 5 a , the expansion portion 38 is positioned in a first or retracted position when being towed behind a towing vehicle 24 . When the towable accommodation or storage assembly 10 is to be used the expansion portion 38 is pivoted through a series of intermediate positions, one of which is illustrated in FIG. 5 b , until it is in a second or extended position as illustrated in FIG. 5 c , whereafter it is locked in place. Once in position the walls 62 , 64 and roof 60 can be attached as previously illustrated in FIG. 4 . The walls 62 , 64 and roof 60 may be constructed from a canvas material or similar. Alternatively, the walls 62 , 64 and roof 60 may be semi-rigid and removably attached in place or may comprise panels that are hingedly or slidably connected to the body 18 or expansion portion 38 and which may be pivoted or slid into place and locked with appropriate fixing means.
[0083] When in a closed or retracted position, as illustrated in FIG. 5 a , during transit the expansion portion 38 covers and seals the floor area 42 beneath it and seals access to the internal living or storage space 54 . Opening of the expansion portion 38 is supported and controlled in stages via interaction with the fixed first floor portion 42 beneath and also the second floor portion 46 .
[0084] The reader should however appreciate that the opening and/or closing of the expansion portion may be undertaken by way of electric or mechanical assistance and include actuators, levers, pulleys, cables or any other necessary apparatus that are required to assist the user in moving the expansion portion, with appropriate stops and override mechanisms to inhibit damage to the apparatus.
[0085] A lower edge of the expansion portion 38 may include sliders, rollers and brush seals (not shown) to permit the smooth opening and closing thereof. When fully open, as illustrated in FIG. 5 c , the outside corner of the expansion portion 38 is latched to the second floor portion 46 to provide horizontal and vertical support.
[0086] As illustrated in FIG. 6 the expansion portion 38 is secured to the body 18 during transport by way of latches 70 , with appropriate seals (not shown) to inhibit ingress of dust or moisture.
[0087] The roof 30 or a portion thereof, may be raised from a lowered position as shown in FIG. 7 into a raised position as illustrated in FIG. 9 . This is commonly referred to in the art as a pop-top configuration. As further shown in FIG. 7 the expanded living space 44 may be used as a wet area having a shower collection tray/drain 72 in the first floor portion 42 for collecting grey water. A fixed partition wall 74 separates a part of the expanded living space 44 from the internal living or storage space 54 . In the present embodiment, the fixed partition wall 74 forms a rear side of the shower recess and is used to mount a showerhead 76 thereto. A pivoted wall portion 78 is configured to act as a sidewall for the shower or as a door between the expanded living space 44 and internal living or storage space 54 . The expansion portion 38 may include a toilet 80 and storage shelves 66 .
[0088] The reader will appreciate that other configurations are possible within the scope of the patent and include, but are not limited to sinks, cooking facilities, sleeping structures, foldable tables and seating.
[0089] As illustrated in FIG. 8 , an exterior of the towable accommodation or storage assembly 10 includes appropriate plumbing and couplings 82 , 84 for connection to inlet pipe 86 in fluid communication with a water source (not shown) and outlet pipe 88 for connection to a dump point (not shown). The couplings 82 , 84 are preferably accessible from an exterior of the expansion portion and may include covers or caps (not shown) to protect them when not in use. In other embodiments, some of the coupling and a hot water system may be concealed behind the second floor portion 46 when it is in the raised position.
[0090] FIG. 9 illustrates the main roof 30 in a raised position and the walls 62 , 64 and roof 60 attached or repositioned to at least partially enclose the expanded living space 44 . A door 90 is located in wall 64 to permit access to the interior of the towable accommodation or storage assembly 10 .
[0091] FIGS. 10 and 11 illustrate an upper front boot 92 with corresponding lid 94 and a lower storage area 96 that is sealed by the second floor portion 46 , as shown in FIG. 10 . The upper front boot 92 and lower storage area 96 include respective seals and latches (not shown).
[0092] As illustrated in FIG. 12 , in another embodiment the chassis 12 is supported on dual axles 14 a , 14 b and a door 97 is located in the rear wall 32 of the body 18 and used to form a ramp to assist in loading a vehicle such as a quad bike into the storage area 54 .
[0093] In another embodiment, as illustrated in FIG. 13 the main roof 30 and roof 60 may be replaced by a single segmented or expandable roof 98 that includes a plurality of segments 100 , 102 , 104 , 106 , 108 , which are configured to cooperate to thereby form the roof of the towable accommodation or storage assembly 10 when expanded. The segments 100 , 102 , 104 , 106 , 108 , may comprise a flexible roof with internal frame (not shown) or the segments may cooperate in such a way as to provide a barrier to the ingress of water and dust.
[0094] Turning to FIGS. 14 to 16 b there is illustrated another embodiment of the towable accommodation or storage assembly 10 that includes an ablutions cubicle 116 formed by movable partition walls 118 , 122 . As shown in FIG. 14 the pivoted wall portion 78 form a door that seals the internal living or storage space 54 . This door 78 may include a lockable handle so that at least the internal living or storage space 54 can be locked up if the towable accommodation or storage assembly 10 is left unattended for a period of time. This would be particular relevant where the expanded living space 44 is at least partially constructed from canvas.
[0095] As further illustrated in FIG. 14 partition wall 118 is attached by hinges 120 and can be either positioned against door 78 when the expansion portion 38 is in the closed position or moved to a position where it forms one of the walls of the ablution cubicle 116 , as illustrated in FIG. 16 a . The partition wall 118 may also act as a door for providing access to the ablutions cubicle 116 and moved as indicated by the arrow and dotted lines of FIG. 16 a.
[0096] The partition wall 122 in the present embodiment is bi-fold and includes panels 124 , 126 , hingedly attached by hinges 128 and 130 .
[0097] The first floor portion 42 in the present embodiment is slatted and includes slots 132 that fluidly connect the upper surface of the first floor portion 42 with the collection tray/drain 72 . The reader should appreciate that the second floor portion 46 may similarly be slatted.
[0098] The present embodiment includes a kitchen module 134 that is located within the expansion portion 38 . The kitchen module 134 includes a bench 136 or preparation area and, although not illustrated, may include shelves, a fridge, microwave or other kitchen appliances or infrastructure.
[0099] As illustrated in FIG. 15 the expanded living area 44 is enclosed by a flexible tent 138 , such as, but not limited to canvas. The tent 138 is stored within a roof cavity (not shown) when not in used and when the roof 30 is lifted the tent 138 is pulled out and attached around an edge to the floor 42 , 46 , expansion portion 38 and wall 34 by way of zips, clips or other fastening devices. The tent 138 is supported by poles 140 a , 140 b and includes door 90 .
[0100] FIGS. 16 a and 16 b show two different top schematic views of the layout of the towable accommodation or storage assembly 10 . In FIGS. 16 a the panels 124 , 126 of the partition wall 122 are positioned so that a user can have full access to the ablutions cubicle 116 . In this arrangement panel 126 abuts or at least conceals part of the kitchen 134 . As further illustrated in FIG. 16 a the partition wall 118 can be moved in the direct of the arrow to act as a door to provided assess to the toilet 80 and shower 76 . Any water that falls onto the floor 42 passes through the slots 132 into the drain 72 .
[0101] When the user wants full access to the kitchen 134 , the panels 124 , 126 of the partition wall 122 can be pivoted around hinges 128 , 130 and repositioned into the arrangement as illustrated in FIG. 16 b . In this configuration, a kitchen sink 142 that is attached to the rear side of panel 126 is exposed for use.
[0102] As further illustrated in FIGS. 16 a , 16 b the internal living space 54 may include a raised double bed 144 and benches 146 , 148 at a lower level which extend under bed 144 and can be converted into individual single beds. A table 150 is locatable between the benches 146 , 148 and can be slid under the bed 144 when not required as illustrated by the arrow in the figures.
[0103] In another embodiment, as illustrated in FIGS. 17 to 19 , there is provided what is commonly referred to as a tear drop camper configuration. Typically, in the prior art a tear drop camper will open rearwardly and the bed will be located at a front of the body. In the present invention, the bed 144 is located at a rear of the body 18 , as illustrated in FIG. 17 and a portion 152 of the roof 30 is configured to open to provide access to the front of the body 18 , as illustrated in FIG. 18 .
[0104] The tent 138 can then be retrieved from within the roof cavity and be supported by poles 140 a , 140 b as previously discussed. The tent 138 may also include an awning 154 that extends outwardly or connects thereto as illustrated in FIG. 19 . The awning 154 is connected to, or extends over, a rear of the towing vehicle 24 . In this way, the towable accommodation or storage assembly 10 is connected directly to the towing vehicle 24 and the expanded living space 44 can act as a foyer or intermediate area between the towing vehicle 24 and the towable accommodation or storage assembly 10 , thereby allowing covered access to the rear of the towing vehicle 24 through a window 156 or by opening the rear door of the vehicle 24 . This is particularly beneficial if a bedding area, storage draws or a fridge are located in the rear of the vehicle 24 .
[0105] The skilled addressee will now appreciate the advantages of the illustrated invention over the prior art. In one form the invention provides a second floor portion that is fixed on its lower horizontal edge with a hinge so it can be lowered forwardly over the drawbar to thereby create a forward expanded floor area over space that is normally void due to the required towing vehicle's turning clearance. Accordingly, the present invention uses space that is typically not utilises in existing caravans, campers and the like.
[0106] The expansion portion 38 can be swung open to expand the footprint of the towable accommodation or storage assembly 10 to one side. The expansion portion 38 can also be partially opened to access the interior of the towable accommodation or storage assembly 10 such as at a roadside stop. Accordingly, the present invention provides benefits or at least a useful alternative to current caravan and camper configurations.
[0107] Various features of the invention have been particularly shown and described in connection with the exemplified embodiments of the invention, however it must be understood that these particular arrangements merely illustrate the invention and it is not limited thereto. Accordingly, the invention can include various modifications, which fall within the spirit and scope of the invention. | There is proposed a towable expandable accommodation or storage assembly that includes a floor portion that is affixed to or supported on a drawbar, wherein an expansion portion is configured to be pivoted to one side of said floor portion to form at least one wall when the assembly is being used for the purpose of accommodation or utility. The assembly may provide a collapsible ablutions cubicle or kitchen area that can be reduced in size during transportation of the assembly. In this way, the assembly can be towed to a site and expanded to provide an expanded living area. Furthermore, the configuration of the floor portion means that grey water can be captured for the ablutions cubicle or kitchen area for storage in a tank or to be directed to a drain. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/069,969, filed Mar. 18, 2008, which is incorporated by reference.
BACKGROUND
[0002] The present disclosure is directed to draft arresters for overhead retractable doors and, more particularly, to non-contact draft arresters for roll-up overhead retractable doors.
INTRODUCTION TO THE INVENTION
[0003] Exemplary embodiments include a draft arrester for an overhead door. An exemplary embodiment may include a flexible draft curtain extending between a ceiling structure and a wound-up portion of the overhead door. The draft arrester may include a follower assembly, which may include one or more rollers arranged to roll against the overhead door. An exemplary embodiment may include a repositionable arm arranged to press the rollers against the wound-up portion of the door.
[0004] In an aspect, a draft arrester for a roll-up overhead door may include a draft curtain including a lower end and an upper end; a first pair of spaced-apart rollers operatively coupled to the lower end of the draft curtain, the first pair of spaced-apart rollers biased against a portion of the roll-up overhead door; and a curtain support coupled to the upper end of the draft curtain and adapted to be mounted above the first pair of spaced-apart rollers.
[0005] In a detailed embodiment, the first pair of spaced apart rollers may be mounted approximate a first end of a first repositionable arm, and the first repositionable arm may be pivotable about a pivot located proximate a second end of the first repositionable arm. In a detailed embodiment, a draft arrester may include a spring component arranged to bias the first end of the first repositionable arm towards the portion of the door. In a detailed embodiment, at least one of the rollers may be weighted, and the weighted roller may be arranged to bias the pair of spaced-apart rollers towards the portion of the door. In a detailed embodiment, a draft arrester may include a second pair of spaced-apart rollers operatively coupled to the first end of the draft curtain, the second pair of spaced-apart rollers being biased against the portion of the door. In a detailed embodiment, a draft arrester may include a substantially horizontal rail extending along the lower end of the draft curtain and interposing the first pair of spaced-apart rollers and the second pair of spaced-apart rollers. In a detailed embodiment, the draft curtain may be substantially flexible.
[0006] In an aspect, an overhead door assembly may include a rotatable spool; an overhead door windable onto the rotatable spool, the door being arranged to at least partially cover an opening having a width, a height, and at least one overhead boundary; a first wheeled follower biased against a portion of the overhead door wound around the rotatable spool; and a draft curtain extending vertically between the wheeled follower and the overhead boundary, while at the same time the draft curtain extends horizontally approximately the width of the opening.
[0007] In a detailed embodiment, the overhead boundary may be a ceiling. In a detailed embodiment, the draft curtain may be substantially flexible. In a detailed embodiment, the first wheeled follower may include a first pair of spaced-apart rollers mounted proximate a first end of a first repositionable arm, and a second end of the first repositionable arm may include a pivot. In a detailed embodiment, the first wheeled follower may include a spring component arranged to bias the first pair of spaced-apart rollers against the portion of the overhead door wound around the rotatable spool. In a detailed embodiment, at least one of the rollers may be weighted, and the weighted roller may be arranged to bias the first pair of spaced-apart rollers against the portion of the overhead door wound around the rotatable spool. In a detailed embodiment, an overhead door assembly may include a substantially horizontal rail extending from the first wheeled follower and along the draft curtain. In a detailed embodiment, an overhead door assembly may include a second wheeled follower biased against the portion of the overhead door wound around the rotatable spool, and at least a portion of the substantially horizontal rail may interpose the first wheeled follower and the second wheeled follower.
[0008] In an aspect, a draftless overhead door may include a flexible overhead door; a rotatable spool adapted to have at least a portion of the flexible overhead door wound therearound; a motor operatively coupled to the rotatable spool to wind and unwind the flexible overhead door, where unwinding of the flexible overhead door lowers the flexible overhead door and winding of the flexible overhead door raises the flexible overhead door; a vertical door track arranged to guide movement of the flexible overhead door; a roller biased against a portion of the flexible overhead door wound around the rotatable spool; and a curtain extending vertically between an upper structure and the roller, while at the same time extending horizontally proximate a width of the overhead flexible door.
[0009] In a detailed aspect, an overhead door may include a spring component arranged to bias the roller towards the rotatable spool. In a detailed embodiment, the roller may be mounted to a first end of a repositionable arm, and a second end of the repositionable arm may include a pivot. In a detailed embodiment, the roller may include a pair of spaced-apart rollers. In a detailed embodiment, the door may have a width, and the draft curtain may extend substantially the entire width of the door.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The detailed description refers to the following figures in which:
[0011] FIG. 1 is a cross-sectional view of a repositionable door incorporating an exemplary draft arrester, which may be operative to inhibit drafts between the door roll and the header, where the door is shown in a barrier position;
[0012] FIG. 2 is a cross-sectional view of a repositionable door incorporating the exemplary draft arrester of FIG. 1 , where the door is shown in an intermediate position;
[0013] FIG. 3 is a cross-sectional view of a repositionable door incorporating the exemplary draft arrester of FIG. 1 , where the door is shown in a retracted position;
[0014] FIG. 4 is a frontal view, from the exterior, of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester;
[0015] FIG. 5 is an elevated perspective view, from the interior, of one corner of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester; and
[0016] FIG. 6 is an elevated perspective view, from the exterior, of one corner of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester.
DETAILED DESCRIPTION
[0017] Exemplary embodiments described and illustrated herein include apparatus and methods for inhibiting drafts over roll-up retractable doors. It will be apparent to those of ordinary skill in the art that the exemplary embodiments discussed herein are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed herein may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present disclosure as defined by the claims.
[0018] An exemplary door draft arrester 10 is shown in FIGS. 1-6 . In exemplary form, a door draft arrester 10 may be a component of a repositionable door 12 , which may selectively close off an opening of a building. In exemplary form, the building may be a drive-through car wash, and the opening may be at the end of the car wash path through the building. For purposes of explanation only, the opening may be generally rectangular with a vertical lengthwise dimension 18 and a horizontal widthwise dimension 20 . In an exemplary embodiment, the opening may be defined by generally vertically oriented left and right side walls 22 , 24 and a generally horizontal header wall 26 which may spans overhead between the side walls 22 , 24 . The plane of the opening may interpose the interior of the building and its exterior.
[0019] In an exemplary embodiment, a door frame 28 may be inset within the interior of the building proximate the opening. The door frame 28 may include opposing vertical members 30 , 32 that may be mounted respectively to the left and right side walls 22 , 24 . Each vertical member 30 , 32 may include a pair of channel guides 34 that cooperate to define a vertical channel 36 into which lateral ends 38 of a repositionable door 12 may extend. In exemplary form, a channel guide 34 may comprise a vertically oriented angle iron segment 42 having a deflector 44 mounted to its proximal end. An exemplary deflector 44 is adapted to be angled outward away from the channel 36 so that adjacent deflectors 44 cooperate to provide a tapered mouth feeding into the channel 36 . In this fashion, as the door 12 is repositioned from a retracted position toward a barrier position, the free horizontal end of the door may contact one of the deflectors 44 , which may route lateral ends 38 of the door 12 into the channel 36 . The precise dimensions of the angle iron segments 42 and deflectors 44 may be a matter of design choice. Likewise, the angle at which the deflectors 44 are oriented may be a matter of design choice; the greater the angle, the less gradual the taper.
[0020] In an exemplary embodiment, a horizontal header 46 that spans the complete widthwise dimension of the opening may be mounted on the interior side of the opening. In exemplary form, the header may comprise a Lexan or metal boxed framework that mounts directly to the header wall 26 to provide a partial enclosure for a repositionable curtain assembly 48 . The curtain assembly 48 may be mounted to the framework 46 by way of a generally horizontal molding 50 , which may extend substantially the entire width of the opening, using a plurality of fasteners 52 . A curtain 54 may be mounted to the heater 46 by the molding 50 . The curtain may be fabricated from the same material as the door 12 . Nevertheless, it is to be understood that other materials could be utilized to fabricate the curtain 54 depending upon the end application. The curtain 54 , in exemplary form, may be generally rectangular with its widthwise dimension dominating its lengthwise dimension. Specifically, it is the lengthwise dimension that may span between the molding 50 and a horizontal rail 56 mounted to a pair of opposing arms 58 mounted to corresponding perpendicular plates 60 extending from the upper portions of the left and right side walls 22 , 24 and adjacent the header wall 26 . Each arm 58 may include a pair of wheels 62 , 64 that may be interposed by the horizontal rail 56 . Each wheel 62 , 64 may be adapted to ride upon the exterior of the door 12 as it is rolled up responsive to the arm 58 being forced against the door roll. However, as the diameter of the door roll changes, whether increasing as the door is retracted or decreasing as the door is deployed, the arm 58 may force the wheels 62 , 64 against the door roll to substantially maintain a constant axial gap between the horizontal rail 56 and door roll.
[0021] In an exemplary embodiment, the door 12 may be repositioned between a retracted position and a barrier position using a motor assembly 66 . In exemplary form, one end of the door 12 may be mounted axially to a horizontal roller which may be turned either clockwise or counterclockwise by the motor assembly. The motor assembly 66 may include an electric motor 70 coupled to an output pulley 72 that repositions a belt 74 engaging a input pulley 76 coupled to the roller 68 . It is too be understood, however, that various drive mechanisms could be utilized, such as using the output shaft of the motor 70 to directly engage the roller 68 or one could easily devise a set of gears to interface between the roller 68 and the motor 70 to accomplish a similar result. In an exemplary embodiment, as the roller 68 is rotated to move the door 12 toward its retracted position, the door 12 may wind around the roller 68 to provide a cylindrical roll (i.e., a “door roll”) that gradually increases in diameter as the door is retracted until a maximum diameter is reached corresponding to substantially the entire door being wound around the roller 68 . It should be noted, however, that it may not be necessary to wind the entire door around the shaft to allow egress of automobiles through the opening as in an exemplary carwash.
[0022] The present disclosure contemplates that a problem experienced with conventional roll-up doors is the occurrence of a draft between the header and the door roll. In some conventional door systems, the gap between the door roll and the header may vary and may be quite substantial to allow air to freely pass therebetween and create a draft that in certain instances is operative to allow liquids and other flowing materials within the interior of the building to escape or conversely to allow external fluids and debris to enter the building even while the door is in its barrier position. Exemplary embodiments described herein, however, may overcome these drawbacks by arresting the draft using the repositionable curtain assembly 48 to substantially decrease fluid flow between the horizontal shaft and header, thereby substantially decreasing any draft.
[0023] In an exemplary embodiment, the repositionable curtain assembly 48 may comprise a fixed length curtain 54 that may be mounted at one end to the molding 50 and may be mounted at an opposite end to the horizontal rail 56 . In exemplary form, the horizontal rail 56 may be substantially in parallel with the door roll and/or roller 68 to maintain a substantially constant spacing between the rail 56 and door roll of approximately two inches. This constant spacing may be accomplished by providing a reactive system that starts with the reactive arms 58 .
[0024] In an exemplary embodiment, each arm 58 may include a polyethylene unibody construction having a through hole 78 that receives a bolt extending from a corresponding perpendicular plate 60 toward the door roll. The end of the bolt may also receive a series of washers and/or a lock nut to provide play and freedom of movement rotationally between the bolt and the arm 58 . In other words, this arrangement may allow each arm 58 to freely rotate/pivot around its corresponding bolt. This rotation may be caused by the change in diameter of the door roll as the door is either retracted or deployed. As discussed previously, each arm 58 may include a pair of wheels 62 , 64 adapted to ride upon the exterior of the door as it is rolled up and/or down. In order to maintain the wheels against the exterior of the door roll, the arm 58 itself may be biased towards the door roll. This biasing may be accomplished by using weighted wheels that gravity directs against the door roll or alternatively using a spring biasing structure (not shown) circumscribing the bolt to apply a spring force resisting rotation of each arm 58 . However, those skilled in the art will understand that other mechanisms may be used to maintain the wheels 62 , 64 against the door roll in accordance with the present disclosure.
[0025] As mentioned previously, an exemplary door draft arrester 10 may find application in a carwash facility. By way of illustration, and not limitation, an exemplary draft arrester may be installed at the exit of a carwash. In exemplary form, an electric motor 70 may be electrically controlled by an automated control system (not shown) and at least one position sensor for sensing the presence of an automobile in proximity to the exit. Those skilled in the art are quite familiar with automated controls and a discussion of such a system in detail, with sensors, has been omitted for purposes of brevity. In exemplary operation, the door 12 may be selectively repositioned from a barrier position to a retracted position to allow egress of automobiles through the exit. Specifically, in a carwash, the door's default position may be the barrier position and movement of the door to the retracted position may only occur when the automated system senses an automobile in proximity to the exit or opening 14 . At this time, the automated system may engage the electric motor 70 to rotate the roller 68 in the appropriate direction to retract the door from its barrier position (see FIG. 1 ) through an intermediary position (see FIG. 2 ) to a retracted position (see FIG. 3 ). As can be seen from the foregoing figures, repositioning of the door 12 does not compromise the draft arresting capabilities of the exemplary draft arrester.
[0026] In an exemplary embodiment, the curtain 54 may operate to substantially shut off the widthwise opening between the door roll and the header 46 . As can be seen by the change in position of the arms 58 , the wheels 62 , 64 may continue to ride upon the exterior of the door roll and correspondingly pivot each arm 58 as the diameter of the door roll decreases (as the door is deployed) or increases (as the door is retracted). Correspondingly, the horizontal rail 56 mounted to each arm 58 at the rail's axial ends may maintain a substantially constant spacing from the door roll, regardless of the diameter of the door roll. To accommodate the changing door roll diameter, the curtain 54 may floats and/or deform. In an exemplary embodiment, at no time, however, does the deformation of the curtain 54 result in the absence of a barrier arresting drafts between the door roll and the header 46 .
[0027] The material composition of the components of the instant invention may be a matter of design choice and may be selected from composites, metals, alloys, ceramics, plastics, or other materials. Those skilled in the art will recognize that different applications for an exemplary draft arrester may require selection of differing materials. By way of example, and not limitation, an exemplary repositionable door 12 may be fabricated from any weatherproof material and may include a series embedded horizontal ribs 80 to generally maintain the door in a planar orientation. The door material, by its nature may be flexible and able to be deformed, and may include weights (not shown) attached proximate to the exposed horizontal end of the door nearest the floor. One of the advantages of using a flexible door is that collisions with automobiles cause less damage to the door itself and the automobile.
[0028] Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatus herein described constitute an exemplary embodiments, the disclosure contained herein is not limited to these precise embodiments and that changes may be made without departing from the scope of the disclosure as defined by the claims (for example, and without limitation, it is within the scope of the invention that the base plate and cover plate take different forms, such as a box and a lid that are separate from each other or even connected by a hinge). Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects disclosed herein in order to fall within the scope of any claim, since the invention is defined by the claims and since inherent and/or unforeseen advantages may exist even though they may not have been explicitly discussed herein. Finally, it will be apparent that additional claims may be inherent in the disclosure and may not be expressly described herein. | A draft arrester for an overhead door. An exemplary embodiment may include a flexible draft curtain extending between a ceiling structure and a wound-up portion of the overhead door. The draft arrester may include a follower assembly, which may include one or more rollers arranged to roll against the overhead door. An exemplary embodiment may include a repositionable arm arranged to press the rollers against the wound-up portion of the door. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to snow removal and more particularly to a snowplow carriage assembly for removing snow by plowing it manually.
2. Prior Art
Heretofore the removal of snow manually at residences by homeowners has been accomplished by use of conventional snow shovels and the use of brooms. The shoveling of snow by homeowners subjects the heart of the shoveler to considerable stress, and even young people have been known to have a heart attack after shoveling snow. Doctors now warn people that if they are fifty years of age, they should not shovel snow.
While a conventional snow shovel can be used to plow the snow in an area for removal without pitching the snow or shoveling it, which is stressful, a conventional snow shovel used for simply plowing the snow still requires a considerable amount of energy input by the user. There is a need for a device for clearing areas of snow by manual plowing of the snow for removal without subjecting the snow remover to excessive harmful stresses.
SUMMARY OF THE INVENTION
The snowplow carriage assembly, according to the invention, is a collapsible or foldable carriage on which is transportably mounted a snowplow. The snowplow is a conventional snow shovel removably and replaceably mounted on the carriage on which it is transported and pushed forwardly for plowing and removing snow from an area to be cleared.
The snowplow carriage assembly is constructed as a structure which can be collapsed and folded into a compact assembly with the snowplow thereon, or off of it, for storage, and can be readily prepared to use by opening the assembly into an expanded or unfolded state for plowing snow. Provision is made for adjustably positioning the snowplow at different acute angles relative to the surface on which the snow is being plowed. The carriage can accommodate different types of snow shovels having different length handles.
BRIEF DESCRIPTION OF THE DRAWINGS
The snowplow carriage assembly, according to the invention, description can be readily understood with reference to the appended claims and drawings in which:
FIG. 1 is a perspective view of a snowplow carriage assembly, according to the invention;
FIG. 2 is a side elevation view of the snowplow carriage assembly in FIG. 1;
FIG. 3 is a side elevation view of the snowplow carriage assembly in FIG. 1, illustrated in a folded state for storage;
FIG. 4 is a section view taken along section line 4--4 in FIG. 1;
FIG. 5 is a fragmentary perspective view of a second embodiment of a snowplow, according to the invention;
FIG. 6 is a fragmentary perspective view of a third embodiment of a snowplow, according to the invention;
FIG. 7 is a perspective elevation view of a second embodiment of a snowplow carriage assembly, according to the invention;
FIG. 8 is a section view taken along section line 8--8 of FIG. 7;
FIG. 9 is a section view taken along section line 9--9 of FIG. 7; and
FIG. 10 is a section view taken along section line 10--10 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A snowplow carriage assembly 2, according to the invention, is illustrated in FIG. 1, on which is mounted a snowplow illustrated as a conventional snow shovel. The carriage assembly consists of a single frame which has handles 5, 6 having elongated arms 8, 9 extending therefrom and which can be made tubular, for example. The elongated arms 8, 9 have tubular legs 10, 11 each connected pivotally and the snow shovel is used to function as a blade of the snowplow to the respective arms by a pivot such as a pivot 13. The carriage arms and legs are each provided with wheels 14. The wheels on the arms can be provided with swivels.
Provision is made for the legs 10, 11 to extend away from the arms 8, 9 in an unfolded state of the carriage as shown in FIG. 1 and to be foldable as shown in FIG. 3. A pair of linkage systems in the known form of relatively slidable links 16, 17 are respectively pivotally connected to a corresponding arm and leg. When the links are in an extended condition the individual legs are moved, and held, outwardly spaced away from the corresponding arms. The linkage system link 16 has an end pivotally connected at a pivot 20 to the corresponding leg 11 and has a longitudinal slit 21 in which a pivot pin 22 fixed on the other link 17 slides. The other link 17 is pivotally connected by a pivot 23 to the arm 9. When the carriage is in an unfolded state or condition the links extend from each other as shown in FIGS. 1 and 2. The pin 22 is received in a notch in the end of the slit 21 and locks the corresponding linkage system in an extended condition, and the carriage is held in an opened condition for plowing snow. The links are operable upwardly, as illustrated by an arrow 25 in FIG. 2 to release the pivot pin 22 from the notch so it can slide in the slit 21 to collapse the linkage system in a position shown in FIG. 3 for folding the carriage assembly for storage when not in use.
The two carriage arms 8, 9 are held parallel laterally spaced by two carriage transverse members or cross bars 27, 28 fixed, at ends thereof, axially spaced on the arms. The two cross bars can be made tubular and connected to the arms in any suitable manner such as shown in FIG. 1. The cross bars are arranged so that the upper bar 27 is higher than the lower bar 28 and both are in an inclined plane defined by the arms and the cross bars. This plane makes an acute angle with the horizontal and is the plane in which a snowplow is mounted, as described below, at a suitable acute angle relative to the horizontal, for plowing snow for manual removal thereof.
A snowplow 35 in the form of a conventional snow shovel having a handle 36 and a handle grip 37 is removably and replaceably mounted on the carriage 2 for plowing snow as the carriage is advanced manually. The snowplow or snow shovel is mounted at an angular position relative to the horizontal, as shown in FIG. 2. The carriage 2 is constructed so that in an unfolded condition the snowplow is held in a plane at an angular position relative to the horizontal similar to an acute angle at which snow shovels are used manually to plow snow to clear an area from which snow is being removed by simply plowing.
In order to mount the snowplow on the carriage, the snow shovel is provided with a pair of spaced holders 45, 46 which are fitted axially on the handle 36 of the snow shovel. The holders are constructed so that the upper holder 45 has an upwardly directed hook 50 and the lower holder 46 has a downwardly directed hook 51. These hooks engage the upper cross bar 27 and the lower cross bar respectively on the carriage. The lower hook 51 positions the snow shovel 35 at a position so that the snow will be plowed, for example, along a surface 60. The upper hook maintains the shovel from moving upwardly when snow plowing is taking place. It can be seen that with the holder arrangement illustrated, the shovel handle 36 is subjected to the same type of forces to which it would be subjected if the shovel were being used manually as a plow without being supported and carried on a carriage. The holders are positionable axially spaced on the handle and held in position by bolts 45a, 46a which extend through the handle and have wing nuts on an end thereof so that the bolts can be removed and the snow shovel replaceably removed from the carriage 2.
Snow removal is generally accomplished manually by moving a snow shovel forwardly to plow and move the snow as desired. In order to reduce the workload, snow removal is accomplished by removing snow by plowing a pathway as wide as the shovel 35. People can then walk readily along such a path single file or the path can be widened by making two passes with the snow shovel. The present invention provides for reducing the plowing load in advancing the snow shovel mounted on the carriage by providing for moving the snow laterally as the carriage is advanced for plowing snow.
A snowplow configuration which has a V-shaped front surface is illustrated in FIG. 5. A snow shovel 65 illustrated has a shovel 67 in which a front center section 67a projects forwardly of two trailing opposite side sections 67b, 67c that extend rearwardly of the central section so that as the center section advances, snow being plowed is diverted laterally in two directions by the side sections which trail the center section. The outer side edges of the side sections trail the leading surface of the center section sufficiently so that in effect the shovel is V-shaped. In the V-shaped shovel 67 the side sections 67b, 67c are disposed dimensionally and angularly symmetrically relative to the center section 67a.
Those skilled in the art will understand that the shovel configuration can be that of an asymmetrical V-configuration as well as symmetrical. Moreover, the angle at which the side sections trail rearwardly can be different in the shovel configurations even if the shovel is symmetrical dimensionally. The shovel side sections can be made dimensionally asymmetrical. One side section can extend laterally and rearwardly a greater distance from the center section than the other side section and the respective angle at which the individual sections diverge rearwardly from the center section can be the same or can be different whether the sections are both the same dimensionally or each different dimensionally. Thus, different possibilities of symmetry and asymmetry are possible, resulting by use of same or different angles which the side sections make with the center section and the same or different dimensions of the side sections. In all such cases, the shovel has a V-configuration which has a more open or more closed angle and the sides of such a "V" of different side lengths. Providing the V-configuration makes it possible to provide snowplows for different plowing problems. For example, differences in walks or paths to be plowed can be handled better either by a symmetrical or a non-symmetrical plow depending on the path to be plowed. It is, of course, understood that such V-shaped snowplows would be snow shovels which would generally not be used for shoveling snow and are only for plowing.
The carriage 2 can be used for plowing snow from areas larger than pathways or walks such as driveways. A wider snowplow 70 is illustrated in FIG. 6 as having a shovel 72 which has a conventional handle 73 and is wider than those heretofore described. The wider snow shovel 72 makes it possible to plow an area such as a driveway. The wider snow shovel is illustrated as somewhat arcuate in its height cross section to provide somewhat of a snow scooping action of the snowplow since the shovel is not used on the carriage for shoveling but plowing. The curvature provides the necessary lift to the snow to effectively plow the snow.
Snow shovels generally have handles which have a length on the handle which is straight even if the entire handle is not straight along its full length. Moreover, snow shovels have handles of different lengths. The shovels themselves have different cross section configurations along the shovel height dimension. Generally, snow shovels have a marginal lower edge portion of the height dimension that is arcuate and has curvature along part of the marginal leading edge portion of the shovel so that snow can be scooped up.
The snowplow carriage assembly, according to the invention, makes provision for differences in length of handles of the different snow shovels and for different curvatures along the height of the different snow shovels. Furthermore, provision is made for mounting the snow shovels without need of holders being provided on the shovels for mounting them on a carriage for transport for plowing according to the invention.
A second embodiment of a carriage is illustrated in FIG. 7 in which a carriage 75 is constructed generally similar to the carriage 2 of FIG. 1. This second embodiment carriage is wheeled and has two arms 76, 77 and legs 79, 80 pivotally connected to the respective arms and has linkage systems 82, 83 so that it can be folded or collapsed and unfolded as the first carriage embodiment described. In order to be able to mount snow shovels of different handle lengths, the carriage is provided with an upper cross bar 85 which is movable to different positions axially of the arms for spacing variably with respect to a lower cross bar 87 which is fixed to the two arms. The arms are provided with a plurality of axially spaced holes 88, 89 along the length of the arms for mounting the upper arm 85 at different axial positions axially of the arms in order to accommodate snow shovels of different lengths of handles for mounting and transport on the carriage 75.
The upper cross bar 85 has at each opposite end thereof a curved hook 85a that rests on the corresponding arm 76, 77 as illustrated in FIGS. 7 & 8. Each hook 85a has a hole of equal dimension as the holes 88, 89 on the arms, and the upper cross bar 85 is mounted with the hook holes in registry with the holes on the arms so that bolts 91, 92, having wing nuts 94, can be inserted through the hook and corresponding arms and the upper arm secured to the carriage. The provision of an upper arm construction as shown in FIG. 8 and the mounting holes 88, 89 on the carriage 75 arms 76, 77 provides for variably adjusting the mounting of different types of snow shovels having different length handles, for example.
The second embodiment carriage assembly provides for easily mounting the different snow shovels by use of two split clamps or holders 90, 91 having hooks 90a, 91a engaging the cross bars 85, 87 as shown in FIG. 9 to maintain a snow shovel 100 and its handle 101 in position when plowing snow as described with respect to the first embodiment carriage assembly. The split holders each can also have a compressible liner as shown at 90b, so they can be clamped on different diameter snow shovel handles. They are held assembled by the bolts 105 with a wing nut 106. Snow shovels can easily be replaced on the carriage.
The second embodiment carriage can be adjusted as to the acute angle that the plane cross bars on the arms 76, 77 make relative to the horizontal. The legs 79, 80 are made so that the legs are made with upper lengths or sections 79a, 80a which telescope into lower sections 79b, 80b. The length of the legs is variably adjusted by providing axially spaced holes 110, 111 on the leg sections so that the length of the legs can be varied telescopically and the adjusted length maintained by bolts 112 which extend through the holes in the upper and lower leg sections which are aligned to set the variable length of the legs to vary the acute angle at which a snow shovel will make with the surface on which the snow is being plowed. Thus, the angle of the plow can be varied. Moreover, this adjustability of leg length makes it comfortable for users of different heights to use the snowplow carriage assembly best suited to their height and the angle at which they wish to use as a setting for the snowplow.
While the members of the carriages are described as tubular, they can be made as solid members of any suitable metallic or plastic materials. Components can be made of strong wood with or without reinforcements. The carriage components can be provided as a kit made for easy assembly. Suitable connections are provided for the various components.
It should be noted that the carriage is constructed so that at times the plowing of snow can be carried out with the legs in a retracted or folded position, if desired. This provides a wide range of possible acute angles at which the snowplow will plow the snow when desired. However, the carriage is intended to provide walking support for the users, old or young, and to be used principally as described in an unfolded state supported on all its wheels. | A snowplow carriage assembly for removal of snow manually by plowing the snow in an area to be cleared of snow. The carriage is a manually propelled wheeled structure made of a plurality of members pivotally connected for collapsing and folding for storage and unfolding for use in supporting and transporting a snowplow in the form of a replaceable conventional snow shovel having a handle straight length portion. The carriage is configured so that the snow shovel handle is removably mounted thereon inclined from the horizontal defining an acute angle relative to a surface on which snow is being plowed. The snow shovel inclination is variable for establishing different acute angles of the shovel relative to the surface for plowing the snow thereon and removal therefrom. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
None.
FIELD OF THE INVENTION
Embodiments of the present invention present an apparatus for attaching sections of ladders together to provide a mechanism for transporting materials up a first ladder section (in one application) over and past the apparatus and onto a second ladder section. In its broadest scope, this apparatus can connect two sections of ladder and provide a pathway for materials transported thereon between the two ladder sections.
BACKGROUND OF THE INVENTION
The present invention relates generally to hoisting systems that can travel over the rails of a ladder and, more particularly, to a ladder bridge apparatus for connecting two ladder sections. In a typical application, one ladder section will be set up on the ground surface and the other ladder section will be positioned on the roof of a building. The connection device can be utilized to provide a bridge between the two ladder sections to transport material, for example, over the roof eave to the roof surface.
Extreme difficulty is often encountered in lifting heavy objects to the top of a house, up and over the roof eave to the roof. This can be accomplished with a crane, but the expense of using a crane is often prohibitive. In addition, it would be difficult and expensive to transport a large piece of equipment such as a crane to a job site. Often there are cramped quarters around the jobsite and there is simply not enough room for large equipment.
Other portable equipment may be utilized but often cause damage to the roof gutters. To overcome these obstacles, the ladder bridge apparatus may be used in conjunction with a transport mechanism to lift materials from the ground to the roof eave and beyond or to transport materials from point A to point B.
A typical transport mechanism that this ladder bridge apparatus can be used in conjunction with is generally described in. U.S. Pat. No. 8,002,512 issued to Blehm in 2011. Other transport mechanisms could be utilized with the ladder bridge apparatus and the scope of the material transport mechanism is not specified herein.
There is a need for an apparatus that can be easily attached to a multi-section ladder and used to move materials from point A to point B. In particular there is a need for an apparatus that can be attached to ladder sections to lift loads over the eave of a roof of a building without damaging the gutters. The portability of such an apparatus is important so that it can be transported by one person to and from a jobsite easily and can also be affixed to and removed from a ladder by a worker with a minimum of effort.
SUMMARY OF THE INVENTION
In accordance with one embodiment of this invention, an apparatus for attaching two ladder sections is disclosed. This apparatus, called a ladder bridge or ladder connection apparatus, is utilized to connect two ladder sections having the same or different ladder widths. The ladder bridge apparatus provides a pathway for a material transport device that typically utilizes the rails of the ladder sections as track for the material transport to travel upon.
The ladder bridge apparatus, in its simplest form, includes an adjustable center stabilizer bar connecting outer rail bridge assemblies. The rail bridge assemblies are directly connected to the adjacent ladder sections.
It is an object of an embodiment of the invention to provide a ladder bridge/connection apparatus which may be easily transported. It is still another object to provide a ladder bridge apparatus which may be used to lift loads up to and over a roof eave onto the roof. Another object is to provide an apparatus that can be utilized to connect two sections of ladder that have the same ladder width or vary in ladder width.
Embodiments of the present invention can also be utilized to move a material load from the eave section of the roof to the peak of the roof without damaging the roof structure. At least one of the stated objects will be satisfied by embodiments of the present invention.
The foregoing and other objects, features and advantages of this invention will be apparent from the following description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
The character of the embodiments of the invention may be best understood by reference to the structural form, as illustrated by the accompanying drawings.
FIG. 1 illustrates a perspective view of the ladder bridge apparatus attached to two ladder sections and in place over the eave of a roof.
FIGS. 2A-D present a side view of ladder bridge apparatus attached to two ladder sections and in place over the eave of a roof showing a material transport being pulled up a ladder and over the ladder bridge apparatus.
FIG. 3 shows a perspective close-up view of components of the ladder bridge apparatus.
FIG. 4 shows the ladder bridge apparatus attached to one section of a ladder. The opposite end of the ladder bridge apparatus is unattached showing the hinged adjustments for connecting to ladder sections of varying widths.
FIG. 5 shows the underside of the ladder bridge apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-5 , which show the general features of a preferred embodiment of the invention, the ladder bridge apparatus 10 contains an adjustable center stabilizer section/bar 20 connecting two outer rail assemblies 12 , 14 . The center stabilizer bar 20 is adjustable to set the outer rail assemblies to the appropriate width for the ladder(s) attached thereto. Attached to the center stabilizer bar is a pulley component 22 which contains at least one pulley roller or wheel 24 for accommodating a pulley cable utilized therewith. The ladder bridge 10 is shown in position connecting two ladder sections in FIG. 1 .
The outer rail assemblies 12 , 14 each contain at least one wheel or roller component 32 , 62 to accommodate movement of a material transport device thereupon. The outer rail assemblies have rail mounting sections 34 , 36 , 64 , 66 for attachment to adjacent ladder rails. These rail mounting sections are adjustable in two directions (about two axes of rotation). The outer rail assemblies 12 , 14 also have guide components 38 , 68 which are utilized to keep the material transport in position when traveling from one ladder section to the other via the ladder bridge.
FIG. 2A presents a side view of a material transport 70 being hoisted up the lower (or first) ladder section. The material transport travels up the lower ladder by rolling via wheels 72 along the ladder rails. The ladder rails provide a “track” for the material transport wheels. The material transport has rails 74 on each side of the transport mechanism. As shown in FIG. 2A , the material transport rails 74 do not touch the ladder rails while the material transport is traveling along the ladder.
In FIG. 2B the material transport is being pulled by a pulley cable 26 and is transitioning from the ladder to the nearest sections of the ladder bridge device. The rear wheels 72 of the material transport are in contact with the ladder rails and the material transport rails are in contact with the wheels of the ladder bridge apparatus.
The material transport has been hoisted further as seen in FIG. 2C to where the contact points are between the material transport rails 74 and the wheels 62 of the ladder bridge rail assemblies. The material transport is traveling along the wheels of the ladder bridge device. The sides 76 of the material transport are kept are kept in place by the ladder bridge guides 68 as the material transport traverses the ladder bridge. The material transport has passed the ladder bridge device 10 in FIG. 2D and is shown on the upper (or second) ladder section.
A close-up view of the left ladder bridge assembly 12 is shown in FIG. 3 . The rail mounting section 34 utilizes a hinge 39 to accommodate for varying widths of ladder sections connected thereto. One hinge flange is connected to the left center plate 30 and a second hinge flange is connected to a hinge plate/bracket 40 which is adjustably connected to the mounting plate 42 .
The angle between the ladder bridge apparatus 10 and the ladder can be adjusted via the positioning holes 44 on the ladder mounting plate 42 . A connection component 46 (typically a bolt) acts as a pivot point for the adjustment. A securing component 45 (typically a bolt) secures the ladder in position. Thus the ladder bridge device is adjustable about at least two axes of rotation.
The ladder mounting plate 42 is typically connected to a ladder section on the side of the ladder opposite the ladder flange as shown in FIG. 3 . Installation of the ladder mounting plate can be accomplished by first positioning the mounting plate on the side of the ladder containing the ladder flange. The first positioning edge 48 of the mounting plate can be aligned with the top edge of the ladder and the second positioning edge 50 of the mounting plate can be positioned inside the ladder flange against the outer arm of the flange (not shown). Holes can then be drilled in the ladder for proper alignment. Thus the ladder mounting plate will contain predrilled mounting and positioning holes 44 , 46 to secure the plate to the ladder by moving the plate to the non-flange side of the ladder and mounting in position as shown in FIG. 3 .
The mounting plate can be secured to the ladder inside the ladder flange if required. Typically the determination of positioning the mounting plate on the inside or outside of the flange will be determined by the ladder rail width. The center of the first wheel of the ladder bridge is ideally aligned approximately with the center of the ladder rail. Therefore one could position the mounting plate on the inside or outside of the flange to best align the first wheel substantially with the center of the ladder rail.
FIG. 4 shows the ladder bridge 10 connected to a single ladder section. The hinge capacity of the hinge plate and mounting plate is clearly illustrated. A bottom view of the ladder bridge 10 is shown in FIG. 5 .
CONCLUSIONS, OTHER EMBODIMENTS, AND SCOPE OF INVENTION
The ladder bridge apparatus disclosed herein presents a novel device that can be utilized to connect two ladder sections to transport materials across. Typically the first ladder section will be located at a lower position than the second ladder section as illustrated in moving materials to the roof of a building. The ladder bridge apparatus can also be utilized to transport materials from point A to point B regardless of any discrepancy in height of the two ladder sections.
The ladder bridge apparatus can be used in conjunction with any suitable material transport device to move material across ladder sections from a first position to a second position. If more than two sections of ladders are needed to be connected in series, more than one ladder bridge apparatus can be used. In this scenario each ladder bridge apparatus will connect two adjacent ladder sections.
Other examples of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying, or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. Thus it is intended that the specification and examples be considered as illustrative only, with the true scope and spirit of the invention being indicated by the following claims. | A ladder bridge apparatus for use in connecting two ladder sections is disclosed herein. The ladder bridge apparatus, in its simplest form, includes an adjustable center stabilizer bar connecting outer rail bridge assemblies. The rail bridge assemblies are directly connected to the adjacent ladder sections. The ladder bridge apparatus can be utilized in conjunction with a material transport device to transport materials over the rails of a first ladder section and onto and across the ladder bridge apparatus to a second ladder section. |
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This is a continuation of application Ser. No. 861,990, filed Dec. 19, 1977, now abandoned.
The present invention relates to a primary carpet backing material and to a tufted carpet constructed from such a material. More particularly, the invention concerns a primary backing which includes a layer of foam compound on the undersurface thereof as shown in the Figure.
The majority of all tufted carpet is manufactured today by tufting a carpet yarn into a synthetic primary backing material. Typically, the primary backing material is a woven flat strand polypropylene material and is passed through a tufting machine where yarn elements are stitched through this primary backing material. Following this tufting operation, a coating of latex material is applied to the back of the yarn loops to anchor the yarn elements in place in the backing, add dimensional stability to the carpet, and provide a smooth undersurface for the carpet. The addition of this back coating of latex material, however, requires extended drying of the carpet product in heated ovens over relatively long periods of time. The length of time required for drying the conventionally manufactured tufted carpet produces obvious operating inefficiences.
Accordingly, is is an object of the present invention to provide a tufted carpet product which is more efficient in construction.
A further object of the present invention is to provide a carpet backing material which may be tufted rapidly to produce a finished product without further drying and curing steps.
These and other objects, features and advantages of the present invention will become apparent from a review of the following detailed description of preferred embodiments of the present invention and the accompanying drawing wherein the FIGURE is a cross-sectional view of the tufted carpet product of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is particularly suited for use in the manufacture of an all synthetic tufted carpet product such as those products conventionally referred to as indoor-outdoor carpet having an appearance similar to grass. However, it should be clearly understood that the present invention may also be used in the construction of other types of tufted carpet products, such as those products employing all natural materials, i.e. jute, cotton and wool. It should also be understood that the present invention may be used together with both woven and non-woven backing materials. A typical carpet construction today includes a woven flat strand polypropylene primary carpet backing material, such as disclosed in Rhodes U.S. Pat. No. 3,110,905. In addition, synthetic polypropylene primary backing is frequently pre-coated with a thin layer of adhesive material according to Patterson U.S. Pat. No. 3,864,195. The present invention is particularly well suited for use with both of these types of primary backing materials.
According to the present invention a primary carpet backing material is coated on its undersurface with a foam compound. The compound may be either a natural or synthetic latex rubber material, or a blend thereof, or a urethane material. The nature and composition of the foam compound is conventional except for the inclusion of a lubricant to enhance tuftability of the backing and foam compound. Several ingredients or combination of ingredients produce the desired degree of lubrication when blended into the compound. These ingredients include silicone compounds, glycols such as polyethylene glycol, diethylene glycol, triethylene glycol and the like and various stearates such as potassium stearate, calcium stearate, zinc stearate and the like. A preferred lubricant is diethylene glycol.
The glycol is added in a quantity ranging from about 5 to about 15 parts by weight per 100 parts by weight of rubber or urethane compound. The stearates may be added alone or in combination with the glycol in the range of about 5 to about 15 parts by weight per 100 parts by weight of rubber or urethane compound.
The foam compound, if coated directly onto the primary backing material, may be formulated in a conventional fashion to have good specific adhesion to woven flat strand polypropylene, to be fire retardant and to be quite flexible when dry.
Prior to coating onto the primary backing, the foam compound is frothed in a conventional Oakes foam machine to standard density. The foam compound is then coated onto the undersurface of the primary backing to produce a cross-sectional thickness of foam and backing of between 35 and 45 mils, or a foam thickness of between 20 and 35 mils. The weight of foam compound applied to the carpet backing is in the range of 3 to 7 ounces per square yard of backing material, with 5 ounces being a preferred weight of foam compound per square yard of backing.
After coating the foam compound on to the backing, the backing is passed immediately into a heated forced air oven at a temperature which is sufficiently hot to evaporate any moisture in the compound and cure the foam compound to a finished and dry layer. One significant advantage of the present invention is that the oven may be operated at temperatures which are elevated over normal drying oven temperatures. When drying a standard tufted carpet product, the temperature of the oven has to be limited in order to preserve the appearance and feel of the face yarn. Since the backing has not been tufted with yarn when it is coated and dried in the present invention, the oven may be operated at higher temperatures. Operating efficiencies and speeds normally result from an increase in the oven temperature.
It has been found that when the foam compound is coated onto a flat strand woven synthetic backing which has been pre-coated according to Patterson U.S. Pat. No. 3,864,195 excellent adhesion to the synthetic backing is obtained. For that reason, it is preferred that a pre-coated synthetic backing material be used as the base material. According to the Patterson patent a very thin layer of adhesive material is coated onto the backing material and then dried and cured to reduce ravelling of the backing and increase adhesion of compounds to the backing material.
After drying and curing of the foam compound in an oven according to the present invention, the backing is passed through a standard carpet tufting machine and yarn is tufted through the foam compound and through the primary backing material. Due to the resiliency of the foam compound the loop backs of face yarn compress the foam compound beneath the loop back. As a consequence, the back surface of the tufted material is relatively smooth and does not present the typical irregular texture which is produced by tufting into a standard primary backing material. It should be clearly understood that, when practising the preferred embodiment of the present invention, the tension on the tufting machine is adjusted so that the foam compound is compressed beneath the loop backs to produce a relatively smooth back for the tufted product.
After tufting, the carpet product is complete for many applications. It has been found that the foam compound grips the face yarn as it passes through the foam compound to such a significant degree that the tufted product has utility in many floor covering applications. When the tufted product is glued down to a floor surface, as is often done with indoor-outdoor carpet materials, the glue material will both secure the carpet product to the floor surface and also further secure the face yarn in the backing material.
In one alternative embodiment of the present invention, the tufted backing is passed through a coating operation where a very thin layer of adhesive compound is applied to the loop backs. Since the loop backs have compressed the foam compound and therefore present a relatively smooth surface with the tops of the loop backs at substantially the same level as the uncompressed foam compound between adjacent loop backs, the adhesive material may be applied to fill the depressions around the loop backs (where the adhesive is most effective) and may be doctored off the adjacent foam compound surfaces (where it has relatively little effect). The thin back coat layer of adhesive compound may range in weight from 0.1 oz. per square yard to 8 oz. per square yard of backing material. Since a very thin layer is used, it is possible to dry and cure the layer with a very samll oven at very high production rates. The adhesive compound employed in this invention includes standard latex rubber compounds (both natural and synthetic) and urethane compounds. This alternative embodiment need be followed only when increased yarn adhesion is required.
With particular reference to the Drawing, it may be seen that the present tufted carpet product 10 includes a woven primary backing 12, a layer of foam compound 14 on the undersurface thereof and loops of carpet yarn 16 piercing the foam compound and the primary backing to produce a face of yarn 18 and loop backs of yarn 20. As explained earlier, the carpet yarn 16 is tensioned during tufting so that the foam compound is compressed beneath the loop backs 20 and is uncompressed in areas 22 adjacent the loop backs. The Figure does not show the thin back-coat of adhesive material. When such material is added to the back surface of the carpet product, the adhesive material adheres to the loop backs and fills the depressions around the loop backs but is doctored off the surrounding foam compound 22. In addition, indentations created by each loop of yarn as it passes through the foam compound will also be filled with adhesive material to secure the yarn in position.
While this invention has been described in detail with particular reference to preferred embodiments thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinbefore and as defined in the appended claims. | A tufted carpet product including a woven or non-woven primary backing material, a layer of foam compound adhered to the undersurface of said primary backing, rows of yarn elements tufted through the primary backing and the layer of foam compound to form a face of yarn on the upper surface of the primary backing and loop backs on the undersurface of the backing and foam compound, and optionally a thin layer of adhesive compound applied to the loop backs of the yarn elements. |
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PRIORITY CLAIM
[0001] This is a U.S. national stage of application No. PCT/EP2008/009340, filed on Nov. 6, 2008 which claims priority to the German Application No.: 10 2007 054 463.6, filed: Nov. 13, 2007, the content of both incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a connector module for a door operator with at least one base element, a first and a second front element and two lateral elements, the elements being interconnected and at least one of the elements being configured with a breakthrough for the passage of an electrical connecting element, which may comprise electrical conductors, control cables, or the like.
[0004] 2. Related Art
[0005] Electrical connector boxes to connect electrical conductors are generally known in the state-of-the-art, wherein these connections are accommodated within the connector box in an electrically insulated manner. Utility Model DE 20 2005 008 385 U1 discloses a cuboid, electrical connector and junction box, which is closable via a cover. In reality such boxes have proven to be difficult to close with the cover, if many and/or long electrical conductors are accommodated within the box. Moreover, the connection of the electrical conductors is practically very often difficult and expensive, because only one access to the connector box via the opening in the box is possible, which is closed by the cover.
[0006] An electrical connector box closable with a cover is likewise known from DE 196 04 564 C1. In this case, the connector box has a cuboid body, wherein the cover not only closes a lateral opening, but extends over almost three sides. Thus, when connecting the electrical conductors, three open sides of the connector box are accessible, which sides are closable by the correspondingly moulded cover, once the connections are established. A simpler manipulation of the connector box when establishing the connection is hereby possible. However, it is disadvantageous that too many and/or long electrical conductors can be pinched and damaged by the cover to be installed.
[0007] Connector modules of the above mentioned species serve to receive electrical connecting elements, such as electrical conductors, electrical cables, and electrical terminals, which are necessary to operate a door operator and/or closing operator. The aforementioned door and/or closing operators for doors serve to automatically open and/or close a door, a window or the like. For the purpose of simplification, in the following description, only the term door operator will be used, this term comprises likewise closing operators, respectively closing elements. In this case, the connector module may be provided within a housing of the door operator. It is likewise conceivable that the connector module itself represents a portion of the housing of the door operator. Usually, connector boxes of the aforementioned species are utilized as the connector modules. During installation or service work on the door operator, the shock-proof shielding of the connector module is momentarily neutralized, to allow for access to the electrical connecting elements within the connector module. In this case, the same issues already mentioned in conjunction with the connecting boxes may occur.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a connector module for a door operator, which offers a cost-effective option, to accommodate electrical connecting elements electrically insulated and shock-proof within a door operator and to reduce and simplify the manipulation of the connector module.
[0009] According to one embodiment of the invention, at least one of the first and the second front elements and the two lateral elements, is disposed foldably at the base element. This foldable disposition of at least one element at the base element allows on the one side for a large-area access to the electrical connecting elements of the connector module, whereby the manipulation is considerably simplified, in particular when connecting the electrical connecting elements. On the other hand, closing the connector module is easier, because, in the area of the foldable connection between the base element and the hinged element, the connecting elements are reliably prevented from being pinched or from protruding. It is furthermore intended that at one of the elements, for example the first front element, at least one fastening element, in particular two fastening elements are moulded. It is via these fastening elements that the connector module is mechanically and reliably connected to the rest of the door operator, in particular to a mounting plate of the door operator. For this purpose, appropriate counter-fastening elements, which positively and/or non-positively cooperate with the fastening elements of the connector module, are provided at the rest of the door operator.
[0010] The electrical connecting elements themselves may be provided with a connector, a plug-and-socket connection, or the like, to simplify the electrical connection. For this purpose, the opening in the connector module is configured appropriately large sized. Usually, the electrical connecting elements are introduced into the connector module via a wall side and are electrically connected at that location via plug-and-socket connections, screw terminals, or the like. The corresponding screw terminals or plug-and-socket connections may be disposed on a connecting unit for this purpose, which is preferably configured as a circuit board. The connecting unit is configured to receive connecting terminals, circuit boards and/or other electrical components or circuit components, such as filters or the like.
[0011] Because the at least one element is disposed at the base element is foldable, it can not disappear or be lost like a removable cover can. This element will likewise not fall down when manipulating the connector module. Thus, the one-piece configuration of the connector module additionally simplifies the manipulation. Moreover, such a connector module is cost-effectively manufactured, in particular if it essentially consists of plastic material.
[0012] All front elements and/or lateral elements are preferably disposed at the base element to be foldable, which results in a completely free access to the connector module and in a particular easy manipulation. In this case, the structure of the connector module is simplified by a cuboid configuration, because the foldable elements can be joined to form a (closed) housing via their rectangular sides.
[0013] According to one embodiment of the invention, the base element is rectangular, in particular flat. The rectangular configuration of the base element benefits a uniformly shaped and functional connection to the door operator. It is advantageous in this case that the electrical clamps, connectors, or the like, for electrically or electronically connecting the door operator, to be incorporated or disposed on the flat surface of the base element, in order to connect the door operator to an external energy supply and/or control.
[0014] In a preferred embodiment the base element is configured, at least at one side, with a U-shaped contact surface. The U-shaped contact surface provides a re-enforced reception area for the incoming electrical connecting elements. At the same time, the U-shaped contact surface may serve as an abutment for a foldably configured front element or lateral element. Moreover, it is thus possible to support the entire connector module via the U-shaped contact surface on the correspondingly configured element.
[0015] Furthermore, the possibility is given that the first front element, in one terminal position, can be disposed to partially bear against the U-shaped contact surface. It is furthermore conceivable in this case, that the U-shaped contact surface is configured such that the first front element, in the terminal position, can be disposed to be partially located within the U-shaped contact surface. This overlapping support of the first front element within the U-shaped contact surface, in the terminal position, provides a positive reception of portions of the first front element partially within the U-shaped contact surface of the base element.
[0016] Advantageously, the breakthrough for the passage of electrical connecting elements, in the terminal position of the first front element, is partially disposed to be congruent with an opening in the U-shaped contact surface. The partially congruent disposition of the breakthrough of the first front element and the opening of the U-shaped contact surface allows the electrical connecting elements to be led into the connector module, wherein the front element may be likewise configured to be foldable with regard to the base element.
[0017] In one embodiment of the present invention, the base element be configured with an almost vertically disposed connecting web, at least at one side, in particular at two wide sides with two connecting webs. It is particularly advantageous that the connecting webs are configured uniformly from the same material and integrally with the webs of the U-shaped contact surface. This configuration of the surface of the base element creates a stable base for the disposition of the elements complementing the connector module. Furthermore, the space between the two connecting webs may serve to receive a provided connecting unit, at which the connectors or screw terminals are disposed. In this case, energized components may be disposed between the base element and the connecting unit such that they are not exposed.
[0018] Furthermore, the option is given for at least one of the elements, in particular for the base element, to be equipped with at least one retaining device for disposing at least one connecting unit, wherein the connecting unit has a corresponding counter-retaining device. It is possible in this case that, within the base element, the retaining device is configured as a breakthrough which is reversibly and/or non-positively and positively connectable to corresponding clips at the connecting unit.
[0019] A particularly cost-effective embodiment of the invention provides that the connector module be configured as an injection moulded part, wherein at least one connection between the base element and the elements at its side has a hinge-type disposition, wherein in particular the front elements are connected to narrow sides and the lateral elements to wide sides in a hinge-type manner. Due to the hinged configuration of the connection between the base element and the front elements, respectively the lateral elements, the connector module remains one piece during the transfer from the terminal position to a basic position. In this case, the lateral elements, respectively the front elements, which, in the terminal position, are disposed almost vertical with regard to the base element, can be folded-down at their location connected to the base element in a direction opposite to their corresponding lateral element, respectively front element.
[0020] Furthermore, in one embodiment, the connector module is configured as one piece and uniformly produced from the same material, realized in particular via the connection of one or more elements to the base element by rebated or film hinges. Advantageously the connector module is manufactured from a current-insulating plastic material in an injection moulding process, to keep manufacturing cost low. A configuration of the hinge-type articulation with an axis is likewise conceivable. In this case, in a dual injection moulding process, the axis may be embedded or injected in one process step as a joint pin between the elements of the connector module to be connected.
[0021] In a particularly advantageous variant, in the basic position of the connector module, in which all the elements are folded-down, the base element and the respective front element, or lateral element are disposed almost parallel to each other.
[0022] Another measure of improvement provides that the connector module, at least at one element, is configured at least partially with reinforcing ribs, and in particular the lateral elements at the inner sides are configured at least partially with reinforcing ribs. It is in particular advantageous, if the reinforcing ribs are configured honeycomb-shaped, because a higher strength of the structure of the lateral elements can be achieved with simultaneous material savings. This is insofar particularly practical, because, when mounting the connector module to the door operator, these elements serve as grip ends, and the additional reinforcement guarantees the shock-proof shielding of the connecting elements located inside the connector module. It is likewise conceivable, that the base element and/or the front element and/or the lateral elements are provided with an electromagnetic shielding, to prevent electronic, respectively electromagnetic interference. The aforementioned elements may be coated with a metal layer for this purpose. It is likewise conceivable to incorporate an appropriate shielding layer within the elements, for example by a wire mesh.
[0023] In a further embodiment, the lateral elements are configured with a latch, which, in the terminal position rest in counter-latch, which are configured or at the front elements. It is particularly advantageous if the latch is configured as latching hooks, which positively bear in or against counter-latch configured as a recess. This configuration of the latch and counter-latch, is very easy to realize in an injection moulding process, and allows for a simple transfer of the connector module from the basic position to the terminal position and protects the location of the elements in the terminal position. In this case, it is particularly advantageous, if the latching hooks are integrally configured with the lateral elements.
BRIEF DESCRIPTION OF DRAWINGS
[0024] Further measures improving the invention are indicated or are illustrated in detail in the following, in conjunction with the description of one preferred embodiment of the invention and based on the Figures, in which:
[0025] FIG. 1 is a perspective view of a connector module in a basic position II;
[0026] FIG. 2 is another perspective view of the connector module in a basic position II;
[0027] FIG. 3 is another perspective view of the connector module in a terminal position I with connecting elements, and
[0028] FIG. 4 is a perspective view of a door operator with the connector module, without housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] FIG. 1 shows a folded-down connector module 1 . The connector module 1 is intended for a door operator 2 , which is illustrated by way of example in FIG. 4 without a housing. The connector module 1 is in a basic position II in FIG. 1 . Front elements 4 , 4 . 1 , 4 . 2 and the lateral elements 5 are folded-down and are disposed almost parallel to the base element 3 . As can be seen, free and easy access to an existing connecting unit 50 is possible, which has screw terminals and plug-and-socket connections, to electrically connect the non-illustrated electrical connecting elements to the door operator 2 . The connecting unit 50 is preferably configured as a circuit board, which is releasably mounted to the base element 3 preferably by screws or latches.
[0030] As can be clearly seen in FIG. 2 , the base element 3 is rectangular and flat. A U-shaped contact surface 8 of the base element 3 is configured at a narrow side 7 . 1 . Connecting webs 11 are almost vertically disposed to the base element 3 at the wide sides 7 . 2 of the base element 3 . In the area of the U-shaped contact surface 8 , the connecting webs 11 are configured as continuing webs 8 . 1 .
[0031] A first front element 4 . 1 , disposed at a narrow side 7 . 1 of the base element 3 , is configured with a breakthrough 6 . In a terminal position I, illustrated in FIG. 3 , the breakthrough 6 of the first front element 4 . 1 corresponds to an opening 10 , which is configured within the U-shaped contact surface 8 of the base element 3 . The access to the connector module 1 , resulting therefrom, allows to lead the electrical connecting elements into the connector module 1 . In this case, the electrical connecting elements may be provided also with connectors, because the resulting access is configured to be sufficiently large. It is likewise conceivable to provide the breakthrough 6 with a watertight membrane, which allows for a waterproof sealing of the electrical connecting elements which are led therethrough.
[0032] The connector module 1 is illustrated from its front side in FIG. 1 , such as it might be attached in the basic position II at a door operator 2 , to connect the electrical connecting elements to the door operator 2 . Once the electrical connecting elements are led through the breakthrough 6 , facing the wall, which breakthrough is disposed in the first front element 4 . 1 , a connection of the electrical connecting elements to the connecting unit 50 may be established. Subsequently, the two lateral elements 5 can be folded up, wherein they are then orthogonally aligned with the base element 3 and prolong the connecting webs 11 over a large area (see FIGS. 3 and 4 ).
[0033] The second front element 4 . 2 can be folded up in a next step, such as to be likewise orthogonally aligned with the base element 3 . A box with four sides and an orthogonal base surface is essentially created thereby. Finally, the entire base element 3 , with the folded-up elements 4 . 2 and 5 , is folded against the first front element 4 . 1 , whereby the terminal position I is achievable, which is shown in FIGS. 3 and 4 . In the terminal position I, all electrical connecting elements are accommodated electrically insulated and shock-proof within the connector module 1 . Moreover, the aforementioned folding movements will not pinch the electrical connecting elements and in addition they are easy to accommodate in the connector module 1 . Depending on the configuration of the door operator 2 , the connector module 1 may be covered or closed with a housing. It is obvious that, for performing maintenance or repair work or the like for example, the connector module 1 may be transferred from the terminal position I into the basic position II in an order, which is reversed to the above described order.
[0034] For attaching the connector module 1 to the door operator 2 , a mounting plate 40 , preferably two attachment elements 9 are disposed at the first front element 4 . 1 . In this embodiment, the attachment elements 9 are cylindrically shaped and, at their side facing the U-shaped contact surface 8 , they have an almost circular breakthrough. Screws may be already pre-mounted in the attachment elements 9 to screw the connector module 1 tightly to the door operator 2 , respectively the mounting plate 40 . The first front element 4 . 1 is configured in webs. In the terminal position I, the first front element 4 . 1 is partially disposed as bearing against the U-shaped contact surface 8 .
[0035] FIG. 4 shows how the connector module 1 is attachable to and releasable from the counter-attachment elements 16 , which correspond to the attachment elements 9 , by screws on a mounting plate 40 of the door operator 2 . For this purpose, appropriate threads, respectively nuts for the screws may be present in the counter-attachment elements 16 .
[0036] In FIG. 1 , the reinforcing ribs 15 are visible at the inner sides 5 . 1 of the lateral elements 5 . The honeycomb-shaped structure of the reinforcing ribs 15 represents a particular material-saving manner to reinforce the structure of an element 3 , 4 , 5 . In the present case, the connections between the elements 3 , 4 , 5 are executed as film hinges 14 . The lateral elements 5 are disposed at the base element 3 via connecting webs 11 .
[0037] In a terminal position I, illustrated in FIG. 3 , the front elements 4 . 1 , 4 . 2 and the lateral elements 5 are disposed almost vertical to the base element 3 . In this case, the breakthrough 6 in the first front element 4 . 1 is disposed almost congruent to the opening 10 of the U-shaped contact surface 8 . This guarantees passing the electrical connecting elements through into the connector module 1 .
[0038] In the connector module 1 , illustrated in a basic position II in FIG. 2 , the retaining elements 12 are configured as breakthroughs within the base element 3 . In this case, the breakthroughs 12 are configured as oblong double breakthroughs 12 , which are disposed parallel to each other. The breakthroughs 12 correspond to clip-like configured counter-retaining elements 13 , which are disposed at the connecting unit 50 and allow for fastening the connecting unit 50 on the base element 3 .
[0039] Furthermore, the latches 17 are visible in FIG. 2 , which are moulded at the lateral elements 5 and the base element 3 . The latches 17 are configured as latching noses, which, in the terminal position I illustrated in FIG. 3 , can be disposed positively and/or non-positively in or at corresponding counter-latching elements 18 of the front element 4 or the base element 3 .
[0040] At the second front element 4 . 2 , counter-latching elements 18 are configured as breakthroughs 18 for receiving the corresponding latches 17 of the lateral elements 5 . At the side of the web 8 . 1 facing the U-shaped contact surface 8 , the base element 3 is executed with a contact surface 18 , configured as a counter-latching element 18 , against which, in the terminal position I, the latches 17 bear under tension.
[0041] FIG. 3 shows the connector module 1 in the terminal position I. It is illustrated in this case that the elements 4 and 5 are disposed almost vertical to the base element 3 . In the terminal position I, the latches 17 , disposed at the lateral elements 5 , are connected to the counter-latches 18 at the front elements 4 , respectively at the base element 3 , whereby a more stable union of the connector module 1 with its front and lateral elements 4 and 5 is achievable in the terminal position I.
[0042] FIG. 4 illustrates the door operator 2 with the mounted connector module 1 in the terminal position I. In this position the electrical connecting elements are electrically insulated and shock-proof disposed inside the connector module 1 . In this case, the entire connector module 1 is configured to be open at the right side, wherein this side is closed by further structural components of the door operator 2 . In the terminal position I, the base element 3 is essentially disposed vertical to the mounting plate 40 of the door operator module 2 . The base element 3 itself may represent a front surface of the door operator 2 in this terminal position I. Usually, the door operator 2 is closed by an essentially U-shaped housing. In the present example, the entire connector module 1 may be screwed to the mounting plate 40 at the counter-attachment elements 16 via the attachment elements 9 . When performing maintenance work or the like, the connector module 1 may be transferred from the terminal position I to the basic position II, by folding to the left the base element 3 together with the associated front elements 4 and the lateral elements 5 , namely from the vertical position into the horizontal position. Subsequently, the individual elements 4 , 5 can be likewise folded away from the base element 3 , in order to allow the optimum access to the electrical connecting elements and, if required, to the connecting unit 50 .
[0043] Instead of or in addition to the above described attaching, respectively mounting the connector module 1 to the door operator 2 , latching connections may be provided, which are configured for example analogously to the latching connections described above in conjunction with the connecting unit 50 and the base element 3 .
[0044] As an alternative, pure clamping attachments can be provided such that there are no particular attachment devices neither at the connector module 1 nor at the door operator 2 .
[0045] As an alternative, it may be provided to permanently mount the connector module 1 to the door operator 2 by a rivet connection, welding, or glueing.
[0046] Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | A door operator with at least one base element, a first and a second front element and two lateral elements, the base, front, and lateral elements being interconnected and at least one of the elements being configured with a breakthrough for the passage of electrical connecting elements. At least one of the base, front, and lateral elements is disposed at the base element to be foldable. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to static magnetic card readers and control systems for electrically operable apparatus, e.g., doors, turnstiles, printers, etc.
2. Discussion of the Prior Art
Static card readers are known which employ a plurality of stationary electromagnet sensors, and which are adapted to receive and hold a spot magnetized card. Sensor coils are pulsed to develop logic level signals representing the polarity distribution of the card spots, and hence the code of the card. See U.S. Pat. Nos. 3,686,479 and 3,885,130, assigned to the same assignee as the present application.
Where such readers are provided at various doors throughout a building, it is known to incorporate all readers into an on-line system wherein they are queried from a station query and stored data comparison console. When a card is inserted in a reader at a particular location, on the next query the code data in the card is transmitted to the console for comparison with stored data. If there is a match, the console transmits a "go" command pulse to the reader so as to enable it for energizing the relay or solenoid for the door strike at that location. If there is no match, a "no-go" signal is transmitted which may be the termination of a query pulse or equivalent wide pulse that prevents operation of logic circuitry to enable the reader for actuating the door strike.
Heretofore, when the console failed to operate in such a system, i.e., to query and send command pulses, the security represented by the system was completely lost. The fact of failure is instantly known, and it has been necessary for security personnel to man the different locations for identifying, and opening doors to permit entry of, authorized persons.
SUMMARY OF THE INVENTION
This invention embraces a system for operating an on-line magnetic card reader whenever the on-line controls fail, but in such a way as to make it appear that there is normal on-line operation. Included are means operable in the off-line situation to read particular spots of a card, to generate a "go" pulse of the same width as a "go" pulse from the console of the normal on-line system operation, to apply such simulated "go" pulse to the reader to cause it to enable logic circuit means for operating the access apparatus, and for generating and applying to the reader a simulated "no-go" command pulse to prevent such reader operation when the particular card spots are not present or are not of the proper polarity distribution. Also included in the scope of this invention is means for preventing application of a "go" pulse to the reader for a period corresponding to that which is required for the normal on-line system to effect actuation of the access apparatus.
BRIEF DESCRIPTION OF THE DRAWING
The lone FIGURE is a block diagram of the system of this invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawing, a magnetic card 10 is provided for insertion in a housing (not shown) within which are a plurality of sensors. The card 10 is spot magnetized so that the poles of all spots are perpendicular to the card faces, and when the card is fully inserted in the housing each such spot is coaxial with a respective sensor. Sensors employed preferably are the type having a coil wound on a core of saturable material of high initial permeability requiring a sufficiently low magnetomotive force to saturate it that the spot of a card will effect such saturation. Se U.S. Pat. Nos. 3,686,479 and 3,717,749 assigned to the same assignee as the present application.
When a voltage pulse is applied to such a coil, the decay thereof is slower in the presence of an opposing spot field than the decay of a pulse in the presence of an aiding field. Via logic devices coupled to the coils, respective binary logic level outputs are derived for the aiding and opposing relations.
In the drawing, two sets of sensors are illustrated which are respectively labeled on-line sensors 12 and off-line sensors 14. Each sensor has one end of its coil connected to a voltage source as indicated at 16. The other ends of the coils are adapted to be connected to a point of reference or ground potential in a sequence desired, as determined by decoder or switching circuitry to which they are connected. In this latter regard, when the card 10 is fully inserted in the housing, the inner end of the card actuates the movable contact of a switch 18, shown as a single pole, double throw switch, the fixed contacts of which are connected to circuits for reading the sensor conditions.
The on-line sensors are connected to a data reader and transfer network 20 which is adapted to effect the pulsing of the sensors 12 and to transfer the data represented thereby to a station query and stored data comparison console 22. Such data reader is enabled upon actuation of the switch 18, and the data it obtains from the card 10 is transferred to the console 22 on being queried by the console.
As heretofore employed, such console is directly coupled to each of a plurality of data reader and transfer networks 20, and repeatedly transmits query pulses to them in succession. Each query pulse conditions the network to transfer to the console any data being read from a card that is in place. If there is no card, the query pulse terminates. If a card is in place, the first query pulse occurring after the card actuates the switch 18 is effectively expanded wherein a clock circuit is enabled and a multi-baud serial data stream is sent to the console. The serial transmission format comprises a start bit followed by serial data bits which represent the information encoded in the card.
If the console detects that the card code matches a stored code, the console transmits a "go" command pulse to logic circuitry for the purpose of causing access apparatus 24 to be actuated. In one example, the "go" command pulse occurs within the span of a clock pulse to cause a flip flop to be set and thereby effect operation of the driver and relay network 28 that actuates the access apparatus 24.
If the console detects that the card code does not match a stored code, the console transmits a "no-go" command pulse. Such a "no-go" pulse exceeds the duration of the clock pulse during which the flip flop is permitted to be set. The flip flop is accordingly not set, and the access apparatus is therefore not actuated.
In accordance with this invention, failure of the console to transmit query and command pulses does not cause shut down of security or indicate that normal on-line operation is not continuing. The D-type flip flop 26 illustrated is set so that the driver and relay network 28 and access apparatus 24 are operated in response to a valid card 10 whether the on-line system is functioning or not functioning.
In this regard, connection of the console 22 for querying and commanding purposes during on-line operation is via lines 30, 32 to a gate network 34, and lines 36, 38 to the flip flop 26 and to the data reader and transfer network 20. The gate network 34 is normally conditioned to maintain the connection between lines 32 and 36, 38. For this purpose, a timer 40, indicated as a 50-sec. timer, is also connected between the console 22 and the gate network 34. The timer 40 is normally on, and is reset by each query pulse from the console. The timer 40 in normal operation enables gate conditions in the network 34 to insure the direct coupling between the lines 32 and 36, 38.
If signals from the console 22 do not appear in line 30, e.g., as where the line 30 is cut, data in a valid card that is sensed via off-line sensors 14 is utilized to operate the access apparatus in the same manner as though commanded from the console. To this end, each card contains a predetermined number of spots which are aligned with respective off-line sensors. A decoder/driver network 46 is connected to the ends of the sensors 14 that are to be selectively connected to reference potential. In this regard, the fixed contacts of the switch 18 are also connected to logic circuitry in the decoder/driver 46, which functions as heretofore explained to develop logic level signals representing the polarity distribution and hence the code of the off-line card spots.
A data buffer 48 connected to the decoder/driver 46 is to have the data loaded therein. Such data buffer may be a conventional multi-bit shift register. As will be more fully explained below, the gate network 34 enables the data buffer to accept the data from the decoder/driver.
A code set circuit 50 is connected to the data buffer 48, and a go/no-go pulse control network 52 is connected between the code set circuit 50 and the gate network 34. The code set circuit 50 is adapted to be set or wired in accordance with one of the number of possible pattern combinations of the spots encoded for off-line purposes. For example, the card 10 may have four spots in addition to the regular on-line spots, and at a particular reader location the code set circuit 50 is set in conformance with the one of the sixteen possible patterns for which it is desired that the four spots have in cards that are to be used for access apparatus at that location.
The code set circuit may be conventional logic circuitry operable so that if the four inputs thereto in the present example are all correct, it develops one logic level output, e.g., a true or "1" output. If any input is incorrect, the code set circuit output is false or "0".
The pulse control network 52 is adapted to respond to the outputs of the code set circuit 50 to develop pulses of widths of the "go" and "no-go" pulses transmitted by the console 22 when in normal on-line operation. In one example, the console-generated "go" pulses are 1-millisecond pulses, and the console-generated "no-go" pulses are 60-millisecond pulses. In the pulse control network 52, the time constant may be set so that the wider "no-go" pulse is generated in response to a false output from the code set circuit 50. A true output from the code set circuit causes smaller resistance to be operable in parallel to that which provided the longer time constant, and thereby causes the narrower pulse to be generated.
When the query pulses from the console 22 fail to appear in line 30, the gate network 34 is made to function to effect direct coupling from the pulse control network 52 to the lines 36, 38. For this purpose, the timer 40 ceases operation at the end of the period set therefor following the last received query pulse. At the end of such period, gates within the network 34 which coupled lines 32 and 36, 38 are disabled, and gates are enabled which couple the line 54 from the pulse control network 52 to the lines 36, 38. Thus, command pulses continue to be supplied. Further, the gate network 34 also functions at such instant to enable the data buffer 48 so as to cause the data read by the decoder/driver to be loaded therein.
Desirably, transmission of pulses from the pulse control network 52 are delayed for a predetermined time corresponding to the period which the on-line system requires to operate the access apparatus in response to a validly coded card. In one example, the total time for the on-line system to respond to a card insertion and to complete actuation of a door strike is in the neighborhood of 0.7 -sec. In accordance with this invention, 0.7-sec. timer 58 is provided which is rendered operable via connections thereto from the switch 18 and the gate network 34, and such timer via connection to the pulse control network 52 is effective to prevent transmission of pulses from such network to the data reader in network 20 and to the flip-flop 26 for the desired 0.7-sec.
Accordingly, persons using their validly coded cards to gain access at any location are not given any indication that the normal on-line system is not functioning. Meanwhile, suitable indicators at the console will have alerted those responsible for maintenance and repairs to take the necessary steps to discover the reason for the cessation of on-line operations and to restore the affected portions to their on-line condition. | A card has two sets of magnetized spots, one set being readable by a reader in an on-line system, and the other set being readable by an off-line reader. Coupled to the off-line reader is a pulse generator adapted to develop pulses of the same character as "go" and "no-go" pulses generated by a station query and stored data comparison console in response to data from the on-line reader. A gate network normally keeps the console in communication with the on-line reader, but is operated to couple the pulse generator to the on-line reader when the console fails to query and cannot send command pulses. Also disclosed are timing devices for delaying operation of the output apparatus for a period corresponding to the time required for the normal on-line system operation to actuate such apparatus. |
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to utility vehicles, such as industrial or agricultural tractors. Particularly, the invention relates to tractors utilizing a rockshaft or three point hitch and an attachable rear-mounted implement.
BACKGROUND OF THE INVENTION
[0002] Utility vehicles typically include an internal combustion engine, which delivers power to a transmission and ultimately to a wheel for traction, and also delivers power to pressurize hydraulic fluid, via one or more pumps, to operate hydraulic tools or implements.
[0003] In this regard, it is known to provide three hydraulic pumps driven from the engine. A first pump generates pressurized hydraulic fluid to charge a steering cylinder of the vehicle. A second pump generates pressurized hydraulic fluid to charge a power takeoff clutch pack and at least one hydraulic cylinder which operates a three point hitch or “rockshaft.” The power takeoff is a shaft that is rotated by the vehicle transmission and is used for supplying rotational power to tools, such as mower decks, where rotation is required. The first and second pumps are driven by an auxiliary drive of the engine.
[0004] The third pump is usually fixed directly to the crankshaft of the engine and is used to charge pressurized hydraulic fluid to the loader and the backhoe hydraulic cylinders.
[0005] Typically, the first pump requires 1.4˜8 horsepower, depending on steering demand and 6 GPM of hydraulic fluid. The second pump requires 1˜9.5 horsepower, depending on demand from the auxiliary circuit, and 5.4 GPM of hydraulic fluid. The third pump requires 3.2˜21.3 horsepower, depending on demand from loader or backhoe circuits and 12 GPM of hydraulic fluid. The engine typically delivers 42 horsepower.
[0006] When a backhoe is attached to the utility vehicle, the rockshaft is not needed, nor is it practically operable. The present inventors have recognized the desirability of disabling the rockshaft when a backhoe is attached to the utility vehicle. The present inventors have recognized the desirability of diverting hydraulic fluid that would otherwise supply the rockshaft, when the backhoe attachment is attached. Furthermore, the present inventors have recognized the desirability of using the circulating hydraulic fluid otherwise available to the rockshaft, to improve the effectiveness and efficiency of the utility vehicle.
[0007] The present inventors have recognized that a proper balance of available engine horsepower directed to the various tractor functions at the proper time is required for best operation of the machine. While the loader is in use, the transmission must necessarily also be in use simultaneously. As such, it is desirable to limit the available horsepower consumed in the operation of the loader while demands are placed on the transmission, to prevent engine stalling.
[0008] Conversely, the inventors have recognized that the backhoe is used without demand on the loader, transmission, rockshaft, or steering circuits. Furthermore, the backhoe has very high hydraulic power requirements. This is because in normal operation, 3 or more hydraulic cylinders (of a typical 7 total cylinders) may be in motion at any given time For this reason, the inventors have recognized that it would be desirable to utilize additional flow from tractor systems which are sitting idle while the backhoe is in use.
SUMMARY OF THE INVENTION
[0009] The present invention provides a method and apparatus for diverting pressurized hydraulic fluid, otherwise available to a utility vehicle rockshaft system, to be used by another hydraulic fluid powered implement on the utility vehicle. Particularly, the invention provides a method and apparatus for diverting pressurized hydraulic fluid from the rockshaft hydraulic system to be available to a backhoe attachment hydraulic system.
[0010] The method and apparatus of the invention are advantageously accomplished by use of a rockshaft disable switch. The switch is placed in a position such that installation of the backhoe attachment on the utility vehicle automatically changes the state of the switch.
[0011] The switch is connected to a solenoid operator that moves a valve spool to divert pressurized hydraulic fluid from a rockshaft control valve to other hydraulically operated tools, such as to the backhoe attachment. Additional hydraulic fluid available to the backhoe attachment allows for faster movements of the backhoe attachment operating hydraulic cylinders, and thus faster manipulations of the backhoe arms and backhoe bucket.
[0012] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a fragmentary elevational view of a tractor incorporating the present invention with a foreground rear wheel removed to view portions behind the wheel;
[0014] [0014]FIG. 2 is an enlarged fragmentary elevational view of a backhoe attachment being installed on the tractor of FIG. 1;
[0015] [0015]FIG. 3 is a schematic diagram of a hydraulic fluid system of the tractor shown in FIG. 1;
[0016] [0016]FIG. 3A is a schematic diagram of a rockshaft control system of FIG. 3; and
[0017] [0017]FIG. 4 is an enlarged diagrammatic view of a rockshaft disable switch mounted to a surface of a tractor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0019] [0019]FIG. 1 illustrates a utility vehicle 20 with an attachable rear-mounted implement, such as a backhoe attachment 24 . The utility vehicle 20 includes a cab or operator's station 28 including a seat 32 , a steering wheel 34 , and loader controls 36 . The cab is supported on a chassis 42 which is supported on front wheels 44 and larger rear wheels 46 . The utility vehicle 20 can be equipped with a front mounted loader assembly 48 .
[0020] The backhoe attachment 24 includes a bucket 54 , a distal arm or dipperstick 58 , an intermediate arm or boom arm 62 , a swivel arm or swivel tower 66 and a base assembly or mainframe 67 . The distal arm 58 can be pivoted about a point 58 a with respect to the intermediate arm 62 by a hydraulic cylinder 70 . The intermediate arm 62 can be pivoted about a point 62 a with respect to the swivel arm 66 by a boom cylinder 74 . The swivel arm 66 can be swung about a vertical axis with respect to the base assembly 67 . The bucket 54 can be rotated about a point 54 a with respect to the first arm 58 by a hydraulic cylinder 76 and linkages 54 b, 54 c. The operation of the hydraulic cylinders is by rear-mounted controls 82 .
[0021] The backhoe base assembly 67 includes laterally directed, laterally spaced apart, round bars 92 (one shown) extending on opposite sides of the base assembly 67 on a bottom thereof. The base assembly 67 further includes laterally spaced apart cylinder bosses 102 (one shown) located substantially above the round bars 92 and extending laterally on opposite sides of the base assembly. The bars 92 and bosses 102 are arranged in mirror image symmetrical fashion across a longitudinal vertical plane.
[0022] The utility vehicle chassis 42 includes a mounting structure 42 a comprising hooks or seats 106 (one shown) opened upwardly and located on opposite lateral sides of the rear portion of the chassis 42 . The seats 106 are sized and shaped to each receive a round bar 92 therein. The mounting structure 42 a further includes two laterally spaced apart receivers 112 (one shown) which are sized and shaped to receive the bosses 102 therein. The receivers 112 are open substantially horizontally toward the backhoe attachment. The mounting structure 42 a is configured in mirror image symmetrical fashion across a longitudinal vertical plane.
[0023] [0023]FIG. 2 illustrates, in an enlarged view, the base assembly 67 of the backhoe attachment 24 partially engaged to the utility vehicle 20 . The round bars 92 are already fit into the seats 106 . The boss cylinders 102 are then rotated up to engage the receivers 112 , 114 . The receivers 112 each include a semi-circular rim portion 112 a and a pin receiving cylinder 112 b having a base 112 c. Each boss 102 includes a central bore 102 a. When a boss 102 is fit into the receiver rim portions 112 a the bore 102 a aligns with the bore 112 c as the boss 102 fits coaxially against the cylinder portion 112 b. Two cylindrical connector pins 115 are fit through the central bores 102 a of the bosses 102 , respectively, and through the adjacent bores 112 c of the cylinder portions 112 b of the receivers 112 to lock the backhoe attachment 24 to the utility vehicle 20 . Means, such as a radial locking pin 117 that penetrates the cylinder 112 or the boss 102 and the connector pin 115 , can be provided to lock the connector pins 115 in place.
[0024] The backhoe attachment is removeable by removing the connector pins 115 when it is desired to install a different rear attachment, such as a mower deck, or a tiller.
[0025] [0025]FIG. 3 illustrates a hydraulic system 120 of the invention. The hydraulic system 120 is charged by three pumps. A first pump 124 and a second pump 126 are driven by the auxiliary drive of an engine 130 . A third pump 134 is driven by the crankshaft of the engine 130 . The first pump 124 charges the power steering system 142 and ultimately powers a steering cylinder 144 . Hydraulic fluid out of the steering system 142 charges a hydrostatic transmission 148 which transfers power from the engine to the utility vehicle gear train. The second pump 126 charges a power takeoff system clutch pack 156 , and a rockshaft system 162 , particularly directing hydraulic fluid through a rockshaft selective control valve 163 (shown in FIG. 3A) which powers at least one rockshaft hydraulic cylinder 164 (shown in FIG. 3A). The hydraulic cylinder(s) 164 controls vertical and/or attitude and/or pitch adjustment of the three-point hitch.
[0026] The third pump 134 charges a loader selective control valve 166 and a backhoe selective control valve 168 . The selective control valves 166 , 168 each include an operation control lever for precise manipulation of hydraulic cylinders which control movements of the associated implement.
[0027] According to the invention, a diverter valve in the form of a spool valve or cartridge valve 174 is hydraulically connected to pressurized hydraulic fluid from the second pump 126 . In the absence of the backhoe attachment, a solenoid 176 of the valve 174 is normally energized, to overcome spring force, to deliver pressurized hydraulic fluid to the clutch pack 156 and to the rockshaft system 162 . When the backhoe attachment is subsequently installed onto the utility vehicle 20 , the backhoe attachment 24 makes contact with, and trips a switch 178 such that power is disconnected from the solenoid 176 and spring force moves a spool 180 of the valve 174 to connect the backhoe system to pressurized hydraulic fluid from the second pump 126 , and to simultaneously disconnect pressurized hydraulic fluid to the rockshaft system 162 .
[0028] By causing this diversion of hydraulic fluid, the third pump 134 can be made correspondingly smaller, having less fluid capacity. The second pump 126 , which is needed for rockshaft operation, but heretofore represented unused capacity during backhoe operation, can now be used to increase total pump capacity to the backhoe attachment.
[0029] The size of the pump 134 is typically selected to correspond to the total horsepower demand of the front loader, via the valve 166 . The engine is typically sized to provide reserve power over the horsepower demand of the loader to power the hydrostatic transmission 148 during loader work, when the backhoe is not in use. Thus, sufficient engine horsepower is available to drive both pumps 126 , 134 to supply the backhoe with increased hydraulic capacity. The invention is therefore particularly advantageous to retrofit existing utility vehicles or existing designs for utility vehicles.
[0030] [0030]FIG. 3A illustrates a rockshaft or three point hitch control scheme including the rockshaft control valve 163 having an operator controlled lever 163 a for manipulating a valve spool 163 b. The spool 163 b communicates pressurized hydraulic fluid through a system of valves to the hydraulic cylinder 164 . The hydraulic cylinder 164 includes a rod that is configured to extend or retract to pivot a hitch arm 165 to adjust the rockshaft. Although one cylinder 164 is shown, plural cylinders 164 can be used to adjust height, attitude, pitch, etc. Other rockshaft or three point hitch systems are disclosed in U.S. Pat. Nos. 6,216,072; 5,152,347; 4,216,975; and 3,990,520, all herein incorporated by reference.
[0031] [0031]FIG. 4 illustrates the switch 178 in more detail. The switch includes a switch component 184 which can be a commercially available switch. The component 84 can be mounted on or in a frame or box 185 . The switch component 184 includes a switch button or trigger 186 . The trigger can be a momentary switch which must be continuously depressed to maintain an actuated state. A resilient switch lever 190 is mounted to the frame 185 at an attachment point 192 . The switch 190 includes a button engaging portion 194 , an extending portion 196 , and a roller portion 198 mounted to the extending portion 196 .
[0032] When the backhoe is installed, a surface 67 a of the backhoe attachment base assembly 67 presses the roller portion 198 in the direction A, which pivots the extending portion 196 and the engaging portion 194 about the attachment point 192 to press the button 186 inwardly, to change the state of the switch component 184 , i.e. to open (or alternatively to close) the switch component 184 . An electrical signal is thus sent to the solenoid 176 and hydraulic fluid is thus diverted from the rockshaft to the backhoe attachment. When the backhoe attachment is removed, the lever 190 springs away from the button 186 to change the state of the switch component, i.e. to close (or alternably to open) the switch component 184 , and hydraulic fluid is diverted back to the rockshaft system.
[0033] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A hydraulic fluid diverting arrangement for a utility vehicle provides additional pressurized hydraulic fluid supply to an installed backhoe attachment by diverting hydraulic fluid from the unused rockshaft or three-point hitch of the utility vehicle. A solenoid operated valve manifold is switch actuated by contact from the backhoe during installation of the backhoe to the utility vehicle and diverts hydraulic fluid flow from rockshaft hydraulic cylinders to backhoe hydraulic cylinders. The system increases the available horsepower to the backhoe by using hydraulic fluid otherwise dedicated to the idle rockshaft. |
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BACKGROUND OF THE INVENTION
In my U.S. Pat. No. 4,404,775, which issued on Sept. 20, 1983 I disclosed new and novel rain-water deflector devices. Such devices utilize surface tension to overcome other forces acting upon rain-water falling down the surface of a roof, to cause the rain-water to be deflected into the associated gutter while leaves, pine-needles, sticks, and other debris borne by the water are jettisoned away from the gutter. As a result, clogging of the rain gutters is avoided and it is unnecessary to clean them out manually. Devices embodying that patent, which are currently being marketed commercially under the trademark "Gutter Helmet", have proved successful. However, considerable effort has been expended on means for mounting such deflectors that will be efficacious, inexpensive, and easy and quick to install, but, at the same time, will not introduce other difficulties. For example, it was clear from the outset that such deflectors would have to be anchored securely against wind, rain and other forces. However, simply screwing the outermost end of the deflector bracket to the outer lip of an associated gutter presented several difficulties. Whether being so installed by one working from the roof (a usual situation) or by one working from beside the gutter, even if the lowest end of a bracket were pre-drilled to receive a screw extending through the gutter lip and into the bracket, the work had to be done essentially "blind" because visibility of the bracket end is blocked by the gutter edge. Such practices are not only tedious in requiring that the various alignments be made "blind" but are also dangerous, particularly to one working from the roof and having to reach out over the edge to set screws and to make drill holes through the gutter lip and the bracket end. Further, the rain-water deflector is in close proximity to virtually the entire gutter-roof edge area. This provides little space in which to work and severely restricts the available light and visibility of the worksites. Further, disturbance of existing structures is undesirable, as by dis-assembly to any extent of the existing gutter structures in order to get access to the existing gutter brackets. In addition, such procedures may be too intricate or extensive for home-owners or other non-skilled tradesmen who may be involved in rain-water deflectors as a "retro-fit" of existing gutter systems. In this connection, reference is made to my U.S. Pat. No. 4,497,146 which issued on 2/5/85 and the references cited therein. Accordingly, it is an object of this invention to provide means for the installation of rain-water deflectors.
Another object of this invention is to provide such means in a form which will be easy to utilize with existing gutter systems.
Yet another object of this invention is to provide means for achieving the foregoing objectives which will not require substantial reconstruction of existing gutter systems.
Still another object of this invention is to provide means for achieving the foregoing objectives which will also accomodate the physical changes which may occur after installation, such as thermal expansion and construction.
SUMMARY OF INVENTION
Desired objectives may be achieved through practice of the present invention, embodiments of which include a rain-water gutter deflector bracket having a substantially straight upper section and a reverse-curved, downward oriented lower section, including upward facing tab means in the upper section to be received in corresponding apertures in an associated deflector, and downward facing tab means in the lower section to receive the upper edge of an associated rain gutter. Other embodiments include such bracket devices in combination with associated deflector devices wherein the deflector has apertures for receiving the tabs in the upper portion of the bracket that are separated from other holes at one or both sides by means of a thin web through which the associated bracket tab will break upon linear migration of the deflector due to temperature change.
DESCRIPTION OF DRAWINGS
This invention may be understood from the description which follows and from the accompanying drawings in which
FIG. 1 depicts a perspective view of a bracket embodying this invention,
FIG. 2 depicts a cross-sectional view of the embodiment of this invention shown in FIG. 1 in use on a rain gutter with an associated rain-water deflector, and
FIGS. 3A and 3B depict rain-water tab hole configurations useful in the practice of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. #1, there is depicted a bracket 10 which embodies the present invention. As shown it is in the form of a flat continuum preferably made from metal which is strong, durable, weather-resistant, easily formed, and substantially rigid, yet susceptible to some bending without breakage. Heavy gauge aluminum has been found suitable for such use, but it is within the contemplation of this invention that other materials, such as galvanized steel, copper or cuprous alloys, or even plastic might also be utilized. It is also within the contemplation of this invention that even though a substantially parallel-sided flat continuum is shown and discussed, other cross-sectional shapes for the basic bracket stock might also be utilized, provided they accomodate substantially the physical displacements and affixation means herein disclosed or their effective equivalents.
As shown in FIGS. 1 and 2, the bracket 10 has an upper portion 12 which is substantially straight or at most slightly convexly curved. As shown in FIG. 2, it is designed for its upper end to be located in proximity to or even to rest on an associated roof 50, while it supports an associated rain-water deflector 40 and has its lower end supported by the upper edge 32 of an associated rain gutter 30.
FIGS. 1 and 2 also illustrate the lower portion 14 of the bracket 10, which has a reverse-direction upper curve 16, and a second reverse direction lower curve 18, the lowest end 19 of which is adapted to rest on the upper edge 32 of the outside wall 31 of the gutter 32. The upper portion 12 of the bracket 10 includes tabs 20, 21, which are punched out of the bracket stock so that they are at substantially right angles to the upper surface of the upper portion 12. This facilitates insertion of the tabs 42, 43 through corresponding tab apertures in the rain-water deflector to be positioned atop the bracket. Following such insertion, the tabs may be bent over with a wrench or other tool to hold the deflector affixed to the bracket. The effects of this latter sequence may be seen by comparing, in FIG. #2, the position of tab 20 (which is shown before being bent) with that of tab 21 (which is shown after having been bent). The lower portion 14 of the bracket 10 has a tab 22 punched out of its basic stock, but the orientation of this tab with respect to the surface of the bracket is substantially V-shaped. Thereby, the free end of the tab 22 and the undersurface of the bracket gutter rest portion 19 form an open-ended receptacle into which the upper edge 32 of the associated gutter 30 may be received for positionally fixing the bracket with respect to the gutter.
As shown in FIG. 2, this invention may be used in connection with standard, existing building construction wherein a gutter 30 is affixed to the fascia 54 next to a soffit 52, in the area where the roof 50 overhangs the fascia. The bracket is positioned with the top edge 32 of the gutter 30 inserted into the opening formed by the divergence of the tab 22 from the lowermost end region 19 of the bracket 10. When so positioned, the entire reverse curved lower portion 14 of the bracket 10 elevates the lower end of the straight portion 12 of the bracket 10, with the higher reverse curved portion 16 acting as a support for the underside of the "nose" of the deflector 40. In that position, the bracket and the deflector which it supports are positioned well above the edge of the roof 50, while the uppermost end of the straight portion 12 of the bracket extends some distance back from the edge of the roof. The effect of this is to cause a rain-water deflector of the type shown in my above-mentioned patent, when positioned atop the bracket, to present a more gentle or shallower slope to water coming off the roof. It also supplies a support base for the associated deflector 40 while providing sufficient spacing of the deflector above the gutter edge to permit the deflector to function as intended. Thus, the deflector is positioned to deflect water into the gutter while jettisoning any leaves and other debris that are carried along by the water off of its curved surface 16 and outside the front wall 31 of the gutter 30. Any such leaves and/or debris that are not so jettisoned by the water will merely accumulate on the deflector top surface, to be blown away by the wind after subsequent drying. By either process, the leaves and other debris will effectively have been kept from falling into the gutter. With several other brackets similarly installed and positioned at approximately five foot intervals along the length of the gutter at locations corresponding to the position of tab aperatures in the associated deflector, the deflector may then be positioned atop the brackets. Although the top ends of the brackets may be in contact with the roof (for example, where the panel has been cut back for aesthetic reasons, so as to extend less far up a steep roof), the deflector panels preferably extend above the upper ends of the support brackets, so that the under-side of the upper edge of the deflector panels come into contact with the upper surface of the associated roof. By this means, through use of an adhesive coated sealing strip 46 on the underside of the top edge of the deflector, that edge may be pressed against the roof surface following removal of a protective cover to produce an upper seal to inhibit water coming down the roof against passing under the deflector edge. The upper edge of the deflector panels may also include nail apertures 44 through which nails 48 may be loosely driven so as to anchor the upper edge of the strip against radical displacement while still permitting the deflector panels to move laterally as the deflectors expand or contract in response to temperature changes.
Another aspect of the present invention is illustrated in FIG. 3A and 3B, showing unique structural features in the formation of receptacle holes to receive tabs and/or roof nails of the type and for such purposes as those described above. FIG. 3A shows one embodiment of such structures comprising a central tab aperture 60 that extends through the deflector sheet, corresponding to those shown as 42, 43 in FIG. 2. The central hole 60 preferably is oblong, with its longer axis oriented in the direction of the long dimension of the deflector 40. As such, it is particularly adapted to receive a tab 20A which is longer in cross-section in that same dimension when deflector panels and their associated support bracket are in situ. On either side of the central hole 60 in that same long dimension, and separated therefrom by thin webs of metal 64 that are left from the original sheet stock from which the deflector panels are formed, are smaller side holes 62. When a deflector panel is positioned atop brackets as herein disclosed with a bracket tab 66 positioned in central hole 60, as noted above, the tab may be bent over, using a wrench or simple slotted tool in order to hold the deflector panel in place atop the deflector against movement induced by wind, water, or other forces. Subsequently, if sunlight hitting the panel, or a raise in ambient temperature, or other change causes the temperature of a deflector panel to rise, consequent expansion of the panel may cause a net linear displacement of the deflector panel in the direction of its long dimension at any given bracket tab affixation location. In that event, this unique structural feature will permit the associated tab to break through the web on one side and utilize the additional space provided by the side hole without the deflector panel being blocked from migrating by the tab, thereby avoiding the buckling of the panel that might otherwise occur. Conversely, if the temperature of the panel drops and the panel therefore contracts, any consequent net migration of the panel in the opposite direction is accomodated by the tab breaking the web into the other side hole, thereby avoiding buckling, tearing, or other adverse affect on the deflector panel. An advantage of the "central hole - two ancillary hole" configuration shown in FIG. 3A is that by making an installation initially with the support tabs in the central hole when the panel is at or near a median of the range of temperatures to which it will be exposed in the normal course, the adverse effects of both temperature increase and decrease can be avoided. Even if such care as to temperature condition is not taken at the time of installation, a single sidehold-web combination will usually provide sufficient relief to accomodate most situations. Thus, FIG. 3B illustrates an alternative configuration to demonstrate that although an elongated central hole is preferred, other configurations, such as the round hole shown in FIG. 3B, will also work, and that a single ancillary side hole may also be utilized. Thus, embodiments of this invention include brackets of the type disclosed in combination with deflector panels having bracket tab holes which include structural features of the type disclosed herein.
In practice, embodiments of this invention may be utilized in connection with the installation of rain gutter deflector panels in the foilowing manner. First, a mounting bracket of the type disclosed may be affixed to each end of a deflector panel by inserting the panel affixation tabs on the top of the bracket through the corresponding tab aperatures in the panel. Optionally, a seal strip may be adhesively fixed to the upper edge of the panel, to provide a means for securing the upper deflector panel edge to the shingles of the associated roof. The panel is then positioned in line with and over the gutter with which it is to be associated. The protective cover on the outside of the edge seal strip (if one has been used) may then be removed. Then, whether or not an edge seal strip has been used, the upper edge of the deflector may be laid on, or (preferably) slid under the edge of, a course of the roof shingles. The front end of each of the brackets may thus be positioned on the top edge or bead of the front wall of the associated gutter with the bead residing in the V-shaped slot formed by the lower end of each bracket and its lower tab. If more than one deflector panel is to be used (e.g., in order to extend the panels over a greater length along the edge of the roof), the next panel, but without a bracket affixed to its end that is next to the first panel, is positioned atop the end of the first panel to which it is to be join, with the upper tabs of the first panel bracket on that end extending through the tab apertures in the second panel. The upper tabs may then be bent over, using a wrench or other tool, and nails may be loosely driven into the roof through holes in the upper edge of the panels, thus affixing the panels in place.
It will be apparent from the foregoing that through use of the present invention, it is possible to make effective and durable installations of rain-water gutter deflectors without having to utilize screws or other such fasteners. It will also be clear that by aligning the brackets with the pre-formed tab apertures, the possibility of faulty installations is substantially reduced.
Although the present installation is shown and described in the context of its particular suitability to use with a gutter of the so-called "K" type which is herein illustrated, brackets according to this invention are also readily adaptable to use with gutters which are of other cross-sectional configurations, such as an upwardly opening half-round, and with wooden gutters. This may be accomplished by bending the tab 22 downward so that it is substantially at right angles to the lower portion 19 of the bracket, in which posture it may be held to the top of the outside wall of the associated gutter using, for example, a screw inserted through the gutter edge and the now bent-down tab 22.
It is to be understood that the embodiments of this invention herein shown and discussed are by way of illustration and not of limitation, and that other embodiments may be made without departing from the spirit and scope of this invention. | This invention relates to rain gutter devices, and in one embodiment comprises a bracket for use in supporting a rain-water deflector. The bracket is in the form of a flat continuum having a straight upper section and a double-reverse lower section. The lowermost portion includes a tab adapted for receiving the top edge of an associated rain-gutter. The upper section includes tabs for insertion into corresponding apertures in associated rain-water deflectors. Other embodiments include such brackets in combination with rain-water deflectors having bracket tab apertures, each of which consists of a central opening and side-openings that are separated from their associated central opening by a narrow web. Thereby, upon movement of the rain-water shield in its long dimension as a result of thermal expansion and contraction, the associated bracket tabs will break through the webs, eliminating restraint on migration of the shields and avoiding buckling of the rain-water shield. |
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FIELD OF THE INVENTION
This invention relates to workspace partition systems such as might be used in an office building to provide individual work stations. In principle, however, the invention could find application in any partition system for space within a building.
BACKGROUND OF THE INVENTION
Partition systems for office buildings typically comprise groupings of inter-connected wall panels arranged to define individual work areas. The wall panels may extend from floor to ceiling, in which case the partition system usually has a fixed overall configuration. Cables for providing power and data communications connections can then be routed through the wall panels themselves to appropriate locations within the workspace. Typically, cabling is run overhead and then brought down through the wall panels to work height. Where the wall panels are less than full height, cabling can be run through a column or pole that extends upwardly from the partition system to the ceiling.
Electrical codes require that certain precautions be taken to protect cables within a partition system. Appropriate protection can be achieved relatively easily where the system is substantially fixed. However, flexibility often is required. For example, in some office environments there may be a need to reconfigure a partition system at relatively frequent intervals and/or to change the locations at which power and communications services can be accessed within the system. Electrical receptacles and data jacks may be required at desk height at some locations within the partition system, and at floor height at other locations within the system, and these requirements may change over time.
An object of the present invention is to provide a workspace partition system and a wall panel for use in such a system, in which power and/or data access points can readily be relocated on site, while at the same time providing appropriate protection for the cabling.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention there is provided a wall panel for a workspace partition system in which the panel includes a rectangular structural frame and a plurality of cladding elements removably secured to the frame. The frame is made up of a pair of spaced parallel uprights and at least two transverse frame members that extend in spaced parallel positions between the uprights generally at right angles thereto. The panel includes a cable raceway that extends between the uprights of the frame and that is defined at the top or bottom side by one of the transverse frame members and at the other side by a raceway element. The raceway element is made up of a frame member that extends parallel to the structural frame member between the uprights, and spacer means extending from the raceway frame member and co-operating with the structural frame member to position the members in spaced parallel positions. Raceway cover plates are coupled to the frame members to define with those members a substantially closed cable raceway extending transversely through the panel. The raceway element is removably coupled at its ends to the uprights so that the element can be repositioned on site in co-operating relationship with another transverse structural frame member of the panel, for relocating the raceway. At least the uprights of the frame include openings for permitting cables to enter and leave the raceway irrespective of the location of the raceway within the panel.
The raceway is not intended as a structural part of the panel in the sense that the panel has sufficient structural strength to be functional even without the raceway in place, though the raceway may add strength. Once the panel has been installed in a partition system, the location of the raceway can easily be changed by removing the raceway element and simply repositioning it in co-operation with a different transverse member of the structural frame. Different configurations of cladding panels will of course be required. Whatever its location, the raceway comprises a substantially closed conduit for cabling extending transversely through the panel. The cabling is protected top and bottom by the frame members and back and front by the cover plates.
Typically, the structural frame of the panel is a metal fabrication comprising primarily channel-shaped members spot welded or secured together by screws. The raceway element can be a channel-shaped member with two or more short channels projecting outwardly from the base to serve as the spacer means referred to previously. Preferably, the transverse frame member which co-operates with the raceway frame member is also channel-shaped and is positioned so that the bases of the channels of the two members face one another. The sides of the channels can then be used as attachment faces for the cover plates. The short channels defining the spacer means can align with openings in the base of the raceway frame member so that the short channels can serve as “chimneys” through which some of the cables can be routed. For example, data communication cables can be routed through the “chimneys” so that they will be maintained separate from and screened from the power cables.
When the top member of the structural frame is a channel, it preferably is positioned so that the channel is open to the top of the panel. Not only is the base of the channel then positioned appropriately to co-operate with the raceway element if required, but the channel itself can serve as a trough into which some of the cabling can be laid for routing of the cabling through the partition system. For example, in a particular grouping of wall panels, data communications cables may be routed into the trough formed by the frame member at the top of one of the panels at an entry point, laid along the trough of that panel and then into the corresponding troughs of other panels. Where a communications jack is required in a particular panel, one of the cables can be routed downwardly through an opening in the base of the channel of the top frame member, to the raceway. Electrical cabling can then travel separately through the panel and is kept away from the data cables.
In the minimum case, the structural frame of the panel has two transverse frame members, one at the top and one at the bottom. The raceway element can then be used in conjunction with either of those two members. Additional transverse frame members can be provided at one or more intermediate locations depending on the height of the panel and its intended application. For example, power and data connections typically are required at floor height or at desk height. In a relatively tall panel, the raceway element will be used in conjunction with the bottom transverse frame member to provide power and data connections at floor level, or in conjunction with an appropriately positioned intermediate member where connections are required at desk height.
BRIEF DESCRIPTION OF DRAWINGS
In order that the invention may be more clearly understood, reference will now be made to the accompanying drawings which illustrate a particular preferred embodiment of the invention by way of example, and in which:
FIG. 1 is a simplified perspective view of a partition system in accordance with the invention;
FIG. 2 is a partially exploded perspective view showing the structural frame members and raceway elements of the system of FIG. 1;
FIG. 3 is an exploded perspective view of part of the wall panel that appears at the right in FIG. 2 showing the raceway at desk (“belt line”) height;
FIG. 4 is a view similar to FIG. 3 showing the raceway positioned at the bottom of the wall panel (“baseline”);
FIGS. 5 and 6 are elevational views of a complete panel showing these two alternative locations for the raceway; Ac
FIG. 7 comprises views denoted (a) and (b) showing a raceway element in two alternative orientations;
FIG. 8 is a vertical sectional view generally on line VIII—VIII of FIG. 4, with the panel assembled and showing electrical receptacles accessible at both sides of the panel; and,
FIG. 9 is a view similar to FIG. 8 showing the raceway at a belt line location and single side receptacle access only.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2, a workspace partition system in accordance with the invention is generally denoted by reference numeral 20 . In this embodiment, the system includes three wall panels 22 that are positioned mutually at right angles and extend outwardly from a column member 24 to which the panels are secured by fasteners (not shown). FIGS. 1 and 2 merely show one very simple configuration of wall panels. Other and more complex configurations are of course possible.
The wall panels 22 are essentially the same but of respectively different heights. Each panel includes a rectangular structural frame and a number of cladding elements that are removably secured to the frame. The frames of the three panels 22 are shown in FIG. 2 and two typical cladding elements for one of the panels are shown in exploded positions at 26 . A cap for the top edge of the panel is shown at 28 . Elements 26 are provided with clips (some of which are indicated at 30 ) for engagement in openings in the frame of the panel (e.g. as indicated at 31 in FIG. 3) for removably securing the cladding to the frame. Obviously, a range of elements will be provided in different sizes to suit different panels. The cap 28 snap-fits onto the top edge of the frame; again, similar caps will be provided for each of the panels.
Referring now more particularly to FIG. 2, the frame of the panel 22 that appears on the right is generally denoted 32 and will now be described as a representative example of any of the panels. Frame 32 is made up of a pair of spaced parallel uprights 34 , 36 and top and bottom transverse frame members 38 and 40 respectively. Each of the frame members has a generally channel-shaped configuration. It can be seen that the two uprights 34 , 36 are oriented with their channels facing inwardly and that the channel members comprising the top and bottom frame members 38 , 40 are positioned with their channels facing outwardly and with their end portions received within the channels of the uprights 34 , 36 . The bottom transverse frame member 40 is positioned at a spacing above the bottom ends of the uprights 34 , 36 to accommodate a kick panel 42 . In this embodiment, a third transverse frame member extends between the uprights parallel to the top and bottom frame members, and is denoted 44 . Shown immediately below member 44 in FIG. 2 are a pair of electrical receptacles 46 and a data jack 48 . FIG. 5 shows these components as they would appear in a finished panel and it will be seen that they are positioned generally at the so-called “belt line” of the panel, which would be immediately above a desk surface indicated in ghost outline at 50 . FIG. 6 by contrast shows the same components in a “baseline” location immediately above the kick panel 42 .
Reverting to FIG. 2, the third frame member 44 co-operates with a raceway element 52 (shown in detail in FIG. 7) to define a raceway 54 that extends transversely of the panel, and in which the receptacles 46 and jack 48 are located. The vertical position of frame member 44 is selected so that, when the raceway is assembled, the receptacles 46 and the jack 48 are in the required belt line location shown in FIG. 5 .
The other two panels shown in FIGS. 1 and 2 also have raceways 54 at the belt line. As will be described in more detail below, each of the raceways or any one of the raceways can be moved down to the baseline location illustrated in FIG. 6 by simply repositioning the raceway element 52 , or removed altogether.
In the embodiment of FIG. 2, electrical power is supplied to the partition system through a main power supply cable 56 that leads to a junction box 58 carried by the bottom frame member 40 of one of the panels. From the junction box 58 , the power cable is led vertically upwardly within the panel, inside an armoured conduit 60 to the receptacles 46 . The main power supply cable is connected to a wiring “harness”, parts of which are indicated at 62 and 64 . The harness includes various snap connectors (see FIGS. 3 and 4) which allow additional wiring to be connected for extending the wiring through the panel system as required. It will be seen that the uprights 34 and 36 of the wall panel frames are provided with relatively large rectangular openings 66 through which the power and data cables are routed. Similar, aligned openings 68 provided in the column 24 at which the panels meet.
Data communication cables preferably are routed through the partition system separately from the power cables. In this embodiment, the data cables are shown extending downwardly from above to the partition system and are indicated at 70 . The main power cable 56 could be similarly routed. Whichever cables enter the partition system from above, they will normally extend through a decorative enclosure or column that would in effect be a vertical extension of column 24 . From their point of entry at the top of column 24 , the data communications cables 70 are laid into troughs that are formed by the top transverse frame members 38 of the panels. The cables can be routed on beyond the panels shown to other adjacent panels, as indicated at 72 . At the same time, connections to the jacks 48 within the respective panels can be taken vertically downwardly as indicated at 74 through openings in the bases of the top frame members 38 .
FIG. 3 shows in detail the raceway 54 that is formed in part by the intermediate transverse frame member 44 shown in FIG. 2, and by the raceway element 52 shown in FIG. 7 . FIG. 4 shows the same raceway element used in conjunction with the bottom frame member 40 to form a raceway at the baseline as shown in FIG. 6 . In FIG. 3, the raceway element 52 is below the transverse frame member 44 , while in FIG. 4, the raceway element 52 is inverted as compared with FIG. 3 and co-operates with the bottom frame member 40 .
FIG. 7 ( a ) shows the raceway element 52 in the position it occupies in the belt line position shown in FIG. 3, while FIG. 7 ( b ) shows the element in the position of FIG. 4 . Raceway element 52 comprises a frame member 74 that is essentially the same as the top and bottom frame members 38 and 40 (i.e. all three members are the same). The member is channel-shaped and is shown in FIG. 7 ( b ) with its channel facing upwardly, so that its base 74 a confronts the corresponding face of the bottom frame member 40 as it appears in FIG. 4 . Tabs 74 b are folded upwardly at the ends of the frame member 74 for receiving sheet metal screws that are driven through those tabs and into the respective uprights 34 and 36 of the frame, for securing the raceway elements within the frame.
The raceway element 52 also includes spacer means in the form of a pair of short channel members 76 that extend outwardly from the base 74 a of frame member 74 . The two channel members 76 are symmetrically offset to respectively opposite sides of the base 74 a of the frame member and are positioned with their channels facing outwardly in opposite directions, so that the raceway element overall is symmetrical. Openings 78 in the base 74 a of the frame member align with the respective channel members 76 . The channel members 76 are welded in place.
It can be seen that the outer ends of the channel members 76 are notched as indicated at 76 a . Corresponding openings, one of which is indicated at 78 in FIG. 4, are provided in the transverse frame members 38 , 40 and 44 of the panel frame, so that the notches 76 a in the channel member 76 can fit into the openings in the frame members for locating the channel members with respect to the frame members and providing a conduit or “chimney” through which data cables can be conducted into, out of or through the raceway, for example as indicated by the cable denoted 80 in FIG. 4 . In this way, the data cables are mechanically and electrically isolated from the power cables in the raceway.
In FIG. 4, the power cables are indicated at 72 . Plug-in connectors incorporated in the power cables are indicated at 84 . It will of course be appreciated that there is an opening 78 at the bottom of the “chimney” through which the data cable 80 passes so that the cable could in fact be conducted straight through the raceway if appropriate.
The raceway is always positioned so that the base 74 a of its frame member 74 confronts a corresponding base surface of the frame member with which the raceway element is to co-operate. Thus, FIG. 7 ( a ) shows the raceway element positioned for co-operation with a frame element above, with its base facing down, as in FIG. 3 .
In each of FIGS. 3 and 4, the raceway is completed by front and rear raceway cover plates 86 and 88 that are secured to the side flanges of the respective frame members 74 and 40 . It is an electrical code requirement that the cover plate should not be removable by hand. Accordingly, tabs 86 a are provided on the top edge of cover plate 86 for receiving sheet metal screws 90 that are screwed into corresponding holes on the side flanges of the respective frame members 74 , 40 . Tabs similar to tabs 86 a are provided at the bottom edge of cover plate 86 but are not visible in FIG. 4 . The receptacles 46 are secured to the cover plate in conventional fashion using screws and nuts (not shown) via isolation plates 46 a . Jack 48 snap-fits into an opening in the cover plate. The cover plate 86 is visible in the assembled panel and therefore has an appropriate decorative appearance to match the cladding panels 26 (e.g. fabric covering). The plate may have the same profile shape (in section) as the cladding panels 26 . The cover plate 88 at the opposite side of the panel, however, is not visible in that it is covered by one of the cladding panels (as panel 26 —FIG. 2) in the assembled wall panel. Accordingly, plate 88 is simply a flat steel plate having appropriate tabs for receiving screws used to secure the plate to the frame of the wall panel.
FIG. 8 shows an example of a raceway which is designed to provide double-sided access to electrical receptacles and/or data jacks at a baseline location in a partition system. In this embodiment, both cover plates 86 , 88 are visible at the exterior of the panel and can if necessary be removed to provide access to cabling within the raceway. FIG. 9 on the other hand shows an embodiment in which there is only single side receptacle access and plate 88 is covered by one of the cladding panels 26 .
It will be appreciated that, in a panel configured for baseline power and data access, it is a relatively simply matter to reconfigure the panel on site for belt line access. Referring to FIG. 4, the cover plates 86 and 88 are first removed and the wiring is removed (after of course removing the cladding panels). Raceway element 52 is then removed by removing the sheet metal screws that extend through the tabs 74 b at the ends of the frame member of the raceway element (see FIG. 7 a ). The raceway element is then lifted out, inverted and reinstalled in the reverse fashion as shown in FIG. 3 . In both locations, the wiring that extends through the raceway is mechanically protected within the raceway. Access to cabling within the raceway is relatively straightforward. It is simply necessary to remove the cladding panels and then one or both of the cover plates 86 , 88 . The raceway itself can easily be relocated as described previously.
In concluding, it should of course be borne in mind that the preceding description relates to a particular preferred embodiment of the invention only and that many modifications are possible within the broad scope of the invention. Some of those modifications have been indicated previously and others will be apparent to a person skilled in the art. | A workspace partition system, for example, for an office building includes a relocatable cable raceway that can be positioned selectively at the belt line or at the baseline of a wall panel of the system depending on where power and data communications are required. Each wall panel of the system includes a structural frame. A raceway element can be selectively coupled to the frame in co-operation with any transverse member of the frame. Front and rear cover plates can be attached to mechanically protect cabling within the raceway. This design allows the panel to be reconfigured on site to change the location of the raceway. |
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This application is a continuation of application Ser. No. 08,291,977, filed Aug. 17, 1994 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a swab-resistant packer device for use in a subterranean well.
2. Brief Description of the Prior Art
During certain operations in a subterranean oil or gas well, such as during a completion or workover procedure, it is commonplace to utilize a packer assembly, bridge plug, or other isolation tool to separate one section or zone of a well from another section or zone. As used herein, the phrase "packer apparatus" includes all such types of tools.
Typically, the packer apparatus will be introduced and/or withdrawn from the well upon a conduit, such as a wireline, cable, or, more particularly, a cylindrical production or workstring through which fluids are introduced and/or withdrawn from the well during certain procedures involved in the completion and/or workover technique. To such conduit is secured at a given location thereon the packing apparatus. The conduit then is introduced into the well concentrically through another cylindrical conduit, which may be casing, or a larger inner diameter production or work string.
The packer apparatus will have an elastomeric sealing element disposed thereon which may be manipulated by hydraulic, mechanical, or electric means to urge the elastomeric seal to expand outwardly into a sealing engagement along the inner diameter of the second or outer conduit, such as the inner smooth wall of casing. In such "set" position, the primary sealing element of the packer apparatus will prevent transmission of fluids there across to isolate one portion of the well from another portion of the well within the annular area defined between the inner diameter of the outer conduit and the outer diameter of the inner conduit.
It is quite desirable to run the packer apparatus into and out of the well as quickly as possible, in order to reduce the time of a trip into and/or out of the hole to thereby reduce labor and other rig costs. In many cases, a trip into or out of a subterranean well with a packer apparatus, as above described, will be delayed because of "swabbing" of the sealing means of the packer apparatus onto the inner diameter of the outer conduit, or casing. Although not fully understood, it is believed that when fluid within the well and carded within the annular area between the inner and outer conduit members rushes over the top of the outsides of the packing seal during movement of the inner, or production or work conduit, it acts similar to an air flow resulting in the presence of a higher velocity fluid on the outside of the packing element and a slower velocity fluid around the interior of such packing element, thus causing a considerable pressure drop that urges the packing element outwardly to form a temporary seal with the wall of the outer conduit. When so sealed, the inner conduit, when moved, swabs or carries fluid with it. This, in turn, results in a substantial reduction in the rate of movement of the production string through the well.
The present invention is directed to abating the problems associated with such "swabbing" problems during insertion or removal of a packer apparatus within a subterranean well.
Applicant is aware of U.S. Pat. No. 4,326,588, entitled "Well Tool Having Knitted Wire Mesh Seal Means And Method Of Use Thereof", and U.S. Pat. No. 4,219,204, entitled "Anti-Extrusion Seals And Packings".
BRIEF DESCRIPTION OF ILLUSTRATIONS
FIG. 1 is a schematic illustration of a typical and conventional prior art packer being shown in run-in position, with the sealing element of the packer being urged outwardly toward the second conduit or casing wall thus resulting in "swabbing" of the well.
FIG. 2 is a vertical quarter sectional view of the apparatus of the present invention shown in run-in position within the subterranean well.
SUMMARY OF THE INVENTION
The present invention provides a swab-resistant packer apparatus which is adaptable for insertion on a first conduit and which is movable through a second conduit concentrically disposed relative to the first conduit within a subterranean well. The packer apparatus comprises a housing communicable to the first conduit and including a cylindrical mandrel. An elastomeric packing means has first and second ends and further defines an exterior circumferentially extending therearound which faces the second conduit. The packing means is carried exteriorly relative to the mandrel and is movable from a first, pre-set retracted position to a second, expanded position into sealing relation relative to the second conduit to thereby prevent fluid transmission there across. Means are placed immediate and circumferentially around the exterior of the first and second ends to prevent the packing means from moving outwardly away from the mandrel toward the second conduit when the swab resistant apparatus is moving through the second conduit and, concurrently, when the sealing means is in the first, pre-set retracted position. By providing such packing means for the packer apparatus, "swabbing" of the well during tripping is abated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIG. 1, which is a description of a representative prior art device, there is shown a packer apparatus A carried on a first or inner conduit B concentrically disposed within a second conduit, such as casing C, thereby defining an annular area D therebetween. The packer as shown in FIG. 1 contains a circumferentially extending element E carried around a control mandrel F with upper and lower gauge rings G and H, respectively. Since no means have been provided in the device shown in prior art FIG. 1 to prevent the sealing element E from being urged outwardly of the outer face G', H', the elastomeric packing component E will thus have its outer surface E' circumferentially extended away from the outer surfaces G', H' of the gauge rings G, H, and into the annular area D toward the inner wall of the casing C. In many instances, the outer surface E' will actually contact the wall of the casing C to thereby form a temporary seal within the annular area D. The temporary seal then moves or compresses well fluid which slows or prevents movement of the packer apparatus. In some cases the elastomeric packing element is hydraulically forced off the packer apparatus. This results in what is commonly referred to as "swabbing".
Now referring to FIG. 2, there is shown a packer apparatus 1 including a housing 1-A with a mandrel 2. The housing 1-A is communicable with a first conduit 100. The mandrel 2 is functional during the setting and/or unsetting of the packer within the subterranean well. The packer apparatus 1 is carded into the subterranean well W on the first conduit 100 which is concentrically and interiorly disposed within a second conduit 200, such as casing.
In a still more preferred embodiment, the packer apparatus 1 is shown as being of the typical three-piece element design having upper and lower seal rings 5-A, 5-C, and a main elastomeric packing element 5B sandwiched therebetween. Members 5-A, 5-C, and 5-B thus combine to form the elastomeric packer means 5. Upper and lower gauge rings 3 and 4 are provided in known fashion and may be actually a part of the packer apparatus 1, or may be provided as a separate auxiliary component on the mandrel 2, or housing 1-A. The upper and lower seal rings 5A and 5-C serve primarily as anti-extrusion barriers relative to the main packer 5-B such that upon sealing, the main packing element 5-B does not extrude across either the upper or lower gauge rings 3 and 4.
An inflection point 10 of pyramid shape is provided approximate the middle vertical length of the main packer 5-B to permit the main packer 5-B to flex during setting and unsetting.
The main packer 5-B has an exterior surface 5-D which, during the pre-set position while making up the packer 1 onto to the first conduit 100, is in substantial vertical alignment with the outer edges 3' and 4' of the upper and lower gauge rings 3, 4, respectively. However, the surface 5-D is radially inward, slightly relative to the surfaces 3' and 4'. The main packer element 5-B also has first and second ends 5-E and 5-F. Upon the outer surface thereof is carried circumferentially and horizontally there around a continuous metal or other cable or line 8 and 8-A, preferably shown in a retainer means 9, 9-A, defined within "U"-shaped grooveways being angularly and horizontally offset from a vertical axis 7.
As shown, the retainer means 9, 9-A are grooveways and grooveways are horizontally angularly disposed from the vertical axis 7 such that the closed or looped end of the "U"-shaped grooveways is slightly further inwardly toward the mandrel 2 than is the open or head of the "U"-shaped grooveways. Of course, the grooveways 9, 9-A with the cables 8, 8-A disposed therein may be filled with epoxy, resin, or other material to assure that contaminants which might otherwise interfere with the setting and retrieving operation of the packer 1 do not fill the balance of the grooveway 6 outwardly of the cable or line 8.
During manufacture of the packer 1, the main packer 5-B of the elastomeric packer means is made up by first engrooving by molding, machining, or etching the grooveways 9, 9-A around the first and second ends 5-E, 5-F, and by placing a clamp around the main packer 5-B to compress the elastomer thereof. With the elastomer 5-B so compressed, the upper and lower cables 8 and 8-A are placed within the respective grooveways 6 and 6-A and the clamp removed. The cable or lines 8 and 8-A now mechanically and compressively urge the main packer 5-B toward the mandrel 2. Alternatively, the swab-resisting means may be molded or otherwise placed within the interior of the main packing element 5-B.
It will be appreciated that the geometric configuration of the grooveways 9 and 9-A is one of preference. Ninety degree offset wall constructed retainer means 9, 9-A could also be utilized. Likewise, the particular construction of the cable or lines 8 and 8-A is not critical to the invention, but such cable or line should be continuous in length completely around the main packer 5-B first and second ends 5-E and 5-F, and be manufactured from such material so as to apply such hoop strength to the main packer 5-B to apply sufficient compressive load thereon, yet permit satisfactory sealing of the packer element 5-B when the apparatus 1 is in "set" position.
The geometry of the cables 8, 8-A should conform to that of the geometry of the grooveways 9, 9-A and may be either circular, square, triangularly shaped, or the like. The cables 8, 8-A preferably are made of strong metallic material which is capable of withstanding the high temperatures and pressures involved in the operations in the subterranean well W requiring a packer 1. A satisfactory cable is that known as "plasticable" manufactured by the Cable Manufacturing & Assembly Co., Inc. of Rockaway, N.J.
Although the invention has been described in terms of specific embodiments which have been set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto. Since alternative embodiments and operation techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | A swab-resistant packer is disclosed which prevents the packing element from expanding outwardly to cause swabbing during tripping of the apparatus in a subterranean well. Preferably, a metallic or other cable or cord is placed immediate and circumferentially around the exterior of the first and second ends of the packing element to prevent the packing element from moving outwardly away from the first, pre-set retracted position to thereby abate any tendency to swab. |
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REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 61/310,895 filed on Mar. 5, 2010, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to collapsible steps and more specifically relates to a collapsible step assembly for storing in the unused space under a kitchen cabinet.
[0004] 2. Description of Related Art
[0005] The use of collapsible steps is known in the prior art. More specifically, by way of example, U.S. Pat. No. 7,017,708 to Lynn discloses a portable unit that allows the user to have an additional step. The device is in the shape of a hollow, rectangular box with a piece of wood with a hole in the middle. This piece of wood rotates up and down and provides the additional step. The hole in the center of the piece allows the owner to carry the device from location to location with relative ease.
[0006] U.S. Pat. No. 6,439,342 to Boykin discloses an apparatus having one or two steps which is stored under a counter. When in its single step configuration the apparatus has a front wall, side walls, a rear wall, and a top wall that provides a first step. A folding line formed in the top wall enables the structure to be rotated to provide a second step.
[0007] U.S. Pat. No. 6,425,457 to Lundry discloses a collapsible step assembly for storing in a drawer of a cabinet. An end of the staircase is pivotally coupled to the drawer between an extended position and a retracted position. In the extended position the staircase extends out through an opening in the drawer. In the retracted position the staircase is in the interior of the drawer.
[0008] U.S. Pat. No. 5,755,498 to Cutler discloses a pull out step for a bathroom vanity wherein a child may stand on the step. The step slidably projects out from under a floor of a vanity cabinet.
[0009] U.S. Pat. No. 5,697,470 to Carle discloses a ladder with integral housing, hinges, and axle for use in conjunction with independent support structures. The device can be used to extend a users reach height, and then stowed away within the housing.
[0010] U.S. Pat. No. 5,341,897 to Gross discloses a collapsible and retractable step apparatus having first and second steps. The steps extend from a shelf above a floor. A support and suspension leg unit is free at a first end and is rotationally secured at a second end to the second step. The leg unit positions and supports the first and second steps in a contiguous plane.
[0011] U.S. Pat. No. 5,131,492 to Caminiti, et al. discloses a collapsible folding step-stool which is mountable to a cabinet door. The step stool has a platform which is movable between a lowered horizontal position and a raised vertical inoperative position.
[0012] U.S. Pat. No. 5,005,667 to Anderson discloses a retractable step assembly for a floor cabinet having an open rectangular base slidably mounted in an interior space at the bottom of the cabinet immediately above the floor and is located in the cabinet or in front of the cabinet. A step which fits inside the base can be raised up from the base when the base is extended in front of the cabinet.
[0013] U.S. Pat. No. 4,846,304 to Rasmussen discloses a collapsible step apparatus for use in combination with a kitchen cabinet shelf. The step is secured to the underside of the kitchen cabinet shelf and can be extended or retracted relative to the cabinet shelf.
[0014] U.S. Pat. No. 3,481,429 to Gaede discloses a draw step for mounting in a kitchen cabinet and having legs which slid and fold for storable within the frame
SUMMARY OF THE INVENTION
[0015] In an exemplary embodiment of the present invention, there is disclosed a lift assembly for extending the upward reach of a person comprising:
[0016] a non-movable section of a telescoping frame located in the unused space under a kitchen cabinet,
[0017] a movable section of the telescoping frame movably coupled to the non-movable section between an extended position and a retracted position wherein the non-movable section is located outside the unused space under the kitchen cabinet when in the extended position and is located under the kitchen cabinet when in the retracted position;
[0018] a gear rack attached to the non-movable section of the telescoping frame;
[0019] a gear coupled to the movable section and positioned to engage the gear rack;
[0020] a motor coupled to the gear to urge the movable section to its extended position or its retracted position;
[0021] a step having a rear edge facing the back of the kitchen cabinet and a front edge facing away from the back of the kitchen cabinet;
[0022] a first pair of support legs for supporting the rear edge of the step and a second pair of support legs for supporting the front edge of the step; and
[0023] step height controlling means located between the step and the movable section for raising the step to its elevated position or retracting the step to lying flat within the interior of the movable section.
[0024] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0025] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0026] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the 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.
[0027] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
[0029] FIG. 1 is a side elevational view of a step for extending the reach of a person to a high kitchen cabinet where the step is in front of its storage space under the base of a kitchen cabinet in accordance with the principles of the invention;
[0030] FIG. 2 is a front elevational view of the step retracted to its storage condition under the base of a kitchen cabinet in accordance with the principles of the invention;
[0031] FIG. 3 is a top perspective view of the step fully retracted within a movable section of a telescoping support frame located in a non-movable section which normally resides under the base of a kitchen cabinet in accordance with the principles of the invention;
[0032] FIG. 4 is a top perspective view of the step fully retracted within the movable section of the telescoping support frame of FIG. 3 where the movable section of the telescoping support frame is fully extended;
[0033] FIG. 5 is a top perspective view of the step inside the movable section of the telescoping support frame partially raised; and
[0034] FIG. 6 is a top perspective view of the fully raised step inside the movable section of the telescoping support frame.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] Referring to FIG. 1 , there is disclosed a side elevational view of the Assist Lift here disclosed in its retracted storage position. The step, when elevated, allows a person to extend his/her reach to a high kitchen floor cabinet where the step is in front of the floor cabinet and its storage space in accordance with the principles of the invention. While the invention disclosed is described as being used in a kitchen, it is understood that the invention may be used in any room of the house.
[0036] A kitchen 10 has a counter top 12 mounted on top of a floor kitchen cabinet 14 which has a base 16 that is normally elevated about three and one half inches above the kitchen floor to provide an enclosed unused space 18 . Located above the floor cabinet is a wall mounted cabinet 20 which normally includes shelves for storing breakfast, lunch and dinner plates, glasses, cups, saucers, etc. The Assist Lift 22 includes a retractable step 24 which is stored in a collapsed or retracted condition in the unused space 18 under the floor cabinet when not in use and, when in use is located in front of the floor cabinet and is fully raised to allow a person to extend their reach to place and/or retrieve plates, glasses, cups, etc. located in the wall mounted cabinet by stepping on the elevated step.
[0037] The Assist Lift is stored in the unused space between the kitchen floor and the bottom of the kitchen floor cabinet and, when in use, a movable section 26 of a telescoping support frame, which is movably connected to a non-movable section 30 (see FIG. 3 ) of the telescoping support frame which normally resides under the base of the kitchen floor cabinet. The movable section can extend beyond the front of the floor cabinet and includes a step which can be elevated to a desired height of between four inches and ten inches, more or less, for a person to step on.
[0038] Referring to FIG. 2 , there is shown a front elevational view of the Assist Lift which provides a step for extending the reach of a person to a high kitchen cabinet where the front movable section 26 of the telescoping support frame step 24 is in front of its storage space under the base of the kitchen floor cabinet and the step is elevated.
[0039] Referring to FIG. 3 , there is shown a top perspective view of the step collapsed inside the not extended movable section of a telescoping support frame having a non-movable section which normally resides under the base of a kitchen cabinet.
[0040] The Assist Lift includes a telescoping frame 32 that has two sides 34 , 36 and may have a back which makes up the non-movable section that supports the front movable section 26 which in turn supports the retractable step 24 and its height controlling structure. The front of the movable section is the face of the cabinet base kick. The size of the height controlling structure can vary to fit different applications. In the embodiment here disclosed the size of the non-movable section of the telescoping support frame is about 22 inches wide, approximately 18 inches deep and 3.5 inches high.
[0041] Located within the front movable section of the telescoping support frame are two acme lead screws 40 , 42 (see FIG. 6 ) which are used to raise and lower the step 24 . Four polyurethane rollers (not shown) are rotatably attached to the front movable section of the telescoping support frame to allow the front movable section 26 of the telescoping frame to easily roll in and out.
[0042] Located in the front movable section 26 of the telescoping frame is a mechanism that includes a first small drive motor and gearing for moving the front movable section 26 in and out of the non-movable section of the telescoping support frame and a second small drive motor and lift mechanism for raising and lowering the retractable step 24 . An electronic control module which controls and monitors the in and out motion of the movable section of the telescoping support frame, controls and monitors the up and down motion of the retractable step and is connected to safety sensors via associated electronic i.e.: switches, motors, sensing etc. A person with ordinary skill in the art can provide the electronic control module for performing the various noted functions and, therefore, the electronic control module is not shown or described.
[0043] Located on the front wall 26 of the movable section of the telescoping support frame is a spring loaded switch plate (not shown) that initiates the sequence of events of urging the movable section of the telescoping support frame to move out from under the kitchen counter and activates the lift mechanism to safely and efficiently raise the retractable step to a desired height.
[0044] Referring to FIGS. 4 , 5 and 6 where FIG. 4 shows a top perspective view of the step fully retracted within the fully extended movable section of the telescoping support frame; FIG. 5 shows a top perspective view of the partially raised step inside the movable section of the telescoping support frame; and FIG. 6 shows a top perspective view of the fully raised step inside the movable section of the telescoping support frame.
[0045] A first drive motor 44 is coupled to a shaft 46 which drives twin gears that are coupled to the front movable section 26 of the telescoping frame. The twin gears engage rack races 51 located on each side wall 48 , 50 on the non-movable rear section of the telescoping frame. The first drive motor 44 drives the twin gears against the fixed gear races 51 to cause the front movable section of the telescoping frame to move in and out of the non-movable section of the telescoping frame.
[0046] A second drive motor 49 (see FIG. 6 ) is coupled to a gear box that turns acme screws 40 , 42 which engage drive nuts 47 , 50 that are attached to the rear legs 52 and front legs 54 of the retractable step. More specifically, as acme screws 40 and 42 turn in one direction such as clockwise, the bottom ends of the rear legs 52 and front legs 54 of the retractable step move away from each other and the step rises. In a similar manner, as acme screws 40 and 42 turn in the other direction, counter-clockwise, the bottom ends of the rear legs 52 and the bottom ends of the front legs 54 of the retractable step move toward each other and the retractable step retracts into the front movable section of the telescoping frame.
[0047] The Acme screws are perpendicularly mounted to the drive motor and are housed in the front movable section of the telescoping frame. The motor and drive assembly can be mounted inside or outside the front movable section of the telescoping frame. Four free wheeling polyurethane rollers are rotatably mounted to the front movable section of the telescoping frame to allow the front movable section of the telescoping frame to freely move in and out of the non-movable section of the telescoping frame.
[0048] The retractable step 24 can have a length of 15 inches and a depth of 12 inches more or less. Switches (not shown) that act as limit or position indicators for the front movable section of the telescoping frame and the retractable step, and a load sensing system for monitoring the lift mechanism are provided. Located on the front wall of the front movable section of the telescoping frame is a spring loaded kick plate that causes a contact switch to activate the in/out drive motor 44 . Also located on the front wall of the movable section of the telescoping frame are locations which are allocated for mounting a false front that matches the surrounding cabinetry wood species or other material.
[0049] To operate the Assist Lift disclosed, a person upon approaching the cabinet simply taps his/her toe against the spring-loaded kick plate mounted on the front of the movable section of the telescoping frame. The control electronics recognizes that the faceplate switch has been activated and sends a signal to the drive electronics which first activates the first drive motor 44 to drive the movable section of the telescoping frame out from under the floor mounted kitchen cabinet until the drive position switch is triggered to tell the motor control to stop driving and begin activating the second drive motor 49 until an upper lift position sensor detects that the retractable step is at its desired height. At this time the Assist Lift is ready to use. The retractable step is coupled to a sensor that tells the electronics that there is a load on the step when a person has stepped onto the step 24 and is using the device. After use, when the person steps off the retractable step, the sensor no longer senses a load and the electronics is triggered to begin lowering the retractable step. Once the retractable step is lowered and is located in the movable section of the telescoping frame, the electronics tells the first drive motor 44 to reverse direction and urge the movable section of the telescoping frame into the non-movable section of the telescoping frame. A position switch acknowledges that the front movable section has been fully retracted and shuts off the drive current and resets the system for further use. This entire process can also be controlled with a manual control pad mounted in a desired location. A remote control with a parental lockout feature can also be provided to prevent possible child injuries.
[0050] The telescoping frame can be made using prefabricated sides, front, back and, if desired a bottom which provides support for the drive components and associated electronics. Rollers can be attached to the movable section of the telescoping frame and a spring-load faceplate can be attached to the front wall of the movable section. The motors and gearing can be located within the telescoping frame and carefully positioned for non-interruption of movement. The telescoping frame can be a simple two-sided/single backed surround structure that can quickly and easily be mounted under the floor of a kitchen cabinet.
[0051] Any one of several embodiments can be used to drive the front movable section of the telescoping frame in and out of the non-movable section. For example, in one embodiment the first motor can be located in the movable section of the telescoping frame and a drive screw that contacts the back of the movable unit can be provided for moving the front movable section. In another embodiment the drive motor can be mounted outside the front movable section and the drive screw length can be used to drive the assembly. Single motor applications can also be used. In another embodiment optical sensing or discrete sensing, capacitive technology, solid state and/or mechanical switching/sensing, pneumatic drive or even possibly hydraulic drive can be used. In another embodiment slide guides which are mounted to the sides of the telescoping frame can be used instead of rollers. This can also serve as a way to remove the telescoping frame assembly from the surround for easy access and maintenance.
[0052] This system can be installed inside a cabinet with a false bottom to drive a shelve out and raise it up to allow better access. It can be used in any lift process desired that fits within the physical, mechanical, electrical, etc, limitations of the design.
[0053] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled. | The lift assembly eliminates the need for unsightly items such as step ladders, stools etc. in the personal kitchen area. It provides safe, easy access to upper areas that are difficult to reach. The lift assembly has a step that extends automatically by a convenient and simple toe tap to the cabinet kick panel located at the bottom of all standard kitchen cabinets. Upon extension, the step raises to a height of up to ten inches. Once a person has stepped off the step a load sensor first triggers the automatic lowering of the step and then urges the front movable section of the telescoping frame to retract back under the cabinet where it is out of sight and ready for use again. No unsightly ladders, no tripping over step stools. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional patent application No. 62/361,309, entitled “Method for Making Insulated Door Panels Using Separate Façade Surfaces”, filed on Jul. 12, 2016, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] This disclosure relates to manufacturing garage door panels, in particular, to manufacturing insulated garage door panels.
BACKGROUND
[0003] Exterior cosmetic design of door panels, such as those for garage doors, is often integrated with the door panels. For example, an exterior cosmetic design is often stamped onto the structural component, such as a “U” shaped steel sheet to form an exterior structure of a door panel. The exterior structure may then be married with an interior structure with expanded foam or other insulation material filled in between the exterior structure and the interior structure to form an insulated garage door panel. The tooling cost is often substantial as a result of the complicated shape of the exterior structure that includes both a design pattern and different structural elements and is thus a disincentive for providing various trendy designs.
SUMMARY
[0004] This disclosure describes assemblies and methods for making insulated door panels using separate façade surfaces, in order to separate the manufacturing process of the exterior cosmetic design surface from the structural components of the door panels. This allows for a same production line for the door panels to accept façade surfaces of different designs and to produce door panels of these different designs and lowering the overall tooling costs for the different designs.
[0005] The facade surfaces are made in separate production lines using various techniques, including casting, molding, vacuum forming, extrusion, and the like. A particular production technique may be selected based on the desired material, cost consideration, or both. The façade surfaces are then fed into door panel production lines that fill polyurethane foams to form complete insulated garage door panels.
[0006] There are several advantages using such offline façade surfaces to make door panels. First, different door panel façade designs can be created on demand without altering the door panel production lines. Second, compared to previous manufacturing methods, a wider selection of materials and costs of the façade surfaces becomes available to the market using this method. Third, using this manufacturing method, different lamination structures (e.g., steel to foam, urethane to foam, fiberglass to foam, or wood to foam, among others) can be selected to cope with geographical requirements in terms of wind, rain, temperature variation, humidity, etc. Last but not least, the raw material for making the separated façade surface can be substantially two dimensional (such as a steel or plastic sheet) and the tooling cost for creating new and different designs on the two-dimensional raw material is significantly lowered due to the offline façade surface production.
[0007] In a first general aspect, a method for making an insulated door panel includes providing a façade surface having a design pattern. The design pattern is surrounded by a planar frontal surface near edges of the façade surface. A backing bracket is provided to receive the façade surface. The backing bracket includes a top wall, a bottom wall, and a pair of side walls to form an interior area. The façade member is aligned with the backing bracket such that a rear surface of the façade member contacts the backing bracket top wall. The façade surface is adhered to the backing bracket directly or via an expandable medium.
[0008] In some embodiments, providing the façade surface includes providing a design member onto the façade member front surface. For example, the design member may be stamped or roll-formed onto the façade member.
[0009] In some other embodiments, providing the façade surface includes stamping or roll-forming the design pattern in the originally flat piece of material to form the façade surface. For example, the originally flat piece of material is a metal sheet, such as steel.
[0010] In yet some other embodiments, providing the façade surface includes heat-forming at least one of the design pattern in the originally flat piece of material to form the façade surface. For example, the originally flat piece of material is a polymer based plastic sheet.
[0011] In some embodiments, providing the backing bracket includes providing a metal sheet and forming the metal sheet in a tool into a pan shape having a cross section of at least four folded corners. The receiving planar frontal surface if formed at an edge of the metal sheet. For example, the metal sheet can be made of steel. In some specific examples, forming the metal sheet in a tool further includes forming a groove and a tongue, wherein the groove is in between a first and a second folded corners and the tongue is in between a third and a fourth folded corners. The groove and tongue have matching outer profiles such that when the garage door is at a closed position, the groove and tongue form a barrier against rain, wind, and dust.
[0012] In yet some other embodiments, producing the planar frontal surface near edges of the façade surface includes molding a compliant material to form the planar frontal surface along with the design pattern on the façade surface. For example, the compliant material can be a curable composite that is one of urethane, a mixture of epoxy and fiberglass, and a mixture of resin and filler material.
[0013] In some embodiments, an overlay surface is adhered on top of the façade surface, wherein the overlay surface includes natural wood.
[0014] In a second general aspect, a garage door panel assembly includes a façade surface having a planar frontal surface near edges of the façade surface. A three dimensional design pattern is within the planar frontal surface. A backing bracket has a receiving planar frontal surface that is mate-able with the planar frontal surface near edges of the façade surface. The backing bracket is assembled to the façade surface. An adhesive holds the façade surface to the backing bracket.
[0015] In some embodiments, the façade surface further includes a convex guide next to the planar frontal surface. The convex guide abuts the edges of the façade surface.
[0016] In some other embodiments, the convex guide abuts a transitional planar frontal surface meeting the edges of the façade surface.
[0017] In yet some other embodiments, the backing bracket further includes a concave guide for receiving the convex guide.
[0018] In some embodiments, the backing bracket comprises at least four substantial right-angle folds.
[0019] In some other embodiments, the receiving planar frontal surface is between an edge of the backing bracket and one of the at least four substantial right-angle folds that is closest to the edge.
[0020] In yet some other embodiments, the backing bracket further comprises a groove and a tongue, the groove and the tongue having a substantially similar shape such that the tongue can fit into the groove conformingly.
[0021] In some embodiments, the façade surface is a piece of metal, a piece of urethane, a piece of composite including fiberglass and resin, or a piece of plastic.
[0022] In some other embodiments, the adhesive is expandable foam filled in between the façade surface and the backing bracket.
[0023] In a third general aspect, a garage door panel assembly includes a stainless steel backing bracket bent to form at least four bends and having a receiving planar frontal surface between an edge of the stainless steel backing bracket and one of the at least four bends closest to the edge. A flat plywood layer is mated onto the receiving planar frontal surface and aligned with the stainless steel backing bracket. A filler material fills in between the flat plywood layer and the stainless steel backing bracket for insulation and adhering the flat plywood layer to the stainless steel backing bracket. An outer layer is adhered onto the flat plywood layer, the outer layer made of real wood and shaped with decorative designs.
DESCRIPTION OF THE FIGURES
[0024] FIG. 1A is an illustration of an assembly and method for producing an insulated garage door panel using a separate piece of façade surface.
[0025] FIG. 1B illustrates a cross sectional side view of the assembly of FIG. 1A .
[0026] FIG. 2A is a first embodiment of an assembled insulated garage door panel of FIGS. 1A and 1B .
[0027] FIG. 2B is a second embodiment of an assembled insulated garage door panel of FIGS. 1A and 1B .
[0028] FIG. 3A is a high-speed embodiment of an assembly of a steel façade surface and an backing bracket.
[0029] FIG. 3B is a high speed embodiment of an assembly of a urethane or fiberglass façade surface and the backing bracket of FIG. 3A .
[0030] FIG. 4A is another high-speed embodiment of an assembly of a steel façade surface and an backing bracket.
[0031] FIG. 4B is another high-speed embodiment of an assembly of a urethane or fiberglass façade surface and the backing bracket of FIG. 4A .
[0032] FIG. 5A is yet another high-speed embodiment of an assembly of a steel façade surface and an backing bracket.
[0033] FIG. 5B is another high-speed embodiment of an assembly of a urethane or fiberglass façade surface and the backing bracket of FIG. 5A .
[0034] FIG. 6A illustrates a front view of several garage door panels made using the assembly of separate façade surfaces.
[0035] FIG. 6B illustrates a detailed view of an example of the façade surface of FIG. 6A .
[0036] Like elements are labeled using liked reference numerals.
DETAILED DESCRIPTION
[0037] FIGS. 1A and 1B are illustrations of an insulated garage door panel assembly 100 in which a separate façade member 110 is employed to advantage. In the embodiment illustrated in FIGS. 1A and 1B , the garage door panel assembly 100 includes the façade member 110 , a backing bracket 120 , and a filler 130 deposited between the façade member 110 and the backing bracket 120 to act as an insulator and in some embodiments, an adhesive, to at least partially secure the façade member 110 to the bracket 120 .
[0038] In the embodiment illustrated in FIG. 1B , the backing bracket 120 includes a top wall 120 a, a bottom wall 120 b and a pair of sidewalls 120 c and 120 d formed from four substantial right-angle folds 142 , 144 , 146 and 148 to enclose an interior area 133 . In the embodiment illustrated in FIGS. 1A and 1B , the top wall 120 a includes an opening 131 , which enables access to the interior area 133 when filling the interior area 133 with the filler 130 . When assembled, the top wall 120 a, provides support to and enables attachment of the of the façade member 110 to the backing bracket 120 . In particular and specifically referring to FIG. 1B , the top wall 120 a of the backing bracket 120 is sized and otherwise configured to receive and/or mate with the façade member 110 near and/or otherwise adjacent to edges 111 of the façade member 110 . As illustrated in FIG. 1B , for example, when the façade member 110 is secured to the backing bracket 120 , the edges 111 of the façade member 110 generally align with the folds 142 and 148 ; however, it should be understood that the size of the façade member 110 may vary such that the edges 111 may not extend and to and otherwise align with the folds 142 and 148 .
[0039] According to some embodiments, the backing bracket 120 includes a tongue 122 and a groove 124 formed in respective sidewalls 120 c and 120 d. The tongue 122 and the groove 124 have complementary shapes such that a tongue 122 in a first panel assembly 100 fits within the groove 124 of a second and adjacent panel assembly 100 , as best illustrated, for example, in FIGS. 2A and 2B , when multiple panel assemblies 100 are secured together. When securing adjacently positioned panel assemblies 100 together, traditional panel hinges (not illustrated) are secured to the bottom wall 120 b of the backing bracket 120 for pivotably connecting adjacently positioned door panel assemblies 100 . According to some embodiments, the backing bracket 120 may have different thicknesses 130 and lengths 132 to accommodate different product lines.
[0040] According to some embodiments, the backing bracket 120 is formed by a separate stand-alone manufacturing process, such as, for example, roll forming, stamping, or other suitable methods. For example, according to one particular embodiment, the backing bracket 120 is produced using steel sheets that are roll-formed into a desired cross-sectional shape.
[0041] In the embodiment illustrated in FIGS. 1A and 1B , the façade member 110 includes a front surface 114 and a rear surface 115 . According to some embodiments, all or a portion of the front surface 114 and/or the rear surface 115 includes a three-dimensional design or pattern 112 extending therefrom. In other embodiments, the front surface 114 and/or the rear surface 115 can be formed without any design or pattern 112 extending therefrom, can include indentations, print, can optionally can be curved, stepped or any other configuration and/or can include any combination of these particular configurations. In other embodiments, an additional overlay layer can be secured onto the front surface 114 , such as, securing a natural wood overlay onto the front surface 114 . According to some embodiments, the façade member 110 is formed by a separate manufacturing process, such as stamping from sheet metal, molding (such as vacuum forming or otherwise) from sheet plastic or composite materials (such as urethane, resin, epoxy and fiberglass).
[0042] During assembly, the backing bracket 120 and the façade member 110 are aligned and assembled by confining their bodies using a plurality of rollers, such as a pair of side rollers 150 a and 150 b, a bottom roller 152 , and a top roller 154 , as best illustrated in FIG. 1A . Although only four rollers 150 a, 150 b, 152 and 154 are illustrated, any number of rollers can be used to confine, position and/or otherwise resist relative movement of the façade member 110 and the backing bracket 120 , especially when the foam 130 is deposited within the interior area 133 and expands during curing. In operation, the top roller 154 and the bottom roller 152 (or additional rollers, as needed, including downstream of the assembly line) may be used to exert a force to push or otherwise sandwich the façade member 110 and the backing bracket 120 together. It should be understood that although the bottom roller 152 and the top roller 154 are illustrated as cylindrical bodies, in some embodiments, the rollers may include two or more wheels spaced or otherwise positioned across the width of the façade member 110 or the backing bracket 120 in order to avoid contact with and potentially damaging the design pattern 112 .
[0043] In addition, the side rollers 150 a and 150 b provide side/lateral support for the side walls 120 c and 120 d of the backing bracket 120 such that the side walls 120 c and 120 d resist and otherwise prevent deformation outwards (i.e., away from the interior area 133 ) under any internal pressure generated by the expandable foam 130 . According to some embodiments, the side rollers 150 a and 150 b also function to align the façade member 110 with the backing bracket 120 such that the frontal surface 114 is aligned with the top wall 120 a. Although rollers 150 , 152 , and 154 are illustrated to assemble the façade member 110 to the backing bracket 120 , it should be understood that other methods may also be used to guide and assemble the façade surface 110 to the backing bracket 120 . According to embodiments disclosed herein, the illustrated assembly method enables rapid assembly of the same backing bracket 120 to façade members 110 having different designs 112 .
[0044] According to various embodiments disclosed herein, the configurations of the façade members 110 and the backing bracket 120 , and in particular, the top wall 120 a, may vary. For example, in the embodiment illustrated in FIG. 2B , the top wall 120 a is formed having an upturned end portion 210 to increase the strength of the top wall 120 a and thus, resistance to overall bending.
[0045] In some embodiments, the filler 130 is an expandable foam disposed inside the interior area 133 that functions as both an insulator and an adhesive. Thus the expandable foam 130 holds the façade surface 110 to the backing bracket 120 and fills any empty space within the interior area 133 . In addition to the expandable foam functioning as an adhesive, it should be understood that other method of securing the façade member 110 to the backing bracket are available, such as, for example, the use of an adhesive provided on the top wall 120 b of the backing bracket 120 or by use of bolts or any other type of securing or clamping mechanism.
[0046] FIG. 3A is another embodiment illustrating a door panel assembly 310 having a façade member 312 attachable to a backing bracket 120 . In FIG. 3A , the façade member 312 includes a self-aligning guide structure 314 extending from the edge 111 of the façade member 110 for mating with a corresponding receptacle 324 on the top wall 120 a of the backing bracket 120 to facilitate high speed assembly. In operation, the self-aligning guide structure 314 is formed of a curvilinear structure extending from the edge 111 of the façade member 314 and is shaped such that as the façade member 314 is positioned adjacent to the backing bracket 120 , the self-aligning structure 314 self-aligns and nests within the corresponding receptacle 324 to align the façade member 314 with the backing bracket 120 . As illustrated in FIG. 3A , As illustrated, the self-aligning structure 314 is formed of a convex shape and is sized to nest within the concave receptacle 324 . Such contoured coupling between the convex and concave guides 314 and 324 enables a much faster assembly speed than using the planar frontal surface 114 alone, even if the rollers 150 provides a certain amount of alignment. For example, the convex and concave guides 314 and 324 allow for a production speed of about 100 feet per minute, while using the planar frontal surfaces 114 and 120 a can only allow for a production speed of about 9 feet per minute. This difference is a result of the alignment efficiency and accuracy that the convex/concave coupling contours provide. After production, such concave and convex contours may further reinforce the bending rigidity, and/or improve the overall structural integrity by enabling the façade member 312 to limit the bending movement of the tongue 122 and the groove 124 . According to some embodiments, the façade member 312 is preferably formed of steel; however, it should be understood that other materials may be used for form the façade member 312 .
[0047] FIG. 3B is a high speed embodiment of an assembly 320 of a urethane or fiberglass and the interior structure of FIG. 3A . The assembly 320 uses the same configuration for the backing bracket 120 and replaces the stainless steel façade surface 312 with a molded façade surface 332 . The molded façade member 332 may be made from urethane, fiberglass, plastic, or other moldable materials. The façade member 332 is formed having a concave slot 333 on the planar rear surface 115 thereof. The concave slot 333 may avoid any substantial thick portion in the façade surface 332 in order to prevent molding shrinkage or other potential manufacturing defects.
[0048] In the embodiment illustrated in FIG. 3B , the concave slot 333 receives a tubular or cylindrical guide 334 , which is sized to align the façade member 332 to the backing bracket 120 , as similarly described above. According to some embodiments, the tubular or cylindrical guide 334 is made of a different material than the façade member 332 . For example, the façade member 332 may be made from a mixture of resin and fiberglass and the tubular or cylindrical guide 334 may be made of extruded plastic or rubber. However, it should be understood that the façade member 332 and the guide 334 may be integrally formed (i.e., a single unitary piece) of the same material. Compared to the assembly 310 of FIG. 3A , the assembly 320 enjoys similar production speeds. In addition, the different geometries can be selected based on different design patterns. For example, some design patterns are more suitably formed using stamping while other design patters are more suitably formed by molding.
[0049] FIG. 4A is another high-speed embodiment of an assembly 410 in which a façade member 412 is employed to advantage. Similar to the façade member 312 , the façade member 412 includes convex guides 414 extending from an edge of the façade member 412 for alignment during high speed production. Correspondingly, the backing bracket 120 includes corresponding concave guides 424 to receive the convex guides 414 therein. As illustrated, the convex guides 414 are formed having a triangular cross section having an apex 416 ; however, it should be understood that other cross-sectional shapes may be utilized. Regardless of the cross-sectional shape of the guides 414 , the corresponding guide 424 is formed of a complementary shape to receive the guide 414 therein. According to preferred embodiments, the façade member 412 is formed of a steel material, however, it should be understood that other materials may be utilized.
[0050] FIG. 4B is another high-speed embodiment of an assembly 420 in which a urethane or fiberglass façade surface 432 is employed to advantage. As illustrated, the façade member 432 is formed having integral convex guide 434 for insertion within a corresponding concave guide 424 of the backing bracket 120 . In some embodiments, additional structures may be provided to increase the bending stiffness of the façade surface 432 , such as additional extrusions or ribs 436 .
[0051] FIG. 5A is yet another high-speed embodiment of a door panel assembly 510 in which a steel façade member 512 is employed to advantage. In the embodiment illustrated in FIG. 5A , the façade member 512 includes an upturned portion 514 formed having a first leg 516 extending from a rear surface 115 , a second leg 518 extending generally perpendicularly from the first leg 516 and a third leg 520 , extending generally perpendicular to the second leg 518 and generally parallel to the first leg 516 . As illustrated, the upturned portion 514 , and in particular, the third leg 520 , serves as a ledge or surface to receive and otherwise engage portions of the backing bracket 520 , and in particular, a fold 511 at the edge of the. Such configuration enables high speed assembly without substantially altering the backing bracket 120 of FIGS. 1A and 1B . The backing bracket 120 may further include a fold or otherwise upturned end 522 formed on the top wall 120 a. In use, the fold 522 provides a rounded contact surface for contacting and otherwise engaging the third leg 520 . The assembly 510 enables similar high speed production as the assembly 310 and 410 .
[0052] FIG. 5B is another high-speed embodiment of an assembly 520 in which a urethane or fiberglass façade member 532 is employed to advantage. In the embodiment illustrated in FIG. 5B , the façade member 532 includes at least one guide member 536 extending from the rear surface 115 of the façade member 532 for alignment with the upturned ends 522 of the backing bracket 120 .
[0053] FIG. 6A illustrates a front, external view of a garage door 600 made using the assembly of separate façade members 610 . FIG. 6B illustrates a detailed cross sectional view of the façade member 612 of FIG. 6A . In this example, the façade surfaces 610 are made by stamping on metal sheets to produce design pattern 612 . The design pattern 612 includes a deep draw portion 616 and a transitional portion 618 . The total width 615 of the design pattern 612 is less than the width of the façade member 610 . During installation, the façade member 612 is coupleable to a backing bracket 120 , as described above. Alternatively, the frontal surface 114 may be modified into one of the examples illustrated in FIGS. 3A, 4A, and 5A .
[0054] In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
[0055] In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
[0056] In addition, the foregoing describes some embodiments of the disclosure, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
[0057] Furthermore, the disclosure is not to be limited to the illustrated implementations, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment. | This disclosure describes methods for making insulated door panels using separate façade members, in order to separate the manufacturing process of the exterior cosmetic design surface from the structural components of the door panels. This allows a same manufacturing line for the door panels to accept façade members of different designs and to produce door panels of these different designs. The facade members are made in separate production lines using various techniques, including casting, molding, vacuum forming, extrusion, and the like. The façade members are then fed into door panel production lines that fill polyurethane foams to form complete panels. The façade members become the exterior skins of the panels with minimum overlay with any backing structure to reduce material wastes, as well as lowering tooling costs for different designs due to the common backing structure that may be shared. |
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a system for progressively placing the roof structure in place as the tunnel is being bored with a tunnel boring machine (TBM). This invention will be found to be most effectively used on open or main beam type TBM's in situations where a tunnel is being bored in a rock strata wherein the roof is somewhat unstable.
[0002] When boring a tunnel in subterranean rock, the TBM's of the present invention utilize a rotating boring head to spall and crush a rockface by exerting pressure on the rockface by means of a series of cutting elements mounted on a rotating boring head.
[0003] As the rockface is gradually eroded, the forward portion of the TBM on which the boring wheel is mounted moves ahead while thrusting against a gripper system which is wedged into the previously formed tunnel. The thrust system provides the required force to crush the rock at the rockface.
[0004] Because some tunnels must be driven into rock which is unstable or becomes unstable when subjected to the forces exerted on the rockface by the excavation, it is not unusual to have fractures in the strata surrounding the tunnel itself. These fractures produce discrete pieces of rock which can fall into the tunnel opening if they are not held in place after the TBM moves forward.
[0005] If the fractures occur in the bottom or sides of the tunnel, it is of little consequence. However, if the strata through which the tunnel is being bored is of the right type and consistency, rock fractures occurring in the tunnel roof may allow portions of the roof to fall which can have serious consequences for the tunneling operation. Falling rock from the tunnel roof may endanger tunnel workers and the tunneling machinery but the falling rock creates an uncontrolled opening above the tunnel and generally disrupts the excavation process.
[0006] Some TBM's have employed a shield in the form of a partial cylinder which fits close to the most recently formed tunnel roof just behind the boring head of the TBM. The shield is sometimes provided with some means or other to move the shield vertically so as to be able to engage or remain clear of the tunnel roof. The shield provides the protective structure to prevent falling rock from injuring TBM operating personnel but does not provide a permanent support for the tunnel roof. As the shield moves forward with the TBM, it uncovers the tunnel roof which if not otherwise supported, can fall.
[0007] It is not unusual to encounter conditions where falling rock from the roof of a newly formed tunnel can present such a hazardous situation that the boring operation must be halted while a temporary roof is placed in the newly formed tunnel. Arc shaped cylindrical segments of a suitable material (usually steel) may be bolted to the roof by rock bolts. If the TBM shield has a fingered shield which will permit the installation of rock bolts between the shield fingers, metallic roof ribs may be fastened to the roof of the tunnel while the shield is yet above the rib. Of course, the exposed ends of the rock bolts which protrude between the fingers of the TBM shield may present a problem if for some reason the fingers of the TBM shield move laterally, as may well happen during a steering correction operation of the TBM. Rib systems placed with finger shields, though providing support for the tunnel roof at periodic spaced intervals, has the shortcoming of not providing support for the tunnel roof between the placed ribs. Because of the shape of the shield and its extending fingers, a large proportion of the tunnel roof is obscured by the extending fingers and if an attempt is made to install timbers etc. between the fingers of the shield, the previously installed rock bolts prevent the insertion of such roof support members between the extending shield fingers.
[0008] At times wire mesh (similar to chain link fence or concrete reinforcing mesh) has been used between the roof ribs and the fingers of the shield to prevent rock fall from the exposed portion of the tunnel roof between the shield and the roof rib, but this method of support suffers from the lack of rigidity of the mesh between the shield and the last installed rib. The mesh tends to sag as rock drops from the roof, this sagging mesh not only protrudes into the tunnel destroying the tunnel profile, but serious deterioration of the roof may occur above the mesh.
[0009] Before applicants' instant invention, the only effective method previously known for the installation of longitudinally extending support members between the roof ribs was to install such members after the finger shield had moved onward away from the ribs and exposed the whole roof.
[0010] However, if loose roof rock is present above the finger shield, it will usually fall before or during installation of the longitudinal support members. The potential for falling rock endangers personnel and hinders the construction process.
[0011] When boring through other types of strata, problems relating to falling debris from the roof of the tunnel may occur due to the disturbance caused by the TBM's boring activity and this invention may be efficiently employed to provide a safe environment for the tunneling personnel who must perform operations in the tunnel to bring the tunnel construction to completion.
SUMMARY OF THE INVENTION
[0012] The TBM of this invention is provided with a shield which comprises a series of hollow rectangular tubes arranged in an arc (akin to slats in a lobster trap) which are fastened together and mounted on a framework of curved beams so as to extend longitudinally along the tunnel axis and have substantially the same surface curvature as the tunnel roof. The tubes extend from a point immediately behind the TBM boring head to a point where the support of the tunnel roof is completed.
[0013] The framework is attached to the TBM in such a manner that the curved upper surface formed by the tubes forming the shield may be held against the tunnel roof. The height of the shield is adjustable within predetermined limits.
[0014] The tubes forming the shield are of a length required to extend from a point just behind the cutter head to a support installation point and are of such size as to accommodate the elongated members which will provide the primary tunnel roof lining. Thus, the “shield” comprising a plurality of hollow tubes is “loaded” preferably with timber members, such that the ends of the timber pieces protrude from the hollow tubes behind the shield so that they may be fastened by some means or other to the tunnel roof. The tubes are intentionally made to be somewhat larger in cross section than the timber lagging members which are inserted inside the tubes so that the lagging timbers enjoy a “sloppy” fit.
[0015] As the boring machine moves into the rock, more of the timber members are exposed almost as if in an extrusion operation. Metallic or other curved or ring support beams may be subsequently installed by the tunnel building personnel as the machine moves away from the last installed roof beam.
[0016] The ends of the timber lagging members are intentionally staggered lengthwise along the tunnel roof, so that at no time does a pair of coincident joints occur in adjacent rows at the lagging members. Each time a tube is emptied of its lagging timber, a new lagging timber is pushed into the empty tube to be subsequently fed out as the TBM advances. This causes staggered laps in the timber lagging members forming the completed roof.
PERTINENT PRIOR ART
[0017] U.S. Pat. No. 3,989,302 issued Nov. 2, 1976
[0018] This patent describes a TBM having a shield comprising a series of “T” shaped members mounted on a curved beam structure. Lagging members are installed between the T shaped members such as 58 , 59 and the supporting beams such as 30 and 31 .
[0019] The lagging members ( 17 , 48 , etc.) are installed in the space between support beams 30 , 31 and the T shaped members of the shield by lowering the support beams 30 , 31 by means of cylinder actuators 36 , 37 to provide the necessary space to insert lagging members 17 , 48 , etc.
[0020] TBM's must be stopped at intervals to permit the “mined” material produced by the boring head to be removed, and it is during this time that the support beams 31 , 32 may be lowered to permit the insertion of new lagging members 17 , 48 , etc. in the space between T members 17 , 48 , etc. and support beams 30 , 31 .
[0021] If, however, the TBM has moved a sufficient distance that a substantial portion of the tunnel roof has not been lagged due to the progress made in the boring operation, it may be necessary to halt the boring operation to install the lagging members in the shield.
[0022] Additionally, once the lagging members 17 , 48 , etc. have been installed in between the T shaped shield members 58 , 59 ; 60 , 61 ; etc., there is little opportunity to install rock bolts between the T shaped shield members.
[0023] After the shield has left the lagging members 17 , 48 , etc. exposed a support system must be installed to hold the lagging members against the roof.
[0024] The patent describes the use of ring beams 23 , 24 , etc. which are subsequently installed, and wedges such as 79 are used to “jack” the lagging members against the tunnel roof.
[0025] Other methods of securing the lagging members 17 , 48 , etc. to the roof i.e. rock bolts are discussed in the patent but these are almost impossible to install while the TBM shield is between the lagging members and the tunnel roof.
[0026] Lastly, the above U.S. Patent makes no suggestion of staggering the joints in the lagging members; all the lagging members have been purposely manufactured to have the same length so as to be supported at each end by ring supports 23 , 24 , etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a diagram of a prior art finger shield and associated rock stabilizing apparatus.
[0028] [0028]FIG. 2 shows a section of the tubular shield of this invention.
[0029] [0029]FIG. 3 is a sectional view of tunnel showing the location of the tubular roof shield in the tunnel.
[0030] [0030]FIG. 4 shows a similar structure to FIG. 3 but includes part of the tunnel boring machine.
[0031] [0031]FIG. 5 is a sectional view of the tunnel having lagging installed.
[0032] [0032]FIG. 6 is a view along section C-C of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] [0033]FIG. 1 shows a partial view of a TBM shield 10 of the prior art. The shield comprises a steel arch 12 which is attached to the TBM so that the shield may be moved up and down by means of hydraulic cylinders to clear or contact the tunnel roof.
[0034] The trailing portion of the shield 10 comprises a series of elongated substantially parallel fingers 14 , 16 , 18 , 20 , 22 .
[0035] Tunnel personnel are able to install an arched rib 24 beneath the shield fingers by means of rock bolts 26 which pass through clearance holes 28 in rib 24 and penetrate deeply into the roof rock. (Note that rock bolts 26 are situated in the only space where it would be desirable to install longitudinal support members.)
[0036] As the TBM moves forward, the fingers will gradually pull away from rib 24 and the rib must be drawn up against the tunnel roof to secure any loose rock in place. Ribs such as 24 may have to be installed at frequent intervals in tunnels exhibiting roof instability.
[0037] At times during a tunneling operation the fingers 14 - 22 are required to be moved in a lateral direction instead of the axial direction usually followed by the TBM. During such operations, the fingers 14 - 22 tend to shear the rock bolts 26 or fracture fingers 14 - 22 . This causes substantial inconvenience to the tunnel boring personnel who are responsible for the integrity of the TBM and the roof support structure.
[0038] [0038]FIG. 2 shows a portion of the novel tunnel shield 30 of this invention. A series of hollow rectangular tubes 50 , 52 , 54 , 56 are mounted on an arched framework on a TBM. Tubes 50 , 52 and 54 are shown having lagging members 58 , 60 , 62 protruding from the interior of tubes 50 , 52 , etc..
[0039] [0039]FIG. 3 shows a TBM shield 30 comprising tubular members 50 , 52 , 54 , 56 as partially shown in FIG. 2.
[0040] The tubular members are mounted on arched supports 70 on which the tubes are fastened by welding or other suitable fastening means.
[0041] Front support 72 is pivoted at pivot 74 and support 76 and provides rigidity to the frame structure carrying the tubes 50 - 56 . An inflatable air bag device is mounted beneath the tubular shield 30 at point “X” to apply a constant upward pressure on shield 40 . It is important that pressure device is of a compliant nature so that if the TBM is suddenly jostled by some unexpected force during an excavating operation, the shield 30 may be allowed some freedom to move so as not to bend tubes 50 , 52 , etc.
[0042] Lagging members 58 , 60 , 62 , etc. are shown protruding from tubes 50 , 52 , 54 , etc. and are subsequently fastened to the tunnel roof 80 by means of ribs 66 , and roof rock bolts 68 . (If full rings are being used to support the lagging members, it may not be necessary to use rock bolts.)
[0043] As the lagging members such as 58 , 60 and 62 are “extruded” from the rectangular tubes such as 50 , 52 and 54 , the ribs such as 66 are bolted in place (by use of rock bolts 68 ) against the lagging members 58 , 60 , etc. to secure the lagging members firmly against the roof of the tunnel. The tubes 50 , 52 and 54 support the lagging members at their forward end; the ribs 66 supply the anchoring mechanism in the area where the tunnel has been driven. A space shown as “D” between the end of the shield of the TBM and rib 66 is bridged by lagging members such as 58 , 60 and 62 so that workers may safely work in this area to install ring supports such as 66 .
[0044] If the TBM should move so that the tubes 50 , 52 and 54 , etc. move laterally (or rotate about its longitudinal axis), the lagging members 58 - 62 merely swing from the end of shield 40 and pivot from the last rib installed in the roof.
[0045] As the lagging members are fed out of the tubes, such as 50 - 54 , they must be replenished in the rectangular tubes 50 - 54 . Usually, the lagging members are interspersed in such a manner that the joints are staggered along the mine roof. Thus, periodically a new lagging member must be installed in the tubes of the shield, and this may be done while the TBM is operating; it is not necessary to lower the shield to insert a new lagging member. It may be convenient to overlap the ends of the lagging members at the joint.
[0046] [0046]FIG. 4 shows a similar view to that shown in FIG. 3 except that parts of the TBM are present in FIG. 4. Front support lugs 80 used to support the forward portion of the roof shield 30 are shown. Rear support 82 is supported from the main beam 84 of the TBM. A plateau is formed at 86 by member 88 which is supported by member 82 and intermediate support 90 .
[0047] The airbag 92 provides a resilient support for the rearmost portion of shield 30 and is easily adjusted to suit the condition existing at the boring site in the tunnel. The presence of the air bag 92 supplies the upward force necessary for holding shield 30 against the roof of the tunnel.
[0048] [0048]FIG. 5 shows a cross section of tunnel which has had a lining installed during a tunneling operation. Bolts 68 secure arch support member 66 in place to hold the lagging members such as 50 - 54 against roof 81 .
[0049] [0049]FIG. 6 shows a view of the tunnel roof taken along section C-C of FIG. 5. The extruded lagging members such as 50 - 54 are all permanently located under ribs 66 held firmly by rock bolts such as 68 .
[0050] The advantages of applicant's device are many.
[0051] There is no need to install rock bolts in the area of the shield (as shown in FIG. 1) because the lagging members 50 - 54 are supported by the tubes 50 , 54 , at the TBM end of the “bridge” formed between the TBM shield 30 and the latest rib such as 66 installed in the tunnel. Thus, there are no rock bolts to fracture or cause damage to the shield of the machine during any unexpected lateral or twisting motion of the shield 30 .
[0052] The lagging members are deliberately chosen to be somewhat flexible so as to allow substantial motion of shield 30 without breakage to shield 30 or the lagging members because the lagging members are flexible.
[0053] Lagging members may be installed in shield while the TBM is operating.
[0054] The ribs are installed against the lagging members 50 , 54 , etc. at some distance behind the shield of the TBM so that ribs 66 need to be tightened only once against the lagging members 50 - 54 , etc.
[0055] The preferred material for lagging is lumber, such as building grade spruce 2″×4″, 1″×2″, 2″×3″ depending on the nature of the fractures occurring in the tunnel roof. In some instances, heavier timbers may be required. The size of timber lagging will depend on the stability of the rock formation and the diameter of the tunnel being bored.
[0056] It may be possible to use plastic or steel lagging in tubes which are other than of a rectangular cross section. Those skilled in the art, will immediately know the size of lagging required for a safe and secure primary tunnel lining for the tunneling conditions encountered. This invention functions best when the timber lagging members are given a generous amount of clearance in the hollow tubes of the shield.
[0057] This invention will function in most adverse tunneling conditions to protect tunnel personnel and tunnel machinery during tunneling operations. Loose rock that falls on shield 30 is held first by the shield and then by the lagging members 50 - 54 etc. Rock pieces are prevented from falling on the tunnel workers or the tunneling machinery.
[0058] Because of the continuous barrier created by the shield 30 and the lagging members 50 - 54 etc., consistent excavation of the tunnel results, and productivity gains will result during the tunnel excavation. After the excavation has been completed, it is not unusual to undertake additional work to “line” or “finish” the tunnel. In prior art structures, situations have been encountered where concrete must be pushed upwardly into caverns left by the falling roof rocks.
[0059] If a wire mesh has been employed to stabilize the tunnel roof, it may have sagged in areas of roof instability and protrude into the tunnel destroying the circular profile of the tunnel. Considerable time and energy must be expended to remove the “intrusions” before lining of the tunnel takes place.
[0060] Problems such as those outlined above are eliminated with the present invention.
[0061] Although alternatives will be apparent after reading this specification, the applicant wishes the scope of this invention to be limited only to the breadth of the following claims. | A primary support for a tunnel roof comprising elongated lagging members which are “extruded” from tubes forming a shield for a tunnel boring machine.
The lagging is inserted into the tubes at different times so as to avoid having the ends of adjacent lagging members coincide. As the tunneling machine progresses in the direction of boring, the lagging members emerge from the shield tubes to form a primary tunnel roof lining. Ring beams or arc beams may be installed as required by means of rock bolts or other fastening means. |
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BACKGROUND AND SUMMARY OF INVENTION
This invention relates to a locking device for excavating equipment and, more particularly, to a device including a C-shaped clamp member and a wedge member useful in securing an adapter to the lip of a shovel dipper bucket, etc.
This invention is related to the co-pending application of Frederick C. Hahn and Larren F. Jones, Ser. No. 112,160, filed Jan. 16, 1980 to which reference may be made for additional details of construction not specified here.
For years, workers in the excavating tooth fastening art have been entrigued by the idea of using corrugated pins and locks to develop greater holding power in the lock. In this connection, reference may be made to co-owned U.S. Pat. Nos. 3,126,654 and 4,061,432. In some instances, the art workers have gone to a ratchet type of corrugation--see U.S. Pat. No. 3,722,932--because of the ease of installation but the greater resistance to inadvertent disassembly. However, conventional ratchets as seen in the '932 patent are unsatisfactory because when it does comes time to disassemble, this is very difficult.
The mutually exclusive problems of good, strong holding power during operation yet easy disassembly when desired have been reconciled according to the instant invention which makes use of a unique lock engaging the ratchet which is partly metal and partly resilient material such as rubber and which is conveniently upsetable when disassembly is indicated.
DETAILED DESCRIPTION
The invention is described in conjunction with an illustrative embodiment in the accompanying drawing, in which
FIG. 1 is a fragmentary perspective view of a dipper lip equipped with an adapter and showing the inventive lock in the process of assembly;
FIG. 2 is a view similar to FIG. 1 but showing the lock installed in place with the lock parts in section to show engagement thereof and in which the lock is in the process of being disassembled;
FIG. 3 is a fragmentary side elevational view, partially broken away showing the working parts of the inventive lock;
FIG. 4 is an enlarged sectional view taken along the sight line 4--4 of FIG. 3;
FIG. 5 is a front elevational view of the arcuate lock portion of the invention; and
FIG. 6 is a fragmentary perspective view of the top portion of the C-clamp showing the locking shoulders which releasably restrain the arcuate lock member in position until disassembly is indicated.
In the illustration given and with reference first to FIG. 1, the numeral 10 designates generally a portion of the lip of an excavating machine such as the shovel dipper, drag line bucket, etc., and which is equipped with a plurality of spaced apart openings slightly rearward of the forward edge of the lip--one of which is indicated at 11. Straddling the lip 11 is an adapter 12 equipped with the usual forwardly projecting nose 13 for the receipt of a point (not shown). For the purpose of straddling the lip 10, the adapter 12 is equipped with rearwardly extending legs 14 and 15 each of which is equipped with a lock receiving opening as at 16 and 17, respectively. In FIG. 1, a C-shaped clamp member 18 shown installed in the aligned openings 16, 11, 17.
Cooperating with the clamp member 18 in locking the adapter 12 in place on the lip 10 is a wedge member 19 and a lock member generally designated 20. The way the members 18-20 are assembled can be appreciated from a consideration of FIG. 3.
In FIG. 3, it is seen that the wedge member 19 is equipped with a rear face 21 on which are provided a plurality of serrations in the form of ratchet teeth 22. The wedge shape is developed by longitudinally tapering the front wall 23 relative to the rear face 21. As can be appreciated from a consideration of FIG. 4, the ratchet teeth 22 are narrower than the wedge 19 and are rearwardly tapered so as to sit within a correspondingly contoured slot 24 in the clamp member 18.
Referring again to FIG. 3, it will be noted that the clamp member 18 adjacent the upper end thereof is equipped with an arcuate passageway 25 in which is received the lock member 20. The lock member 20 has a forward portion as at 20a which is constructed of metal and terminates in a sloping face to develop a contour corresponding to that of the ratchet teeth. The rear portion 20b of the lock member 20 is constructed of resilient material such as rubber and is suitably bonded to the forward portion 20a. The rear portion 20b is seen in a temporary holding position by virtue of shoulders 26 provided within the passageway 25.
Referring now to FIG. 2, it will be seen that a screwdriver S is in the process of being inserted within the upper end 27 of the passageway 25 for the purpose of dislodging the resilient portion 20b from its "held" position under the shoulders 26. By bending the resilient portion 20b to the dotted line position designated 28 in FIG. 3, the lock between the lock member 20 and the wedge member 19 is released so that the lock member 20 can move further into the passageway 25 when the wedge member 19 is moved upwardly--as by applying force to the bottom thereof as at 19a by a sledge, hammer, etc.
The C-shaped clamp member 18 is reversible by virtue of being symmetrical about a mid-plane and is equipped with a lower passageway 25' (see FIG. 6) should the member 18 be inserted in reverse fashion from that shown in FIG. 3.
In the operation of the invention, the lock member 20 is normally inserted into the C-shaped clamp member 18 from the front, i.e., into the slot 24 defined between the sidewalls or flutes 29. This insures that the resilient portion 20b will engage the shoulders 26 with minimum of difficulty. This disposes the forward portion 20a between the flutes 29 and serves as a ratchet or pawl for the ratchet teeth 22 of the wedge member 19. Thereafter the wedge member 19 is inserted in the fashion depicted in FIG. 1 with the lock member 20 sliding along the sloping portions of the teeth 22 until the wedge member 19 is fully engaged. During this operation, the resilient portion 20b is alternately compressed and relaxed, the compression being implemented by virtue of bores 30 (see FIG. 5) within the resilient portion 20b. Simultaneous with the foregoing, the flutes 29 not only serve to guide the wedge member 19 but by lateral confinement serve to stabilize the movement into a linear downward movement and thus insure proper engagement of the lock member 20 therewith. The arrangement of the teeth 22 and the flutes 29 (see FIG. 4) in what might be considered a trapezoidal shape makes for an effective lock irrespective of dimensional variations arising out of casting techniques. Further, it is advantageous to undercut the teeth 22 slightly as at 22a (see FIG. 3) which avoids the possibility of build-up of material within the spaces between adjacent teeth and which might impair the seat between the teeth of the lock member 20. Thus, each time the wedge member 19 is to be reinstalled, it can be quickly cleaned of clinging debris by means of a wire brush or like available tool.
When removal of the adapter 12 is indicated, the previously referred to operation depicted in FIG. 2 is performed. The screwdriver S is inserted into the slot 31 (see FIG. 6) developed between the shoulders 26 so as to engage the upper end of the lock member 20 and pivot it to the dotted line position designated 28 wherein the resilient portion 20b now is disposed in the passageway enlargement 25a (see FIG. 6).
After the wedge member 19 has been removed, the lock member 20 is readily pushed back into the locking position shown in FIG. 3. The relaxed configuration of the lock member 20 is that illustrated in solid line in FIG. 3 wherein the resilient portion 20b is defined by essentially flat front and rear surfaces as contrasted to the arcuate front and rear surfaces of the forward metal portion 20a. This also facilitates the insertion of the lock member 20 into the passageway 25 at the time of initial assembly.
While in the foregoing specification a detailed description of an embodiment of the invention has been set down for the purpose of illustration, many variations in the details hereingiven may be made by those skilled in the art without departing from the spirit and scope of the invention. | A locking device for excavating equipment including a C-clamp member and a wedge member, the wedge member having ratchet-type teeth held in position against the C-clamp member by means of an arcuate lock which itself is resiliently mounted within the C-clamp member. |
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RELATED APPLICATIONS
This application is a continuation-in-part of assignee's copending application Ser. No. 926,023, filed Oct. 31, 1986, now abandoned on "A Process for Treating Drilled Cuttings."
BACKGROUND OF THE INVENTION
This invention relates to a process for training used drilling fluids and drilling cuttings, particularly those in which the salt content is high enough to present a disposal problem. More particularly, the invention relates to a staged water washing and solids removal process for converting used salt water drilling fluids, drilled solids and/or drilling fluid mud pit residues to a source of desalinated solid particles of selected sizes suitable for uses as, for example, construction or restoration materials, or for disposal as a non-hazardous waste.
In various regions, tanks are used for storing drilling fluids and cuttings because reserve pits are not permitted. In addition, removal may be required from presently existing reserve pits. In such reserve pits, the used drilling fluid contents are mixed with, or contaminated by, top soil and the material used in constructing the pits. The present process avoids the onerous expense of hauling such materials from reserve pits or tanks to hazardous waste disposal locations which may be hundreds of miles from the drilling sites.
SUMMARY OF THE INVENTION
The invention relates to a process for converting components in drilled cuttings to substantially non-saline solid materials, which may be reused in some useful manner, or disposed of as a non-hazardous waste material. The drilled cuttings components are mixed and agitated with water in successive steps to separate substantially all of the larger particles in a variety of size ranges and to suspend the very fine particles in water. The largest particles are separated and washed with water. The slurry resulting from separation of the largest particles is mixed and agitated with additional water, and particles of various sizes are removed in successive steps of mixing, agitating and separating. In each of these succeeding steps, where the salinity of water on or draining from the separated particles is insufficient to provide a salinity level acceptable for reuse of the materials, or for disposal as a non-hazardous waste, both the mixing and agitating of the various sized particles with fresh water and the separating of a given size range of particles are repeated, to the extent necessary, to provide such a salinity reduction. The separated particles are collected, either by size range, or all together, prior to disposal or reuse. The remaining slurry water containing only very fine particles is reused in the separation process or in some other useful manner, or disposed of in some environmentally acceptable manner.
For convenience, the term "drilled cuttings" is used herein to refer to used drilling fluids, drilling solids and/or drilling fluid mud pit residues and/or slurries of such materials. As used herein, the term "salinity" of a substance refers to an amount of disssolved or soluble salt, such as an alkali or alkaline earth metal, which, in solution, releases the same number of ions that would be released by the same amount of sodium chloride (NaCl). Drilled cuttings commonly contain NaCl, potassium chloride (KCl), magnesium chloride (MgCl 2 ), and calcium chloride (CaCl 2 ), and the present process is well suited for reducing the salinity due to any or all of such salts.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a flow sheet for a preferred embodiment of the present process.
DESCRIPTION OF THE INVENTION
The present invention is, at least in part, premised on a discovery that the presently described combination of procedures and devices are advantageous relative to various other combinations. For example, the ojective of desalinating the components of drilled cuttings might be accomplished by subjecting those components to (a) aggregate washing equipment combined with a clarifier or (b) subjecting such components to such washing equipment combined with mud plant and solids control devices.
It was found that the first option, utilizing the clarifier was significantly less efficient in handling fine materials because when isolated, the fine materials have a water content higher than those of the same material isolated by means of solids control equipment. Because of that, less salt would be removed during each cycle through the clarifier and more recycling would be needed to reach a selected reduced salinity. In addition, when the fresh water consumed per pound of salt removed is compared, a clarifier does not perform as well as solids control equipment.
The drawing illustrates a particularly suitable treatment of drilled cuttings components by means of a combination of aggregate washing equipment and mud plant solids control equipment in accordance with the present invention. As shown, the salt contaminated materials being treated are dumped from trucks into hopper 1 which feeds a conveyer, such as a belt, for carrying the material to a blade mill and screen 2.
A suitable blade mill is basically a horizontal tub which encloses a conveyor shaft on which are mounted screw flights and paddles. The purpose of such a blade mill is to precondition material for separation by forming a slurry of the drilled cuttings. Water is introduced to saturate the materials uniformly while the paddles agitate, scrub, and abrade the material so that lumps are broken up and the individual particles form a slurry. The slurry drops onto a screen associated with the blade mill, where jets spray water onto the cuttings. In the illustrated embodiment, particles which are generally larger than sand size and have average diameters greater than about 3/8-inch, are separated by the screen and are transported to a stockpile. The wet or water-suspended slurry of finer particles that pass through the screen associated with the blade mill are fed, preferably by a chute (not shown), to a sand screw means 3.
A sand screw of the type shown separates particles such as coarse sand-sized particles between about 150 mesh and 3/8-inch from finer materials. A suitable form of such a sand screw includes a base tub in which the materials enter and an inclined tub that contains an auger. The particles are subjected to a tumbling action of the rotating continuous screw flights of the auger and an introduction of a rising current of fresh water into the base tub of the sand screw means. A suspension of the finer particles are carried upward by a flow of water and pass over a weir into a mixing tank while the coarser particles are conveyed by the auger and are substantially drained and squeezed dry of water, for example, to a water content of about 18-25 w%.
In the preferred embodiment, the salinity of the water drained from the coarse sand-sized particles is measured by an electrical resistivity measuring device (not shown) arranged to control a flop gate 4 for directing separated particles to either a stockpile or a salty particle return. If the water drained from, or remaining on the surfaces of such particles, has a salinity equivalent to no more than a selected target concentration, such as less than about 2500 ppm NaCl equivalent, the particles are sent to a stockpile. The target concentration may be set by criteria for non-hazardous waste disposal.
Where the salt concentration of such water (which amounts to a salt-leaching water which contacted the particles) is higher than the target concentration, the particles are returned for remixing and reseparation within the sand screw 3, as indicated by the arrow labeled "salty particle return." Such remixing and reseparating is repeated until a selected level of salt concentration is reached. During this processing, feeding of the new batches of contaminated materials into the hopper 1 and on the blade mill 2 may be delayed.
The water suspended slurry of particles smaller than about 150 mesh are conveyed to a mixing tank 5 in which the water is circulated by a pump 6. More water is added to the suspension, preferably until a precentage of the suspended solids within the liquid is about 5 to 7% by volume, and is within the operational constraints of a relatively fine solids control means, such as a desander 7 and desilter 8. As known in the art, the concentration of such slurried particles can be measured manually by vaporizing water from the slurry or automatically by means of gauges of the types used in municipal sewage plants. The slurry is displaced by pump means 9 into desander 7.
A suitable desander consists of a series of tapered cones in which solid particles are separated from liquid by means of the centrifugal force generated by the swirling of the slurry inside the cones. The solid particles exit through the tapered end of the cones while the liquid flow out the top. The desander 7 is preferably arranged to remove isolated fine sand-sized particles having average sizes in the range of about 80-100 microns to 150 mesh. Most of the liquid and the clay and silt-sized or smaller particles are displaced by pump 10 into the desilter 8.
The water draining from, or left on the surfaces of the relatively fine sand-sized particles separated from desander 7, is measured for salinity by a measuring device (not shown) which controls flop gate 11 to direct those particles onto the shaker 12 or, where the salinity is equivalent to a value higher than the target concentration, to tank 13. In that tank, the salty particles are mixed with relatively fresh water circulated by pump 14, and delivered through the salty particle return line to a point upstream of the desander for redilution and reseparation within the desander.
The slurry of substantially clay and silt sized particles, which may have sizes ranging from about 12 microns to about 80-100 microns, are separated in desilter 8 in a manner analogous to that of desander 7. The separated clay and silt-sized particles are similarly measured for salinity and directed by a flop gate 15 to either the shaker 12, when their salinity is equivalent to or less than a selected target value, or to tank 16, in which they are mixed with fresh water circulated by pump 17 through the salty particle return line for redilution and separation in desilter 8.
The slurry water separated by desilter 8 is preferably monitored for salinity and where it is substantially fresh water, it is either directed through the water recycle line 19 for reuse. Where the water is unsuitable for reuse in the process, it is directed to some environmental acceptable disposal, such as injection into a saltwater disposal well 18 for underground injection. The water could also be used in a secondary recovery water flooding operation, or for some other useful purpose.
A suitable shaker 12 is arranged to receive the relatively fine sand-sized particles from desander 7 or clay and silt sized particles from desilter 8, and to allow any free moisture to drain through the shaker screen and return to tank 13. The particles separated from shaker 12 are conveyed to a stockpile.
In the illustrated embodiment of the present invention, substantially salt-free particles from drilling fluid cuttings are made available for some useful purpose, such as the construction of well site access roads, drilling pads or central production facilities, etc. In the winter the sand-sized materials can be used for sanding roads. Very fine materials having no construction value can be added to topsoil or tilled with other soils for restoration of construction or drilling sites. Other useful purposes are considered to be within the scope of the invention. Alternatively, the separated particles may be disposed of in a manner suitable for non-hazardous wastes.
The present invention is particularly applicable to the treating of salt water muds and drilled cuttings saturated with saline fluid or substantially any mixture containing significant proportions of dissolved and granular salt, as well as the reserve pit residues inclusive of the drilling fluid permeated layers of soil underlying such mud pits. Examples of suitable types of drilling fluids include any brine mud made from water and commercially prepared salts or brine water produced in association with oil and gas.
In general, the equipment such as pumps, screens, blade mills, sand screws, desanders, desilters, shakers, and the like, can be substantially any of the currently available devices or techniques designed for use in oil field operations such as the drilling of oil and concrete batching operations. Examples of particularly suitable items of such equipment include the SWECO 12 cone desilter, Model PO4C12, and Brandt SE-10 desilter; SWECO 2 cone desander, Model P10C02, and Brandt SRC-2 desander; Kolberg Series 8000 Log Washer blade mill, and Eagle 18-inch×24-foot blade mill; Eagle 44 in. Single Screw Washer-Classifier-Dehydrator sand screw, and Kolberg Series 5000 Sand Prep, Single Screw sand screw.
Where desirable or necessary, the present process can be operated to reduce the salinity of the produced solid materials to salinities significantly lower than 2500 ppm NaCl equivalent. In a preferred operation, the recycling stages are repeated to the extent necessary to reduce the salinities to less than about 1000 ppm NaCl equivalent. | Used drilling fluids, drilled cuttings and salt contaminated soil, etc., are processed for disposal or reuse by staged water-washing and solids separating procedures which are monitored for the salinity of the water contacting the particles and are repeated to the extent necessary to obtain selected low values, in order to produce saline wash water suitable for injecting into a disposal well and size-graded substantially salt-free materials suitable for construction operations or non-hazardous waste disposal. |
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BACKGROUND OF THE INVENTION
The invention relates to suspended ceiling construction and, in particular, to improvements in so-called three-dimensional ceilings.
PRIOR ART
Suspended three-dimensional ceilings with gentle wave-like configurations have been available for specialty applications where a dramatic or custom look is desired. Such ceilings find application in contemporary office environments, entertainment and gaming complexes, high-bay areas and retail space, for example.
The subject ceiling structures include convex (vault) and concave (valley) main grid runners or tees assembled with grid cross members in the form of cross tees or stabilizer bars. Typically, the primary purpose of three-dimensional ceilings is to provide a highly visible decorative structure. Consequently, a precision assembly is especially important so that visually distracting misalignments are avoided. A popular form of three-dimensional ceiling is a one-directional type where the lay-in panels are relatively long and where the joints between panels are not masked by visible cross ties. These one-directional systems are particularly prone to show misalignments of the grid structure and lay-in panels especially where the lay-in panels have a geometric pattern. In prior art constructions, the lay-in panels can take a skewed position on the supporting grid tee flanges. This misalignment is very visible and in severe conditions can even result in a panel falling off of a tee flange.
Installation of the main runners of a three-dimensional ceiling is more complex and requires more care than normally expended for conventional planar suspended grid ceilings. For example, considerable care is necessary in placement of suspension hanger wires so that when completed they hang relatively plumb in both directions of the grid. Achieving this condition is made difficult because the spacing between wires is variable depending on the inclination of the area of the grid being suspended. The extra time and effort involved in laying out and achieving a proper spacing for hanger wires longitudinally along the runners can detract from the time and effort spent in properly locating the lateral positions of the wires. These factors are in addition to the physical obstacles or conditions that can exist in the ceiling space which interfere with the proper spacing of the hanger wires. These problems have given rise to the need for a three-dimensional grid system that is more tolerant of imperfect suspension conditions and contributes to efforts at precisely positioning the grid ceiling structure.
SUMMARY OF THE INVENTION
The invention provides an improved three-dimensional ceiling that has self-aligning features which contribute to increased positional accuracy of both the grid and the panel members. More specifically, the ceiling system has main tees with a cross-sectional configuration that cooperates with specially proportioned lay-in panels to improve the parallelism of the grid tees as well as the parallelism of the panels to the grid tees. In one disclosed system, the main tees have a stem configured with an increased thickness at its lower edge where it joins the panel supporting flanges. Preferably, the thickness of the stem at its lower edge is at least about as large as its thickness adjacent its upper edge where it has a typically enlarged cross-sectional area or bulb for stiffening. This thickened stem geometry allows the components to be dimensioned so as to eliminate excessive lateral clearance between the tees and lay-in panels. The disclosed geometry still allows the panels to be assembled on the tees from a point above the grid without interference with the upper regions of the main tees.
The wide stem geometry of the main tees of the invention and correlated width of the lay-in panels is particularly important with one directional three-dimensional style ceilings. This style has no cross-tees at the visible lower face of the grid and, therefore, cannot rely on such structures to gauge and control the spacing between main runners at this face.
Stabilizer bars conventionally used to connect adjacent main tees together have a stepped or bridge-like construction to provide clearance for the installation of the lay-in panels. Typically, one-directional panels have their ends bent upwardly to form a flange that is used to couple with a mating end of another panel. The configuration of the stabilizer bars allows end-wise motion of the lay-in panels during installation and must be high enough above the supporting main tee flanges to allow the upwardly extending panel flanges to pass under the stabilizer bars. The somewhat complex geometric stabilizer bar configuration does not lend itself to precise control of the spacing of the lower visible faces of the main tees.
Many of the lay-in panel materials are relatively shear because of their translucence and/or perforated design. It is a practice to stagger the locations of the stabilizer bars between successive rows of main tees so that any shadow of a stabilizer bar visible through a lay-in panel is discontinuous and, therefore, less conspicuous. This practice exacerbates the difficulties in precisely positioning the main tees with the stabilizer bars since they do not stack up in a direct line.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, from above, of portions of a three-dimensional ceiling system embodying the invention, with the majority of the lay-in panels not shown for purposes of clarity;
FIG. 2 is an enlarged cross-sectional view of the ceiling system taken in the plane 2 — 2 indicated in FIG. 1;
FIG. 3 is a fragmentary perspective view of a stabilizer bar of the illustrated ceiling system;
FIG. 4 is an enlarged fragmentary cross-sectional view of the end joint of a pair of abutting lay-in panels and an associated panel splice, taken in the plane 4 — 4 indicated in FIG. 1;
FIG. 5 is an enlarged fragmentary perspective view of the ceiling showing an integral hold down tab restraining a lay-in panel against the flange of a supporting tee;
FIG. 6 is a cross-sectional view of a modification of a main tee of the invention;
FIG. 7 is a cross-sectional view of another modification of a main tee of the invention; and
FIG. 8 is a cross-sectional view of still another modification of a main tee of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a specialty three-dimensional suspended ceiling system 10 constructed in accordance with the invention. The system 10 includes parallel rows of main runners or tees 11 interconnected with cross runners 12 to form a grid 13 . Supported on the main runners 11 are decorative lay-in panels 14 . Segments 16 , 17 of the main runners 11 are curved in vertical planes so as to form vaults 16 or valleys 17 . Typically, an architect or designer can select combinations and patterns of these vaults 16 and valleys 17 or simply all vaults or all valleys as he or she chooses to construct the desired look. The adjacent ends of the segments 16 , 17 of the main runners 11 are joined together by suitable clips 18 having bendable tabs inserted into appropriate slots provided in the segments adjacent their ends. The main runners 11 are suspended from overhead structure by wires 19 in a generally conventional manner except that the horizontal spacing between wires along a given main runner varies in relation to the inclination of the local part of a runner since the holes for receiving the suspension wires are uniformly spaced along the arcuate length of the runner. This irregular spacing requires extra attention by the installer and can present situations where accurate placement of the suspension points for the wires in both the longitudinal direction of the main runners 11 and in the lateral direction of the cross runners 12 suffers. Inaccurate location of the suspension points causes the wires to be out of plumb and makes it difficult to locate and construct a grid that is “square” so that the cross-runners and joints between panels are perpendicular to the main runners and also makes it difficult to hold the main runners in a straight line lying in an imaginary flat vertical plane. When properly installed, the main tees 11 lie in vertical planes and, from row to row, are in phase with one another so that the local elevation of one main tee is the same as the other tees along a horizontal line perpendicular to all of the tees. A main tee can be manufactured with a radius of curvature, measured at the visible face of its flange 21 , of between 30.5 in. (77.5 cm) to about 229 in. (582 cm) or larger, for example.
FIG. 2 illustrates the cross section of a main tee vault segment 16 . The cross section, which is symmetrical about an imaginary vertical central plane has a lower, generally horizontal flange 21 and a generally vertical stem 22 . With reference to FIG. 2, the main tees 11 are of a “narrow face” design such that the flange is relatively narrow, e.g. about {fraction (9/16)} in. (1.43 cm) measured across its edges 23 . The stem 22 includes a narrow, vertical web 24 and an enlarged hollow stiffening bulb 26 adjacent the upper edge of the web 24 . Integrally formed on the stem 22 between opposed portions 27 of the flange 21 adjacent a lower edge of the web 24 is a protrusion or spacer 28 that is preferably continuous with the length of the segment 16 , and is symmetrically disposed about the central imaginary plane of the cross-section.
The spacer 28 has generally vertical surfaces 29 that extend above the flange portions 27 a distance that is large in comparison, for example, to the wall thickness of either the flange 21 or web 24 , for example.
In the construction illustrated in FIG. 2, the main tee segments 16 , 17 are made of roll-formed sheet metal such as steel painted or otherwise provided with a protective coating. More specifically, the main tee segments 16 , 17 are formed of two metal strips, a first strip 31 forming essentially the outline of the tee section and a second strip 32 being a cap that locks the first strip 31 in its rolled configuration when it is rolled over the flange areas of the first strip. The lower or visible face of a tee 16 , 17 has a hollow, central groove, which is the interior of the protrusion 28 , that is aesthetically desirable for its “reveal” character. Integral “hold-down” tabs 34 are stamped from the web 24 at regularly spaced locations along the segments 16 , 17 . The valley segments 17 have a cross-section configuration like that of the vault segments except that the area of the bulb 26 is crimped to facilitate forming them into their convex or valley-shape.
FIGS. 2 and 3 illustrate details of a typical cross-tie or stabilizer bar 12 that extends between and interconnects with adjacent main runners 11 . The stabilizer bar 12 is preferably formed as a unitary sheet-metal stamping having a main channel body 36 . Each end of the body 36 has a depending leg 37 . The legs 37 are formed with a web mid-section 38 so that the plane of an upper portion 39 of the leg 37 is off-set from the plane of a lower portion 41 of the leg. The offset leg configuration enables the lower portions 41 to abut the web 24 of a main tee segment 16 , 17 while the upper part 39 extends past the bulb 26 of the main tee segment.
The stabilizer bars 12 are assembled on the main tees 11 so that upon completion of the ceiling they are above the planes occupied by the lay-in panels 14 . The stabilizer bars 12 are assembled by positioning integral tabs 42 in slots stamped through the webs 24 of the main tees at regularly spaced locations. Once fully received in the slots, the tabs 42 are bent over against the webs 24 to lock the bars 12 in position. The depending legs 37 of the stabilizer bars 12 hold the channel section 36 well above the main tee flanges 21 .
The three-dimensional ceiling system illustrated in FIG. 1 is sometimes referred to in the industry as a “one-directional” style. This style is typically characterized by the absence of visible cross tees and inconspicuous joints between lay-in panels. The lay-in panels 14 are relatively long in comparison to their width being a nominal six feet (1.83 meters) long and a nominal two feet (0.61 meters) wide. The illustrated panels 14 have their ends turned up into flanges 46 . Abutting flanges 46 of adjacent panel ends can be held together with an inverted U-shaped joint splice 47 . The joint splice 47 is advantageously formed of a soft metal capable of being squeezed with pliers or like tools to tighten the abutting flanges 46 together. The lay-in panels 14 are assembled on the grid 13 by sliding them under the stabilizer bars 12 . The vertical height of the main channel body 36 of the bars 12 above the main tee flanges 21 provides ample clearance for the end flanges 46 of the panels 14 . The lay-in panels 14 are typically offered in a variety of materials of different opacity, translucency and/or perforation patterns. Typical lay-in panel materials include smooth or perforated painted aluminum, brass or stainless steel woven mesh, anodized aluminum and translucent fiber-reinforced plastic panels. The thickness of these panels can range from 0.020 in. (0.051 cm) to 0.080 in. (0.203 cm) so that they are relatively flexible.
The hold down tabs 42 are bent out of the plane of the web 24 and down against the panels 14 at appropriate locations to make the panels conform to the curvature of the main tees 11 . Typically, the material of the panels 14 is somewhat resilient and tends to maintain a planar configuration when not constrained by the tabs 43 . The lay-in panels 14 have increased lateral stiffness, i.e. compression, between main tees 11 when they assume the curved configuration of the main tees.
In accordance with the invention, the main tees 11 and lay-in panels 14 are configured to inter-engage in such a manner that they contribute to their mutual alignment so that the main tees and the panels are urged into precise parallel alignment. By way of example, but not limitation, a panel 14 can be sized with a nominal width of 23.75 in. (60.3 cm) and the stem spacer 28 can have a nominal horizontal thickness of 0.220 in. (0.559 cm). These proportions leave a relatively small nominal clearance of 0.030 in. (0.076 cm) between a panel and the adjacent main runners 11 . This clearance, theoretically, would require adjacent main tees 11 to be parallel to one another and to a panel at the plane of the flange 21 within 0.030 in. (0.076 cm) in six feet. While a nominal clearance of about 0.030 in. (0.076 cm) is most preferred for some applications such as illustrated in FIG. 1, the invention can be practiced by using other clearance dimensions with decreasing precision of positioning. For example, clearances ranging from a nominal clearance dimension of 0.060 in. (0.152 cm) up to as much as about 0.090 in. (0.229 cm), if desired or necessary can be used.
It will be appreciated from an understanding of the geometry of the stabilizer bars 12 and their locations remote from the plane of the flanges 21 and their manner of field installation that it is difficult to maintain precise parallel positioning of the main tees 11 at the plane of the flanges 21 simply with the stabilizer bars. The positional accuracy of the flanges 21 , of course, is important because it is these elements that are visible from the space below the ceiling system 10 . Precise control of the position of the main tees 11 with the stabilizer bars 12 is made more difficult by the practice of staggering these stabilizer bars in patterns like that shown in FIG. 1 . The close parallel registration that can be maintained between the tees 11 and panels 14 with the invention results in a high quality finished appearance of the ceiling system 10 . This is especially important with the general type of disclosed three dimensional ceiling since it is under increased visibility by virtue of being a specialty item intended to draw visual attention. Often, the lay-in panels 14 have a regular geometric pattern that accentuates any misalignment between them and the main tees 11 .
It is important that the width of the stem of the spacer is at least approximately as large as the maximum width of other portions of the stem—specifically the stiffening bulb 26 —so that the panels 14 can be laid in the grid 13 without undue interference. FIGS. 6-8 illustrate other examples of main tee cross-sectional shapes that can be used in practicing the invention. Typically, the cross-sections are symmetrical about an imaginary vertical central plane. In FIG. 6, a main tee 51 has a cross-section like that of the main tee 11 of FIG. 2 except that the flange portions 52 are proportionately wider. A main tee 53 of FIG. 7 is an extrusion of thermoplastic or thermosetting resin or of aluminum. The tee 53 includes panel supporting flange portions 54 , a stem 56 comprising a web 57 , a solid stiffening bulb 58 and a solid spacer 59 . The spacer 59 includes vertical surfaces 61 for cooperation with the edges of a lay-in panel sized to minimize horizontal clearance between the panels and the main tees 53 as disclosed hereinabove. FIG. 8 shows the cross-section of an extruded main tee 63 formed of suitable plastic or aluminum or other suitable rigid material. The tee 63 includes panel supporting flange portions 64 and a hollow stem 66 . The stem 66 includes vertical spacer surfaces 67 adapted to cooperate with a lay-in panel sized in the manner described above to improve positional accuracy of the grid and panel.
It will be understood from the foregoing disclosure that the invention can be employed in various other types of three-dimensional ceiling styles such as those in which the panels are shorter rectangles of nominally 2 ft.×4 ft. (0.610 meters×1.22 meters) or are square, nominally 2 ft.×2 ft. (0.610 meters×0.610 meters). Still further, variants of the invention can utilize conventional cross tees, known in the art, visible from below the panels at selected centers.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | A suspended three-dimensional ceiling system of improved appearance and performance that includes closely dimensioned main tees and lay-in panels. The main tees have opposed vertical surfaces adapted to abut the edges of the panels to avoid any noticeable non-parallelism between the main tees and/or panels. The vertical surfaces are provided by a protrusion at the juncture between a panel supporting flange and a vertical stem of the main tee. The protrusion allows the panels to be dimensioned to avoid undue interference with a stiffening bulb on the upper part of the stem and provides an attractive reveal on the visible face of the flange. |
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TECHNICAL FIELD
The disclosed embodiments relate to the construction and nailing of shear walls.
BACKGROUND INFORMATION
A shear wall is a wall that typically includes braced sheathing panels (also known as shear panels) nailed to framing members and an associated set of hold-downs. The shear wall counters the effects of lateral loads. When building a shear wall, structural plywood or particle-board sheathing panels are typically applied to cover wood stud framing. A nail gun is then typically used to nail the panels to the underlying framing in a specified nailing pattern. The particular pattern is important and is specified by a structural engineer.
One of several methods may be used to construct a shear wall in the field. In one method, the appropriate lengthwise (vertical) spacings between nails are measured and the nail locations are manually marked with a pencil. The marks on the sheathing are then used to place nails during the nailing operation. The manual pencil marking is time consuming. Moreover, the nails are to be properly spaced in not just one dimension (the lengthwise or vertical dimension), but rather are also to be properly spaced offset from the edge of the sheathing (the horizontal dimension). Typically the nails are specified to be spaced a certain distance from the edges of the sheathing panels or from edges of the underlying framing members, depending on the nailing pattern and nailing density specified. Sometimes a chalk line is used to accomplish this horizontal marking. Often, however, the extra trouble of using a chalk line is dispensed with and the horizontal spacing of the nails is just “eyeballed”. Due to this eyeballing, the horizontal spacing of the nails may be irregular and imprecise.
In a second method, no marking whatsoever is performed. The individual with the nail gun simply “eyeballs” both the vertical and horizontal placement of each nail at the time of nailing and then drives the nail using the nail gun. The resulting spacing of nails is therefore not always precise. The person doing the nailing may intend to place nails with a specified three inch vertical spacing, but when the spacing between the actual nails as placed is measured, the spacing may be four inches in places.
SUMMARY INFORMATION
A non-structural shear wall nailing template bears a pattern of shear wall nailing pattern markings. The template may, for example, be made of paper, mylar, or other printable substrate. In one example, the pattern is a “field” nailing pattern and the template also bears a second pattern. The second pattern is an “edge” nailing pattern. The template bears lettering (numerals and/or lettering and/or a symbol) that indicates the type of nailing pattern that the nailing pattern markings conform to. If, for example, the nailing pattern markings are for the nailing of a “type 3 shear wall”, then the lettering on the template might be a “3”. If, for example, the nailing pattern markings are for the nailing of a “type 4 shear wall”, then the lettering on the template might a “4”.
In one example, a very long length (for example, one hundred feet) of the template material is rolled into a roll. Such rolls are sold at the retail level. An individual who is constructing a shear wall in the field separates a length of the template material from such a roll to form the template. The length may, for example, be torn from the roll by hand without the use of any cutting tool. Alternatively, the length can be cut from the roll using a scissors or box cutter or knife or serrated edge or another suitable cutting implement. Alternatively, the length can be extended from a roll and then cut off from the roll using an ordinary handheld packing tape dispenser.
The template is then fixed to one or more sheathing panels that are to be nailed to framing members in accordance with a specified nailing pattern. The template may include an adhesive layer that is usable to fix the template in place to the sheathing panel(s). The template may be tacked in place using a few nails or staples. The template is fixed to the sheathing panel(s) such that the template is aligned in a pre-defined way with respect to a framing member behind the sheathing panel(s).
A different nail is then driven through the template at each different marking location of the pattern on the template. Each such nail is driven through the template, then through the sheathing panel, and then into the framing member. By driving a nail at the location of each marking on the template, the shear wall is constructed with proper nailing spacing. The manual measuring and pencil marking described above in the background information section can be avoided. The eyeballing described above in the background information section can be avoided.
The nailing template is made of a lightweight inexpensive non-structural material and need not be removed once construction of the shear wall has been completed. The template may, for example, be made of inexpensive and lightweight paper or mylar or another suitable inexpensive sheeting material that will not interfere with the further construction of the building if the template is not removed.
This summary does not purport to define the invention. The invention is defined by the claims.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a diagram of a shear wall nailing template in accordance with one novel aspect.
FIG. 2 is a diagram that illustrates one example of how the shear wall nailing template of FIG. 1 can be used in the making of a shear wall.
DETAILED DESCRIPTION
FIG. 1 shows a lightweight non-structural shear wall nailing template 1 in accordance with one novel aspect. Template 1 is a strip at least five feet in length. Template 1 preferably has a uniform width of between one inch and eight inches wide. The template material is therefore referred to here as “tape”.
In the specific example illustrated, template 1 is a portion of a roll of a one hundred foot length of tape, where the tape is two and one half inches wide. The one hundred foot roll of tape weighs less than one hundred sixty ounces (five pounds). The tape is made of an inexpensive, flexible, non-metallic, lightweight non-structural material (for example, paper or mylar or polyester) through which standard nails used in making shear walls can be easily driven using hand tools. The tape material is such that the tape can be cut easily with ordinary box cutters or scissors or a knife or a serrated edge such as that found on a typical packaging tape dispenser. In one embodiment, lengths of the non-structural template tape material can be torn from the roll by hand without the use of box cutters or scissors or any other tool. Template 1 may, for example, include an adhesive layer on one side such that the template strip can adhere to ordinary plywood or particle-board sheathing material. Template 1 may involve two layers where one of the layers is a disposable backing layer. When the backing layer is removed, an adhesive side of the other layer is exposed.
There are two sets of nailing pattern markings on template 1 . The markings are printed on the template tape material. The markings of the first set of nailing pattern markings are denoted 2 - 9 . This first set of markings is to be used when template 1 is used to determine nail placement at edges of panels. Instructional lettering 10 corresponds to the first set of nailing pattern markings. The instructional lettering 10 states “PANEL EDGE: FILL ALL RED SQUARES”. The markings of the first set are colored red so that the markings of the first set can be visually distinguished from markings of the second set.
Markings of the second set of nailing pattern markings are denoted 11 and 12 . Instructional lettering 13 corresponds to the second set of nailing pattern markings. Instructional lettering 13 states “FIELD NAIL: FILL ALL BLACK SQUARES”. The markings of the second set are colored black so that the markings of the second set can be visually distinguished from markings of the first set.
In addition to the first and second sets of nailing pattern markings, template 1 bears a heavy dashed centerline marking 13 as illustrated in FIG. 1 . Centerline marking 13 is usable to place and align template 1 properly with respect to a vertical joint between abutting plywood panels, or with respect to a vertical line such as a chalk line or a line of nails.
In addition, template 1 includes an indication of a particular nailing pattern to which to the markings on the template conform. One nailing pattern is commonly referred to as a “3” and the associated type of shear wall is commonly referred to as a “3 shear wall”. The numeral “3” lettering (the term “lettering” here is used to denote numerals and/or letters and/or symbols) in the triangular symbols 14 and 15 indicate that the nailing pattern marked on template 1 is the nailing pattern used to make a “3 shear wall”. The “3” is referred to as the nailing pattern type. In the “3” nailing pattern type, edge nail markings disposed along the same sheathing panel are separated by three inches and alternate between two vertical lines. Marks 2 and 3 are, for example, separated by a distance of three inches. Marks 2 and 4 are, for example, disposed along the same vertical line and are separated by six inches (three inches twice). Similarly, marks 3 and 5 are disposed along the same vertical line and are separated by six inches. Marks 7 and 9 are disposed along the same vertical line and are separated by six inches. Marks 6 and 8 are disposed along the same vertical line and are separated by six inches. The staggering of the markings in both the vertical and horizontal dimensions is as specified by the “3 shear wall” specification.
FIG. 2 is a diagram that illustrates a method of using template 1 of FIG. 1 . A frame includes horizontal framing members 20 - 22 and vertical framing members 23 - 27 . Vertical framing members 23 , 24 , 26 and 27 are, in this specific example, 2×4 wood studs that are pictured on edge in the diagram. Framing members 23 , 24 , 26 and 27 are approximately one and half inches wide as viewed in FIG. 2 . Framing member 25 is a 3×4 wood stud. The side of framing member 25 that is seen in FIG. 2 is the side of member 25 that is approximately two and one half inches wide.
Two standard four foot by eight foot plywood or particle-board sheathing panels 28 and 29 (also referred to as “siding panels”) are oriented edge-to-edge such that the large face-sides of the panels are disposed in the plane of the page in the illustration of FIG. 2 . Line 30 illustrates the vertical boundary between the two abutting edges of panels 28 and 29 . These two sheathing panels are to be nailed to the framing members to make the shear wall. In a first step, the two panels are tacked in place with a few holding nails. Rather than abutting one another, the two sheathing panels may actually be separated by a small specified gap.
Next, five template strips 31 , 32 , 1 , 33 and 34 of the novel template strip tape material are attached to the front side of the sheathing panels 28 and 29 as illustrated. Each of the templates is an eight foot piece taken from the same roll of the template strip material. If templates 31 , 32 , 1 , 33 and 34 are self-adhesive and have an adhesive on one side, then the adhesive holds the templates to the sheathing panels. Alternatively, templates are tacked in place with a few holding nails or staples.
Next, templates 31 , 32 , 1 , 33 and 34 are used in the nailing process. Templates 31 32 , 33 and 34 are disposed over framing members 23 , 24 , 26 and 27 as illustrated. These templates are not aligned along edges of the panels. The nails in these portions of the shear wall are therefore said to be in the “field” of the panels. Nails are therefore placed using the “field” nailing pattern of nail markings (see FIG. 1 ). Which markings are the field markings and which markings are the edge markings are designated by the instructional lettering on the template strips. A nail is driven through each of the field nailing markings in templates 31 , 32 , 33 and 34 such that the nail extends through the template, then through the sheathing, and then into the framing member behind the sheathing. The markings used are illustrated in FIG. 2 as solid black markings.
Template 1 , however, is disposed over the rightmost edge of panel 28 and over the leftmost edge of panel 29 . The centerline 13 of template 1 is aligned over the boundary 30 between the two panels 28 and 29 as illustrated in FIG. 2 . This template 1 is not disposed in the “field” of the panels, but rather is disposed along edges of the panels. The pattern of nails to be used in the nailing process is therefore said to be an “edge pattern”. Nails are therefore placed using the “panel edge” pattern of markings (see FIG. 1 ). A nail is driven through each of the panel edge markings in template 1 at a specified distance from an edge of the sheathing. The nail passes through the template 1 , then through the sheathing, and then into the framing member 25 behind the sheathing. The markings used are illustrated in FIG. 2 as solid black markings.
FIG. 2 shows the structure of the framing in the cutaway portion 35 at the top of the diagram. FIG. 2 also shows a cutaway portion 36 of how the structure would look with the sheathing applied but before the templates 31 , 32 , 1 , 33 and 34 are applied. The vertical dashed lines in cutaway portion 36 indicate where the framing members are located behind the sheathing. Cutaway portion 37 of FIG. 2 shows the structure after the templates 31 , 32 , 1 , 33 and 34 have been applied to the surface of panels 28 and 29 .
In one example, a selection of rolls of template strip material is made available to a framer. In this selection, there is a roll that bears nail markings for each nailing pattern to be used in the framing of a building. The framer uses a set of constructions plans, identifies from the construction plans the pattern of nailing specified for a particular shear wall, selects the associated roll whose marks 14 and 15 identify that nailing pattern, and then fixes strips of the template tape as illustrated in FIG. 2 . The framer works around a building being framed in this manner, attaching the proper types of templates. The templates are then used as guides in the subsequent nailing process so that the nailing schedule as specified on the construction plans is followed. The non-structural template tape material remains in place after nailing so that a subsequent inspection of the nailing is made easier. The non-structural template tape material is made from an inexpensive material so that using the template material does not add an undesirably large amount of material cost to the building. The non-structural template tape material is made of a material that can be readily pierced by nails and staples so that the presence of the in-situ template does not interfere with subsequent attachment of materials to the nailed surface of the finished shear wall.
Although certain specific exemplary embodiments are described above in order to illustrate the invention, the invention is not limited to the specific embodiments. In one embodiment, the nailing markings are actually small holes in the template tape material. Although an example of a shear wall nailing template is described above that is less than eight inches wide, a shear wall template in some novel embodiments is wider than eight inches and includes nailing markings usable for nailing a sheathing panel to two different parallel extending wall studs that are disposed at a distance (for example, twelve or sixteen inches) from one another. The template may, for example, be a sheet that covers the entire surface area of a four foot by eight foot sheathing panel. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the following claims. | A non-structural shear wall nailing template bears a pattern of shear wall nailing pattern markings. The template is made of an inexpensive sheeting material that will not interfere with the further construction of the building if the template remains in-situ after construction of the shear wall. In one example, the template is a strip. The strip bears lettering that indicates the type of nailing pattern to which the nailing pattern markings conform. After fixing the template to one or more sheathing panels such that the template is aligned in a predefined way with respect to framing members behind the panel(s), nails are driven at the locations of the markings on the template. By driving a nail at the location of each template marking, the shear wall is constructed with proper nail spacing. A set of templates is provided to facilitate nailing in different shear wall nailing patterns. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to protective ground covers for the region surrounding upright elements and, more particularly, to a permanent tree well cover having an opening which can be enlarged in-situ.
2. Description of the Prior Art
As depicted in FIG. 1, the typical prior art cover which has been installed about the base of a tree is constructed of concrete, asphalt or in some cases cast iron. Covers constructed of these materials suffer greatly from the sheer weight thereof and the inherent difficulty in handling. After a period of time the covers typically become cracked as the foundation thereunder becomes eroded, overgrown, or for whatever other reason. This allows for unsightly weeds and plant growth to appear. Such structures also do not include any means for enlargement and must be broken-up with sledge hammers and the like and removed to provide for the growth of a tree.
German Pat. Nos. 2,517,949 and 2,317,216 have attempted to overcome the above problem by providing covers with segmented annular parts. The parts or segments can be removed to provide for the increase in diameter of a growing tree. However, since the removable parts are preformed, their versatility for expansion is greatly limited. Unfortunately, having preformed segments also makes the covers more susceptible to vandalism.
Additionally, since the patented structures utilize concrete and cast iron as materials of construction, they are costly to manufacture and cumbersome to handle. Still further, such materials of construction suffer the prior art disadvantages of being breakable or allowing cracks to form through which unsightly weeds can grow as shown in FIG. 1.
SUMMARY OF THE INVENTION
In accordance with the present invention, a tree well cover is provided which is light-weight in construction and can readily be severed by a saw or the like to allow for the growth of a tree or the use of various external elements such as lighting fixtures, drainage and support means.
The invention is constructed of reinforced plastic or fiberglass wherein two or more sections interfit and surround the base of a tree with a central opening. On the underside of each section are a plurality of downwardly extending rings which are radially offset from each other. Each of the rings provide reinforcement for each section and further, when located in a predetermined manner, provide for a convenient guide means for the subsequent removal of portions of each section. In this way the central opening can be enlarged in-situ without the disadvantages of the prior art.
Each section is further provided with a peripheral downwardly extending wall comprising an outer portion which defines the configuration of the cover and matching inner face portions which operate to abut against corresponding face portions of other sections. With the above construction, each individual section is self-supporting and can be any of the hereinafter described configurations as dictated by environmental, manufacturing and asthetic needs.
Adjacent the outer peripheral wall portion is an optional preformed framework having the same configuration as the overall cover. The framework is utilized as a concrete form and facilitates the proper alignment of the sections positioned therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view depicting the prior art and some of the problems inherent therewith.
FIG. 2 is a perspective view showing the present invention installed within an optional framework along a sidewalk adjacent a curb.
FIG. 3 is an exploded perspective view of the invention shown in FIG. 2.
FIG. 4 is a cross-sectional view taken along lines 4--4 of FIG. 2.
FIG. 5 is a top plan view of the invention shown in FIG. 2.
FIG. 6 is perspective view showing the top side of one section of the cover of the present invention.
FIG. 7 is an exploded perspective view of the underside of the section shown in FIG. 6 depicting portions thereof which can be removed.
FIG. 8 is a perspective view of the optional framework shown in FIGS. 2-5.
FIG. 9 is an enlarged fragmentary cross-sectional view taken along lines 9--9 of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, more particularly, to FIGS. 3, 6 and 7 thereof, the tree well cover 10 of the present invention will be described. In the embodiment shown, the cover comprises two sections 12 and 14. Each section is a mirror image of the other section. The sections shown are generally rectangular in overall shape with a semi-circular cutout 20, 22 located about midpoint along the inwardly-facing wall portions 24, 26 of each respective section.
It will be understood, however, that more than two sections may be utilized with the present invention and that said sections may be of any convenient geometrical configuration to form the desired cover. For example, the overall shape of the cover may be round, oblong or oval shaped and there may be three or more individual sections having a wedge-like shape which interfit to form the complete cover. Similarly, the overall configuration may be triangular, quadrilateral or polygonal. For example, when the assembled cover resembles a triangle, the individual sections would have a triangular or rhombic-like shape.
In any case, the sections should include an outer peripheral wall structure, shown generally in FIGS. 3 and 4 by reference numeral 16. The peripheral wall comprises one or more outer portions 18 and the aforesaid face portions 24, 26 adapted for abutment with each other and/or corresponding face portions of other sections. The wall may be continuous throughout as shown or it may comprise a series of spaced-apart legs to conserve on materials of construction (not shown).
As shown in FIG. 3, the semi-circular cutouts 20,22 form a central circular opening 34 when the sections 12 and 14 are placed adjacent each other. In this case the matching inner facing surfaces 24, 26 abut against each other and the opening 34 is defined by inner rings 30,32.
Depending from the underside 36,38 of each section, are downwardly extending semi-circular rings shown by reference numeral 40. The rings are spaced successively radially outwardly from the innermost rings 30,32.
In the preferred embodiment, each of said rings are arranged concentric with the inner rings and extend downwardly a distance successively less than the height of outer wall portions 18 to a minimum height represented by the inner rings. In this manner each section will have a tendency to be properly supported by ground-fill materials when interfitted about the base 50 of a tree.
As described hereinabove, the sections are constructed of severable fiberglass or reinforced plastic materials well known in the art. As such, correspondingly larger diameter central openings 34 may readily be created simply by cutting along the inwardly facing surface of a predetermined underside ring 40.
As best shown in FIG. 7, cutting along the inside surface of ring 40a of each section results in the removal of a small semicircular portion, partially depicted by fragment 42, and creates a slightly enlarged circular opening. Creation of the largest possible opening is accomplished by cutting along the inner surface of ring 40c and removal of all the prior succeeding inner flanges, a fragment of which is shown by reference numeral 44.
The particular ring to be cut along will be dictated by the size and type of tree base to be encompassed--taking into consideration other environmental conditions and necessities. For example, space should be provided for irrigation and/or mulching implements, if desired, and room should be provided for any support means which may be needed in the case of young and/or small caliper trees located in windy areas. In these cases, partial cut-outs may be made such as, for example, from only one section or from a part of one section or different parts of two or more sections. In this regard, it is clear that opening 34 can have a wide variety of configurations other than circular. Likewise, inner rings 30,32 and rings 40 can have configurations other than semi-circular and each can be different from the other. Of course, as the tree grows successively larger, cutouts along rings 40 are made to accommodate the increasing diameter of the tree trunk.
Preferably, the area to be covered by the tree well cover of the present invention is overlaid with a granular ground-fill material 54 such as sand, rocks, gravel or other material, taken alone or in combination, which permits the flow of air and water thereabout. Use of such material further permits penetration therein of the annular rings 40 and peripheral wall structure 16 thereby providing a solid stable placement of the cover sections.
When the cover is located within an opening surrounded by concrete, such as that envisioned in FIG. 2 with sidewalk 56 or curbing 58, the cover may be secured and properly sealed with a resilient sealing material placed about the periphery of the cover and along the abutment of wall portions 24,26. Examples of such are mastic, polyurethane resins, latex caulking compounds and the like.
In many cases, use of the present invention will be contemplated prior to the formation of a sidewalk, patio, curbing or the like. In such cases the present invention comprehends the use of an optional premolded outer framework 60, preferably constructed of fiberglass or plastic.
As best shown in FIGS. 8 and 9, the framework is L-shaped in cross-section and has the same geometrical configuration as that defined by the periphery of the assembled tree well cover. Such framework is typically provided with at least one point of severance such as that shown by reference numeral 62.
By virtue of the inherent resilience of the material of construction thereof, the frame may be twisted to separate the severed ends. With such a manipulation, the distance of separation of the ends can be made large enough to permit passing of the tree trunk and allow one to position the frame on the surrounding ground in a manner to completely encircle the tree. In this manner the frame will act as a form about which concrete may be poured and which will therein provide a method of creating a properly dimensioned opening into which is placed the sections of the tree well cover without fear of uneven or non-square corners causing a misaligned, skewed or canted placement.
As best shown in FIG. 4, the frame becomes a permanent part of the surrounding concrete structure. The frame provides a further advantage wherein the frame foot portion 64 operates as a level solid support for the peripheral wall 16 of each section.
Additional features of the present invention include the provision of optional drainage holes 70 extending through the thickness of the cover. In this regard it will be noted that the topside of each section is slanted downwardly from the outer periphery of the cover toward the central opening 34. In this manner, rain water will be directed toward the base of the tree carrying moisture enrichment to the tree roots.
It will be understood that for purposes of the present invention, the term "tree" as used herein, is to include inert upright elements such as street signs, poles, rods and the like and other forms of plant life besides a tree per se such as, for example, shrubs or flowers or any combination thereof.
A particular advantage of the present invention resides in its fiberglass or reinforced plastic construction which allows for ease of forming, handling, cutting and subsequent lightweight use. Additionally, during the cover molding process, the top surface may readily be provided with any one or more embedded pebbles, gravel, rocks, coloring or texturized finishes dictated by the contemplated end use and environment in which the cover is to be used. Also, as a result of the plastic or fiberglass construction, it is easy to provide for the installation of electrical fixtures, and the like in-situ, which heretofore were difficult and expensive to install in the prior art concrete and cast iron structures.
While the invention has been described with respect to preferred embodiments, it will be apparent to those skilled in the art that other modifications and improvements may be made without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrative embodiments, but only by the scope of the appended claims. | Two or more fiberglass preformed sections interfit to form a cover about the base of a tree. The sections are provided with a series of underlying rings spaced apart concentrically radially outward from a central opening through which the tree extends. The rings provide reinforcement to each section and function as guides for subsequent cutting of larger holes as the tree grows. When concrete or the like is to be poured about the tree, a framework is used as a concrete form to insure the cover sections fit together properly. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to a method and apparatus for inhibiting vandalism to highway bridges and similar structures, and in particular, to a method for preventing vandals from standing on the I-beams which support the bridge while vandalizing the bridge.
Vandalism to public property, and in particular graffiti, has long been a nuisance in large cities. When graffiti appeared, it was usually painted over within a short period of time to prevent the loss to property value in the surrounding community. Overall, this graffiti presented a small problem when compared to other issues faced by cities.
Recently, however, the problem of graffiti and other similar vandalism has increased significantly in big cities and has spread rapidly across the entire country. The problem is no longer confined to major metropolitan areas, but is increasingly present in medium-sized cities and even small towns. One primary source of graffiti is "taggers"--teenagers who wish to leave their mark in as many public places as possible. The other primary source of graffiti is gangs which use the graffiti to mark their "territory". Regardless of its source, the graffiti is usually an eyesore and decreases property values in the area.
The surge in graffiti from both sources is spreading across the country at an alarming rate. Virtually everywhere the problem is increasing. An official of one western state recently noted that his state's transportation department had spent three times as much money removing graffiti in the first three months of 1994 as had been spent during the entire year of 1993. He noted that, despite the significant increase in expenditures on graffiti removal, the vandals appeared to be gaining ground as each day additional graffiti was visible along the roadsides and on bridges.
A particular problem with graffiti is that done on bridges. When writing on the bridge, the vandals will typically climb on to the I-beams which support the bridge and stand on the lower flange of the I-beam while the graffiti is applied. To remove the graffiti, the public works employees are faced with the challenge of either (a) repeating the dangerous climb of the vandals; (b) blocking off traffic while some sort of raised platform is used to allow workers to paint over the graffiti; or (c) use long telescoping poles to cover the graffiti and attempt not to drip paint onto cars passing beneath the bridge.
These difficult options have resulted in many areas of the country simply giving up on removing the graffiti. Rather than painting over the graffiti, the bridges are allowed to become an eyesore and free advertising for the particular cause of the vandal. Consequently, the neighborhoods around the bridge begin to deteriorate as the presence of graffiti attracts more graffiti. Eventually, the property values may decrease and the neighborhood may fall into disrepair.
Thus, there is an urgent need for a method and apparatus which will hinder the application of graffiti to bridges, overpasses and the like. It is also important that the method be relatively inexpensive so to not offset the savings obtained in preventing the vandalism.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an apparatus and method which will decrease the ability of vandals to paint graffiti on bridges, overpasses and the like.
It is another object of the invention to provide an apparatus which may be attached to the structure of existing bridges.
It is yet another object of the invention to provide a method and apparatus which prevents vandals from standing on the I-beams while applying graffiti.
The above and other objects and features of the invention are disclosed by an slant plate device including a generally sloped plate extending from a center position of a vertical wall forming the I-beam to a position adjacent a lateral extreme of a flange forming a lower portion of the I-beam. The sloped plate is positioned so as to prevent a vandal from standing on the lower flange of the I-beam, or using it for support. The sloped portion can be attached to the I-beam in numerous different ways including adhesives, screws, bolts and the like.
The method of the present invention includes providing piece of material and positioning it to form a sloped surface adjacent to the I-beam. The slope should be at a sufficient angle to prevent a person from standing on the lower flange of the I-beam, thereby making it much more difficult to vandalize the bridge.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings, in which:
FIG. 1 shows a side cross-sectional view of an I-beam, such as that typically used to support highway bridges and other similar structures, with a slant plate device positioned adjacent the lower portions of the I-beam.
FIGS. 2-5 show alternate embodiments of slant plate devices made in accordance with the present invention, each device showing a different method of mounting the device upon I-beams.
DETAILED DESCRIPTION
Reference will now be made to the drawings in which like structures will be given numeral designations, and in which each aspect of the invention will be explained in detail. Referring now to FIG. 1 there is shown a cross-sectional view of an I-beam, generally indicated at 4, such as those typically used for structural support of bridges and overpasses along highways. The I-beams 4 are usually positioned below the roadway and extend from one pillar to another, or from a pillar to the side of the bridge.
The I-beam 4 typically has an upper flange 8 and a lower flange 12, each of which extends generally horizontally. The flanges, 8 and 12 respectively, are separated by a web 16, or a generally vertical wall which joins the two flanges and provides structural support.
Also shown in FIG. 1 is a slant plate device, generally indicated at 20, which includes an elongate plate 22 positioned so as to provide a sloped surface 24 between the web 16 and the lower flange 12. The sloped surface 24 of the elongate plate 22 is designed so as to prevent a person from standing on the lower flange 12. As graffiti vandals often stand on the lower flange 12, the positioning of the slant plate device 20 prevents vandals from vandalizing the bridge.
The elongate plate 22 is supported by a horizontal wall 28 which runs generally parallel to the lower flange 12 and a generally vertical wall 32 which runs generally parallel to the web 16. The two walls, 28 and 32, provide support for the sloped surface 24 of the elongate plate 22, and an area for attaching the elongate plate to the I-beam 4. Adhesive can be placed along the outside edge 28a and 32a, respectively, of each wall so as to affix the walls, and thus the entire slant plate device 20 to the I-beam.
It is anticipated that the sloped surface 24 will have an angle of at least 45 degrees so as to prevent people from standing thereon. The slant plate device 20 should be made of a material, such as metal or rigid plastic which is durable enough to withstand the attempts of vandals to remove them from the I-beams 4. Additionally, the slant plate device 20 should be sufficiently visible that potential vandals will be able to see it, thereby preventing accidental injuries caused by someone falling from an I-beam due to a lack of footing. It is anticipated that the slant plate device 20 will be made of metal and painted so as to increase visibility and decrease corrosion due erosion by the weather.
Referring now to FIG. 2, there is shown an alternate embodiment of the present invention mounted to an I-beam 4. The slant plate device 40 is analogous to that shown in FIG. 1 in that is has an elongate plate 22, forming a sloped surface 24, and support walls 28 and 32. However, the slant plate device 24 is different from that shown in FIG. 1 in that the sloped surface 24 extends beyond the lateral limits of the lower flange 12 of the I-beam 4. As shown in FIG. 2, the slant plate device 40 forms a clamp for holding the device to the I-beam 4. The clamp involves a retainer section 44 which is held by a cord, cable or elastic device 48 to an extension 52 which projects down extension 52 which extends down from the slant plate device 40. When the cable or elastic device 48 is tightened so as to pull the extension and retainer together, the slant plate device 40 is held securely to the I-beam 4 so as to prevent vandals from standing on the lower flange 12. Those skilled in the art will recognize the numerous ways in which the cord, cable or elastic device 48 could be mounted between the retainer section 44 and the extension 52. As shown in FIG. 2, the cable is fixedly attached in the retainer section 44 and is adjustable relative to the extension 52 by rotating a nut 54.
An advantage of the clamp arrangement shown in FIG. 2 is that the slant plate device 40 can be attached or removed by adjusting the cable or elastic band 48. This is beneficial in that the slant plate device 40 can be removed if work was to be performed on the bridge. Additionally, if the particular I-beam 4 to which the slant plate device 40 is attached must be replaced, the slant plate device can simply be removed and reattached to the new I-beam.
Referring now to FIG. 3, there is shown a side-cross sectional view of a slant plate device 60 positioned between the web 16 and the lower flange 12 of an I-beam 4. The slant plate device 60 has an elongate plate 22 which forms a sloped surface 24. The elongate plate 22 is supported by a single support wall 64 which extends perpendicular from the sloped surface 24. The single support wall 64 is beneficial in that it provides a lighter-weight slant plate device 60 in the event that weight is a concern. The support wall 64 can be adhesively affixed to the I-beam 4 or can be bolted or otherwise attached.
As was mentioned, with respect to the embodiment shown in FIG. 1, the angle of the sloped surface 24 should be great enough so that vandals may not stand on the lower flange 12. Thus, it may be beneficial to provide an adjustable attachment between the support wall 64 and the sloped surface 24 so as to achieve the proper slope with I-beams of different widths.
Referring now to FIG. 4, there is shown a slant plate device 70 similar to that shown in FIG. 1. Rather than being attached by adhesives, the slant plate device 70 is attached by a bolt 72 extending through the vertical side wall 32 and into the web 16. The slant plate device 70 is also affixed by a bolt 74 which extends through the horizontal support wall 28 and into the lower flange 12. While the use of two bolts is preferred for secure attachment, either of the bolts could be removed without rendering the device inoperable.
Referring now to FIG. 5, there is shown yet another embodiment of the present invention mounted to an I-beam 4. The slant plate device 80 has an elongate plate 22 forming a sloped surface 24 similar to that of the other embodiments. In contrast to the other embodiments, the slant plate device 80 has only a horizontal support wall 84 extending along the Lower flange 12. A projection 88 extends downwardly from the sloped surface 24 and wraps under the lower flange 12. The projection 88 is held in place by a set screw 92 which extends through the projection and into the lower flange 12.
The positioning of the set screw 92 allows for simple and efficient removal of the slant plate device 80 if such becomes necessary. Thus, the slant plate device 80 can be readily moved from one I-beam to another should the need arise.
Usually, a slant plate device such as those described above will be needed on the exposed side of the outermost I-beams. Thus, if a bridge has four I-beams supporting it, only the two outermost will need the slant plate device. This is due to the fact that graffiti between the I-beams will generally be less noticeable than that on the sides of the bridge. With the considerable resources which are being expended on graffiti removal, it would seem that such graffiti would be far lower in priority. However, if sufficient funds exist, a particular government agency may wish to prevent vandals from defacing any part of the bridge and may place a slant plate device on both sides of each I-beam.
In the manner described above, an apparatus and method is disclosed for preventing vandalism to bridges and the like. It will be understood that other variations and modifications of the apparatus and method will be apparent to those skilled in the art without departing from the scope of the invention. The describe method and apparatus are not meant to be a delineation of the scope of the invention, but merely an example of several embodiments thereof. | An apparatus and method are disclosed for preventing or inhibiting the vandalism of bridges and other like structures. The apparatus includes a slant plate device having an elongate plate which is positioned so as to extend downwardly and outwardly from a central position on the vertical wall of an I-beam to a position adjacent a far lateral edge of the bottom flange of the I-beam. The plate is sloped sufficiently to inhibit a person from standing on the lower flange of the I-beam while applying graffiti or otherwise vandalizing the bridge. Several different support and attachment structures are also disclosed. The method includes positioning the elongate plate at an angle and attaching the plate to some permanent structure associated with the I-beam. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a well apparatus and, in particular to a pressure control device for the controlled containment and release of entrapped pressure in a plugged tubing string as the string sections are uncoupled.
2. Description of the Prior Art
In the operation of an oil or gas well in which production is obtained through tubing extending through a larger size casing, it often becomes necessary for the operator to extract the tubing for repair, inspection, or replacement. Occasionally, during production of the well, the tubing string becomes plugged in one or more places with sand, paraffin, or other contaminants requiring the removal of the tubing string to locate and remove the plugs.
The tubing string is raised a joint at a time. As each joint is raised from the well, it is unscrewed and checked for plugs. After the topmost joint of pipe has been removed from the next succeeding joint, the raising mechanism connects to the open end of the new top joint of pipe to continue the sequence of raising the tubing string. For those wells in which the fluids or gases are subjected to high pressures within the earth's formations, considerable danger exists during the extraction of the string because of the presence of high pressure product trapped or plugged in the tubing string. This pressure may suddenly be released upon disconnection of the sections of the tubing string.
In an effort to eliminate the hazards to life and property that this released pressure presents, pressure-control devices have been employed to contain this released pressure and allow for its controlled disposal.
A typical example of a prior-art pressure-control device for removing a plugged drill string is shown in U.S. Pat. No. 2,994,379 to C. C. Brown, et al. The prior-art pressure-control device exemplified by the above-mentioned patent includes a tubular body containing a pair of sealing units located at opposite ends of the body. The sealing units have a central opening through which the tubing string passes. The body contains two side connections. A pressure gauge in series with a release valve is secured to one of the side connections while a disposal line in series with a second release valve is secured to the opposite connection. The release valve and disposal line are used to bleed off the pressurized fluid from the interior of the tubular body. The two sealing units are longitudinally spaced from each other to accommodate between them the threaded pipe connection of the tubing string that is next to be uncoupled. Located above and below the two sealing units are slip sets for gripping the tubing string above and below the threaded pipe connection.
In operation, the threaded pipe connection is disconnected with the connection located between the upper and lower sealing units. Having disposed of any released pressure, the upper joint is removed from the device. After removing the upper joint, a safety valve must be lowered through the uppermost slips, through the upper sealing unit and mated to the open end of the tubing string. This operation is complicated because of the weight involved and the fact that the crew cannot see the threads to be mated. The crew must use trial and error to engage the threads. While attempting to engage these threads, the crew must have their hands and bodies in contact with a safety valve and above the top of the pressure control device. Any jarring or bumping of the tubing string could cause the plug in the tubing to release and expose the crew to the blast of suddenly released pressure. It would also leave them with no immediate method of stopping the flow. Additionally, the sealing units of this prior-art pressure-control device were constructed with restricted internal diameter rubber sealing portions constantly in contact with the tubing being hoisted from the well. As a result, many tools and devices which were a part of the tubing string but of a greater outside diameter than the tubing, could not be hoisted through the pressure-control device.
It is an improvement, therefore, to provide a pressure-control device in which the open end of the tubing string following disconnection of the topmost joint of pipe can be exposed above the pressure control device for connection to the safety valve without exposing the crew to unnecessary dangers. It is a further improvement to provide a pressure containing device that can be elevationally adjusted relative to the threaded pipe connection to position the sealing units relative to the threaded pipe connection. It is also an improvement to provide a pressure-containing device with a blowout preventor that can be positioned above the open end of the tubing string, and closed to shut off any uncontrolled flow of pressurized fluids or gases from the open end of the tubing string. It is also an improvement to provide a pressure-control device having an internal bore diameter larger than the largest outside diameter of the drill string so that the drill string may be raised unobstructed through the pressure-control device. It is also an improvement to provide a pressure-control device that can be coaxially aligned with the axis of the tubing string, to permit lifting of the string without interference with the internal bore of the device. It is also an improvement to provide a pressure-control device capable of permitting upward movement of the pressure-containing device as the threaded pipe connection is unscrewed and to absorb the shock of any released pressure tending to force the unscrewed top length of tubing out of the pressure-containing device.
SUMMARY OF THE INVENTION
A preferred embodiment of the present invention comprises a lower and upper slip set assembly, a pair of hydraulically actuated pistons, a pair of hydraulic fluid accumulators associated with the hydraulic pistons and a series connection of various pressure sealing devices which provide a pressure enclosure around a threaded pipe connection in a tubing string.
The lower slip set assembly contains a set of slips to grip the string below a threaded pipe connection to support the weight of the string and to prevent rotation of the lower joint of pipe. The lower slip set assembly provides a base to which the remaining elements of the pressure-control device are attached. Included with the lower slip set assembly is a set of adjusting screws to plumb the entire pressure-control device.
The upper slip set assembly contains a set of slips for securely gripping an upper joint of pipe above a threaded pipe connection to prevent any upward movement of the pipe relative to the upper slip set assembly. The upper slip set assembly is rotatable to thereby provide the rotation necessary to unscrew the threaded pipe connection.
Suspended below the upper rotatable slip set assembly is the serial connection of elements comprising the pressure-control assembly within which the threaded pipe connection is disconnected. The pressure-control assembly is composed, from top to bottom, of a ram blow out preventor, an upper sealing unit, a pressure containing chamber and a lower sealing unit. The ram blow out preventor is used to close off the central opening of the pressure control assembly above the open ended string when an uncontrolled flow of fluids or gases is escaping through the open pipe connection. The upper and lower sealing units are used to provide a pressure seal against the outside wall of the joints of pipe in the tubing string above and below the threaded pipe connection. The pressure-control chamber interposed between the upper and lower sealing units provides a housing around the threaded pipe connection during disconnection to contain any released pressure between the pressure seals above and below the pipe connection. Pressure release valves are connected to the chamber through which the pressure within the control chamber is monitored and through which pressurized fluids or gases within the chamber are transferred to a disposal area.
A pair of hydraulic pistons connect the upper slip set assembly to the lower slip set assembly. The hydraulic piston piston cylinders are attached to the lower slip set assembly while the hydraulic pistons, contained and movable within the cylinders, are attached to the upper slip set assembly. The hydraulic pistons are used to position the pressure-control assembly so that the tubing connection is contained within the pressure chamber prior to disconnection, and that following disconnection, the open end of the tubing string can be exposed above the pressure-control device for the safe and rapid connection of the safety valve.
Associated with each of the hydraulic pistons is a fluid accumulator that serves two functions. First, the accumulators allow for slight upward extensions of the upper slip set assembly necessary to accommodate the increasing length of the string between the upper and lower slip set assemblies during disconnection of the connection. Secondly, the accumulators act as shock absorbers to dissipate the forces generated by released pressure upon disconnection of the connection which acts to force the upper joint of tubing out of the pressure-control assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of this invention are set forth in the appended claims. The invention and advantages thereof may best be understood by reference to the following detailed description of illustrative embodiments, when read in conjunction with the accompanying drawings which form a part of this specification, in which corresponding numerals indicate corresponding parts.
In the drawings:
FIG. 1 is a composite view of the pressure control device in its fully collapsed position, showing the open-ended tubing string above the device awaiting connection of the safety valve.
FIG. 2 is a partial cutaway side view of the pressure control device in its fully extended position with a threaded pipe connection positioned within the pressure control chamber.
FIG. 3 is a partial cutaway view of the pressure control assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and first to FIG. 1, a pressure control device 1 embodying this invention is shown in place on a rig floor over a well from which the tubing string is to be extracted. The pressure control device 1 is in its fully collapsed position with the open end of pipe joint 6 extended above the device. The open end of pipe joint 6 contains a threaded pipe connection 4 that is typical of the connections that are used to couple the joints of pipe that comprise the tubing string. The topmost joint of pipe in the tubing string is shown extending from the well bore hole and passing through the lower stationary slip set assembly 26, the lower sealing unit 16, the pressure containing chamber 14, the upper sealing unit 12, the blowout preventor 10 and the upper rotatable slip set assembly 8. The lower slip set 34 is shown engaging pipe joint 6 to support the weight of the remaining joints of the tubing string while the safety valve 2 is shown in position for attaching to the open end of the tubing string at the threaded pipe connection 4.
The lower stationary slip set assembly 26 provides a base platform on which are mounted two hydraulic piston assemblies. Hydraulic cylinders 22 and 22a, which comprise the outer housings of the piston assemblies, are mounted to the lower stationary slip set assembly. Hydraulic pistons 40 and 40a (FIG. 2) which are contained within the hydraulic cylinders 22 and 22a, respectively, are connected to the upper rotatable slip set assembly 8. Suspended below the upper slip set assembly 8, in a serial fashion, is a blowout preventor 10, an upper sealing unit 12, a pressure containing chamber 14 and a lower sealing unit 16. Hydraulically connected to the top end of the hydraulic cylinders 22 and 22a are fluid accumulators 18 and 18a, respectively. Connected to opposite sides of the pressure-containing chamber 14 are two pressure release valves 20 and 20a. Attached to release valve 22a is a pressure gauge 24 for indicating the internal pressure of the pressure containing chamber 14. Pressure release valve 22 is connected to a product disposal line 38 through which will flow the pressurized fluids or gases released within the pressure control chamber.
Referring now to FIG. 3, a partial cutaway view of the pressure control assembly 13 is illustrated. An upper joint of pipe 30 and a lower joint of pipe 6 that are joined by threaded pipe connection 4 are shown contained within the pressure containing chamber 14. Suspended below the upper rotatable slip set assembly 8 is the pressure control assembly 13. Blowout preventor 10 is included in the pressure control assembly 13 to provide a means to stop the uncontrolled release of pressurized fluids and gases which are escaping from the open end of the tubing string once the upper joint of pipe 30 has been removed. Blowout preventor 10 is known by those skilled in the art as a "ram" type blowout preventor. The blowout preventor used in the embodiment of this invention is a standard model hydraulic blowout preventor manufactured by Cameron Oil Tools, but could also have been a heavy duty hydraulic blowout preventor manufactured by Bowen Oil Tools, Inc. or similar models from other manufacturers. This type of blowout preventor is actuated by pumping hydraulic fluid into a cylinder to cause a piston to push a ram into the central opening. If hydraulic pressure is not available, a manually actuated pusher may be used to push the ram into the opening. Dual cylinders and rams are provided, one on each side of the central opening, with each ram closing one half of the opening. The ram actuators 58 and 58a are identical in construction and operation and a discussion of only one will be provided.
Hydraulic fluid that is pumped into the ram actuator 58a through supply line 54a, forces piston 60a to move towards the central opening 68. This movement causes ram 62a, which is attached to the end of piston 60a, to begin closing off one half of the chamber of opening 68. A rubber insert 64a is mounted on the opposite end of ram 62a from where piston 60a is attached. Rubber insert 64a is compressed against a like insert from opposite side ram 62 (not shown) to form a pressure seal and close off the entire central opening 68. Ram 64a is opened by removing the pressure in fluid supply line 54a and pumping hydraulic fluid into supply line 56a. Pressurized fluid in line 56a forces piston 60a to move in the opposite direction as before to retract ram 62a from within the opening 68.
When pumped hydraulic fluid is not available, it is possible to open and close ram 62a by turning crank 66a to manually push and pull the piston 60a. It will be appreciated by those skilled in the art that other types of devices, such as a full opening valve, may be used to shut off the opening 68 to control the escaping fluids and gases from the open ended tubing string. A discussion of when and how the blowout preventor will be used is provided herein in the discussion of how the pressure control device is used.
Again referring to FIG. 3, suspended below blowout preventor 10 are the upper and lower sealing units 12 and 16, with a pressure-containing chamber 14 interposed between. The two sealing units 12 and 16 used in the embodiment of this invention are identical in operation and a discussion of only one will be provided. The sealing units are of standard manufacture such as those manufactured by Bowen Oil Tools. It will be appreciated by those skilled in the art that there are devices manufactured by other companies that may be used in place of the illustrated sealing units to generate a pressure seal around the pipe joints to be disconnected. In situations where the internal bore of the sealing units 12 and 16 are inadequate for the tools that will be pulled through the units or where there are exceptionally high well pressures involved, ram-type blowout preventors may be substituted for the illustrated sealing units 12 and 16 of FIG. 3. These substitute blowout preventors will be outfitted with pipe rams that will seal around the exterior wall of the tubing contained in the central opening 68.
Upper sealing unit 12 is actuated by pumping hydraulic fluid into the unit through supply line 52. This hydraulic pressure forces sealing ram 72 to move toward the rubber seal 70, forcing the seal to close uniformly around pipe joint 30 contained within central opening 68. Sealing ram 72 continues to urge rubber seal 70 against the pipe wall until a pressure seal is achieved. To release the pressure seal, hydraulic pressure is removed from supply line 52, thereby permitting return spring 74 to force sealing ram 72 to return to its relaxed position.
Pressure-containing chamber 14 is interposed between the upper and lower sealing units 12 and 16. Threaded pipe connection 4, which is to be uncoupled, is positioned within this chamber prior to disconnect. Attached to opposite sides of chamber 14 are two release valves, 20 and 20a. Attached to release valve 20a is a pressure gauge 24 that permits the crew to monitor the internal pressure within the chamber when release valve 20a is open. Attached to release valve 20 is pressure disposal line 38 that pipes the pressurized fluids and gases to a disposal area when release valve 20 is opened. The central opening of each of the elements that compose the pressure control assembly 13 are selected to have an inside diameter greater than the largest outside diameter of the drill string. This permits the pressure control device to remain in place while the string, containing tools or devices of greater diameter than the string tubing, is passing through the device.
Now turning to FIG. 2 which shows the pressure control device in its fully extended position, the upper set of slips 32, which are part of the upper rotatable slip set assembly 8, are shown engaging the outer surface of pipe joint 30. The gripping slots or teeth of the slips 32 are oriented so that the upper joint of pipe 30 is prevented from moving in an upwards direction in respect to the upper rotatable slip set assembly 8. The upper slips 32 perform two functions. First, in order to uncouple pipe joint 30 from pipe joint 6, pipe 30 must be rotated in the appropriate direction relative to pipe joint 6. This rotation is accomplished by rotation of the rotatable portion of the upper slip set assembly 8. This rotation is imparted to upper pipe joint 30 by the gripping action of slip set 32. During the rotation of the upper joint 30, lower joint 6 must be held stationary. Pipe joint 6 is held stationary by the lower slip set 34. Secondly, when pipe connection 4 is uncoupled, any released pressure will tend to force the upper joint 30 out of pressure control assembly 13. The gripping action of slip set 32 counteracts that expelling force and holds the pipe within the assembly.
FIG. 2 shows the lower set of slips 34, which are part of the lower slip set assembly 26, gripping lower pipe joint 6. The slots or teeth of the lower slip set 34 are oriented so that movement in a downwards direction is prevented. The lower slip set 34 serves two functions. First, the weight of the entire tubing string is supported by the lower slips, and secondly, the gripping action of the slips prevents lower pipe joint 6 from rotating while the upper joint of pipe 30 is rotated.
The lower stationary slip set assembly 26 provides a base platform to which the remaining elements of the pressure control device are mounted. Incorporated within the lower stationary slip set assembly is a set of alignment screws 36. The rig floor 28 (see FIG. 1), as a general rule, will not be perfectly level. Alignment screws 36 are provided to plumb the pressure control assembly 1 so that the longitudinal axis of the tubing string will be coaxial with the center line axis of the pressure control assembly 13. In this manner, as the tubing string is raised, contact with the inside surfaces of the pressure containing assembly will be minimized and the joints of pipe will pass through the assembly as smooth as possible. Although screws are used to plumb the device in the preferred embodiment, other ways to plumb the pressure control device could be used such as, hydraulic leveling pistons, jacks, etc.
The upper rotatable slip set assembly 8 is connected to the lower stationary slip set assembly 26 by means of two hydraulic piston assemblies. The hydraulic piston assemblies are identical in construction and operation and a description of only one will be given. Illustrated in FIG. 2 is a hydraulic piston assembly which is composed of a hydraulic cylinder 22a whose base is mounted to the lower stationary slip set assembly 26. Contained within cylinder 22a is piston 40a, one end of which is attached to the upper slip set assembly 8. Hydraulic fluid supply lines are provided at the top and bottom of cylinder 22a, respectively. By pumping fluid into cylinder 22a through line 48a and permitting the displaced fluid caused by the upward movement of piston 40a to escape through supply line 50a, piston 40a will be raised. To lower piston 40a, the process is reversed. Supply line 50a is pressurized and line 48a is allowed to drain.
Connected to supply line 50a is pressure accumulator 18a. The accumulator used in the preferred embodiment of this invention is of standard commercial design such as those manufactured by Greer Hydraulics, Inc., the capacity of which varies with the application. For an average application, the capacity of the accumulators is approximately five gallons. Contained within accumulator 18a is a flexible diaphram 44a that acts as a container for gas 46a and as an interface between the gas and the hydraulic fluid 42a that is delivered from the hydraulic fluid supply line 50a. The accumulator serves two functions. First, when upper pipe joint 30 is rotated to disconnect the threaded pipe connection 4, the length of pipe between the upper and lower slips, 32 and 34, increases. Accumulator 18a permits the slight upward extension of the upper slip set assembly 8 resulting from the unscrewing of the pipe connection 4. The upward movement of slip set assembly 8 causes piston 40a to likewise move up. The hydraulic fluid displaced by the upward movement of piston 40a enters accumulator 18 a. This displaced fluid in turn compresses gas 46a as it enters the accumulator to accommodate the increased volume of fluid within the accumulator.
Secondly, accumulator 18a functions as a shock absorber to absorb the shock produced by the sudden release of pressure as pipe connection 4 is disconnected. Forces created by the released pressure tend to propel upper pipe joint 30 out of the pressure control assembly 13. Because the upper slip set 32 will not permit pipe joint 30 to move relative to the slip set assembly 8, this pressure-created force is transmitted to piston 40a. As piston 40a begins to move upwards, it displaces hydraulic fluid from cylinder 22a into supply line 50a and into accumulator 18a. This displaced fluid compresses gas 46a within the accumulator. Compression of gas 46a increases the pressure in the hydraulic fluid which in turn increases a counteracting force on piston 40a which retards the upward movement of the piston. As more fluid is displaced, the counteracting force acting on piston 40a is increased because the compressability of gas 46a has decreased. In this manner, the accumulator allows for limited rapid upward movement of pressure control assembly 13 created by the sudden release of pressure within the assembly by dissipating the generated forces in the compression of gas 46a.
The above-described pressure control device is employed in the following manner: Pressure control device 1 is first mounted to the rig floor and alignment screws 36 adjusted to plumb the assembly to align the center line axis of the assembly with the tubing string. The tubing string is raised until the threaded pipe connection 4 that is next to be disconnected is properly positioned with respect to the lower slip set. The lower slips are then set to firmly grip the lower joint of pipe to support the weight of the tubing string. Next, the pressure control assembly 13 is positioned so that the threaded pipe connection 4 is within the pressure control chamber by actuating the hydraulic piston assemblies. Now, the upper slip sets are set to rigidly grip the upper joint of pipe to be removed. A pressure seal above and below the threaded pipe connection is made by actuation of the upper and lower sealing units 12 and 16. The upper joint of pipe is then unscrewed by rotating the rotatable portion of the upper slip set assembly 8. Any released pressure, upon disconnect, is piped to a disposal area through release valve 20 in pressure disposal line 38. When the pressure within the pressure control chamber, as indicated on pressure gauge 24, is at a safe level, the pressure seals above and below the threaded pipe connection are released and the upper slip set disengaged.
The upper pipe joint is now removed from within the pressure control assembly. The pressure control assembly 13 is lowered by the hydraulic piston asemblies so the open end of the tubing string extends above the top of the pressure control device. With the open end of the tubing string positioned above the pressure control device, the crew can safely engage safety valve 2 into the threaded pipe connection. Having safely connected the safety valve to the pipe connection, the hoist then lifts the tubing string to permit the disengagment of the lower slip set. When the lower slips have been removed, the hoist raises the string to position the next threaded pipe connection to be disconnected at the proper position. At this point, the process of uncoupling the threaded pipe connection can be repeated as before.
Between the time that the upper joint of pipe has been uncoupled and removed from the pressure control assembly 13 and the time that safety valve 2 has been secured to the open end of the drill string, a blowout can occur in which pressurized fluids or gases begin to escape from the open end of the tubing string. In such a situation, the following steps will be carried out. If the unit has been lowered to expose the open end of the tubing string above the pressure control device and a blowout occurs, the pressure control assembly will be raised until the open end of the string is below blowout preventor 10 but above the lower sealing unit 16. The lower sealing unit 16 is actuated to form a seal about the pipe's exterior wall while blowout preventor 10 is closed. As a result, the uncontrolled release of fluids and gases is stopped. The released pressurized product may then be diverted to the disposal area through release valve 20. If the blowout occurs while the threaded pipe connection is contained within the pressure control assembly, the only action required to contain the blowout is to close blowout preventor 10 and cause lower sealing unit 16 to seal about the exterior wall of the lower joint of pipe.
Further modifications and alternative embodiments of the apparatus of this invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art one manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and described are to be taken as the presently preferred embodiments. Various changes may be made in the shape, size and arrangement of parts. For example, equivalent elements or materials may be substituted for those illustrated and described herein, parts may be reversed, and certain features of the invention may be utilized independently of those of other features, all would be apparent to one skilled in the art after having the benefit of this description of the invention. | A pressure control device is disclosed which forms a pressure containing enclosure around a tubing string coupling to contain therein any released pressure as the tubing is uncoupled. Means are provided to form a pressure seal against the outside surface of the tubing string above and below the pipe coupling. This means also includes a blowout preventor to seal off the open end of the tubing string in the presence of uncontrolled release of fluids and gases. Lifting means are provided to raise and lower the pressure containing enclosure, to permit exposing the open end of the tubing string above the device for the safe and rapid attachment of a safety valve. Slip sets are provided to grip the lower and upper joints of pipe to support the weight of the tubing string and to allow the upper joint to be rotated relative to the lower joint to thereby uncouple the joints. Means are provided to plumb the device to align the central opening of the pressure control device, through which the tubing string passes, with the axis of the string. The central opening of the pressure containing enclosure is of sufficient diameter to permit the passage of tools and controls of larger diameter than the tubing but which are part of the tubing string. |
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BACKGROUND OF THE PRESENT INVENTION
1. Field of Invention
This invention relates to the field of river floods control and management, more specifically, it is a method of controlling river flood by means of astronomical tidal current at the estuary (a river mouth open to the sea) to control and discharge floods in upper stream.
2. Description of Related Arts
Floods disaster has been very serious in China. According to the imperfect statistics, there were 1092 major floods during the 2,155 years between 206 B.C and 1949 A.D. i.e. once every two years in average. Countless lives and properties were lost. There is an old saying about the Yellow River “bursts twice every three years, changes of its course once every hundred years”.
From the olden days, Chinese people combat hard with the serious floods, specially, from the foundation of the People's Republic of China. The Chinese government constructed many river conservancy projects. The new measures include both engineering and non-engineering approach. Gradually, a more comprehensive floods control system was founded. As a result, the Yellow River did not have great floods for the past 50 years and the Chinese people were proud of having no major flood problem for 50 years in the yellow river. This is indeed a great achievement in Chinese history. However, we should notice that China had still great difficulties in river flood control. The flood control standard is still not high enough. Whenever there is abnormal heavy rainfall, China is still facing dangerous situations, directly endangering embankments, reservoirs and other hydraulic projects etc. and will still cause catastrophe.
Rich experiences were gained during the long term floods fighting history in China, although nowadays new technology and new materials, enriches and improves the methods of dealing with floods. However, during the great floods at Yangtze River in the year of 1998, there are still more than 9,000 dangerous locations and incidents found on the river banks along the Yangtze River.
For case study, in the year 1999, heavy rainstorm occurred in the tributaries of the Yangtze River upper stream, such as Min River, Tuo River, Jiangling River, Wu River, and also occurred in the Yangtze River middle & lower stream, such as Dongting Lake and Boyang Lake.
As a result, serious floods happened in all sections of the Yangtze River, such as Xiang, Zi, Ruan, and Li in the Dongting Lake area and the Chang River, and Lean River in the Boyang Lake area and so on. Four crests developed at trunk stream of the Yangtze River upper stream consecutively.
The water level of most of the main hydrology station from Yichang to Nanjing along the trunk stream had risen beyond the caution level, among these figures, such as that recorded at the hydrology stations of Shashi, Shishou, Jianli, Lianhuatang, Luoshan, Wuxue, Jiujiang and ChengLingji of Dongting Lake and Hukou of Boyang Lake were approaching the highest historical record. The third highest water level happened at the hydrology stations of Hankou and Datong City. The fact that the flood level reached the record high in most segments of the Yangtze River reviews the fact that the flood conditions is deteriorating continually.
There were local rainstorms at the Yangtze River upper stream in the year of 1999, and floods water levels were reported to have been well above the caution level at Wu River and Min River. The floods at Wu River were very serious. The highest floods level 204.63 m which was 12.63 m higher than the safety pledged level (192.00 m), and 0.12 m higher than the historical highest level (204.51 m in 1955) which happened in June at Wulong (of Chongqing City). The corresponding flow rate recorded was 22,500 m 3 /s, which was the largest flow rate ever recorded (the old historical largest flow rate was 21,000 m 3 /s in the year 1964).
Being affected by the tremendous amount of rainfall from Yangtze River upper stream, it was found that a historical biggest floods happened in July 1999 at the Cun Tan (near Chongqing) hydrology station at the trunk stream of Yangtze River upper stream with the floods peak of 180.02 m, which was 0.02 m higher than the caution level (180.00 m), and the corresponding water flow rate was 48,700 m 3 /s.
Four floods crest were recorded at the hydrology station of Yichang, with the flood peak levels reaching 51.38 m, 52.20 m, 53.68 m, and 51.73 m, and the corresponding flow rate were 46,800, 51,800, 57,200 and 44,200 m 3 /s respectively. All of these crests were still considered to be ordinary flooding in Yangtze.
Having been affected by the great amount of water from the Yangtze River upper stream and the two major lakes and other branches, the trunk stream water level of Yangtze River middle and lower stream began to rise after mid-June. The water level at the hydrology stations at Shishou and Wuhu was the first to rise beyond the caution level.
The water levels of different river segments from Jianli to Liauhuatang and from Jiujiang to Datong have also risen beyond the caution levels gradually in different stages afterwards, and the important segments from Lianhuatang to Hankou had also reached the caution level.
The highest water level occurred at most of the main hydrology stations along the Yangtze River after mid-July, 1999. The peak water level of 44.74 m at the hydrology station of Shashi in July was the second highest record ever, which was 1.74 m higher than the caution water level (43.00 m), although lower than the historic record of the year of 1998 (45.22 m). The highest water level in July at the Jianli hydrology station was 38.30 m, which was 1.02 m higher than the pledged water level (37.28 m), and was only 0.01 m lower than the historical highest water level (38.31 m in 1998).
The highest water level in July at the Lianhuatang hydrology station was 35.54 m, which was 1.14 m higher than the pledged water level (34.40 m), and was the second highest water level, of actual record in 1998 (35.8 m) . The highest water level in July at Luoshuan hydrology station was 34.60 m, which was 0.59 m higher than the pledged water level (34.01 m), and it was the second highest water level of actual surveying record in 1998 (34.95 m).
The highest water level in July at the Hankou hydrology station was 28.89 m, which was 1.59 m higher than the caution water level and it was the third highest water level (29.73 m in 1954, and 29.43 m in 1998). The highest water level in July at the Jiujiang hydrology station was 22.43 m, which was 2.93 m higher than the caution water level (19.50 m) and it was the second highest water level recorded in 1998 (23.03 m). The highest water level in July at Datong hydrology station was 15.87 m, which was 1.37 m higher than the caution water level (14.50 m).
At present, the overall standard for preventing floods is still not very high. If there are some floods which are concentrated and are developed within a very short period, dangerous flood situations and disasters will be formed. These will bring great lost to the country and the people. If there is a comparatively simple and efficient method to discharge the floods, it will be beneficial to the country and the people and the people in the future generations inside.
SUMMARY OF THE PRESENT INVENTION
Owing to the more and more frequent human activities which brought about the lost of surface soil, diminishment of lakes and the change of climate, floods will became more and more serious. The present floods preventing measures cannot deal with some serious floods. The purpose of this invention is to supplement the insufficient flood control measures and to provide an easy to construct, user friendly method with a greater water discharge ability to combat floods.
This invention is a method to speed up the rate of floods flowing into the sea by utilizing the property of the tidal current through the following method. By constructing a Programmable Tidal Current Control Gate (PTCCG), the previous name of which is “Tide Sluice Gate”, was changed in order to avoid any confusion with “storm surge barrier” which has exactly the same in Chinese name, anywhere within the tidal current limit of an estuary (coast tangent or any narrow part at the estuary); the PTCCG should be built across the river theoretically.
Whenever there are dangers of floods, the PTCCG should be closed at high tide to stop the seawater from entering the inner river. At low tide, the PTCCG is re-opened and the floods water collected and withheld will be discharged into the sea. The PTCCG is normally open when not in use and is thus environmentally friendly.
The PTCCG can be built at the narrower part of the estuary. The PTCCG can be made up by different kinds of gates, for example, rolling gate, or multi-section flat sluice gate. The multi-section flat sluice gate will be used in the following examples.
In order to achieve the function of floods prevention, it is, unnecessary to cover the full span of the river mouth with PTCCG. It would be sufficient to build only 20%˜80% of the narrower part of the river in the case of Yangtze River. Even when there is a danger of serious flood, the PTCCG will only be used for about 7˜14 days. The number of days of using the PTCCG depends on the span of the PTCCG and the amount of rainfall.
The advantage of this invention is that, by utilizing the natural and readily available tidal current at the estuary to prevent flooding is a low running cost method, and with very great capacity to control floods and with high speed of discharge of flood water into the sea.
Take Yangtze River as an example to show the great advantage of this invention. The following is the quantitative analysis of the flood preventive effect of PTCCG. The flood control capability of the PTCCG can be determined by the volume of tidal current that is excluded from entering the river by the new PTCCG mechanism.
1. Method I: By the Volume of Tidal Current Excluded from Statistics
According to the relevant records, between 1958 and 1988, there were records of a total number of 62 tides (including spring, middle, neap tide and no floods tide). The total tidal current volume was 118.05 billion m 3 and each tide was 1.904 billions m 3 . Of those tides records, there were four tides, each had a tidal current volume 1.99 billions m 3 . It shows that the average tidal current was about 2 billions m 3 , including spring tide, neap tide, flood tide and no flood tides. (Note: If there is the latest tidal current information the impact of the greenhouse effect and the rise of sea-level on rivers floods can be reckoned.)
2. Method II: By circumscription and calculating the physical volume occupied by the tidal current at the estuary according to the data of factual average tide range.
If the PTCCG is established at Hengsha Island, the average tidal range is 2.67 m. Assuming at the time of the average tidal range, the water level increase at the tidal current limit—Jianyin to be 0 m, and we assume the water level increase is linearly proportional to the distance along the river. This is a rough circumscription and reckoning. There must be quite a big difference, because there are phase differences when the tide waves were transferred to each section and this has not been taken into account.
The width of the estuary at Nangang is 7 km, Qiyakou is 9 km, Xuliujing is 5 km, and Jiangyin is 2 km, while it is 180 km from Hengsha Island to Jiangyin. If we calculate the volume of the river segment by segment, the total volume of tidal current region which is affected by the PTCCG is around 2 billion cubic meters.
Inferred from both of the above reckoning and estimations, we can conclude that at each tide (average tidal range) at the mouth of Yangtze River, the river bed can withhold and discharge 2 billion m 3 more floods water by using this invention and this is equivalent to 44,000 m 3 /s.
These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following is the further description of how to carry out the invention with examples.
To construct the PTCCG at the estuary: The PTCCG can be set up at the front most edge of the estuary, i.e. on coast tangent, or down to the narrower part of the river mouth. Of course, much bigger Floods Receiving Lake will be created if the PTCCG is set up at the front most edge of the estuary. However, after constructing the PTCCG, when we compare the flood with the discharge capability, the scale of flooding would be relatively much smaller than before.
So if it is chosen that the PTCCG is to be built at coast tangent, it would only increase the cost and will not benefit much more when dealing with floods. That is the floods discharge ability will be too much if the PTCCG is set up at the coast tangent. That is “breaking a fly on the wheel”. It would be advisable to set up the PTCCG at the narrower part of the estuary, so as to reduce the construction cost, or at any other suitable place between the estuary and tidal current limit, for instance, taking into account of the requirement of transportation and the need of roads building.
By setting up PTCCG at the estuary, it can stop the tidal current (together with river water) from flowing backwards into the inner river. When a flood occurs at the middle stream of Yangtze River, we can close the PTCCG before high tide, and the tidal current cannot enter the inner part of the river.
The original space occupied by the sea water is emptied out and will be transformed into an enormous size empty “Floods Receiving Lake”, which can withhold and discharge a lot of water from the middle stream of the Yangtze.
When the tide ebbs, and since the water level in the Floods-Receiving Lake is higher than the sea level, tremendous amount of floods water will be discharged into the sea. This is just like an exchange station running and operating continuously without any stop, the same can be re-used every 12 hour and 25 minutes. This will resolve most of the over-flooding problems at low gradient plains and river delta areas. This is a more effective system to prevent flooding than most existing flood control systems.
The design requirement of the PTCCG will be relatively simple if the only function is used to stop the tidal current from entering the inner river. If there is no atrocious weather, then it is only necessary to build the PTCCG at a height which is enough to prevent the tidal current from entering the inner river at high tide.
In order to achieve this target, it is only necessary to get the hydrology record of the highest tide level and/or the highest runoff water level at the estuary, and build the PTCCG a little higher than the above two levels to stop the tidal current. In fact, the requirement to construct the PTCCG for stopping tidal current from entering into the inner river is not enough, because the PTCCG is set up at the river mouth area. It has to face with atrocious sea weather, especially at Yangtze River mouth and Rhine river mouth etc, where storm surge occurs very frequently.
So the factor of durability of PTCCG should not be ignored, therefore, the design standard should be much higher than that for stopping tidal current only. It should be designed and constructed in such a way that it can resist salt, wave and storm in the long run and can stand against atrocious stormy environment.
The choice of the PTCCG could be rolling gate (like the one in Thames River) or multi-section flat sluice gate (like the one in River Rhine). The following example assumes to use a multi-section flat sluice gate, each section of the PTCCG is about 20 meters wide. If the river mouth is 680 meters wide, then 34 PTCCG sections should be built. Since the total span of all the PTCCG is the summation of all the width of PTCCG sections built, the total number of PTCCG sections to be built when the necessary span of the PTCCG is decided.
Our target is to stop the tidal current at the location of PTCCG, the artificial tidal current limit, even when we encounters with the biggest tidal current. It is still unnecessary to build 100% full span of PTCCG at the narrower part of the river. The PTCCG is also unnecessary to conform to the coast tangent so as to get the biggest floods prevention capability.
After the set up of PTCCG, the water flow from the middle and lower stream of the Yangtze River will become relatively small because of the high discharge efficiency of the PTCCG. It is unnecessary to construct the PTCCG conforming to the coast tangent in order to solve the floods problems in the middle and lower stream of the Yangtze River.
As a result, the construction cost will become our main concern. Take the Yangtze River as an example. If we have decided to set up the PTCCG at the narrower part of the estuary, using the average tide range as the basis of reckoning, it can discharge the “50 billion cubic meters excess flood” by operating PTCCG for 13 days. The figure 50 billion cubic meters was the true record of excessive floods water in Middle and Lower Stream of the Yangtze River as announced by the water authority.
If we choose to build the PTCCG at the coast tangent, the same volume can be discharged by reducing the operating day to 3˜5 days. In fact, reducing 8 days is of minimal consequence during the floods seasons. Since we have more and more scientific rain forecast, we can operate the PTCCG in advance and to control and keep the water at a lower level in Wuhan and Hunan Province. Setting up the PTCCG at the coast tangent will increase the span of the PTCCG and the construction cost. In order to reduce the discharge time from 13 days to 5 days, if we need to use much more resources and money (in the order of 10 billion Chinese Yuan) to achieve this, then this is quite uneconomical and unnecessary.
Because the volume of the tidal current entering the estuary is directly proportional to the cross-sectional area of the upper layer of water at the river mouth (since the thickness of tidal current is more or less the same along the PTCCG, the volume of the tidal current is also directly proportional to the width of the river mouth), when the width of the river mouth is temporary and gradually reduced by closing some sections of the PTCCG, the volume of tidal current entering the river mouth is also reduced.
In order to evaluate the best and critical numbers of sections of the PTCCG to be built, it is only necessary to calculate what the percentage width of river mouth that should be blocked is, so as to achieve the target of keeping the tidal current to a standstill. Once we conclude that the width of the river bed to be reduced so that the tidal current cannot surpass the PTCCG, we can define this width to be the best (economically speaking) span of the PTCCG to control flood, (or we can call this “the best critical span”.
Best critical span=width at the narrower part of the river mouth−the width of the river mouth that the PTCCG is not required; or
Best critical span=the width at the narrow part of the river mouth−(the biggest rate of flow of runoff during the flood seasons/the rate of flow of tidal current per unit width). For example, during the floods seasons, the runoff flow rate was 10,000 m 3 /s, whereas the tidal current flow rate was 40,000 m 3 /s, and the width of the river is 2,000 m, then the unit capacity for the tidal current flow is 40,000/2000=20 m 3 /s/m.
Then the total portion of width that there is no demand to build PTCCG is equal to 10,000/20=500 m. Suppose the original width of the narrower part at the river mouth is 100 m, if we need to reduce the width temporary by 500 m, so that the rate of flow of runoff will be equal and opposite to the rate of flow of tidal current. Based on the above reckoning, we can conclude that the best critical span of the PTCCG is: 1100 m−500 m =600 m.
Assuming that the PTCCG is to be built at the coast tangent of the Yangtze River mouth, and that the average tidal difference of 2.67 m, the rate of tidal current entering the inner river is 266,300 m 3 /s. At spring tide is about 400,000 m 3 /s, and at neap tide is about 140,000 m 3 /s. The record of the highest runoff flow rate of Yangtze River was 93200 m 3 /s.
In order to keep the tidal current limit during the flood seasons to be at the position of PTCCG without surpassing the PTCCG, we shall use the PTCCG to trim down the width of river mouth and only leaving the width which can allow the capacity of 93,200 m 3 /s tidal current to enter the river, then at this critical moment, the momentum of the runoff and the momentum of the remaining portion of tidal current will be equal and opposite, and the tidal current will be kept standstill.
If we want to reduce the tidal current entering capacity from 400,000 m 3 /s to 93,200 m 3 /s, the mouth of the Yangtze River should be temporary reduced by: (400,000−93,200)/400,000, which is equal to 76.7%.
In other words, to achieve target of the tidal current to be standstill at the location of PTCCG, we can spare 23.3% of the coast tangent without setting up the PTCCG. Assuming that the PTCCG is set up at some narrower part of the Yangtze River mouth, as Yangtze River mouth is cornet shaped, the difference of width between the narrow part and the coast tangent of the river is very great, if we select a narrower part of a river mouth with its width of 40% of that at the coast tangent, then we only need to build 40%−23.3%=16.7% of the coast tangent width. This 16.7% is the best critical span.
The tide and tidal current has its own cycle and it is not the same every day. The flooding time of tide occupies only a small portion of the tide cycle and flood tide occupies only several days in a lunar month. Therefore, the chance to utilize the maximum number of sections of the PTCCGs only happens in several hours in several days in each lunar month.
Furthermore, during the days of flood tide, the quantity of tidal current entering into the river mouth increases gradually and slowly, and the period of biggest tidal current takes place only up to a few hours and it is only a small portion of the high tide cycle. Therefore the time taken to utilize all the PTCCGs would not be long. For example, the biggest tidal current in each tide only happens in 2.5 hours, which is ⅕ of each tidal period of 12 hours and 25 minutes.
Therefore, it would be uneconomical if we build too many sections of PTCCGs to improve this very short period of time by only a little. As the floods control capability of PTCCG is very great. Even if the PTCCG is built a litter shorter, with fewer sections, it will only increase the application duration of the PTCCG by a little. Nowadays, we have more and more advanced technology.
If we can obtain more exact rain forecast in the upper and middle stream of the river, then we can start to utilize the PTCCG one or two days ahead of the arrival of crest. It is not necessary to spend too much money on setting up a full range “perfect span” of PTCCG, which will be beyond the actual need.
In order to achieve some or incomplete floods control results, we only need to build several sections of PTCCG across the two banks of the river. However, if the numbers of PTCCG sections to be built are too small, for example, only three or four sections are built, we cannot ensure that the greater floods can be discharged within a short period of time when there is a really heavy rainstorm at the middle or upper stream of a river.
This effect is just like to have taken insufficient dosage of medicine when we are sick. If the numbers of PTCCG to be built is not enough, it ends up with the ability to combat weaker floods which happened once every 10 years, but not those severe floods, which can bring about disasters e.g. those happened once every 100 years or 1000 years.
In order to build PTCCG lesser than required, we may use the PTCCG in advance, but if we are enforced to use PTCCG too early or very often in advance, there are also some disadvantages. For example, when there are a lot of rainfall at the middle and upper stream in the earlier days of the rainy season, but suddenly the weather becomes dry, this will produce an extremely low water storage level and is often a waste of the fresh water resources, when we operate PTCCG too often in advance and discharge the floods too early.
The PTCCG must not be used too often since it has a big flood discharge capacity. The PTCCG can only be used for several times and then stopped during the floods seasons, otherwise, the river water will be over-discharged. If the rainfall becomes very small after the rainy days, it will create low water level even at the rear part of the same floods seasons, not benefiting the sailing of ships.
Take the Yangtze River as an example, the PTCCG can increase the volume of discharge by about 2 billions cubic meters per tide, or 3.8 billion cubic meters per day (because there is 1.93 tides in each Solar day), while the excessive flood during the big flooding in 1954 (which was once 100 years) is only 50 billion cubic meters, (according to the data from the Chinese water authority), then it is only necessary to use the PTCCG for 13 days to overcome the flood disaster. If we utilize the PTCCG for more than 13 days, the river and lake water level might begin to get low.
The Principle of Operation of PTCCG (The Creation of the “WHITE HOLE”:
The prime objective of constructing PTCCG is to stop tidal current from flowing into the inner river. Before the tidal current enters the watercourse of the inner river, we should start closing the PTCCG. The flow of the tidal current will be stopped by the PTCCG temporarily at the river mouth and cannot flow into the inner river. In other words, the tidal current limit has been temporary blocked up at the position of PTCCG, and the location of the PTCCG becomes the temporary tidal current limit at this particular moment.
When the PTCCG is built and operated at the Yangtze River mouth, an empty space is created within the estuary, let us call this Flood Receiving Lake, the Flood Receiving Lake has recurrent floods absorbing and discharge power. This special function can be repeated every 12 hours and 25 minutes. The tidal current is prohibited to enter into the estuary. The original salt wedge in the estuary brought about by the tidal current is emptied out and changed into a hollow space, which we can call it “White Hole”.
The said White Hole has a low elevation of about ±5 meters from the sea level, far below the floods level on the plain, so it is able to absorb the nearby flood continually as well as discharging the water from the White Hole into the sea at low tide. We call it White Hole so as to distinguish it from “Black Hole” in astronomy.
The Black Hole can only absorb things inwards and nothing can come out, whereas in the case of White Hole, it not only can absorb water into its body without a definite limitation, since the water can be discharged out into the sea. The White Hole has a big water absorbing power, its performance is just like the drinking action of the human being, one mouthful after the other. PTCCG can drink another gigantic mouth after 12 and half hours elapsed, until it's satisfied and close the throat.
By the reckoning with different methods, the floods preventive capability of White Hole Flood Receiving Lake is 2 billion cubic meters in average for each tide (12.4 hours), and 3.8 billion cubic meters for each solar day in the case of Yangtze River.
The huge magnitude and capability of flood control and the impulsion all originates from the potential energy difference of the tide and the kinetic energy of the tidal current. If we evaluate the energy withheld by the PTCCG in each and every tide, according to the potential energy difference of the volume of water kept in the Flood Receiving Lake, it is about 1.12×10 14 Joule (J).
This potential energy withheld is used to push the floods water into the sea. It is equivalent to the summation of the energy consumption by using 3500 sets of 375 KW hydraulic pumps (assume 100% efficiency) to pump the river water into the sea 24 hours a day.
Very big space between the river segment of the old and new tidal current limit of the river is no longer filled up by seawater and is left empty. The capacity of the empty space to absorb the flood water from upper stream becomes much greater than the natural situation. The White Hole is not just like the shape of the salt wedge in the estuary, but like a long floor carpet of several meters thick forming a very big and empty temporary lake, we can call it “White Hole Flood Receiving Lake.”
The river flowing into the area between the old and new tidal current limit is just like flowing into a lake. Whereas the physical behavior of a lake is totally different from that of the complex estuary, i.e. the natural flow pattern has been temporary and completely modified. The water level in the White Hole Flood Receiving Lake is higher than the sea at low tide, and the water thereof withheld will be discharged into the sea and another cycle will start again.
The PTCCG has the ability to prevent and control floods because it can change the complex hydrodynamic conditions of the estuary temporarily and completely. There are many factors affecting the hydrodynamic conditions at the estuary and the mutual relationship among them is very complex. Each of the said hydrodynamic condition is by itself changing all the time. These conditions are constantly, continuously and mutually affecting, re-grouping and re-adjusting with each other and producing different resultant combination effect in the estuary.
These complicated hydrodynamic factors include, the runoff which varies greatly between floods and no-flood seasons, tide of two cycles each day, spring and neap tides of two cycles each month, sand content which varies greatly in each year, numerous storm and storm surge, ceaseless waves, shape of the estuary, and the cross-sectional area of the river bed etc. and the resultant of the complicated combinations and effects produced by these conditions happening simultaneously. When studying the estuary problems, we should not only pay attention to the effect of each individual condition, but also the combining effects produced by several conditions happening at the same time.
Of these very complex “parameters”, there are two factors which can be modified by human beings (with engineering measures), that is the shape of estuary and the cross sectional area of river bed. Permanent change of shape of estuary is usually not advisable, but the PTCCG can change the cross-sectional area of the riverbed at any time temporarily as desired by mankind.
It provides a secured measure to control the hydrodynamic conditions in the inner estuary when necessary. It creates a great empty space to receive the flood in the watercourse itself. It conserves and provides the energy source for the increase of flow of flood, so it will become the best measure to control flood and the management of the estuary.
The PTCCG is a very flexible institution, which can be used to modify the width of the outlet of Yangtze River estuary temporarily, mainly at the high astronomical tide in order to keep the Yangtze estuary at the ideal cross-sectional area at all times and create the ideal effect at the estuary in order to combat flood. This is a strong and powerful, easy to operate, flexible, durable and effective institution to control floods.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. | This invention discloses a simple and convenient method of floods control and with great discharge capacity. This invention is a method of speeding up the river floods water discharge ability into the sea by means of the natural tidal range. This is done by the following technical proposals. To set up the PTCCG between the tidal current limit of the estuary and the coast tangent or narrower part of the estuary; the said PTCCG should be built across the river from the banks theoretically. When there is a danger of flood during the floods seasons, we can close the PTCCG and prevent the tidal current from entering into the inner river. When the tide ebbs, we can re-open the PTCCG and discharge the freshwater withheld into the sea. The PTCCG is normally open when it is not used. This invention is applicable to all tidal estuaries, which are affected by the astronomical tide range. It makes use of the natural tidal range to control floods in the upper stream of the river, which has a great floods control capacity, and accelerates the speed of floods discharging into the sea. |
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation, under 35 U.S.C. § 120, of copending international application PCT/EP2005/055986, filed Nov. 15, 2005, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German application DE 20 2004 018 084.7, filed Nov. 22, 2004; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an absorber for a pipe or sewer structure comprising at least one feed connection and at least one return connection and one or more absorber channels that connect a feed to a return. The invention also relates to a pipe or sewer structure comprising such an absorber.
Various heat exchanger installations have been disclosed by way of which heat contained in the wastewater can be recovered, for example to supply the heat recovered from the wastewater into a district heating network. German utility model DE 20 2004 005 768 U1 describes a component for channeling water which has a recess in its bottom region. The recess extends over the entire length of the component and serves to accommodate a plurality of juxtaposed square metal pipes intended to form a heat exchanger device (absorber). These metal pipes are arranged in the recess in a grout which, following insertion of the pipes, is poured into the gaps which remain in particular between the individual pipes. By virtue of the metal pipes held in the recess by means of the grout, the recess itself is eliminated again, with the result that the component, in particular when it is embodied as a pipe, does not have its cross-sectional area reduced by the absorber. The pipes inserted in the recess are interconnected at their ends by connecting pieces such that liquid which is fed in from a feed and used for conveying heat is channeled through the pipes and is carried off by a return. The feed and the return are conveniently situated in a manhole. The component known from this document serves to recover heat from the wastewater channeled through the component. The cooler liquid fed into the bottom region of the component via the feed is heated as it flows through the heat exchanger device by the warmer wastewater channeled over the absorber. The recovered heat is delivered via a heat pump connected to the return so that it can be used subsequently.
Finally, the component with its absorber described in this document is one in which, unlike the sewer pipe described in German published patent application DE 35 21 585 A1, the heat exchanger device is integrated subsequently into the pipe wall and not during the construction of the sewer pipe.
To achieve the best possible heat transfer from the wastewater to the pipes of the heat exchanger device, metal pipes are used in this already known heat exchanger device. Although these pipes have good thermal conductivity, the disadvantage with these pipes is that the individual pipes have to be welded together at their ends to form relatively long heat exchanger devices. Moreover, such pipes are not suited for use in existing sewer structures, in particular in those which do not have a recess in their bottom region. Existing sewer structures often have damage, edges or discontinuities which impede the installation of such a heat exchanger device, and such installation can only be achieved with considerable extra expenditure.
German patent DE 197 19 311 C2 describes a further heat exchanger device for installation in a sewer pipe. The installation of that prior art heat exchanger device with its absorber in an existing sewer pipe considerably reduces the free cross-sectional area in the bottom region of the pipe. Furthermore, such an installation unit which significantly increases the bottom region forms a step within the sewer, this again being undesirable. Finally, in that prior art heat exchanger device, too, the same disadvantages arise as described with respect to the above noted German utility model DE 20 2004 005 768 U1.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an absorber for recovering heat from water-carrying conduits or pipes, for example sewer pipes, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and also to propose a pipe or sewer structure suitable for recovering heat.
With the foregoing and other objects in view there is provided, in accordance with the invention, an absorber for a pipe or sewer structure, comprising:
at least one feed connection;
at least one return connection;
one or more absorber channels fluidically connected between the feed connection and the return connection. The absorber channels extend through an absorber channel mat forming a physical unit. The absorber channel mat is made of a material having flexible properties, at least while the absorber channel mat is being laid into the pipe or sewer structure.
This object is achieved according to the invention by a generic absorber mentioned in the introductory part in which the absorber channels of the absorber are combined in an absorber channel mat to form a physical unit, and the absorber channel mat is made of a material having flexible properties at least while it is being laid in the pipe or sewer structure. A pipe or sewer structure according to the invention comprises such an absorber, the absorber being arranged in the bottom of the structure and being held in this position by a tube which is drawn into the structure and lines the inner side of the structure.
In the absorber the individual absorber channels are combined to form a physical unit. This physical unit is configured as a flexible absorber channel mat, with, in principle, the flexible properties of the absorber channel mat needing initially to be present only while it is being laid in a pipe or sewer structure. By contrast, the flexible properties of the absorber channel mat are not required in principle for operation of the absorber. Therefore, the absorber channel mat can retain its flexible properties even after being installed in a pipe or sewer structure. It is equally possible for the flexible material properties of the absorber channel mat to disappear after it is laid, for example by a hardening process or the like. The flexible properties of such an absorber channel mat in which the individual absorber channels are combined to form a physical unit make it easy to mount the absorber channel mat. For example, it can be drawn into an existing pipe or sewer structure, thus making it possible in particular for it to be installed even in pipes or sewers having a smaller diameter. Owing to the flexible properties of the absorber channel mat, edge discontinuities or the like within an existing pipe or sewer structure can be readily bridged. As a result of these material properties, the absorber channel mat lies flat on the upper side of the bottom of the pipe or sewer structure. After being drawn in/laid within such a structure, the absorber channel mat bears snugly by its underside on the bottom of the structure, in particular without additional measures having to be taken in principle for this purpose. The fact that the absorber channel mat bears snugly has the advantage of then establishing heat transfer from the structure in its bottom region to the absorber channel mat, and in particular to the heat exchanger liquid conveyed in the absorber channels. Such heat transfer is desirable since it is thus also possible to recover heat from the ground near the surface via the absorber. To achieve better compensation for uneven areas in the bottom region of a pipe or sewer structure, provision is made according to one embodiment of the invention for the underside of the absorber channel mat to have not only flexible properties but also resilient properties. Uneven areas, small stones or the like thus press into the underside of the absorber mat and in this way avoid the formation of relatively large regions in which the absorber channel mat does not bear by its underside on the bottom of the structure.
In such an absorber mat, the at least one absorber channel advantageously has a meandering course between its feed and its return. Such an absorber mat can be formed either in one piece or from an assembly consisting of a plurality of individual pieces. In the latter case, a central piece can be provided for example in which individual absorber channel sections are arranged so as to extend parallel to one another. The central piece of such an absorber channel mat can be produced in an endless form and thus unrolled in situ from a roll when being drawn into a pipe or a sewer. Not only does this allow the formation of absorbers of variable length, but such a central piece also makes it possible in particular for long absorber runs to be formed. Two end pieces are used to connect the individual absorber channel sections of such a central piece, these end pieces advantageously being made of the same material as the central piece of the absorber channel mat. The end pieces are designed to interconnect absorber channel sections which extend adjacent to one another and to the longitudinal extent of such a central piece in order to provide a single absorber channel or else a plurality of parallel absorber channels having a meandering course. One of the end pieces of such an absorber mat additionally comprises both one or more feed connections and one or more return connections. The number of feed and return connections is governed by the number of absorber channels which are to be operated independently of one another. To line a pipe or sewer, it is also readily possible for a plurality of absorber channel mats to be arranged so as to extend next to one another. With the provision of a plurality of channels extending parallel to one another in such an absorber mat, according to another operating mode the flow through these channels can also take place with all the channels pointing in the same direction, in which case a feed connection is arranged at one end of such an absorber channel mat and a return connection is arranged at the other end. Such an arrangement of the feed and return connections will be used in particular if the absorber channel mat has only a single channel.
Such an absorber channel mat has only a relatively small height. Nevertheless, it is advantageous for such an absorber channel mat to be provided at its longitudinal and transverse edges with outwardly tapering lips as transition pieces for joining the surface facing into the interior of the pipe or sewer to the pipe or sewer wall.
According to a further embodiment, provision is made for the absorber channel mat to have a planar underside and a corrugation extending in the transverse direction to the wastewater flow direction. The absorber channel or its absorber channel sections is or are formed within the elevations of the corrugation. This measure serves the purpose of increasing that surface of the individual absorber channel sections which faces into the interior of the pipe or sewer structure.
The absorber can be produced from various materials as long as the above-described properties are present. For example, various plastics or else rubber mixtures are suitable for forming the absorber channel mat. Should such an absorber channel mat be composed of a plurality of pieces, the individual elements can be connected to one another by adhesive bonding, welding, vulcanizing or by a plug connection.
The above-described absorber or its absorber channel mat is especially suitable for equipping existing pipe and sewer structures, in particular if these are in need of repair anyway and are repaired by drawing in a hardening tube (inliner). When carrying out such a repair, it is readily possible for the absorber or its absorber channel mat to be drawn in at the same time as such an inliner is drawn in to line the inner wall of the structure. The inliner used for repairing the pipe or sewer hardens after it has been drawn in and thus ensures that the absorber is secured at its intended position in the bottom region of the structure. Moreover, the inliner virtually clamps the absorber channel mat between the outer side of the inliner and the inner side of the structure, and therefore this measure also ensures that the underside of the absorber channel mat bears snugly against the upper side of the bottom. Owing to the flexible properties of the inliner, the latter bears readily against the upper side of the absorber channel mat with full surface contact, even if the absorber channel mat is corrugated with respect to the inner side of the pipe or sewer structure in the above-described manner. This structuring of the absorber channel mat is thus reproduced through the repair tube, with the result that the desired increase in the absorber channel surface is preserved.
According to a further exemplary embodiment, the absorber channel mat described forms part of such an inliner intended for the repair of a pipe or sewer structure and, for example, is woven during its production into this inliner or else is subsequently laminated onto the inliner. This has the advantage that, when repairing the pipe or sewer structure, the absorber channel mat is introduced into the structure at the same time as the inliner is drawn in. If the absorber channel mat forms part of such a plastic inliner used for repairing the pipe or sewer structure, the walls forming the absorber channels, at least in terms of the properties which keep the channels open, can be assumed by the inliner itself. It should then be ensured that after the inliner has been drawn in and before it has hardened, the absorber channels are kept open until the tube has hardened, for example using compressed air or the action of liquid.
In the case of a protective sheet (preliner) being drawn in below such a repair tube (inliner), the absorber channel mat can also form part of this protective sheet inliner and be drawn in therewith into the pipe or sewer structure.
In the case that not only the absorber channel mat but also an inliner used for repairing the pipe or sewer structure, if appropriate together with a preliner, are to be introduced into the structure, the absorber channel mat will be arranged to suit the preferred heat recovery in the particular circumstances. If recovering heat from the surrounding ground is the main concern, the absorber channel mat will be arranged under the liner or liners and thus advantageously directly adjoining the inner side of the pipe or sewer structure to be repaired. If, by contrast, recovering heat from the wastewater is the main concern, it will be considered to bring the absorber channel mat as close as possible into the region of the wastewater. Irrespective of the two possible arrangements described above by way of example, it will be understood that heat exchange into the heat exchanger fluid carried in the absorber channels occurs in any event both from one side and from the other side.
According to a further embodiment of the invention, it is proposed that at least two absorber channel mats be arranged so as to lie one above the other, for example also in such a way that their absorber channels are arranged with an offset to one another. In such an embodiment, provision can be made for example for an inliner intended for repair to be arranged between the two absorber channel mats.
Even if the choice of the material used to form the absorber channel mat and, in addition, the possible use of a repair tube mean that the heat transfer from the wastewater to the heat exchanger medium, for example water, carried in the absorber channels has poorer values under certain circumstances than when metal pipes are used, the advantages afforded by this absorber predominate nevertheless. Such a drawback can be readily overcome by correspondingly increasing the length of the absorber, which, as described above, is again readily possible.
The above description of the absorber was given by way of an example in which heat from the ground and/or from the liquid flowing in the pipe or sewer structure is recovered via the absorber. It is also readily possible for the absorber to be operated in reverse, so that heat is released via this absorber into the ground and/or to the liquid flowing in the structure. Within such an embodiment, the absorber can form part of an air-conditioning device, for instance for a building. It is likewise possible for the absorber to be operated alternately in one or other of the above-described operating modes.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in absorber for a pipe construction or channel construction and pipe construction or channel construction provided with this absorber, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a schematic cross section taken through a sewer pipe extending in the ground, with an absorber according to a first embodiment of the invention installed in a bottom region of the pipe;
FIG. 2 is a schematic plan view of the absorber of FIG. 1 ;
FIG. 3 is a cross section of a further embodiment of an absorber channel mat according to the invention; and
FIG. 4 is a schematic plan view showing a further embodiment of an absorber for a pipe or sewer structure according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, in particular, to FIG. 1 thereof, there is illustrated a sewer pipe 1 laid in the ground 2 . The sewer pipe 1 comprises an absorber 3 which is arranged in the bottom region, or the floor, of the sewer pipe 1 . The absorber 3 , which may also be referred to as a heat exchanger, comprises a plurality of absorber channel sections 5 which are combined in an absorber channel mat 4 . The longitudinal-side ends of two adjacent absorber channel sections 5 are in each case alternately interconnected so that in each adjacent absorber channel section 5 the liquid introduced therein via a feed flows in the opposite direction. The absorber channel mat 4 is provided at its longitudinal and transverse sides with respective transition lips 6 in order to form a gradual transition from the inner surface of the sewer pipe 1 to the upper side of the absorber channel mat 4 , thereby avoiding the formation of steps. The absorber 3 and, in particular, its absorber channel mat 4 are made of a flexible material, for example a rubber mixture or the like.
The absorber 2 is shown in a schematic plan view ( FIGS. 2 and 4 ) and an inside view ( FIG. 3 ). The flow direction of the heat exchanger medium, for example water, is indicated therein by arrows. The absorber 3 comprises a feed 7 , or supply stub 7 , which is connected via a feed connection 8 of an end piece 9 . The end piece 9 interconnects adjacent absorber channel sections 5 . Furthermore, a return 11 is connected to the end piece 9 at its return connection 10 . In a manner which is not shown in more detail, the feed 7 and the return 11 are guided out of the ground 2 through a manhole connecting the sewer pipe 1 to the surface and are coupled to a heat pump. The absorber channel mat 4 is provided at its end situated opposite the end piece 9 with a further end piece 12 by means of which, in turn, adjacent absorber channel sections 5 can be interconnected, so that the absorber channel mat 4 , which, in the exemplary embodiment represented, is composed of the two end pieces 9 , 12 and a central piece 13 forming the absorber channel sections 5 , forms a single absorber channel which extends between the inlet 7 and the return 11 .
In the exemplary embodiment represented in FIG. 1 , the absorber 3 or its absorber mat 4 has been drawn into the sewer pipe 1 which forms part of an existing sewer pipe system. To secure the absorber channel mat 4 in the bottom region of the sewer pipe 1 , use is made of an inliner 14 which lines the inner side of the sewer pipe 1 and which is hardened after being drawn into the sewer pipe 1 . Techniques for drawing in and hardening such an inliner 14 are sufficiently well known. In the exemplary embodiment represented here, the inliner 14 also serves at the same time for the repair of the sewer pipe system with its sewer pipe 1 . Thus, not only is the sewer system repaired on its inner side by drawing in the inliner 14 , but the absorber 3 is also secured at the same time. Furthermore, the inliner 14 protects the absorber channel mat 4 from direct contact with the wastewater 15 carried in the sewer pipe 1 . When installing the flexible absorber 3 in a sewer pipe 1 in the manner described with respect to FIG. 1 , the absorber 3 does thus not necessarily need to have wastewater-resistant properties. These properties are possessed by the inliner 14 which separates the absorber channel mat 4 from the wastewater 15 .
The flexible properties of the absorber channel mat 4 , in which respect the underside of the absorber channel mat 4 is additionally resilient in the exemplary embodiment represented, cause the underside to bear snugly and with full-surface contact against the inner side of the sewer pipe 1 without additional binders having to be used. The absorber 3 can thus be used to absorb heat from the wastewater 15 and from the sewer pipe 1 . Although such an absorber 3 will generally be provided in the sewer pipes of a residential area, in which pipes the wastewater ought normally be warmer than the temperature of the surrounding ground 2 and of the sewer pipe 1 , the absorber 3 , by virtue of its virtually full-surface contact with the pipe 1 , can also be used on those sections of pipe which carry cooler wastewater so as then to absorb heat from the ground. Typically, sewer pipes are installed in the ground to a depth of 2-3 m, which means that ground heat can be recovered in this way particularly in the cooler winter months.
FIG. 3 illustrates a cross section through a further absorber channel mat 16 which has the same basic construction as the absorber channel mat 4 of FIG. 1 . Unlike the absorber channel mat 4 , the mat illustrated here is formed with an upwardly corrugated upper wall, that is, the individual absorber channel sections 17 are designed with a domed upper wall or a convex rounding, thereby increasing that surface of the absorber channel sections 17 which faces the wastewater.
FIG. 4 shows yet a further absorber channel mat 18 whose absorber channel sections 19 extend transversely to the longitudinal extent of the absorber channel mat 18 . The flow direction of the heat-exchanging fluid is depicted in this plan view, along a meandering course which, in this case extends chiefly transversely to the flow direction of the sewage. The meander of FIG. 2 extends chiefly in the direction of the sewage flow.
The absorber channel mats 4 , 16 , 18 described can be formed in one piece by an extrusion method or else in two pieces by two interconnected material layers. In the latter case, the sections which separate the absorber channel sections from one another form the connection points between the upper and lower material layer. If appropriate, use can be made of webs to increase the spacing between the upper material layer and the lower material layer or to provide the absorber channel mat with a smooth upper side and a smooth lower side. | An absorber for a pipe or sewer structure has at least one feed connection and at least one return connection. One or more absorber channels connect a feed to a return stub. The absorber channels of the absorber are combined in an absorber channel mat to form a physical unit, and the absorber channel mat is made of a material having flexible properties, at least while it is being laid in the pipe or sewer structure. |
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BACKGROUND OF THE INVENTION
[0001] In the downhole hydrocarbon recovery industry elastomeric seals are used to seal annular areas between concentric tubulars. To prevent axial extrusion of the elastomeric seals at high temperatures and high pressures, backups are employed. Backups are radially expanded to fill the annular area during deployment and are radially retracted during tripping thereof. Although a typical backup can adequately prevent a seal from extruding thereby, each backup can only backup one end of one seal, thereby requiring two backups per seal. With each backup having a separate actuation, two actuations are needed to back up the two ends of a single seal. The industry would be receptive of systems that permit a reduction in the number of actuations required to backup multiple seals.
BRIEF DESCRIPTION OF THE INVENTION
[0002] Disclosed herein is a downhole backup system. The system includes, a tubular positionable within a downhole structure such that an annular space exists between the tubular and the downhole structure, and a plurality of wedges that are radially movably positioned within the annular space, each of two opposing ends of the plurality of wedges are configured to completely cover the annular space at all possible radial positions of the plurality of wedges.
[0003] Further disclosed herein is a method of backing up seals at a downhole tool. The method includes, moving a plurality of wedges radially, and covering perimetrical gaps between adjacent wedges on both longitudinal ends with wings disposed at the plurality of wedges.
[0004] Further disclosed herein is a method of occluding a downhole annular space. The method includes, radially moving a plurality of wedges positioned in the downhole annular space, and occluding the downhole annular space at both opposing ends of the plurality of wedges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0006] FIG. 1 depicts a perspective view of a downhole dual backup 10 disclosed herein;
[0007] FIG. 2 depicts a cross sectional view of the downhole dual backup of FIG. 1 ; and
[0008] FIG. 3 depicts a perspective view of a wedge of the downhole dual backup of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0009] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0010] Referring to FIGS. 1-3 , the downhole dual backup 10 includes, a plurality of wedges 14 , positioned perimetrically adjacent to one another, between a pair of ramps 18 . One or more biasing member(s) 22 , disclosed herein as tension springs (three being illustrated), surround the wedges 14 and bias the wedges 14 radially inwardly. Each wedge 14 has one wing 26 , 28 on each end that extends perimetrically beyond edges 30 , 31 of the wedges 14 , respectively. The wing 26 on a first end 32 extends in a direction opposite to the direction of the wing 28 on a second end 36 , although designs having the wings 26 , 28 extending in the same direction are possible. Each wedge 14 also has a surface 40 on the first end 32 and a surface 44 on the second end 36 . The wedges 14 are configured such that the wing 26 on the first end 32 of one wedge 14 slidably engages with the surface 40 on the first end 32 of an adjacent wedge 14 . Similarly, the wing 28 on the second end 36 of one wedge 14 slidably engages with the surface 44 on the second end 36 of an adjacent wedge 14 .
[0011] The foregoing allows the wedges 14 to provide two continuous perimetrical supports 50 , 54 regardless of a specific radial position the wedges 14 . As such, elastomeric members 58 , shown herein as seals (not shown in FIG. 2 ), are prevented from extruding through annular openings between an outer dimension 62 of the ramps 18 and an inner surface of a downhole structure, such as a liner, casing or open hole (not shown), for example, within which the backup 10 is positioned. These two continuous perimetrical supports 50 , 54 are best seen in FIG. 2 at radial dimensions greater than the outer dimension 62 . Since the dual backup 10 has the two continuous perimetrical supports 50 , 54 , two ends 64 , 65 , of two different seals 58 , can be backed up with just one of the dual backups 10 . A surface 66 , on the wing 26 , creates a portion of the first perimetrical support 50 and the surface 40 forms another portion of the first perimetrical support 50 . As such, the perimetrical support 50 is stepped by a thickness 70 of the wing 26 as viewed while proceeding around a perimeter thereof. The wing 26 provides a portion of the perimetrical support 50 that would be unsupported by perimetrical clearance between the edges 30 and 31 if the wing 26 were not present. Similarly, a surface 44 on the wing 28 creates a portion of the second perimetrical support 54 and the surface 44 forms another portion of the second perimetrical support 54 . The wings 26 , 28 extend sufficiently to overlap with the surface 40 , 44 at all radial positions of the wings 26 , 28 , the radial movement of which will be described below.
[0012] Axial movement of the ramps 18 causes radial movement of the wedges 14 . As the ramps 18 move toward one another by a linear actuator (not shown), for example, angled surfaces 78 and 82 , of the ramps 18 , engage with angled surfaces 86 , 88 of the wedges 14 , respectively. This engagement causes the wedges 14 to simultaneously move radially outwardly causing the springs 22 to lengthen in the process. The lengthening of the springs 22 increases the radial inward bias the springs 22 provide to the wedges 14 . Alternately, axial movement of the ramps 18 away from one another allows the wedges 14 to move radially inwardly under the biasing load of the springs 22 .
[0013] Alignment features 92 in the ramps 18 , shown herein as slots (although protrusions or other details could be employed), engage with complementary features 96 in the wedges 14 , shown herein as tabs, to maintain substantially equal angular spacing between the wedges 14 as the wedges 14 move radially. This assures that the perimetrical distance between adjacent wedges 14 remains uniform and the wings 26 , 28 cover the clearances between edges 30 and 31 at all radial positions of the wedges 14 .
[0014] By assuring that the wings 26 , 28 overlap with the surfaces 40 , 44 the full perimetrical supports 50 , 54 also form barriers that restrict the ingress of contamination to the backup 10 that could adversely affect the radial actuation of the wedges 14 . The elastomeric members 58 , by being on both axial ends of the dual backup 10 , further protect the backup 10 from contamination. This prevention of ingress of contamination coupled with the fact that there is no plastic deformation of the components during actuation of the dual backup 10 the dual backup 10 is capable of an indefinite number of cycles without degradation. Additionally, the dual back up is fully reusable.
[0015] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | A downhole backup system including, a tubular positionable within a downhole structure such that an annular space exists between the tubular and the downhole structure, and a plurality of wedges that are radially movably positioned within the annular space, each of two opposing ends of the plurality of wedges are configured to completely cover the annular space at all possible radial positions of the plurality of wedges. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Benefit of U.S. Provisional Applications for Patent Ser. No. 60/700,723, filed on Jul. 20, 2005, and Ser. No. 60/733,171, filed on Nov. 4, 2005, is hereby claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to a wall building construction unit and methods and is more particularly concerned with a prefabricated insulated and stackable element.
BACKGROUND OF THE INVENTION
[0003] It is well known in the art to build wooden frameworks for housing walls. An insulating core is then usually inserted in-between the studs and lintels or headers and closed with facing panels. This standard operation can be time consuming and have considerable effects in areas where the residential building period is constrained to a few months of the year due to for example a harsh winter climate.
[0004] Numerous construction elements have been proposed for wall construction such as in the following documents:
U.S. Pat. No. 2,902,733 granted to Justus on Sep. 8, 1959 for a “Corner Construction for Sawed Timber Walls”; U.S. Pat. No. 3,552,079 granted to Mortensen on Jan. 5, 1971 for a “Laminated Tongue and Groove Building Element”; U.S. Pat. No. 3,742,665 granted to Henry et al. on Jul. 3, 1973 for a “Modular Building Construction”; U.S. Pat. No. 4,344,263 granted to Farmont on Aug. 17, 1982 for a Building Log with High Thermal Insulation Characteristics”; U.S. Pat. No. 4,503,648 granted to Mahaffey on Mar. 12, 1985 for a “Lightweight Composite Building Module”; U.S. Pat. No. 4,614,071 granted to Sams et al. on Sep. 30, 1986 for “Building Blocks”; U.S. Pat. No. 4,937,122 granted to Talbert on Jun. 26, 1990 for an “Insulated Construction Element”; and U.S. Pat. No. 6,000,177 granted to Davidson on Dec. 14, 1999 for a “Building Structure Having the Appearance of a Log Structure”.
[0013] All the above lack either a provision for an insulated section in the stacking panel; a prefabricated insulated element; or passageways for a conventional approved wooden stud, approved and even required by most territorial or state building codes, forming a self-supporting wall structure, especially for external walls (thereby putting the load-bearing constraints on the stacking wall sections which is not regulated or preferred in building construction).
[0014] Accordingly, there is a need for an improved log, member or unit for wall construction with a simple configuration.
SUMMARY OF THE INVENTION
[0015] It is therefore a general object of the present invention to provide an improved unit for wall construction.
[0016] An advantage of the present invention is that the unit for wall construction is insulated and can be easily mounted on a stud structure which provides the structural support approved for load-bearings under construction codes.
[0017] Another advantage of the present invention is that the unit for wall construction is prefabricated at another location than the wall construction site.
[0018] A further advantage of the present invention is that the units for wall construction being relatively lightweight, can be quickly stacked on one another.
[0019] Yet another advantage of the present invention is that the unit for wall construction enables fast construction of rigid insulated walls which can eventually be disassembled and reassembled at another location.
[0020] Still another advantage of the present invention is that the unit for wall construction provides for sidewalls which naturally oppose warping when each of said sidewalls is made of multiple wood members.
[0021] Another advantage of the present invention is that the unit for wall construction includes stud longitudinal sections extending into through openings and secured to the unit, the stud longitudinal sections being used to support the structural transversal, typically vertical, loads transmitted through the wall structure.
[0022] A further advantage of the present invention is that the unit for wall construction has wall studs extending there through that are spaced from the side wooden planks for increased insulation between the two side planks.
[0023] According to an aspect of the present invention, there is provided a stackable unit for wall construction for cooperation with wall stud members forming a self-supporting wall structure, the unit comprising: first and second opposed elongate side wooden planks secured to one another with an insulating layer bonded thereto, the insulating layer having a plurality of through openings spaced from one another and extending transversely therethrough for receiving a longitudinal section of respective said stud member.
[0024] In one embodiment, respective said stud longitudinal section is permanently secured to the unit when inserted into corresponding said through opening, each said stud longitudinal section being adapted to structurally connect to at least one corresponding said stud longitudinal section of an adjacent said unit via a securing member for forming the self-supporting wall structure and having structural loads transmitted therethrough.
[0025] Typically, each said stud longitudinal section is adapted to be in abutting engagement with and securable to at least one corresponding said stud longitudinal section of an adjacent said unit.
[0026] Conveniently, each said stud longitudinal section has a through hole extending longitudinally therealong for slidably receiving the securing member therethrough for connection with said at least one corresponding said stud longitudinal section of an adjacent said unit.
[0027] Conveniently, each said securing member forces corresponding said stud longitudinal section to be in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.
[0028] Conveniently, the securing member is a screw-nut fastener for clamping corresponding said stud longitudinal section in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit. Conveniently, each said securing member is a screw screwably extending through corresponding said stud longitudinal section and screwing into said at least one corresponding said stud longitudinal section of an adjacent said unit to be in secured abutting engagement therewith.
[0029] Alternatively, each said stud longitudinal section has a protrusion member extending longitudinally outwardly from a first end thereof and a cavity member extending longitudinally inwardly into an opposed second end thereof, said protrusion member being adapted to engage corresponding said cavity member of a stud longitudinal section of a first adjacent said unit, and said cavity member being adapted to receive corresponding said protrusion member of a stud longitudinal section of a second adjacent said unit. Typically, the first and second side planks being adapted to stack over a subjacent unit.
[0030] According to another aspect of the present invention there is provided a method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of: mounting a first of said units on a sole plate and securing said stud longitudinal section thereof onto the sole plate using securing members and bonding therebetween; and assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween.
[0031] Alternatively, the method could comprise the steps of: assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween; mounting the units on a sole plate; and securing the units together and to the sole plate using securing members to longitudinally clamp registered said stud longitudinal sections to each adjacent ones and to the sole plate.
[0032] In one embodiment, the through openings slidably receive respective said stud longitudinal section therethrough.
[0033] Each wooden plank comprises a plurality of individual planks and such individual planks may conveniently be formed with a tongue and groove interlocking arrangement along respective longitudinal edges thereof.
[0034] Moreover, each wooden plank may advantageously be provided with a recess on the top and the bottom thereof for accommodating other building elements such as a sill or sole plate at the bottom or a lintel or top plate at the top.
[0035] Each wooden plank is provided at its ends with a recess for receiving part of a wall stud, typically half the width of the stud whereby wooden planks sitting end to end can accommodate and embrace the complete stud to its full dimension.
[0036] The stackable unit of the present invention may advantageously be provided with a plurality of planks in the form of logs and successive planks are disposed in such manner as to ensure that the heartwood in each is offset from the heartwood of an adjacent plank thereby to reduce the risk of warping or twisting with age.
[0037] According to another aspect of the present invention there is provided a method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of erecting a wood frame including vertical studs upstanding from a sill or sole plate, prefabricating stackable units for wall construction of the kind defined by the first aspect of the invention, feeding such units over the studs thereby to accommodate the studs within the through openings formed in the units, and bonding adjacent units together to produce a unitary wall structure around the studs.
[0038] In an alternative method the prefabricated stackable units for wall construction are assembled one on top of another with suitable bonding therebetween and mounted on a sill or sole plate, and vertical studs are then inserted into the openings and affixed.
[0039] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, wherein:
[0041] FIG. 1 is a top perspective view of an embodiment of a unit for wall construction in accordance with the present invention showing units in the process of being stacked on a stud structure to form a wall construction;
[0042] FIG. 2 is an enlarged perspective view of one embodiment of FIG. 1 without studs;
[0043] FIG. 2 a is a view similar to FIG. 2 , showing another embodiment of the unit with structural stud longitudinal sections permanently secured thereto;
[0044] FIG. 2 b is a view similar to FIG. 2 a , showing another embodiment with stud sections having through hole extending therethrough;
[0045] FIG. 3 is a left section view of the embodiment taken along line 3 - 3 of FIG. 2 ; and
[0046] FIG. 3 a is a view similar to FIG. 3 , showing two units of the embodiment of FIG. 2 a secured to each other via screws;
[0047] FIG. 3 b is a view similar to FIG. 3 a , partially broken, showing a plurality units of the embodiment of FIG. 2 b secured to each other via a screw-nut fastener;
[0048] FIG. 4 is a simplified top view of the embodiment of FIG. 1 showing partially two units without studs; and
[0049] FIG. 4 a is a view similar to FIG. 4 , showing the insulating core spacing the stud from the wooden sides.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.
[0051] Referring to FIG. 1 , there is shown an embodiment of a wall construction unit 10 in accordance with the present invention. The preferably rectangular and generally longitudinal unit 10 comprises mainly a pair of wooden planks, typically engineered wooden planks (EWP), generally flat timber, assembled side planks 20 , 22 or the like sandwiching a heat insulating core 50 or layer made of urethane, polyurethane, foamable plastic polymer or the like. The height H of each wall construction unit 10 is typically of approximately twelve (12) inches or one (1) foot, whilst the length is generally of a multiple of sixteen (16) or twenty-four (24) inches, or typically of up to approximately height (8) or twelve (12) feet. The width of each assembled plank 20 , 22 is of approximately one (1) inch whilst the width W of the insulating core 50 is of about 3.5 inches to be used conveniently with notional two-by-four (2×4) studs 14 as it will be clearly explained hereinafter. Alternatively, the width W of the insulating core could be of 5.5 inches to be used conveniently with notional two-by-six (2×6) studs.
[0052] In territories such as Canada and most States of the United States, construction building codes require a (wooden) wall frame structure to respect certain standards for load-bearing requirements. Notional two-by-four studs 14 can be used with respect to these above-mentioned standards with certain criteria. One of those criteria is the generally horizontal spacing S between the two-by-four or vertical structural studs 14 . In FIG. 1 , the spacing S is understood to respect those construction building codes and are generally of, for example, twelve (12) or sixteen (16) inches.
[0053] As shown in FIGS. 2 and/or 3 , each of the EWP or assembled side plank 20 , 22 is preferably manufactured by a series of wooden planks 24 . Generally vertically, one or a series of intermediate upper grooves 26 are carved on the upper part of each wooden plank 24 to fit or nest with one or a series of intermediate lower tongues 28 carved on the lower part of also each wooden plank 24 , except for the ends of the wooden planks 24 forming the ends of the assembled plank 20 , 22 . Furthermore, each successive wooden plank 24 typically provides for a different grain orientation as indicated by the numeral 30 . As one skilled in the art will understand, any piece of cut wood works over time, or, expressed differently, grain orientation affects the straightness or alignment of the wooden plank 24 , and thereby of the assembled planks 20 , 22 over time. A spiral distortion along the grain creates warping or twisting with ageing of the wood, and this towards the heartwood, represented by the numeral 32 . The heartwood 32 of each consecutive wooden plank 24 , or the position on the wooden plank 24 where the heartwood would be, is therefore preferably positioned alternatively on the left and then on the right from an approximate vertical reference or axial line L (shown in FIG. 3 ). The assembled plank 20 , 22 is thereby prevented from a strong natural warping tendency towards either side.
[0054] Generally vertically, an upper groove 34 is carved on the upper end of the assembled plank 20 , 22 to fit or nest with a lower tongue 36 carved on the lower end of another of the same assembled plank 20 , 22 . Also generally vertically, the amount of insulating core 50 in each unit 10 is such that if two units 10 are positioned one above another, or stacked, there is infinitesimal spacing (not shown) between the two insulating core 50 sections, except for those destined to be lowermost and uppermost insulating core sections 50 of the wall to be constructed. Understandingly, such design of the height H of the insulating core 50 offers the wall to be constructed a thermal insulation across its entire vertical height. As shown in FIG. 1 for a lowermost unit 10 example, the numeral 52 represents a longitudinal void or recess of insulating material adjacent the insulating core 50 for the section of the lowermost (or uppermost) wall construction unit 10 destined to be mounted adjacent a bottom plate 16 (or a top plate, header or lintel not shown), as will be explained further below.
[0055] In the longitudinal direction and as shown in the FIGS. 1 and 2 and more specifically in FIG. 4 , at each longitudinal end of the unit 10 , a recess 54 is left between the insulating core 50 and the adjacent assembled planks 20 , 22 . The thickness T of the recess 54 is preferably of about half the thickness 2T of the generally vertical component used for structural load-bearing walls, i.e. generally two-by-four studs 14 , or three-quarter of an inch (0.75 inch). A void 56 or through opening also of thickness 2T is made in the unit 10 preferably at each equal interval of spacing S. The width W of the void 56 is preferably the same as the width of the insulating core 50 . The studs 14 are preferably insulated studs 14 so as to offer thermal insulation across the entire length of the wall to be constructed. Alternatively and in the event wherein the studs 14 to be used are not insulated, the insulating core 50 of the unit 10 could have a larger width (as shown in FIG. 4 a ) than the width W of the void 56 with two opposed insulating bands 51 spacing the studs 14 from the corresponding plank 20 , 22 , each insulating band being adjacent the void 56 and one of the assembled planks 20 or 22 so as also to offer thermal insulation across the entire length (and height) of the wall to be constructed.
[0056] The manufacturing operation of the unit 10 is generally and advantageously performed at another location than where the wall is to be constructed. Assembling the wooden planks 24 to form the assembled plank 20 , 22 may leave infinitely small openings (not shown) between said wooden planks 24 . The insulating material used for the insulating core 50 has such properties that it infiltrates such openings if they are present to ensure an airtight unit 10 . In the event wherein some insulating material exits on the exterior surface of the assembled plank 20 , 22 , shaving or cleaning said insulating material is performed easily. Advantageously, the outer grooves 38 and/or exterior finishing of the assembled planks 20 , 22 of the wall construction unit 10 are generally machined if desired during the same or in a subsequent manufacturing step. Preferably, a series of units 10 is brought to the wall construction site once each unit 10 has been completely assembled.
[0057] Generally, the structural load-bearing studs 14 for wall construction are mounted vertically on the generally horizontal bottom plate 16 . A joining set retarding and expanding epoxy substance, glue, adhesive, resin, foam or the like (not shown) is layered on the upper part of the bottom or sole plate 16 . The first wall construction unit 10 comprising the lowermost void 52 is positioned above the structural studs 14 with the voids 56 and recesses 54 vertically aligned with the studs 14 . The unit 10 is then lowered down towards the bottom plate 16 as per the general direction indicated by arrows A shown in FIG. 1 . A coating of epoxy substance is then layered on the upper part of the installed unit 10 and another unit 10 is positioned above the structural studs 14 with again the voids 56 and recesses 54 vertically aligned with the studs 14 , and then again the uninstalled unit 10 is lowered down for stacking on and above the initially installed unit 10 , and so on.
[0058] Once the wall is assembled as previously described, the set retarding and expanding epoxy has generally the effect of completely filling and sealing the voids and minimal openings (not shown) between the stacked units 10 , and between the unit 10 and the bottom plate 16 or top plate, header or lintel. It may be necessary to shave or clean the dried epoxy that would be apparent from the exterior of the wall. An appropriate epoxy retarding time is approximately between 10 and 30 minutes. Obviously, doors and windows (not shown) are usually present in this type of construction. Since said doors and windows are usually positioned at standard spacing intervals, to follow the appropriate spacing for the structural studs 14 , the assembly of the units 10 is not adversely affected apart from requiring an appropriate shortening or cutting in some instances, which is standard in the construction industry and not adversely time-consuming. Finally, this example is presented with the structural studs 14 present before the units 10 are stacked one onto the other, but the operations could be reversed, with the studs inserted once the units are positioned stacked onto one another, without departing from the scope of the present invention.
[0059] As shown in FIG. 2 a , in another embodiment of the present invention, each unit 10 ′ has its voids 56 ′ filled with stud longitudinal sections 14 ′ permanently secured to the unit 10 ′ via bonding or the like when inserted thereinto. Each stud longitudinal section 14 ′ is adapted to structurally connect to at least one stud longitudinal section 14 ′ of an adjacent unit 10 ′ via a securing member 60 , typically a screw 60 a (see FIG. 3 a ) that screwably extends through the stud section 14 ′ and is partially screwable into the stud section 14 ′ of a subjacent unit 10 ′, to form the self-supporting wall structure and have transversal structural loads, typically vertical, transmitted therethrough. Typically, each stud section 14 ′ is in abutting engagement with the subjacent stud section 14 ′ or the load support. With this type of securing member 60 a , the lower unit 10 ′ is first secured to the sole plate 16 and then subsequent units 10 ′ are stacked over and secured to the subjacent one, with all the stud sections 14 ′ forming the structural load path of the wall structure.
[0060] Alternatively, as shown in FIGS. 2 b and 3 b , each stud section 14 ′ has a through hole 62 extending longitudinally therealong for slidably receiving a screw-nut fastener 60 b or the like therethrough for connection with the other stud section 14 ′ in register therewith.
[0061] The screw-nut fastener 60 b clamps all the corresponding stud sections in abutting engagement with each other and to the subjacent sole plate 16 or the like and typically a corresponding top plate (not shown). The screw-nut fastener 60 b typically includes an elongate rod 64 having a threaded free end that screwably receives a nut 66 and washer 68 . The head 70 of the rod 64 , or a hidden nut (not shown), is typically locked to the lower plate 16 (see FIG. 3 b ).
[0062] With this securing member 60 b , all units 10 ′ are assembled over each other before they are secured to each other ant to the lower plate 16 and typically the upper plate (not shown) with all stud sections 14 ′ abutting adjacent ones to form the structural load path of the wall structure.
[0063] As schematically shown in dotted lines in FIG. 3 b , each stud section 14 ′ could have a protrusion member 80 , such as a tongue or the like, extending longitudinally outwardly from a first end thereof and a cavity member 82 , such as a groove or the like, extending longitudinally inwardly into an opposed second end thereof. The protrusion member 80 is adapted to engage a corresponding cavity member 82 of an adjacent stud section 14 ′ as an additional securing means as well as a longitudinal guiding alignment means between two adjacent units 10 ′ when being assembled to one another.
[0064] Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. | A stackable insulated unit for wall construction for cooperation with conventional wall studs forming a self-supporting wall structure consists of two side wooden planks spaced apart and provided therebetween with an insulating layer which has at least two transverse through openings for reception of respective wall stud sections, either slidably or permanently secured thereto. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The invention pertains to door locks, or latches primarily for light weight doors and especially for screen doors of the sliding type that slide toward a jamb, or into a pocket in a side jamb.
2. Description Of The Prior Art
Heretofore, the available devices have been quite simple in their adaptation to this general type of lock application and have included a basic hook type of fastening which was manually engageable with a cooperating eye member.
Relatively sliding window members have been secured by means of a fixed lug on one member and a rotatable wedging member on the other window member which were adapted to be interengaged in the closed position of the windows to fix them against relative movement.
Similar devices have been provided to lock the companion doors of a pair of sliding doors where such doors operate in parallel planes.
Sliding door locks have included pivoted latches to engage a cooperating slot, or an associated bracket.
Rotary latches have been provided in combination with door handles as an assembly including a latch hook.
Other latch hook arrangements have included pivoted latch members projecting through the edge of a door to engage a slot, or bracket, in an opposing part to lock a door, with an operating handle accessible from a side face of the door to release the latch from the slot.
Another type of sliding door latching arrangement for doors operating in trackways included a vertically movable latch plate in one door edge adapted to engage and interlock with a fixed keeper on an adjoining door, or on a framing member and having an outside handle to lift the latch plate.
The following patents disclose latching, or locking mechanisms like those described, U.S. Pat. Nos. 3,645,573; 3,785,684; 4,160,560; 4,068,874; 3,065,985; 3,213,652. None of these prior patents, however, suggest any such latching arrangement as the present latch mechanism which has for its primary objective to provide a rotary latch element of molded plastic adapted to be mounted universally for right, or left, installations and disposed to cam a door against a mounting member, and provided with multiple flats on the rotary member to provide a plurality of locking positions.
SUMMARY OF THE INVENTION
The latching mechanism of this invention provides a rotary latching member molded from a plastic material such as a polycarbonate and a companion door pull member also molded from a similar plastic material.
The latching member is mounted by means of a single screw, or the like, to provide a pivot point about which the latch member rotates and which is universally adaptable to either right hand or left hand operation.
A plug member inserted into an opening in the face of the jamb acts to limit the degree of movement of the latching member.
The latch member functions as a camming device and engages through a slot in the door pull to contact directly with the door frame to cam the door outwardly against a retaining member such as a channel member on a door jamb.
The rotary camming member has a plurality of flat faces on its camming surface whereby the door could be cammed outwardly by steps and provide a number of locking positions which enable the door to be "clicked" into final position.
When the rotary cam device is engaged through the slot in the door pull, it is positively locked against relative movement and the several locking positions necessitate manual rotation of the cam to release the door while, by the same token, the door cannot be jarred, or pushed inward from the outside to rotate the cam and cause it to disengage from any of the positive locked positions.
DESCRIPTION OF THE DRAWINGS
The rotary latching mechanism having the features described is illustrated in the accompanying drawings, wherein
FIG. 1 is a general elevational view of a sliding door disposed in sliding relationship to a jamb and equipped with the rotary cam latch of this invention on the jamb and with a pull member on the door;
FIG. 2 is an elevational view of the rotary camming latch member as applied on the jamb member of a door frame, with the door pull member shown applied on a sliding door which is movable toward and away from the jamb, with the camming member disposed in engagement with the door within the slot in the pull member;
FIG. 3 is a detail view to the same scale as FIG. 2, showing the camming latch member applied on the jamb by means of a single pivot screw about which the cam rotates and with the door pull member engaged within its slot by the cam member;
FIG. 4 is a horizontal sectional view taken on the line 4--4 of FIG. 3 showing the relationship of the sliding door with the jamb and the door pull and camming latch operatively engaged and also illustrating an inside main door with the cam between the two doors;
FIGS. 5 and 6 are detail sectional views to larger scale taken respectively on the lines 5--5 and 6--6 of FIG. 2 showing the structure of the cam latch member;
FIG. 7 is a rear elevational view of the cam latch member; and
FIG. 8 is a front face view of the cam latch member mounted on the door jamb and lockingly engaged with a door and having portions of the latch member broken away to reveal the plug member mounted in the jamb to limit rotation of the cam.
DESCRIPTION OF PREFERRED EMBODIMENT
In the drawings a door 10 and a jamb 11 is shown in FIG. 1 with the door 10 equipped with a door pull 12 and the door jamb 11 having a rotary cam type latching element 13 pivotally mounted on the face of the jamb adjacent to the door 10. The door operates in upper and lower tracks 14 and 15 which are disposed in side-by-side relationship so that the door is disposed in overlapping relationship to the jamb when in the fully closed position. The door may be glass panelled, or as shown here, may comprise a screen door, which while fairly light weight, is of rigid construction. The door pull 12 is provided with a vertically disposed slot 16 and in the closed position of the door the cam latching member 13 engages in this slot, as best shown in FIGS. 2 and 8 and contacts the face of the door frame 17 to press the door outwardly under the influence of the camming action of the latch 13.
As best shown in FIGS. 1 and 8, the cam latch member 13 is pivotally mounted in the face 23 of the jamb 11 so that it is disposed in an operating plane at right angles to the slot 16 in the door pull. The pivotal mounting of the cam is obtained by means of a single screw 19 as best indicated in FIG. 3 enabling a controlled light frictional contact of the cam against the face 23 of the jamb 11. The cam 13 is provided with a recess 21 into which the head of the screw 19 is received so that the head of the screw does not project beyond the frontal surface of the cam member but is disposed within the recess at a depth sufficient to prevent contact by anyone manipulating the cam.
On the side of the cam disposed toward the door jamb on which it is mounted, the cam is provided with a projecting flange 22 that is completely circular but is not centered on the pivot point of the mounting screw 19 so that it moves eccentrically when the cam 13 is rotated, as does the entire cam, inasmuch as the cam is eccentrically mounted so as to move toward a fully locked position in the slot 16, when actuated, or toward a fully released position when the cam is moved by hand out of the slot. The circular flange 22 is adapted to act somewhat as a guiding surface for the cam 13 by contact with the jamb face 23 during rotation of the cam and this contact also braces the cam against the possibility of the cam cocking under forces encountered when the cam is engaged in the door pull slot 16. Thus, the cam 13 is braced in movements of the door 10 in either direction.
Rotation of the cam latch member 13 is limited by means of a stop member 18 in the form of a plug inserted into an opening in the jamb 11 and secured by a snap fit. This stop member is disposed in position to be engaged by one or the other of a pair of oppositely disposed web plates 38 formed integrally with the flange 22 surrounding the plates 38 at the back side of the cam latch 13. The plates 38 extend toward the center of the cam from the rim 22 at opposite sides of the cam. This is best shown in FIG. 8 where it will be seen that rotary movement of the cam in an opening direction to release the door 10 and pull member 12, will bring the related web plate 38 into engagement with the stop 18 whereby opening movement of the cam is limited. The web plates 38 at opposite sides of the center of the cam latch member 13 enables the cam latch to be utilized in either a right or left hand mode and obtain the benefit of the limit stop arrangement in either mode.
The door pull 12 and cam 13 are shown generally in FIG. 1 as applied to a door and jamb 10 and 11, but FIGS. 2, 3 and 4 show the detail door locking arrangement as applied in relation to this single door type of installation as adapted to be locked against the jamb structure 24. The functioning of the cam and its relation to the door pull slot is fully revealed in this application. As best shown in FIGS. 3 and 4, the cam 13 is pivotally mounted directly on the face 23 of the door jamb which, as shown, comprises a wood core encased in a PVC enclosure 24, shaped to include a channel shaped recess 25 into which the leading edge of the door, represented by the frame portion 17, enters when the door is closed. The channel 25 has an outside flange 26, see especially FIG. 4, against which the door frame 17 is pressed by the camming action of the latch 13. The door frame 17 includes an outside handhold 27 by means of which the door may be actuated to any position between full open and fully closed when the cam latch is in its released position.
The door pull 12 is mounted on the door frame member 17 at the inner side thereof, by means of screws 28 and is provided with a handhold 29 for operation of the door from the inside between open and closed positions. The door is illustrated as including a screen panel 30, but this could comprise a glass panel if that type of door is required to be used. The slot 16 in the door pull for the cam 13, is located adjacent to the front edge of the pull member 12 and the leading edge of the door pull is tapered, as at 31 to provide a lead-in for the screen door entering the pocket on the jamb.
The cam latch member 13 may be manipulated manually to rotate the eccentrically mounted cam either to its locked position, or to its released position by means of finger hold recesses 33, which are best shown in FIG. 2 and since the pivot point 21 of the cam is off center, also as clearly illustrated in this Figure, the cam when tilted toward the locking position in slot 16 can then be moved toward the fully locked condition on its eccentric mounting. Conversely, if the cam 13 is moved manually out of the slot 16 and tilted about the pivot point 21 toward the released position, its eccentric mount will enable it to be moved toward the fully released position.
The mounting screw 19 provides a degree of tension on the cam 13 in that it develops a light friction of the cam lock against the face 23 of the door jamb 11 and limited movement of the cam is restricted by the stop 18 so that the cam will hold in any position and will not rotate freely but must be rotated manually.
FIG. 2 also best illustrates an important progressive locking feature of the cam 13, where it can be seen that the outer, or peripheral surface of the cam is provided with a plurality of flat surfaces 34, which are formed in continuous succession around the major portion of the outer cam surface. These surfaces are adapted to engage the surface of the door frame 17 through the slot 16 in a step-by-step movement until the cam reaches its final locked position pressing the door frame 17 against the flange 26 on the door jamb channel 25. This might be described as a clicked into place actuation as the cam 13 moved, or is actuated manually, about the pivot 19.
The cam 13 also includes an extended flat surface 35 and it should be noted that the flange 22 does not extend beyond this flat surface but, as shown in FIG. 5, is actually flush with the flat 35 at the maximum point of the flange. When the cam is rotated to dispose the flat 35 in a vertical position parallel to the door and the door pull 12, the flat will clear the door and the door pull so that the door can be slid past the cam 13 without actuating the cam in either direction of movement of the door and without restricting movement of the door.
Both the cam 13 and the door pull 12 are made from a plastic material such as a molded polycarbonate and one material of this type suitable for these parts comprises General Electric's Lexan #143 or, a molded rigid PVC might be used, such as #85856 by B. F. Goodrich.
The cam, of course, is disposed at the inner side of the outer door, as best indicated in FIG. 4, so that when an inner door is also involved, the cam 13 will be disposed on the face 23 of the door jamb element 24 between the inner and outer doors. An inner door 36 is indicated in this Figure and in some installations this may comprise a swinging door or, in other applications it may also be a sliding door.
It should be noted that when any of the flat faces of the cam represented by the several surfaces 34 is in engagement with the surface of the door frame member 17, the face-to-face contact makes it necessary that a positive rotation of the cam member 13 must be resorted to in order for the latch to be disengaged from the door and the slot 16. This face-to-face contact also prevents the cam 13 from being jarred out of its locking position, as by pushing on the door from the outer side.
A seal member 37 may be incorporated on the door frame member 17 where it engages with the jamb element 24 to exclude bugs, or the like, when the installation comparises a screen door, or also to prevent drafts when the door is glass panelled as either a storm door, or a prime door.
From the foregoing, it will be seen that an effective door latching arrangement has been provided wherein nonmetallic operating parts have been utilized to facilitate manufacture and reduce the cost and utilizing a rotary operating camming device to latch the door and which is engaged directly with the door through a locking slot in a door pull member installed on the door and wherein the latching cam operates at right angles to the direction of movement of the door and door pull member and which may be installed for either right hand or left hand operation. The cam member is mounted on a part such as a door jamb, to provide a locked relationship between the door pull and cam to prevent relative sliding movement. | This invention relates to a rotary type latch for sliding screen doors wherein the rotary member is molded from a plastic material such as a polycarbonate and which is rotatable in either direction for universal application to either right hand or left hand door operations. The rotary latch engages a slot in a door pull molded from a similar plastic material and contacts the screen door frame through the slot to cam the door against a retaining channel mounted on a door frame. The rotary latch includes a plurality of flat cam faces affording multiple locking positions and which necessitate positive lock rotation to enable the latch to be disengaged. This latch mechanism is of particular usefulness for application to sliding patio screen doors where the screen door closes into a pocket within the side jamb of the patio door frame. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an electric door opener with a trimmer subject to the action of an armature and a magnet coil and which is adjustably positioned for releasing or locking a door opener latch.
2. Description of the Related Art
A door opener with a trimmer is disclosed in EP 279 878 A1. The function of this electric door opener is based on the fact that the trimmer is held by an armature in the swivelling area of a door opener latch until the armature releases the trimmer by the operation of a magnet coil. With the aid of a trimmer spring the trimmer is brought out of the swivelling range of the door opener latch.
A distinction exists between two types of electric door openers, i.e., between an operating current design and a no-load current design. In an operating current design the armature is operated by energizing the magnet coil counter to the bias of the armature spring, whereas a door opener having a non-load current design can only be opened when the current is disconnected. If a no-load current door opener is energized, locking takes place.
Hitherto it was necessary to provide and keep available two different basic constructions for these two electric door opener types, leading to increased costs, particularly those involved in the storage of the two types.
SUMMARY OF THE INVENTION
One object of the invention is to provide an electric door opener which, without significant extra cost, can be used both as an operating current door opener and as a non-load current door opener.
According to the invention, this object is achieved in the case of an electric door opener with a trimmer actuatable by an armature and a magnet coil and which is adjustably arranged for the release or locking of a door opener latch, in that a device is provided for the, as desired, type switching between the no-load and operating current type by means of an armature travel determining device permitting different armature movement to provide both types of door openers.
Another object of the invention is to provide a switchable door opener, which, in an extremely short time, can be converted from a no-load current design into an operating current design and vice versa. For this purpose a device is provided which can be quickly and easily manipulated to switch between the no-load current and operating current types.
Yet another object of the invention is to reduce costs because only a single door opener design has to be manufactured and stored, where this door opener can be converted for use in accordance with the particular needs for an operating current type door opener or a no-load current type door opener. Furthermore, such a switchable electric door opener has a higher use value due to the possibility of use as either of these two types of door openers.
Still another object of the invention is to associate with the known two positions (locked-unlocked) armature three positions, namely unlocked-locked-unlocked. The construction according to the invention can also be varied so that the positions would be locked-unlocked-locked.
According to the invention, on the basis of a three position armature, a no-load current-operating current switching takes place, in that the first or last position of the armature is disabled or inhibited for the same, i.e. as a function of the construction one of the two "unlocked" positions or one of the two "locked" positions.
Whereas an armature without disabling can assume three basic positions, namely unlocked-locked-unlocked, e.g., for the no-load current design the first position is disabled. This then gives the basic positions disabled-locked-unlocked.
For an operating current door opener the last unlocked position is disabled, so that the positions unlocked-locked-disabled can be assumed.
A disabling of the corresponding basic positions can be achieved with different constructions.
In a preferred, particularly simple and efficient construction use is made of a device, which cooperates with the armature and the trimmer. By an adjustment of this device, which can be carried out without any time and tool expenditure, two positions (locked-unlocked or unlocked-locked) are chosen from the three possible positions (locked-unlocked-locked).
In a preferred embodiment the selection device is constructed as a rotation stop, which is adjustable about a rotation axis parallel to the swivel axis of the trimmer and the armature. This rotation stop can, e.g., be adjusted or rotated with the aid of a commercial screwdriver, so as to be able to obtain both an operating current position and a no-load current position.
In an appropriate construction the rotation stop is an almost circular disk, which has at least one means with which it can be held in the necessary two positions in or on the casing of the electric door opener. Therefore the rotation stop is provided with a stop for its rotary movements and cannot be rotated further than is in each case intended.
Advantageously a catch element can be constructed on the rotation stop and can engage in a complimentary recess for a no-load current position in the, casing or on the base plate or in a recess for an operating current position. If a catch nose is provided on the rotation stop circumference, notches can be constructed in the casing as recesses. It is also possible to provide a catch pin connected in non-rotary manner with the rotation stop and which is adjustably held in at least two positions.
The necessary positions of the armature cooperating with the trimmer, said armature being positioned above the rotation stop and adjustable about a vertical swivel axis, are made possible with the aid of shaped parts, e.g., virtually circular sector-like lugs on the almost circular, disk-like rotation stop.
These lugs on the surface of the rotation stop cooperate with a correspondingly constructed armature and a trimmer head in such a way that of the three possible basic positions of the armature, only the first or third unlocked position is disabled.
In place of a rotation stop it is also possible to use other constructions for disabling these unlocked positions. For example, it is possible to introduce a threaded pin as a disabling element through the base plate or the casing in order to disable the corresponding position.
However, the rotation stop in the described construction gives rise to advantages as regards manufacture and installation, together with an extremely high reliability in use.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a side view of a door opener according to the invention with the casing cover removed.
FIG. 2 is a perspective view of an embodiment of a functional unit comprising rotation stop, armature and trimmer.
FIG. 3 is a perspective view of a rotation stop.
FIG. 4 is a perspective view of an armature.
FIG. 5 is a perspective view of a trimmer.
FIG. 6 is a partial side view of an electric no-load current door opener according to the invention and FIG. 2 in position A.
FIG. 7 is a partial side view of an electric no-load current door opener according to the invention and FIG. 2 in position B.
FIG. 8 is a partial side view of an electric operating current door opener according to the invention and FIG. 2 in position B.
FIG. 9 is a partial side view of an electric operating current door opener according to the invention and FIG. 2 in position C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, it is noted that in order to facilitate understanding only those door opener parts are shown and described, which are directly linked with the construction according to the invention.
FIG. 1, which shows an electronic door opener 2 inside view with a door opener latch 4 deflectably mounted in known manner about a swivel axis 14 in the drawing plane. The door opener latch 4 is subject to the action of a trimmer 6, whose swivel axis 16 is perpendicular to the drawing plane. The trimmer 6 is biased against the door opener latch 4 by a trimmer spring 26, which is supported against a door opener casing 12.
The trimmer 6 is disabled or released by an armature 8, which is constructed in rocking lever-like manner and has a recess 25 for receiving a trimmer head 17, as illustrated in FIG. 2.
In the present embodiment, a magnet coil 13 is located to the right of the armature 8. On energizing the magnet coil 13 a coil core 22 coming out of the coil 13 forces the armature 8 into position B or C which are indicated in FIG. 2.
It is also possible to position the magnet coil to pull instead of push the armature, so that the armature moves against an opposing armature.
The armature 8 according to FIG. 1 is adjustably mounted about a swivel axis 9, which is parallel to the swivel axis 16 of the trimmer 6 and is urged into the position shown by an armature spring 28, which is fixed to the door opener casing 12.
A rotation stop 10, which is located below the recess 25 of the armature 8 for the trimmer head 17, as shown in FIG. 2, is used for converting or switching the electric door opener from a no-load current door opener to an operating current door opener and vice versa.
The essential construction parts for a switchable no-load-operating current door opener are shown in FIG. 2. The trimmer 6, which locks or unlocks a door opener latch 4 according to FIG. 1, cooperates with an armature 8, which is moved by a magnet coil 13 (FIG. 1) and is limited in a defined manner in its swivelling movement about an axis 9 by a rotation stop 10.
Whereas in the hitherto known electric door opener constructions an armature can only implement two positions, namely unlocked or locked, the armature 8 according to FIG. 2 permits three positions: unlocked A--locked B--unlocked C.
A no-load-operating current switching is achieved based upon which of unlocked position A or unlocked position C is disabled or inhibited. For a no-load current door opener the first unlocked position A and for an operating current door opener the second unlocked position C is disabled or inhibited.
As shown in FIG. 1, the armature 8 is forced in one direction by an armature spring 28 and is moved in the opposite direction by the operation of a magnet coil 13 having a coil core 22.
The disabling of the unlocked positions A and C are achieved by the rotation stop 10 in a particularly effective and reliable manner.
The rotation stop 10, which can, e.g., be fixed to a base plate 3 of the electric door opener 2 (FIG. 1), is adjustable about a rotation axis 11 from a position D into a position E. A fixing in the position D or E can be brought about by a shaped part 15 which in the present embodiment appears as an approximately triangular catch nose 15 on the circumference of the almost circular rotation stop 10.
The catch element 15 cooperates with complementary constructed recesses which are not shown. These recesses are provided with a clearly defined spacing as a no-load current notch and as an operating current notch, which notches are in or on the door opener casing 12. The rotation stop 10 can then be rotated with a normal, commercial screwdriver that will engage the catch nose 15 in the no-load current notch or in the operating current notch.
In an advantageous development, the rotation stop 10 is connected in nonrotary manner to a catch pin 30 and its rotary movement D-E is limited by means of a slotted hole 31 in a disk-shaped part 32 of the catch pin 30 and an engagement element (not shown) cooperating with said slotted hole 31 on the casing 12 or on the base plate 3.
On the surface of the rotation stop 10 are provided two lug-like elements 19 for limiting the swivelling movement of the armature 8, which is constructed in swivel clip-like manner.
FIG. 3 shows the roughly circular sector-shaped construction of the lugs 19. These lugs 19 are constructed virtually diametrically to one another on the surface of the rotation stop 10 and cooperate with the armature 8. Wedge-shaped control surfaces 27 of the armature 8 are located in the action zone of the magnet coil 13 (FIG. 1).
An arrow 20 in FIG. 2 illustrates the swivelling movement of the armature 8 and the unlocking or locking positions with respect to the door opener latch 4 brought about by the trimmer 6 and particularly the trimmer head 17.
The switching positions reached by an almost T-shaped trimmer head 17 in vertical longitudinal section and a square recess 25 in the armature 8 are designated A, B and C. Of said three switching positions A, B and C, corresponding to unlocked--locked--unlocked, in each case an outer position, namely an unlocked position, is disabled with the aid of the rotation stop 10.
This disabling with respect to a no-load current door opener and an operating current door opener is described in conjunction with FIGS. 6 to 9.
FIG. 4 shows an armature 8 and FIG. 5 a trimmer 6. The trimmer head 17 with an upper, horizontal notch 23 and a lower, horizontal notch 24 cooperates with the recess 25 of the armature 8. Thus, the trimmer 6 has freedom of movement in the right-hand unlocked position A (FIG. 2).
In FIGS. 6 and 7 the rotation stop 10 is in a no-load current position. In this view of a no-load current door opener 2 it is possible to see an unenergized coil core 22. Therefore, the armature 8 is forced to the right by the armature spring 28. This position corresponds to position A in FIG. 2 and means that the trimmer 6 maintains the door opener latch 4 in an unlocked position. With respect to the rotation stop 10 it is only possible to see an upper lug 19 which, as is apparent from FIG. 7, brings about a leftward limitation of the swivelling movement of the armature 8 following an energizing of the magnet coil 13. In FIG. 7 the armature 8 and trimmer 6 are in the central locked position B according to FIG. 2.
FIGS. 8 and 9 show an electric door opener 2 of an operating current design. For implementing an operating current door opener, the rotation stop 10 has been rotated about its rotation axis 11 into the operating current position, which is made very clear from the modified position of the lugs 19 compared with the position of these lugs shown in FIGS. 6 and 7. FIG. 8 shows the magnet coil 13 in the de-energized state, so that the armature 8 is in the central position B according to FIG. 2. The trimmer 6 is held with its trimmer head 17 in the recess 25, so that the door opener latch 4 is locked.
Due to the energizing of the magnet coil 13 in FIG. 9, the armature 8 is moved by the coil core 22 into the left-hand unlocked position C according to FIG. 2, so that the trimmer 6 can slide past the armature 8 in the "opening" direction.
Obviously, numerous 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 herein. | An electric door opener with a trimmer actuatable by an armature and a mat coil. The trimmer is adjustably positioned for the release or locking of a door opener latch. The door opener is useable as an electric no-load current door opener and as an operating current door opener because a selector device is provided to switch the armature-trimmer system between no-load current movement positions and operating current movement position. |
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BACKGROUND OF THE INVENTION
The present invention relates to a coil tubing injector. More particularly, the present invention relates to a coil tubing injector mounted on a truck with means for evenly reeling the tubing on a storage reel, means for straightening the tubing before injecting it into the well, and means for positioning the injector over the well bore to facilitate injection of the tubing.
Continuous tubing is often used to aid in completion, servicing or production of a well. Often, after the well has been drilled, or even during the drilling process, it is desired to pass a separate tube down the bore hole for passing gasses and fluids down into the hole for a particular purpose. For example, the tubing can be used for the circulation of nitrogen, oil, water, acid, alcohol, chemicals or solvents, for downhole workovers, location of hydrate plugs, placing of cement plugs through packers, and for circulating cement to casing bottoms, among other functions. The placement of the tube in the hole is accomplished by means of a device called an "injector", so-called because the tubing must be forced into the hole until enough of the tubing has been injected that the weight of the tubing inserted into the hole is sufficient to overcome the pressure in the borehole and the resistance to downward movement of the tubing imposed by the straightener.
Normally, the tubing used is a continuous length of tubing without couplings. The use of tubing without couplings decreases the likelihood of rupture of the tubing when injecting gases and fluids into the well hole at extremely high pressures. Also, injection of continuous tubing into the well bore at a steady rate is normally faster than assembling tubing joint by joint for lowering into the hole. Thus, continuous tubing can help save time and drilling costs.
In order to handle and store the continuous tubing, the tubing must be capable of being wound onto a reel or otherwise coiled. If the tubing material is made of PVC pipe or other high-strength plastic, coiling of the tubing for storage poses no significant problems, because the plastic tends to straighten itself when uncoiled for injection into a well bore. However, under certain downhole conditions, more durable materials are required for the tubing. For example, PVC pipe is able to withstand only relatively low pressures. Further, high-strength, low-alloy steel is often used in "sour" environments, i.e., environments in which large amounts of acid or sulfur gases are present. The use of continuous steel pipe which must be stored by coiling poses significant problems because, when uncoiled, the steel pipe tends to retain the curvature imparted to it during storage.
Known tubing injectors consist of a series of moving blocks driven by chains which grip the tubing on opposite sides, pulling it out of storage and and injecting it into the well and straightening it at the same time. However, this type of apparatus for injecting and straightening the tubing often damages the surface of the tubing. Thus, there is a need for a coil tubing injector which both injects and straightens the tubing, but which does not damage the surface of the tubing, thereby extending the life of tubing such as the copper tubing described below, which is relatively expensive to replace. Such a device would be of particular utility for use with special purpose tubing, for example, copper tubing with fiberglass coating such as is used in some segments of the industry for heating thick oil in the well to facilitate production. In these situations, the fiberglass coating is easily damaged by known injecting and straightening devices.
Another limitation of known tubing injectors is the expense of purchasing and maintaining them. By virtue of their size, even second-hand injectors are so expensive to purchase and operate that it is not economical to use them to service moderate or low production wells. In fact, because of this expense, many wells which need to be cemented, an operation which is best carried out by the use of a tubing injector, are not cemented, creating an environmental and safety hazard.
Another problem with known tubing injectors is the interaction between the injecting/straightening unit and the borehole. Because of the many different applications for which tubing may be utilized, the ideal device would be capable of being used on uncased, uncompleted borehole, a producing well which has a well head and "Christmas tree" in place above the borehole, or a well with any other equipment in place. To meet these different operating conditions, without having to alter the well site by removing the Christmas tree or adding well heads, it is desirable that the injecting/straightening unit be capable of operating essentially independently of the well. In other words, to service a producing well, the injecting/straightening unit must be able to rise up over the Christmass tree, some of which are over eight feet high, and operate above it. On the other hand, for an unfinished well, the injecting/straightening unit must operate almost at ground level.
Another consideration in having a tubing injector which operates independently of the equipment on the well is the recent advancement in other areas of oil and gas production in which the tubing injector is used to operate other downhole equipment or as a medium for performing various production tests and remedial operations. When used in this manner, it is desirable that this additional equipment be placed below the injecting and straightening means.
Another problem with known tubing injectors is that the flexibility of their operation is limited by the requirement that the injector be bolted to the well head for support and stability. If the tubing injector is to used on a well before the well head has been attached, or where attachment is inconvenient, a tubing injector which does not need to be attached to the well structure has significant advantages.
U.S. Pat. No. 3,116,781 is directed to a device which injects coil tubing. However, that device is limited in its ability to be adapted to operate over elevated well heads. Further, the utility of that device is limited by the use of the storage reel shown. As tubing is wound on the storage reel as it is retrieved from the well, it will not be distributed across the width of the reel, using its storage capacity to the fullest extent. In an attempt to provide an apparatus which distributes the tubing evenly in storage, injectors have been built with a guide, not unlike the level wind or traverse of a fishing reel, to distribute the tubing evenly onto the reel. However, this design imposes a design limitation on the injector unit which increases the cost and size of the injector unit. To traverse the tubing across the entire width of the reel, it is necessary that the apparatus guiding the tubing be placed at a substantial distance from the reel. Otherwise, when the guiding apparatus moves the tubing to one of the extreme edges of the reel, the tubing will be bent. If the guiding apparatus is positioned on the truck, a greatly increased length of the truck is required, and likewise, an increasingly expensive cost to avoid imparting a bend to the tubing. Further, the increased size creates problems such as the inability of such units to gain access to wells which are, for instance, between structures or other obstacles or in limited working areas.
An example of a design which provides one solution to this design limitation is the tubing injector marketed by Otis Engineering Corporation, which achieves the required distance by mounting the injector/straightener unit on a crane or boom at the rear of the truck or truck trailer on which the unit is mounted. However, the use of a crane creates additional problems such as clearance, increased maintenance and hydraulic system requirements and so forth.
Therefore, it is an object of the present invention to provide a tubing injector which is characterized by its ability to distribute the coil tubing onto a storage means without bending the tubing while still being small enough to be built and operated economically.
It is another object of the present invention to provide a tubing injector comprising a frame with a subframe slidably mounted thereon, a tubing storage means being mounted on the subframe and having coil tubing stored thereon, an injector reel mounted on the frame, means for rotating the injector reel, means mounted around a portion of the circumference of the injector reel for exerting pressure against the coil tubing when the coil tubing is directed between the circumference of the injector reel and said pressure exerting means, means for straightening the tubing, and means for slidably reciprocating the subframe across the frame as the tubing is being returned to the storage means.
It is another object of the present invention to provide a tubing injector unit which does not damage the exterior of the coil tubing.
A further object of the present invention is to provide a tubing injector unit which can operate at different heights above the well.
A further object of the present invention is to provide a tubing injector unit which can be operated without being attached to the well structure.
A further object of the present invention is to provide a tubing injector unit which stores the tubing evenly on a storage reel by traversing the reel as the tubing is withdrawn from the well.
These and other objects of the present invention will be evident to those skilled in the art from the following detailed description of the preferred embodiment.
SUMMARY OF THE INVENTION
These objects are accomplished in the present invention by providing a tubing injector comprising a frame and having a subframe slidably mounted on the frame. A tubing storage means having a length of coil tubing stored thereon is mounted to the subframe, and a rotating injector reel is also mounted on the frame. Means is mounted around a portion of the circumference of the injector reel for exerting pressure against the circumference of the injector reel to provide positive engagement of the tubing by the injector reel when the reel is rotated to pull the tubing off of or return the tubing to the tubing storage means. A tubing straightening means is provided to straighten the tubing after it is pulled off of the tubing storage means. The injector reel may be mounted on a platform which is pivotally mounted to the frame and may be positioned at various heights relative to the frame by a positioning means. Means is provided for reciprocating the tubing storage means while the tubing is being returned to the tubing storage means to distribute the tubing evenly on the tubing storage means.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a tubing injector constructed according to the teachings of the present invention.
FIG. 2 is a side view of the tubing injector of FIG. 1 in operation.
FIG. 3 is a top view of the tubing injector of FIG. 1 with the storage reel traversed to one extreme during the return of the tubing to the storage reel, i.e., while the tubing is being withdrawn from a well.
FIG. 4 is a top view similar to FIG. 3 of the tubing injector of FIG. 1 with the storage reel traversed to the other extreme.
FIG. 5 is a partial cross sectional view of the tubing injector of FIG. 1 taken along the lines 5--5 in FIG. 1.
FIG. 6 is a cross sectional view of the reel of the tubing injector of FIG. 1 taken along the lines 6--6 in FIG. 1, a portion of the reel being broken away to show the details of the tranversing mechanism and the axle coupling.
FIG. 7 is a cross sectional view of the traversing mechanism taken along the line 7--7 in FIG. 6.
FIG. 8 is a schematic diagram of the hydraulic system of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a presently preferred embodiment of the present invention, indicated generally at reference numberal 10. In the embodiment shown in FIG. 1, the device 10 is mounted to a truck 12, but it is understood that the device 10 could be mounted to a trailer or on a frame (not shown) which could be slid or lifted onto or off of a truck or trailer. As shown in FIG. 1, the device 10 is mounted on the frame 14 of truck 12.
A tubing storage means, in the form of a storage reel 16, is mounted to the subframe 17, and coil tubing 18 is stored thereon. The subframe 17 is comprised of base beams 102 which extend in a direction parallel to the axis of the frame 14, and stringers 151, which extend perpendicularly in a transverse position across the frame 14. Reel support beams 100 are affixed to the corners of subframe 17 formed by the stringers 151 and the base beams 102. Horizontal beams 104 are welded to the tops of reel support beams 100 and ear 106 is bolted to the horizontal beam 104 on one side of storage reel 16. Ear 106 contains a bearing (not numbered) in which axle 86 of storage reel 16 is journalled. The horizontal beam 104 on the other side of storage reel 16 is provided with means operable to rotate storage reel 16 in the form of a hydraulic motor 22 in which axle 86 is journalled.
Storage reel 16 is provided with a hub 80 which rides on bearings 88 (see FIG. 6) on axle 86. Spokes 84 are bolted to hub 80 by bolts 89 and extend radially from the hub 80 to support drum 82. Rim 90 is a continuous band around the circumference of storage reel 16, and members 91 are provided at spaced intervals to provide further support for drum 82 and rim 90.
Cement or other fluid travels up through the coupling 120, pipe 122 and elbow 123 into swivel joint 127. Axle 86 rotates with storage reel 16 and is provided with a passage 125 to allow the fluid to flow from swivel joint 127 to the collar connector 124. Collar connector 124 is provided with a coupler 126 into which the tubing 18 is connected to allow the fluid in axle 86 to flow up through the tubing 18 under pressure and down into the well.
Referring to FIGS. 3, 4 and 7, the stringers 151 are slidably received within the channel beams 156 which are integral with frame members 14. Ears 154 are welded to stringers 151 to form a point of attachment for the ram 149 of hydraulic cylinders 50. As can be seen in FIGS. 3 and 4, the hydraulic cylinders 150 are mounted to flanges 152 such that extension of the rams 149 of hydraulic cylinders 150 causes the subframe 17 to be shifted transversely across frame 14 in channel beam 156 a direction substantially perpendicular to the direction of movement of tubing 18 while tubing 18 is being wound onto or off of storage reel 16, while retraction of the rams 149 of hydraulic cylinders 150 causes the subframe 17 to traverse the frame 14 in the opposite direction, but still substantially perpendicular to the direction of movement of tubing 18. By alternating extension and retraction of the rams 149 of hydraulic cylinders 150 as will be explained, subframe 17 is slidingly reciprocated within channel beam 156 to distribute tubing 18 evenly on storage reel 16 while the tubing 18 is being returned to the storage reel 16. When the subframe 17 is in its intermediate position, the rams 149 of each of the hydraulic cylinders 150 are halfway extended.
Referring again to FIG. 1, the device 10 is provided with an injector, indicated generally at reference numberal 24. The injector 24 is comprised of an injector reel 25 mounted on axle 182. The axle 182 is journalled in ears 136, which are bolted to the horizontal beams 134. Horizontal beams 134 are supported by the support beams 132 and vertical beams 133. The support beams 132 and vertical beams 133 are integral with the longitudinal base members 130 of platform 19. Hydraulic motor 207 is mounted to the axle 182 of injector reel 25, and causes the injector reel 25 to rotate on axle 182. Injector reel 25 is provided with a hub 180 to which spokes 184 are welded to provide additional support and rigidity to injector reel 25. The circumference of injector reel 25 is provided with mirror-image flanges 194 which define a U-shaped groove 186. The U-shaped groove 186 is provided with a rubber insert 191 having a channel 193 in the exterior surface thereof for receipt of the tubing 18 (see FIG. 5).
Also mounted to the platform 19 is vertical support bracket 220, which serves to support member 190, which extends upwardly and around in close approximation to a portion of the circumference of injector reel 25. A plurality of axles 192 are journalled in support member 190, each of the axles 192 bearing a pneumatic tire or roller 188 on a bearing 189 (see FIG. 5). Member 190, axles 192 and rollers 188 serve as a means to exert pressure against tubing 18 when tubing 18 is directed into the channel 193 in rubber insert 191 between the injector reel 25 and the rollers 188. As is shown in FIG. 5, the bottom surface of tubing 18 within the channel 193 of the rubber insert 191 is positively engaged with the rubber insert 191 by means of the compression applied against the top surface of tubing 18 by roller 188. In conjunction wih the rotational force imparted to the injector reel 25 by hydraulic motor 207, this positive engagement of the tubing 18 provides the force necessary to force the tubing 18 down into a well bore, overcoming the pressure in the well, the resistance to downward movement imposed by the straightener 26 and the inertial weight of the tubing on the storage reel 16 of the device 10.
Because there is no need to traverse the tubing storage means 16 during the injection of the tubing 18 into the well, the subframe 17 can remain stationary while tubing 18 is pulled off of tubing storage means 16 by positive engagement of the tubing 18 by injector reel 25. When operated in this manner, tubing 18 can be injected into the well and power can be saved because it is not necessary to traverse the subframe 17 back and forth across the truck frame 14. However, when the subframe 17 is not traversed back and forth across truck frame 14, the tubing 18 is pulled off of storage reel 16 from different, continually changing, angles such that the tubing 18 does not always come off of the tubing storage means 16 in alignment with the groove 186 of injector reel 25. For this reason, a guide 222 is provided having rollers 224 mounted therein to align tubing 18 with the groove 186. The guide 222 is mounted on member 226 which is telescopically received in vertical support bracket 220 and which floats therein. Vertical support bracket 220 is integral with platform 19 and does not reciprocate transversely with storage reel 16.
Platform 30 is provided with a plurality of support members 260 pivotally mounted to frame 14 on pins 15 and to platform 19 by pins 262. In conjunction with hydraulic cylinder 32, which is pivotally mounted to the undercarriage 52 of truck 12 on pin 33 and to the support member 260 on pin 261, the support members 260 form a means operable to raise platform 19, having the injector reel 25 mounted thereon, up off of frame 14. As is shown in FIG. 2, support members 260 are mounted toward one end of the longitudinal frame members 130 so that, when the ram 35 of hydraulic cylinder 32 is extended, the platform 19, having injector reel 25 mounted thereon, is raised upwardly off of frame 14 while being simultaneously pivoted toward the rear of the frame 14 of truck 12. The platform 19 is shown in its raised position in FIG. 2 up over a well head 38 for operation. A brace 263 may be provided on both sides of platform 19 to further stabilize the platform 19 when raised. Brace 263 is mounted on pin 264 on longitudinal beam 130 at one end, on pin 265 on frame member 14 at the other end, and provided with threaded turnbuckle 266 to adjust its length. It will be understood by those skilled in the art who have the benefit of this disclosure that the device 10 can also be operated without pivoting the platform 19 to its raised position as shown in FIG. 2 when the device 10 is used in connection with a well head which is not elevated.
As is clear from the above description of the operation of the device 10 of the present invention, the frame 14 of truck 12 must be stabilized during the operations. Stabilization is accomplished by means of the leveling cylinders 72 mounted to the chassis 52 of truck 12. The rams 74 of leveling cylinders 72 are provided with stabilizing pads 76 to insure proper footing on the surface upon which the device 10 is operating as shown in FIG. 2.
Platform 19 is also provided with a means for straightening the tubing 18 as it comes off of the reel 25 on its way down into the well 38. This tubing straightening means 26 is mounted on a frame 200 attached to the back of the longitudinal support beam 130 of platform 19. Frame 200 is provided with vertical support brackets 202 and cross beams 204. The vertical support brackets 202 serve as a mount for the ears 206 upon which the opposed rollers 208 are mounted. As shown in FIG. 2, the top and bottom sets of opposed rollers 208 are in closely spaced, fixed relationship and the middle set of rollers 209 is provided with an adjustment means in the form of screw 212 by which the alignment of the middle rollers 209 can be changed to increase or decrease the amount of force which is applied to the tubing 18 between the top and bottom rollers 208 to straighten the tubing.
Control of the device 10 is provided by a control panel 300 mounted on control box 302. Control box 302 is mounted to the frame 14 and chassis 52 of truck 12. Control box 302 may be provided with a hinged cover (not shown) to cover the control panel 300. Control panel 300 is provided with a valve lever 304 for raising and lowering of the platform 19 and a valve lever 306 for control of the hydraulic cylinders 150. Torque control valves 308 are also provided on the control panel 300, an up and down valve being provided for each of the two reels. Controls 310 are also provided for the leveling cylinders 72. An on-off switch 312 is provided for the brake 340 as will be described. An emergency kill switch 314 is provided to stop the engine of the truck 12. Also provided on the control panel 300 is a storage reel control transmission 316 having an up, down and neutral position, and an injector reel control transmission 318 having up, down and neutral positions. A row of four pressure gauges is provided, one gauge each for the raising and lowering of the tubing 18 for the storage reel 16 and the injector reel 25.
The hydraulic control system is shown in FIGS. 1, 2 and 8. Hydraulic fluid is contained within the reservoir 322 and flows out of the reservoir 322 through line 324 i into filter 324, and on through line 324 o into a T-intersect 325 which splits the hydraulic fluid, a portion of the hdyraulic fluid going through the line 326 i to the feed pump 326, and a portion of the hydraulic fluid going through the line 328 i to the auxiliary pump 328. As shown in FIG. 8, the hydraulic fluid which is pumped by the auxiliary pump 328 is pumped through line 328 o to a pair of T-intersects, indicated generally at 329 and on through line 330 i and line 332 i to the four-way valves 330 and 332, respectively. Four-way valve 330 is active in one position to pass hydraulic fluid into the line 150 i to activate the hydraulic cylinders 150, in another position to pass hydraulic fluid into line 150 o , and in another position to bypass hydraulic fluid into the return line 330 o . The hydraulic fluid which flows through the four-way valve 330 to the hydraulic cylinders 150 through line 150 i , and the T-intersect 307 is returned through T-intersect 309 and line 150 o through the four-way valve 330 and into the return line 330 o .
Similarly, the control 304 of four-way valve 332 is operative in one position to pass hydraulic fluid into the line 32 i to activate hydraulic cylinder 32, in a second position to pass hydraulic fluid into line 32 o , and in another position to bypass hydraulic cylinder 32, routing the hydraulic fluid directly into the return line 332 o . When fluid is routed into the line 32 i to activate hydraulic cylinder 32, the hydraulic fluid is returned to the four-way valve 332 through return line 32 o , and on through the valve 332 to the return line 332 o . Both the return lines 330 o and 332 o route the hydraulic fluid through T-intersects 331 and 333, respectively, into line 334 i , and on into the filter 334, through the filter and on through return line 334 o to the reservoir 322.
The hydraulic fluid is routed to the feed pump 326 through line 326 i and on through line 326 o to the filter 336. The fluid is pumped through line 336 o to the T-intersect 337 where the hydraulic fluid is split between line 312 i , which directs fluid to the brake on-off switch 312, and line 341. Line 341 directs hydraulic fluid to the T-intersect 343, which provides hydraulic fluid to the storage reel pump 342 and injector reel pump 344, through lines 342 i , and 344 i , respectively. The hydraulic fluid which passes through line 312 i and into the brake on-off switch 312 provides power to the brakes 340 through line 312 o . Feed pump 326 operates continuously to keep approximately 200 pounds of pressure on the hydraulic fluid in the line 312 o , the brakes 340 being powered off such that when the on-off switch 312 is in the off position, the brakes 340 engage the brake drums 338 of the hydraulic motors 22 and 207.
The fluid which is provided to the pump 342 through line 342 i is pumped out of the pump 342 through line 342 o to valve 317, and on through line 22 i to the hydraulic motor 22 mounted on the storage reel 16. Fluid passes through the hydraulic motor 22 and is returned to pump 342 through return line 22 o . The hydraulic fluid provided to the pump 344 through line 344 i is pumped through the pump 344 into the line 344 o to valve 319, and on through line 207 i to the hydraulic motor 207 on the injector reel 25. Hydraulic fluid is returned from hydraulic motor 207 through the return line 207 o to pump 344. Pumps 342 and 344 are variable displacement pumps controlled from panel 300 by transmission controls 316 and 318, respectively, which open and close valves 317 and 319, respectively, by means of a bicycle hand brake-type cable (not shown). Reduction gears (not shown) are provided to transmit the rotational movement of the hydraulic motors 22 and 207 into rotational movement of the storage reel 16 and injector reel 25, respectively.
As indicated above, the feed pump 326 operates continuously so that circulation is maintained throughout the hydraulic system at all times. Consequently, appropriate return lines 350, 352, 354, 356, 358 and 360 are provided, all of which are connected by appropriate T-intersects into the line 334 i , thereby returning this continually circulating hydraulic fluid to reservoir 322.
The operation of the device 10 is evident from its construction. Briefly, the truck 12 is positioned in close approximation to the well head 38 and the leveling cylinder controls 310 are used to provide stable footing on the surface upon which truck 12 rests by means of the stabilizing pads 76 and leveling cylinders 72. If necessary, hydraulic cylinder 32 is activated by means of the valve lever 304 to raise the platform 19 up over an elevated well head. Hydraulic motors 22 and 207 are then activated through control of the storage reel control transmission 316 and injector reel control transmission 318, respectively, to pull tubing 18 off of the storage reel 16, through the guide 222, between the rollers 188 and the rubber insert 191 on the U-shaped groove 186 of the injector reel 25, down through the straightener 26, and into the well head 38 (see FIG. 2). When a sufficient length of tubing 18 has been pulled off of the storage means 16 and injected into the well 38, the hydraulic motors 22 and 207 are stopped and the cement or other fluid pumped down the well through the coupling 120, pipe 122, elbow 123, axle 86, collar connector 124, and tubing 18.
To retract tubing 18 from the well, the direction of flow in hydraulic lines 22 i and 22 o , and lines 207 i and 207 o , is reversed by shifting the storage reel control transmission 316 and injector reel control transmission 318 to cause storage reel 17 and injector reel 25 to rotate in the opposite direction. As tubing 18 is retracted from the well, storage reel 17 is traversed first in one direction substantially perpendicular to the direction of movement of tubing 18 and then in the opposite direction by manual movement of the control 306 of four way valve 330, which alternately directs hydraulic fluid into line 150 i and 150 o .
Referring again to FIG. 2, a spring-loaded roller 366 is mounted on frame 200, the spring (not shown) biasing roller 366 against tubing 18 as tubing 18 passes through straightener 26. An odometer-type cable 368 is provided to connect roller 366 to the digital read-out 370 on control panel 300. Roller 366, cable 368 and read-out 370 are not shown in FIG. 1 for purposes of clarity. The size of roller 366 is selected so that roller 366 rotates once for each one foot of tubing which passes it, consequently digital read-out 370 operates as a depth counter.
A nitrogen bottle 362 is mounted between the storage reel 16 and ejector reel 25. The nitrogen bottle contains nitrogen under high pressure, and in the event of a failure of the cement pump, the valve 364 is opened to allow the passage of high pressure nitrogen into the tubing 18 to blow the cement or other fluid out of the tubing 18. The nitrogen in the nitrogen bottle 362 can also be used to clear the lines after all the necessary fluid is pumped to prevent freezing in cold weather.
During the operation of the device 10, it is possible that the hydraulic motors 22 and 207, which power the storage reel 16 and injector reel 25, respectively, will encounter operating conditions in which the weight which the motors are able to pull back up out of the well or the force necessary to inject the tubing into the well is greater than the capacity of the motors 22 and 207. To prevent damage to the motors 22 and 207 under such circumstances, a series of four torque control valves 308 is provided, one torque control valve 308 for each reel in the up and down operating mode. These torque control valves 308 allow the hydraulic fluid in lines 22 i and 207 i to be bypassed around the hydraulic motors 22 and 207, respectively, into the lines 22 o and 207 o , respectively. Some hydraulic motors available commercially are provided with their own pressure relief valves such that the valves 308 may be unnecessary depending upon the construction of those hydraulic motors. The valves and hydraulic lines enclosed within the boxes 348 on FIG. 8 may be omitted when such a hydraulic motor is used.
As is clear from the above description, the positive engagement of the tubing 18 by the rubber insert 191 contained within the flanges 194 of the injector reel 25 is crucial to the ability of the device 10 to inject the tubing into the well and to return the tubing from the well to the tubing storage reel 16. To insure this positive engagement of the tubing 18, the rubber insert 191 is provided with a channel 193 to contain the tubing 18 and to increase the friction between the rubber insert 191 and the tubing 18 by increasing the surface contact between them. Channel 193 is milled into the surface of rubber insert 191, causing the rubber insert 191 to be roughened within the circumference of the channel 193, helping to prevent slippage of the tubing 18 as injector reel 25 rotates. The rollers 188 are pneumatic tires to likewise increase the surface contact between the roller 188 and the tubing 18. The amount of pressure applied to the top surface of the tubing 18 as it is carried around the circumference of the injector reel 25 by the rubber insert 191 can be changed by increasing or decreasing the air pressure of the pneumatic tires which make up the rollers 188.
Although the present invention has been characterized in terms of the above-described presently preferred embodiment, it will be recognized by those skilled in the art who have the benefit of this disclosure that certain changes and variations may be made to that embodiment without departing from the spirit of the present invention. The present invention is not limited to the above-described presently preferred embodiment, and it is expected that such variations will be encompassed within the scope of the following claims. | Apparatus for injecting tubing into a well having a storage reel which traverses in a direction substantially perpendicular to the direction of movement of the tubing as the tubing is being pulled off of or wound back onto the tubing storage means. The unit may also be provided with a platform on which the tubing injector reel may be elevated to allow the operation of the apparatus with elevated well heads. Also provided is a method of retrieving a length of coil tubing and storing the coil tubing on a storage reel. |
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BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to safety devices for door latches to restrict access by children, specifically cabinets and cupboards.
2. Description of Prior Art
Prior art devices of this type have been directed towards a variety of profile locks and handles wherein children are unable to open the door by the usual handle rotation and latch movement associated therewith.
Such prior art devices can be seen, for example, in U.S. Pat. Nos. 5,360,243, 5,785,363 and U.S. Publications 2009/0030427 and 2009/0266121.
In U.S. Pat. No. 5,785,363 a child safety latch can be seen having a dual activation push button configuration wherein both the buttons must be pushed and held simultaneously to activate release of the engagement of an interior latch.
U.S. Pat. No. 5,360,243 claims a latching structure for use with cabinets having electromagnetic member to engage a latch member. A switch provides activation and release of the mechanical latch allowing the cabinet to be open.
U.S. Patent Publication 2009/0030427 A1 illustrates a control handle for a lock wherein a release button is slidably advanced and held to directly engage a shaft or door latch retraction allowing the door to open.
U.S. Patent Publication 2009/0266121 A1 shows a child proofing of a door latch that is adapted to a standard lock set that prevents the door knob from turning when engaged. A sliding plate holds a locking post in place with a notch preventing the door knob rotation unless disengaged by a control lever interengaged therewith.
SUMMARY OF THE INVENTION
A cupboard safety latch device that provides a handle and interior release mechanism which requires multiple user actions to activate and release for access. The handle having a secondary movable element that interconnects rotatable handle input with an interior magnetic release by interlocking drive elements. Two movements are user required both handle rotation and simultaneous button depression to achieve inner latch and interior release engagement.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the invention assembly with portions broken away.
FIG. 2 is an exploded side elevational accessible view thereof.
FIG. 3 is a front elevational view of a drive lock element in the handle thereof.
FIG. 4 is a side elevational view thereof.
FIG. 5 is on lines 5 - 5 of FIG. 4 .
FIG. 6 is front elevational view of an activation button in the handle thereof.
FIG. 7 is a side elevational view thereof.
FIG. 8 is on lines 8 - 8 of FIG. 7 .
FIG. 9 is a front elevational view of a locking nut.
FIG. 10 is a side elevational view thereof.
FIG. 11 is a front elevational view of the drive shaft and sleeve of the invention.
FIG. 12 is a rear elevational view thereof.
FIG. 13 is a side elevational view of a cam release activation rod assembly of the invention.
FIG. 14 is a front elevational view thereof.
FIG. 15 is a partial rear elevational view of a horizontal mount of the cam release activation rod assembly.
FIG. 16 is a front elevational view of a cam assembly retaining disk.
FIG. 17 is a side elevational view thereof.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2 of the drawings, a safety door latch 10 of the invention can be seen having a handle assembly 11 , a cam rod release assembly 12 and a rod latch assembly 13 . The handle assembly 11 has two-part handle housing 14 and 15 respectively with a spring driven activator control button 16 which must be pushed in while the handle is being turned as will be described in greater detail hereinafter for operational engagement.
The control button 16 , best seen in FIGS. 1 , 6 , 7 and 8 of the drawings has a main stepped annular body member 17 with a user end engagement portion 17 A and drive engagement portion 17 B. The drive portion 17 B has an annular gear surface 18 with a plurality of radially spaced teeth 18 A thereon. A rotational limitation engagement channel 19 extends partially within the control button 16 's main body member and an annular spring seat 20 in spaced relation thereto as best seen in FIG. 6 of the drawings. A centered drive shaft receiving cavity 21 extends partially therewithin providing an engagement surface as will be described.
A drive lock fitting 22 , best seen in FIGS. 1 , 3 , 4 and 5 of the drawings has a stepped annular body member 23 having a gear portion 23 A, a housing engagement portion 24 and a nut engagement portion 25 with a central bore at 26 extending therethrough. The gear portions 23 A has a plurality radially spaced teeth 27 for select engagement with the teeth 18 A on the button 16 . The housing engagement portion 24 has annular threads 28 extending therefrom for registration with corresponding threads 28 A on the inner surface IS of the housing part 15 as best seen in FIG. 1 of the drawings.
As assembled, the drive lock fitting 22 is rotatably positioned on a drive shaft housing 29 having a central drive shaft 30 therewithin and extending therefrom as will be described in greater detail hereinafter.
The drive shaft housing 29 is cylindrical having a threaded exterior surface S with a compound smooth annular flange end 31 from which extends a rotational restriction about stopper bar 32 as best seen in FIGS. 1 and 11 of the drawings. The drive lock fitting 22 , as noted, slips over the drive shaft housing 29 and abuts against the end flange 31 and is retained thereagainst by a drive lock nut 33 , best seen in FIGS. 1 , 9 and 10 of the drawings. The drive shaft 30 has a corresponding retainment flange 30 A in retaining registration with the hereinbefore described flange end 31 of the drive shaft housing 29 . The drive shaft 30 has an area of reduced transverse dimension 34 extending from the flange end 31 of the drive shaft housing 29 registering within the shaft receiving cavity 21 of the button 16 . A spring 35 in the spring seat 20 extends about a portion of the drive shaft extension 34 and against the drive shaft 30 imparting a resilient action to the button 16 during use.
Referring now to FIG. 1 of the drawings, the handle housing 15 can be seen having an interior annular stepped configuration corresponding to an exterior stepped surface of the button 16 and with the drive lock fitting 22 aligning same to afford selective button gear teeth 18 A and drive lock fitting 22 gear teeth 27 for selective engagement indicated by directional arrows A upon button 16 displacement within the handle housing portion 15 when in assembly as shown in FIG. 1 of the drawings. The handle housing 14 rotatably supports the drive shaft housing 29 , drive shaft 30 therein and threaded engagement lock nut 33 , as assembled.
A handle spacer 36 and spacer lock retaining nut 36 A are threadably secured on the drive shaft housing 29 retaining the handle housing 14 for adjustable resistant rotation thereon.
The handle assembly 11 as hereinbefore described will provide for select operational rotation of the drive shaft 30 in the following user sequence.
The handle housings 14 and 15 can be freely rotated independently on the drive shaft assembly in non-engagement position illustrated in FIG. 1 of the drawings, however, once the button 16 is depressed indicated by activation arrows A inwardly against the spring 35 , the respective gear teeth 18 A and 27 A engage effectively locking the button 16 to the rotatable drive lock fitting 22 thereby rotating the drive shaft 30 keyed therewithin. The rotational restriction stopper bar 32 extending from the drive shaft flange housing end 32 as described is correspondingly registered within the rotational limitation engagement channel 19 limiting the effective drive shaft 30 and therefore handle rotation when so engaged and turned.
Referring now to the cam rod release assembly 12 , best seen in FIGS. 1 , 2 , 13 and 14 of the drawings, the cam rod release assembly 12 has a rectangular activation frame 37 , best seen in FIG. 1 of the drawings with oppositely disposed top and bottom surfaces 37 A and 37 B respectively and spaced parallel front and back surfaces 37 C and 37 D as positioned in this illustration. The frame 37 has a central contoured opening therethrough at 38 and elongated lug 39 extending from the so defined front surface 37 C in co-planar relation to its bottom surface 37 B.
Pairs of surface engagement arcuate guide feet 40 A and 40 B extend in spaced parallel opposing relation to one another from the so-defined back surface 37 D of the rectangular activation frame 37 .
A cam fitting 41 can be seen in broken lines in FIG. 14 of the drawings and best seen in solid lines in FIGS. 1 and 2 of the drawings, has a cam engagement surface 42 with an extending annular drive shaft engagement sleeve 43 having an interior annular sidewall 44 with oppositely disposed parallel interior key engagement surfaces 44 A and 44 B therewithin. An outer annular spaced sidewall 45 defines therefore a spring channel 46 therebetween with a central opening at 47 extending through the cam fitting providing access for a fastener screw 48 to engage within an apertured end 49 of the drive shaft 30 .
The cam fitting 41 is registerable on the front surface 37 C of the frame 37 so as to rest in non-activated position on top of the elongated lug 39 with the drive shaft support sleeve 43 therefore extending into the contoured opening 38 as shown in FIG. 1 of the drawings. The heretofore free end of the drive shaft 49 has a keyed surface extension of reduced transverse diameter 49 A which is engaged in the inner annular sidewall 44 keyed engagement surfaces 44 A and 44 B when assembled.
An apertured retaining disk 50 , see in FIGS. 1 , 2 , 16 and 17 of the drawings is provided with a disk lock nut 51 is secured to the drive shaft housing 29 . The apertured retaining disk 50 has aligned spring engagement tabs 52 registerable against the outer sleeve 45 . A return spring 53 is secured at 53 A into the cam fitting 41 and extends between the respective inner and outer sleeves 44 and 45 being secured between the engagement tabs 52 of the retaining disk 50 so as to provide rotational spring return resistance to the cam fitting 41 when rotated by the drive shaft 30 during activation as hereinbefore described.
Referring back to FIG. 2 of the drawings the rod latch assembly 13 can be seen having a latch activation rod 54 secured in and extending from the top surface 37 A of the hereinbefore described frame 37 . A rod guide bracket 56 is provided and mounted on the door D assuring latch activation rod 54 retention and alignment. The bracket 56 has a grub adjustment screw 55 therein that when engaged stops the rod 54 from moving so the magnet fitting 58 cannot draw the rod 54 into the locked position. A ferrous metal plate 57 secured to the free end of the activation rod 54 and is magnetically engaged by a magnet retaining fitting 58 mounted on the interior surface of a cabinet C on which the door D, in this example, is positioned.
It will be evident that the engagement rod 54 orientation when retained by the magnet fitting 58 will prevent the door D from freely opening until the handle assembly 10 of the invention is properly activated.
In operation, once the button 16 is pressed and the handle 15 is rotated simultaneously, the drive shaft 30 so engaged will correspondingly rotate the cam fitting 41 engaging and “sliding the frame 37 ” on the inside of the door D thus pulling down in this illustrated orientation the activation rod 54 within the guide bracket 56 releasing same from the magnetic fitting 58 . At this point, the door D can be opened by pulling the handle assembly 10 as will be well understood by those skilled in the art.
As noted, the cam retaining spring 53 will return the cam fitting 41 once the handle 15 is released by the user, not shown. The rod 54 and frame 37 will remain in position and not return with the cam fitting 41 staying in the unlocked position until the magnetic fitting 58 can so engage and draw same to the lock as noted. It will be seen that the cam rod assembly 12 can be mounted in a horizontal orientation as shown in FIG. 15 of the drawings so as wherein the cam fitting 41 is rotated with the engagement sleeve 43 shown in solid lines. The frame 37 will be slid horizontally as indicated by broken lines and the sleeve 43 will slidably engage into the enlarged area of the contoured opening 38 and retain the frame 37 in the “open” position by frictional gravity at 59 as the frame 37 drops slightly down vertical indicated by broken arrow V as well as horizontally as noted, by broken arrow H.
It will be evident from the above description that unless the button 16 is depressed, engaging the drive lock fitting 22 , that the handle 15 will just rotate without effective articulated latch release engagement.
It will thus be seen that a new and novel child safety door latch has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit of the invention. | A closure retainment latch for cabinet doors and the like that provides a child resistant access protocol restricting opening to required user specific actions. A cabinet door handle selectively engages an interior magnet retainer latch allowing the door to open. Multiple handle engagement indicated operations are required to initiate handle drive activation and latch release in a rotational longitudinally engagement configurations of contoured interdependent engagement activation elements within the handle and latch specific cam engagement surfaces. |
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FIELD OF THE INVENTION
This invention relates to bicycle tracks and more particularly to a bicycle track having a degree of self-guidance and a traction portion for improving the performance characteristics of the track.
BACKGROUND OF THE INVENTION
It is obvious from the rapidly worsening damage to human health and the environment from automobile emissions, that prompt action must be taken to encourage non-polluting forms of transportation. Bicycles are an obvious means of efficient, non-polluting local transportation. There is an urgent need for a safe, efficient, economical, non-disruptive bicycle transportation system in view of the inability of current transportation systems to meet the needs of the citizenry. Additionally, since bicycling is an excellent form of exercise, such bicycle track would serve dual purposes in improving the health of the users and relieving the clogged highways, particularly in the urban and city areas.
Bicycle paths to date have been little more than earthen paths running along the side of the highways. As an improvement within that art, macadam bicycle paths of the paved type have been attempted. However, to lay such bicycle paths conforming to the standards published by the American Association of State Highway and Transportation officials, one-way bicycle paths 1.5 m wide require heavy construction equipment to rough out the path, the necessity of an adequate stone or other subsurface base for the macadam overlay and some type of banking at the turns. Such macadam bicycle paths are expensive, permanent and aesthetically unpleasing.
Unfortunately, the existing transportation networks in many parts of the world are not designed for safe or efficient use of bicycles. In the cities, the streets are clogged with automobiles, trucks, motorcycles and the like. In the suburban and country areas, the speeds of the automobiles travelling the roadways are a constant threat to the bicyclists who now use the edges of the highways. Thus, there is an urgent need for a bicycle transportation system which is safe and efficient to ride, easy and economical to install and does not cause disruption to existing natural or manmade terrain features.
There has been little patent activity in the building of prefabricated multi-component tracks or paths capable of or specifically defined for bicycle transport.
U.S. Pat. No. 4,176,982 is directed to a bicycle path transport system consisting essentially of laterally spaced parallel rails having grooves on facing sides within which are positioned a plurality of end-to-end runners. The runners, which are of flexible sheet material, are provided with drain holes to drain off rain water or the like accumulating within the transport system rail and runner structure.
U.S. Pat. No. 4,928,601 is directed to a structure attachable to the rear of a bicycle for preventing an overtaking bicycle from riding up onto a lead bicycle riding along a track system.
U.S. Pat. No. 4,172,593 is directed to a roller skating rink, particularly for use by skateboarding enthusiasts, with the rink having a length of approximately 250 feet and a width of less than half of that. Such structure may be prefabricated and set up on site. The roller skating rink is particularly directed to a generally FIG. 8 shaped track having portions which are raised relative to the others at crossing points.
U.S. Pat. No. 1,445,083 is directed to a ceramic tile having an anti-slipping or abrasive surface in the form of abrasive granules embedded in the outer face or tread portion of the tile.
While these patents tend to show some interest in the creation of a fabricated, or a prefabricated sectional bicycle path transport system, they do not appear to treat the needs of the populace, which involves the construction of a bicycle path, treating aspects of cycler safety, easy and quick installation, ready application to various terrain surfaces without the need for excavation and presurface treatment.
It is therefore a primary object of the present invention to provide an improved bicycle track having a degree of self-guidance for the bicycles traversing the same, with the track configuration and structural makeup enhancing the safety and cycling efficiency of the bicycle riders, which bicycle track can be prefabricated sectionally, quickly installed and removed as needed, which provides a smooth surface for the bicycle wheels, which has excellent traction, which eliminates excavation, soil compaction, rutting and erosion common to unimproved trails, which can be suspended for passage across small gullies, streams and ground irregularities, which is not subject to heaving or cracking due to frost or growth of tree roots, and which permits passing of bicycles travelling in the same direction and ease in entry and exiting of bicycles from the track at various locations.
SUMMARY OF THE INVENTION
The self-guidance bicycle track of the present invention may be of continuous unitary form, but preferably comprises a plurality of longitudinally aligned end-to-end connected, upwardly open U-shaped track sections. Such track sections are preferably of molded rigid plastic (but may be of a semi-flexible mesh design and made of other suitable materials) consisting of a generally flat central traction portion and integral, upwardly, oppositely facing concave sidewalls to laterally opposite sides thereof. The rigid, firm track has higher sidewalls than the central traction portion. Preferably, the traction portion is recessed below the upwardly concave laterally opposed sidewalls. The sidewalls preferably terminate in reversely curved, outwardly directed lips. The ends of the track sections preferably terminate in right angle, apertured flanges such that the flanges of longitudinally abutting end-to-end track sections may be bolted together to form an essentially continuous track.
By recessing the traction surface below the lower ends of the concave sidewalls, the rear drive wheel of the bicycle is prevented from wandering off the traction surface without inhibiting side-to-side motion of the front wheel. The central traction portion may be provided with a high friction traction surface, with abrasive grit molded into the plastic as an upper surface layer of the central traction portion of the unitary track section. Alternatively, an abrasive strip may be adhesively applied to the central traction portion on the upper upwardly facing surface thereof. A plurality of transversely extending, laterally directed, longitudinally spaced narrow slots may be provided within the central traction portion of the track section to permit ready drainage of rain water. Such track slots also allow wind blown sand and grit from the bicycle tires to fall therethrough. The rigid plastic track is relatively weather-proof and maintenance free. Sections having a length on the order of 10-20 feet may be readily dismantled and reinstalled at an another site. The support of the bicycle track sections is preferably from below, using inverted U-brackets which have a transverse base with an upper surface conforming size-wise and shape-wise to the bottom surface of the upwardly open, U-shaped track sections. The bracket top surface terminates at opposite sides in circular projections conforming to the curled lips along the top edges of the track section sidewalls, thereby accepting the projections at the opposite ends of the U-brackets from below, and with the curled lips protecting cyclists from injury, should the cyclists fall during biking. The U-brackets may be mounted directly into the ground, with the base horizontal and with laterally opposed legs on opposite sides of the inverted U-shaped brackets projecting downwardly and having their lower ends penetrating the ground. The U-brackets may be directly anchored by their legs into the ground or supported by stakes driven into the ground, attached to existing objects such as the sides of buildings, pavement, guard rail posts, sides of bridges, etc. Hollow tubular leg sockets terminating at one end in a penetration point are projected into the ground, sized to receive the legs of the inverted U-shaped brackets. Circular collars fitted to the legs and integrated leg sockets have set screws thereof tightened down on the legs at given positions to permit vertical adjustment of respective legs of the U-shaped brackets. Such structure permits readjustment of the position of the brackets at each location over the length of the bicycle track to accommodate for dislodgment of the leg sockets or brackets over time and use of the bicycle track. The collar set screws for tightening down and releasing of the collars readily permit a shift in axial position of the leg of the U-shaped support brackets in bearing the same.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the prefabricated, self-guidance bicycle track forming a preferred embodiment of the invention;
FIG. 2 is a transverse sectional view through a section of the track shown in FIG. 1 taken about line 2--2;
FIG. 3 is a top plan view of the track section of FIG. 2;
FIG. 4 is a side elevational view of the track section of FIGS. 2 and 3, illustrating the bolting together of coupling flanges at opposite ends of the track sections;
FIG. 4a is an end view of a track section of FIG. 4 showing a coupling flange;
FIG. 5 is a transverse sectional view, in enlarged scale, of a portion of the track section of FIG. 2 including the central traction portion;
FIG. 6 is a top plan view of a curved track section of the bicycle track of FIG. 1;
FIG. 7 is a transverse sectional view of the track section of FIG. 6;
FIG. 8 is a front elevational view of a support bracket for supporting a straight track section of FIGS. 3-5 prior to positioning of a straight track section thereon, and as mounted within the ground at the situs of the bicycle track of FIG. 1.
FIG. 9 is a side elevational view of the support bracket of FIG. 8;
FIG. 10 is a front elevational view of the in-ground socket receiving one leg of the support bracket in FIG. 8;
FIG. 11 is a plan view of a split head clamp employed in setting the vertical position of a support bracket leg within the in-ground socket of FIG. 10; and
FIG. 12 is an end view of the split head clamp of FIG. 11.
FIG. 13 is a perspective view of an expandable mesh track section forming a fourth embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in a perspective view a self-guidance bicycle track indicated generally at 10 forming a preferred embodiment of the invention. The bicycle track 10 is formed of prefabricated molded plastic sections including a plurality of end-to-end joined, straight sections 12 and a plurality of like joined curved sections, indicated generally at 14. Alternatively, the bicycle track 10 may be of continuous form. However, by making up the bicycle track 10 from preformed and preferably molded plastic sections 12, 14, the track may be taken up and reinstalled. Preferably, the various track sections, whether curving to the right as at 14, or straight as at 12, or curving to the left (not shown), have a similar cross-section. (But not exactly the same--the outer sidewall on curved sections will be higher. Special transition sections will make a smooth change from curved to straight track or from wide to narrow track.
The straight track sections 12 consist of a center traction portion 22 with oppositely facing concave sidewalls 24, thus creating an upwardly open, U-shaped track with a generally flat traction surface 22a in the middle. This is preferred, but it is feasible to have integrally molded sidewalls attached to a bottom during assembly. As may be appreciated, the cross-section of the track can vary considerably in shape and dimension, but the sides or sidewalls of the track must be higher than the center traction portion. The sections may be of any convenient length on the order, for example, of 4 m in length and for straight section 12, a lateral width of 78 cm, with a central, flat traction portion on the order of 9 cm in width. The track sections may be of extruded, or poltruded molded plastic, of expandable mesh, or may be compression molded with or without reinforcing fibers such as fiberglass embedded within a suitable thermosetting resin. The plastic resin may be polyvinyl chloride (PVC).
In the illustrated embodiment, the end abutting sections of the track at 12, 14 may be bolted together by bolts passing through right angle, downwardly projecting flanges as will be seen hereinafter. Preferably, the track 10 may be laid on the ground without disturbing the terrain by the use of a plurality of longitudinally spaced brackets as at 16 which are contoured to and which engage the bottom surface of the molded plastic track sections 12, 14, FIG. 1.
As may be seen from FIGS. 2 and 5, the basic bicycle track design, as exemplified by the cross-sectional view FIG. 2, of a straight track section 12 consists of a slightly recessed central traction portion 22 and smooth, curved, mirror image sidewalls 24 to each side thereof. The central traction portion 22 should be recessed relative to the curved sidewalls 24 sufficient enough to prevent the rear drive wheel of a bicycle 20 from wandering off the traction surface 22a thereof. In the illustrated embodiment, FIG. 2, the traction surface 22a is recessed at a depth D 0.5 cm below the upper surface of the smooth, curved sidewalls 24 which are integral therewith The recess 23, FIG. 2, is not so deep as to inhibit the side-to-side motion of the bicycle front wheel which may ride up onto the upper surface of the concave sidewalls 24 to each side thereof. Of course, the recess 23 may be of a depth considerably greater than 0.5 cm. The flat central traction portion 22 is integrally joined to the sidewalls 24 by oblique transition portions 26 at 45°.
Further, the outboard edges of the concave, curved sidewalls 24 terminate in reverse bent lips 28 defining longitudinally extending cylindrical cavities 30 of a width N of approximately 2 cm. The vertical height H of each sidewall is in the illustrated embodiment 22 cm. The depth D of the recess 23 being equal to 0.5 cm, the lateral width E of each transition portion is 0.5 cm. The lateral width W' of the central track section traction portion 22 is 9 cm, or greater and the overall effective width W of the bicycle track section 12 W is 78 cm. The lips 28 have a radius r equal to 1.525 (just slightly larger than the 1.5 cm radius of the rounded ends of the support bracket which fit inside) in the example shown. The concave sidewalls 24 each have a radius R equal to 40 cm and offset from a reference circle C (as shown in dotted lines, FIG. 2,) by the width of the flat track bottom.
As seen in FIG. 4, the molded plastic track section 12 terminates at opposite ends in flanges 34 at right angles to the longitudinal axis of the track section, the flanges may be of variable height, but must be of sufficient height to include a plurality of circumferentially spaced bolt holes 36. In the plan view, FIG. 3, it may be seen that the concave, upwardly facing sidewalls 24 of the molded plastic straight track section 12, are of equal width, and that further a plurality of longitudinally spaced, transversely extending slots 32 are molded or otherwise formed within track section 12 extending fully across the central traction portion 22 of molded track section 12. The slots in the illustrated embodiment are approximately 0.5 cm wide, extend across the flat traction surface 22a and are spaced longitudinally about 4.5 cm. As such, the slots provide drainage and allow wind blown sand and other grit from tires to fall through the track bottom. Preferably, the slots taper outwardly from top to bottom to "self clean". As seen best in the enlarged scale sectional view, FIG. 5, the track surface 22a is formed by molding into the plastic material, a thin layer of abrasive grit as at 27. Alternatively, a pressure sensitive adhesive strip provided with an abrasive upper surface may be simply pressed into contact with the molded traction portion 22 of the bicycle track to provide an appropriate traction surface 22a within recess 23 of the unitary molded plastic bicycle track. The molded plastic bicycle track 12, 14 may have a central traction surface formed by slotted or mesh design, or raised knobs, dimples, ridges, etc. Or entire track can be of a semi-flexible mesh design which can be stretched and curved as needed during installation.
Molded plastic bicycle track sections having a molded in high friction surface layer as at 22a are economical to manufacture, ship and install as prefabricated components and as such are relatively weather-proof and maintenance-free. Since they are uniformly upwardly concave to the same degree, they may be readily nested and stacked for shipment. Such track sections may be readily installed by bolting them together and placing them in overlying position on a suitable underlying support system such as longitudinally spaced brackets 16, as will be discussed hereinafter. In areas where snow and ice are common, the track may be dark colored, such as black, to enhance solar warming and subsequent melting of ice and snow on the track. A protective canopy, and indeed sidewalls, may be added to shield the track from the elements and road spray. The track sections 12 are bolted together at opposite ends by bolts 39, which pass through the aligned bolt holes 36 of abutting flanges 34, FIG. 4. Suitable self locking nuts 41 are threaded to the threaded shanks 43 of bolts 39 complete the assembly. If necessary, flat washers 2 per bolt (not shown) may be applied to the threaded shanks 43 of the bolts 39, prior to threading on nuts 41. As may be appreciated by FIG. 1, where the bicycle track 10 curves, the central track portion 22' is both curved and extended laterally in the direction of the outside sidewall in curved section 14, and the width of the sidewall is reduced on that side. With the central traction surface portion as at 22 for straight track section 12 including a curve matching the normal curvature of the smooth sidewalls to provide proper traction for the cyclist 18 on bicycle 20 when cornering. The traction surfaces may be extended laterally as entry track sections, for example. The flat track central traction portion 22 for straight section 12 of the track may be widened to allow passing of bicycles or for use of three-wheeled cycles, bicycle trailers or the like. Such variances are not limited to straight track sections, but apply equally to curved track sections, arched track sections to match upwardly or downwardly vertical terrain changes, transition track sections, Y or other track intersections and entry and exit track sections.
FIGS. 6 and 7 show a curved track section 14, FIG. 1, in enlarged scale, with a widening of the central track traction portion 22' and a concave configuration given to outside curve content of that traction section approaching or equal to the normal curvature of the outside sidewall for curved track section 14. In that respect, the longitudinal spacing and lateral width of the slots 32' match that of track section 12, but the slots are located adjacent to the right side sidewall 24' at transition portion 26 in contrast to the much narrower, upwardly oblique, flat, left side sidewall 24". The same depth is provided to the recessed traction surface 22' and again molded in grit, such as sand, forms a traction surface 22a facing upwardly within recess 23 of that track section, FIG. 6. In this case, the left sidewall 24", instead of being curved, is flat and to the contrary, part of the central traction surface 22' is laterally curved. Further, that smooth, flat, oblique surface portion 24" is of extended height relative to the right side sidewall 24'. In essence, the normal 9 cm central traction portion, which is flat, is extended by an integral arcuate portion also bearing the high friction grit traction surface 22a' as a concave portion at a 40 cm radius R as a right side upwardly concave traction portion, leading to the left side transition portion 26 of the molded plastic curved track section 14, at the 45° angle and of a vertical height of 0.5 cm. In this case, only the 9 cm wide flat central traction portion of the track section 14 is provided with the drainage slots 32' as may be appreciated by viewing FIGS. 6 and 7. As a result, the overall width W" of the track section 14 is increased to 91.8 cm for the example forming a preferred embodiment of the invention as described herein. The traction surface 22a' is extended up the curved sidewall on the outer track radius and the transition portion 26 of the extrusion shifted to the left, FIG. 6, at approximately the same vertical height as the lip 28 to the right of that figure. The transition portions 26 define a recess 23' and act to maintain the bicycle tire of the track cyclist 18 within that recess. By providing adhesive grit over that complete surface area 22a', adequate traction is provided to the bicycle's tires as the bicycle goes through the turn. Preferably, the drainage slots 32', as well as 32 in the straight track section 12, widen slightly from the top surface to the bottom of the extrusion of the track extrusion section to minimize grit clogging. The transition section portion 26 to the left, FIGS. 6, 7, being at a 45° angle, tend to align the bicycle wheels with the upper traction surface 22' and prevent the rear wheel from riding over onto the smooth, flat, oblique surface portion 24", where the bicycle tire would tend to slip for lack of frictional engagement between the tire tread pattern and the flat, smooth, oblique facing surface of sidewall 24". The smooth sidewall surface is important to prevent the front wheel from climbing out of the track when it deviates from the traction surface.
Referring next to FIGS. 8 and 9, each U-shaped bracket 16 is shown as formed of molded plastic, preferably fiberglass reinforced, of a resin such as polyvinyl chloride (PVC). The U-bracket 16 may be compression molded, may be of a thickness of 5 cm and consists of a base 50, from which projects a pair of bracket legs 52 of the equal length. The legs may be 100 cm in length, the overall height of the bracket 128 cm, the diameter of each of the legs 52 may be equal to the 5 cm width of the support bracket 16. Thus, in cross-section the legs 52 are round. The bracket base 50 has a flat bottom surface 54 and a U-shaped top surface 56, which consists of a central, horizontal, flat recessed surface portion 56a, and upwardly concave surface portions 56b to each side thereof terminating in rounded, circular projection 58 to each side thereof. Projections 58 are sized to and receivable in elongated circular cross section cylindrical cavity 30 defined by lips 28 of a straight track section 12 fitted thereto. Bracket legs 52 are driven into the ground G. FIG. 8 shows ground line 60 sloping downwardly from left to right. Preferably, the legs (see the leg to the right, FIG. 8,) are slidably positioned within vertically upright, in-ground adjustment sockets indicated generally at 62, which may be formed of sheet metal or molded plastic, having a sharp V-point 64 at its lower end and having internal dimensions slightly in excess of the cross-section diameter of the round cross-section bracket legs 52. Leg 52 is insertably received within the in-ground socket 62 when driven into the ground as per FIG. 8.
While only a single in-ground socket 62 is shown in FIG. 8, another socket may be driven into the ground to the left of socket 62, in line with the center of the left side leg 52 and receiving the same.
For fixing the vertical height of the bracket base 50 above the ground G and with the bottom surface 54 of the base horizontal, a split head clamp 70 or the like be provided on each of legs 52 prior to insertion. The split head clamp as seen in FIGS. 11 and 12 is formed essentially of two metal or plastic head clamp halves 72 which conform on their inside surfaces to the diameter of the support bracket leg. Just one socket is shown in FIG.. 8, but two would normally be used. Those head clamp halves are of elongated form having a front surface 74, a rear surface 76 and laterally opposed end surfaces 78. The rear surface 76 has gaps between the two collar halves which allows for tightening. The gaps face each other for the head clamp halves 72. Further, paired, aligned holes 82 are drilled within the head clamp halves from the front surface 74 through the rear surface, which holes 82 receive bolts 84. The bolts have threaded shanks and are of a length such that threaded ends 84a project beyond the end of the holes 82 within the other half receiving the bolts. Nuts 86 are threaded onto the projecting bolt ends 84a. With the halves partially separated as shown in FIG. 11, the annular hole formed by the opposing adjustment gaps, between the two collar halves and their concave inner surfaces is of a diameter sufficiently large so as to permit the split head clamp to be slid onto the bracket leg 52 as per FIG. 8. The split head clamp 70 is separate from the in-ground socket, and by opening up or separating the halves 72 from each other, may be slid up and down a support bracket leg 52 and then tightened firmly against a leg at a desired longitudinal portion by rotation of bolts 84. With the split head clamp 70 tightened firmly at a preset position on a support bracket leg 52, contact between the bottom of the split head clamp 70 and the top of the in-ground socket 62 prevents further downward movement of the bracket leg 52 within an in-ground socket.
The in-ground socket 62 is embedded in the ground with the aid of an alignment jig and driving rod which conforms to the inside of the socket 62. The adjustment sockets and split head clamps allow for final vertical track alignment and periodic adjustments to compensate for settling of the track system and heaving of the ground as a result of frost. The track and support brackets can easily be removed from the in-ground sockets so that the grass may be mowed or the track put into storage in the off-season.
As evidenced in FIG. 10, an integral collar 66 is preferably formed on the in-ground socket 62 at its upper end as a radially enlarged flange. Preferably, a hex head set screw is threaded into a tapped hole 69, which extends horizontally through the collar 66 from the outside to the inside. By rotation of the hex head set screw 68, the engagement between a shank end of the hex head set screw and the facing surface of bracket leg 52 secures the support bracket leg in the socket 62 to prevent accidental lifting of bracket leg from the socket by wind or other forces.
The hex head set screw and collar may act in conjunction with, the split head clamp 70 as per FIGS. 11, 12.
Note
Both the split head clamp and the set screw collar are required and perform different functions. The split head clamp is for height adjustment while the set screw collar on the in-ground socket simply prevents accidental lifting of the leg from the socket. The set screw is not sufficient to hold the leg in position when subjected to downward forces.
A slight chamfer is given at 59 at all around to the end of the round cross-section bracket leg 52 to facilitate insertion of the lower end of the bracket leg 52 into the open top of the in-ground sockets 62, i.e. at collar 66, FIG. 10, during assembly of the support bracket to its in-ground sockets 62.
While the preferred track section dimensions are described above, particularly with respect to a track 10 constructed of end-to-end abutting and coupled straight track sections 12 and curved track sections 14, the functional track may have sidewall radii in the range of 12 cm to 46 cm (5 inches to 18 inches). Overall track width may range from 15 cm to 350 cm. The width of track depends on its intended use, i.e. single lane, passing lane, corner. It would appear that the narrowest practical width for a straight, single lane track section is about 80 cm (31.5 inches), but it is theoretically possible to reduce the track width down to as little as 15 cm (6 inches). Prefabricated bicycle tracks similar to that illustrated at 10, FIG. 1, may employ a number of standardized basic components such as the single lane, straight track sections 12 for one-way bicycle travel; a passing lane straight track section wide enough to allow passing in the same direction of two cyclists; or a special width, straight track section for permitting the use of three-wheeled cycles and bicycles with bicycle trailers coupled thereto.
Curved track sections such as right hand curved sections 14, FIG. 1, provide for a horizontal curve without rise or drop in slope. The curved track sections 14, FIG. 1, are merely examples. Various standard radii curved track sections may be provided as stock items, with others made to order. Curved track sections may be of the single lane variety as shown at 14 in FIG. 1 for one-way bicycle travel, or as special width curved track sections which allow use of three-wheeled cycles and bicycles with attached bicycle trailers.
Similarly, arched track sections having a bend in terms of vertical height combined with various standard lateral bend radii form alternatives and may be of the single lane, passing lane or special width varieties similar to the straight track sections and curved track sections. The same is true for transition track sections which initiate a change from a straight lane single track to a curved single track and vice versa; from a passing lane width to a single track width and vice versa; and from a straight special width track section to a curved special width track section and vice versa. Y-track sections permitting intersections of two tracks or as a modification entry and exit track sections permitting bicycles to enter and leave the track may be provided both in the single lane and special width categories.
In addition to the various track sections described above and built in conjunction with the illustrated straight sections within the drawings and described herein, the next most important aspect of the track system of the present invention is the support brackets which have been discussed in some detail and are illustrated particularly in drawing FIGS. 8 and 9. It should be kept in mind that since the track sections are coupled together at right angle flanges which depend downwardly from the bottom surfaces of the molded plastic sections at opposite ends and which are bolted together, when placement of the track sections onto the brackets, the brackets can be aligned with flanged couplings between track sections and to a side thereof. Thus the lateral contact therebetween prevents the tendency for the track sections to shift in the direction of their longitudinal axis during usage. The support brackets, therefore, cooperate with the flanged ends of the track sections to rigidity the track after assembly.
With respect to the support brackets, the standard support brackets for use with straight track sections having been shown in FIGS. 8 and 9, it may be appreciated that support brackets similarly built and of nearly the same dimension are provided for the curved track sections such as 14, in which case only the upper surface 56 of the bracket 50 is varied to conform in size and configuration to the bottom surface of the molded plastic curved track section which is fitted thereto and maintained thereon by gravity and by the curled lips (28) snapping over the rounded, circular projections (58) on each side of the support brackets (FIG. 8). The invention also envisions the utilization of three-way adjustable brackets for installations on unstable ground, double brackets for side-by-side track installations, where one track services riders going in one direction, and the other riders going in the opposite direction. Cantilevered, side-mounted brackets may be employed for mounting track sections to vertical features such as sides of bridges, guardrails, buildings and rock faces or the like. A plurality of support brackets rigidly linked in tandem pairs, and with cable attachment points at each of the four corners will allow suspension of a track on parallel cables for crossing over rivers, ravines, roads, etc.
Bike track 10' using expandable mesh 12', as per FIG. 13, may be shipped in compressed from then stretched into shape during installation. Cross sectional shape of installed sections will be the same as for solid track sections except for the 2-4 cm mesh depth which will give expanded track a greater thickness.
The expanded mesh design will allow sufficient bending to accommodate most horizontal and vertical curve radii and can be bent to the desired curve on site. The support brackets previously described will hold the track in proper alignment once installed. Flexible U-shaped lengths of molding can be slipped onto the upper edges of the track to protect bicyclists from rough track edges.
The expandable mesh design provides significant cost savings in manufacturing and installation. But will provide a lower quality riding surface when compared to track made from solid sections. The expanded mesh track 12' may be converted into a permanent installation with improved riding characteristics by filling the open mesh with a material such as cement which could be smoothed into the mesh then allowed to harden. Occasional mesh openings would be left in the bottom for drainage.
The sample shown above is typical of how the mesh would appear in the flat bottom of the track after it is expanded for installation. Since mesh cells 106 must keep the same orientation throughout the track to allow stretching and bending, the mesh cells 106 on the upper sidewalls 12' of the track would be longer and the mesh openings would be cut at an oblique angle.
It is envisioned that various accessories may be added to the bicycle track 10 of the present invention to enhance performance and to increase safety for the cyclists 18. Such accessories may be clamped or otherwise secured to the bicycle track sections 12, 14 and support brackets 16. Typical of such accessories are flared track entrances to aid in aligning bicycles with the track; flat (horizontal) side surfaces for pedestrian use and/or as dismounting surfaces for increased safety and convenience of cyclists; safety railings to prevent falls from elevated track and/or to provide a visual barrier for adjacent motor vehicles; protection barriers to provide screening to cyclists and pedestrians (if equipped with pedestrian surfaces) from dust, dirt, spray, noise, fumes and vehicle drafting when the track is adjacent to highways and may also be used as a windbreak on exposed sections of a track. Separately supported canopies may be provided for protection from the elements. Spring loaded prongs angled in the direction of travel, i.e. oblique to the traction surfaces of the track sections, may be placed at a track exit to discourage cyclist entrance onto the track 10 in opposition to the normal travel direction.
From the system as proposed, there would appear to be certain disadvantages. Bicycles may only travel one way on the track for the straight and curved sections 12, 14 as depicted. Thus, most situations would require the installation of two tracks, one for each direction of travel, appropriately supported by double, i.e. side-by-side dual support brackets for lowering of cost. Passing of cyclists is limited to locations where a wide track for passing is provided, or where the track exits onto broad, flat surfaces. Such tracks necessarily eliminate pedestrians and their pets, unless the track sections are equipped with flat side surfaces discussed above. These, however, may be an advantage, since the cyclists do not have to weave around slower moving pedestrians, and do not risk head on collisions with other cyclists.
Importantly, there is a large number of advantages of the self-guidance bicycle track as disclosed. The self-guidance bicycle track is less expensive than construction of bicycle paths to AASHTO Standards, provide superior safety and cycling efficiency, can be quickly installed, and provide smooth, firm surface with excellent drainage combined with excellent traction. Formed of molded plastic, the track sections are weather-resistant, do not require excavation, provide minimal disruption of existing vegetation, does not adversely affect the drainage of the installation site and can be installed on steep side slopes.
The sections and the support brackets for supporting the same in standard or modified form can be installed on the side of existing structures such as buildings, guardrails, bridges, the sections can be hand-carried to the installation site, can be erected with simple hand tools, thereby eliminating soil compaction, rutting and erosion common on unimproved trails. The track 10 can be easily removed and reused allowing for seasonal installation or relocation to another site, and can be removed in terms of minutes for special cases where vehicles must cross the track installation. Since the cyclists are required to stay on the track, they do not wander into vehicular traffic. Cyclists constrained to the track are thus freer to sightsee and need pay less attention to their direction of travel. The well-drained non-slip track surface permits cycling in poor weather without fear of falling or slippage, and the track is easy to ride at night due to the self-guiding characteristic of the track sections, can be used easily by unmodified bicycles, and reduces collisions between cyclists and objects near the bicycle paths.
Various modifications of detail, advised by circumstances and practice, may be introduced to the examples described above, are embodied by the present invention as long as those variations introduced do not change, alter or modify the essence of the embodiment described.
Although the present invention has been described in connection with a preferred embodiment thereof, many other variations and modifications may be apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the pendent claims. | A self-guidance bicycle track is formed of a plurality of longitudinally aligned, end-to-end coupled, upwardly open U-shaped molded plastic track sections, each track section has a generally flat, central traction portion and integral, upwardly oppositely facing concave side walls. The central traction portion is recessed below the upwardly concave, laterally opposed sidewalls. The sidewalls terminate in reversely curved, outwardly directed lips. Longitudinally spaced, transverse narrow slots within the molded track central traction portion permit rain water accumulating on the track to drain and surface grit to pass therethrough. Recessing of the traction surface below the lower ends of the concave sidewalls form lateral abutments which prevent a bicycle rear wheel from wandering off the traction surface without inhibiting side-to-side motion of the bicycle front wheel. U-shaped support brackets having an upper surface configured to the underside of the upwardly open, molded plastic, U-shaped track section which snap onto and are supported by the brackets. Tubular leg sockets mounted in the terrain, aligned with the support bracket legs slidably receive the legs. Split head clamps bolted together about the support bracket legs function as stops to limit penetration of the support bracket legs in the in-ground sockets receiving the same. Collars on the sockets bearing set screws prevent the bracket legs from accidentally lifting out of the tubular leg sockets. |
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BACKGROUND
[0001] In the downhole drilling and completion industry flapper valves have been used for an extended period of time. Such devices are useful whenever it is necessary to cause a fluid to move into the downhole environment from a remote location such as a surface location. Flapper valves come in a number of forms but not uncommonly are configured as tubing retrievable injection valves (TRIV), for example. Such valves often comprise a flapper that articulates and a flow tube that translates through a position occupied by the flapper when closed, thereby maintaining the flapper in an open position throughout the injection cycle. The open position is so maintained by the flow tube structurally pushing the flapper out of the way (causing rotation about its pivot) when the flapper valve is in the open position. While such flapper valves work well for their intended purposes, improvement is always desirable whether that improvement be in performance, cost reduction or both.
SUMMARY
[0002] A flapper valve with magnetic field hold open arrangement including a housing; a flapper pivotally mounted to the housing; and a magnet housing slidably mounted to the housing such that a magnetic field generating configuration of the magnet housing is movable between a position where it is capable of holding the flapper in an open position and where it is incapable of holding the flapper in an open position.
[0003] A method for holding open a flapper of a flapper valve including pumping an injection fluid through the valve with magnetic field hold open arrangement including a housing; a flapper pivotally mounted to the housing; and a magnet housing slidably mounted to the housing such that a magnetic field generating configuration of the magnet housing is movable between a position where it is capable of holding the flapper in an open position and where it is incapable of holding the flapper in an open position; fording the flapper to an open position; coupling the magnet housing by fluid friction to the flowing injection fluid; urging the magnet housing downstream whereby the magnetic field generating component is in the position to hold the flapper in the open position; and magnetically holding the flapper in the open position.
[0004] A flapper valve with hold open arrangement including a flapper movable between an open condition and a closed condition; and a magnetic field generating component movable relative to the flapper to be in a position where the component is capable of magnetically holding the flapper in the open condition and a position where the component is incapable of holding the flapper in the open condition.
BRIEF DESCRIPTION OF DRAWINGS
[0005] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0006] FIG. 1 is a schematic view of a flapper valve as disclosed herein in a closed position;
[0007] FIG. 2 is a schematic view of the valve of FIG. 1 in an open position.
[0008] FIG. 3 is a schematic view of a portion of an alternate embodiment of the flapper valve disclosed herein, the portion circumscribed by line 3 - 3 in FIG. 2 .
[0009] FIG. 4 is an alternate embodiment of a flapper valve in a closed position.
[0010] FIG. 5 is an alternate embodiment of a flapper valve in an opened position.
DETAILED DESCRIPTION
[0011] Referring to FIG. 1 , valve 10 such as a flapper valve includes a relatively short flow tube 12 disposed in operable communication with a relatively short housing 14 . The flapper valve 10 further includes a flapper 16 articulated to the housing 14 at a pivot point 18 . A seal 20 is disposed at the housing 14 and positioned for interaction with the flapper 16 when the flapper valve 10 is in the closed position. More specifically, the seal 20 ensures that the flapper 16 when closed will form a fluid tight interface with the housing 14 . Such seals are common and tend to be relatively soft. This makes them vulnerable to flow cutting and hence they require protection. Protection in the illustrated configuration is provided by a flow tube that need be only long enough to extend past the seal 20 when the flapper 16 is open. This is illustrated in FIG. 2 . Further, one of ordinary skill in the art will recognize that as illustrated, the flow tube would not function to open the flapper 16 as is the case in many prior art valves but rather stops short of interacting physically with the flapper 16 . In this configuration, it is the flow of injection fluid that opens and maintains the flapper 16 in the open position. The flow tube in this configuration then has only to protect the seal 20 , which it does in the position illustrated in FIG. 2 . It is noted that it is possible to apply the concepts herein to a valve with a longer flow tube that also has function to open the flapper 16 but such function is not necessary to the teaching herein. In either case, an extension spring 22 in operable communication with the flow tube 12 and the housing 14 will automatically move the flow tube 12 to the operational position when the flapper 16 is opened, that opening being due solely to flow or to flow in combination with another opening impetus.
[0012] The flapper 16 itself comprises an erosion resistance that is either surface concentrated such as in the form of a coating or a surface layer or may be erosion resistant for a greater percentage of the flapper 16 , including but not limited to the entire flapper being composed of erosion resistant material. This configuration allows the use of the valve 10 with high injection flow rates without a flow tube 12 being long enough to cover the flapper 16 .
[0013] Because the flapper is exposed to flow during use of the valve 10 due to a short flow tube, fluid dynamics considerations are of importance when they are traditionally irrelevant to the flapper. The fluid flowing past and in contact with the flapper 16 causes turbulence behind the flapper 16 adjacent an inside surface 24 of a tubular 26 in which the valve 10 is installed. The turbulence can cause the flapper to move into the flow stream and not stay against the surface 24 . This is a hindrance to injection and hence is to be avoided. The problem is exacerbated by higher injection rates. In order to address this issue the inventor hereof has determined that the effect of turbulence with respect to its ability to move the flapper into the injection flow can be minimized by reducing the fluid volume between a surface 28 of the flapper 16 and the surface 24 . It is to be noted that the surface 28 may be of the flapper itself or may be of a material attached to the flapper. In one embodiment, the surface 28 is formed by providing a conformable material 30 attached to the flapper 16 . The conformable material 30 will assume the shape of the inside surface 24 upon contact therewith and prevent any significant turbulent fluid from urging the flapper 16 away from the surface 24 during injection. This embodiment allows for irregularities in the surface 24 to be accounted for without knowing what those irregularities might be. More specifically, the tubing string in which the valve 10 is installed may have experienced flow cutting or erosion or may have become deformed during run in and resultingly does not necessarily present a cylindrical geometry at the surface 24 for a preconceived surface 28 to geometrically mate with. In such situation a conformable material 30 provides a wider range of functional success in reducing any potential volumes within which turbulent fluids might otherwise act. Conformable materials include but are not limited to rubber, nitrile, foams (including shape memory foam), etc. In other embodiments, the material may be a nonconformable material attached to the flapper or may be the flapper itself. In such cases, the material may geometrically mate well with the inside surface 24 and perform substantially as does the conformable material or may geometrically mate less well with the surface 24 but in any event, the material 30 will be formed to substantially geometrically mate with the surface 24 and accordingly will substantially displace turbulent fluid from the volume defined between the surface 28 and the surface 24 . Due to the reduction in turbulent fluid in this location, impetus on the flapper 16 to move into the flow path of the injection fluid is reduced or eliminated.
[0014] Still referring to FIGS. 1 and 2 , the torsion spring 19 operates to oppose the force of flowing injection fluid but without sufficient energy to overcome the force of the flowing fluid. The flapper 16 then will be opened by the flowing fluid but will close automatically upon cessation of flow of the injection fluid. In one embodiment, the torsion spring is configured with a greater spring force than the extension spring 22 such that the flow tube may be pushed back to its unactuated position by the flapper 16 through the impetus of the torsion spring 18 .
[0015] In addition to the foregoing, and referring to FIG. 3 , the flapper may further include a magnetic component 32 that is attractive to the tubing 26 or to another magnetic component 34 disposed in the tubing 26 . The magnet(s) either singly or in combination act to maintain the flapper 16 in contact with the surface 24 thereby reducing any available volume into which fluid may flow which consequently reduces any possible impetus for the flapper 16 to move into the injection flow. In addition, because of the attractive force of the magnets, it is in one embodiment, not necessary to have the surface 28 or material 30 of FIGS. 1 and 2 . FIGS. 4 and 5 illustrate such an embodiment. With respect to releasing the magnetic attraction of any of the embodiments herein that include magnetic field generating components whether of opposing poles or only one sided and attractive to a ferrous material, a sliding action will be used. For an understanding of such an action and one embodiment of a configuration capable of producing the sliding action, see FIGS. 4 and 5 and the description thereof hereinbelow.
[0016] Referring to FIGS. 4 and 5 simultaneously, an embodiment of a flapper valve 100 that ensures the flapper stays in the open position regardless of turbulence as illustrated. Illustrated is a housing 101 having a magnet housing 102 disposed therein. The magnet housing is axially movable within the housing 101 and is fluid sealed thereto by one or more seal 104 . The magnet housing 102 supports a magnetic field generating component 106 that comprises a permanent magnet or an electromagnet. The magnet housing 102 is biased by a compression spring 108 that may be a coil spring as illustrated or any other type of spring that provides resilience in compression. The spring 108 is maintained in position by a shoulder 110 in the housing 101 and a flapper sub 112 that bounds the annular space in which the spring 108 is located. The flapper sub 112 is a non movable component that is at least partially composed of a nonmagnetic material, the part being where a magnetic field would need to pass through the sub 112 . This area is labeled 115 . The sub 112 is anchored by suitable means 114 at recess 116 in housing 101 . The suitable means 114 may be one or more fasteners such as threaded fasteners, welding, adhesive, press fit, etc. at an end of flapper sub 112 opposite the means 114 is a pivot 118 and torsion spring 120 that together allow pivotal movement of a flapper 122 and a bias of the flapper 122 to its closed position (illustrated in FIG. 4 ). Adjacent a portion of the flapper 112 is a flapper seat 124 and a seal 126 thereat. Seat 124 may be attached to flapper sub 112 at and by, for example, thread 128 . A flow tube 130 is positioned radially inwardly of the seat 124 and is moveable therein. The flow tube is connected to a tension spring 132 that is also connected to the flapper seat 124 . The tension spring 132 tends to bias the flow tube toward the flapper 122 such that when the flapper 122 is in an open position the flow tube will protect the seal 126 from erosion due to fluid flow. The flow tube 130 need merely extend a small distance past the seal to provide this protection. It is to be understood that the tension spring 132 is sufficient in spring rate only to move the flow tube 130 to the protective position but is insufficient to prevent closure of the flapper 122 based upon input from the torsion spring 120 . This configuration ensures that the flapper 122 will close properly when it is supposed to without the flow tube interfering with the closure. Finally, the flapper 122 is provided with a magnetic field generating component 136 , which in one embodiment comprises a permanent magnet but may be configured as an electromagnet. In one embodiment the exposed surface of the component 136 will be of an opposing magnetic pole to the exposed surface of the component 106 . It is inconsequential which one of the two is north or south pole oriented.
[0017] In operation, a fluid 138 is applied in the direction of flow arrow 140 toward the flapper valve 100 . The fluid 138 forces the flapper to swing open (position depicted in FIG. 5 ), and simultaneously through fluid drag, moves the magnet housing 102 in the same direction as fluid movement. This action causes the magnetic field generating component 106 to move along with the magnet housing 102 to a position where the arcuate movement of magnetic field generating component 136 will be in register therewith, the movement of component 136 being dependent upon the pivoting movement of flapper 122 . Because the two components 106 and 136 are aligned and positioned in proximity to one another as well as being oppositely poled, the flapper is magnetically held in the open position and hence out of the flow of fluid 138 . By design the spring force of the torsion spring 120 is insufficient to overcome the magnetic attraction between components 106 and 136 and therefore is of no consequence with respect to maintaining the flapper 122 in the open position. As one of skill in the art will recognize, the flapper of a valve of this type must close when injection is stopped. This action is also unimpeded because as soon as the fluid drag on the magnet housing 102 is relieved, secondary to a pause in the flow of fluid 138 , the compression spring 108 will elongate and force the magnet housing 102 to move to the closed position of FIG. 4 . This will cause the magnetic field generating component 106 to slide away from the magnetic field generating component 136 thereby substantially reducing the attractive force therebetween. The flapper is hence free to close under the impetus of the torsion spring 120 .
[0018] In other embodiments, it is noted that the magnetic field generating components need not be on both sides of the resulting attractive interface but rather one could simply be a magnetically responsive material such as a ferrous metal. A reduced attractive force would result but if the component used has a sufficiently potent field, it would still function as noted above. Sliding action would still be used to break the interface wither by moving a nonmagnetic material into proximity with the components while the magnetically responsive material is slidingly moved away or a configuration where a sliding movement would simply position the field generating component farther away from a responsive material such as by sliding one of the structural features described in a direction that allows a recess to be aligned with the filed generating component. In such an embodiment the recess would position a responsive material far enough away from the field generating component to reduce the attractive force to a magnitude less than a closing force supplied by the torsion spring.
[0019] While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A flapper valve with magnetic field hold open arrangement including a housing; a flapper pivotally mounted to the housing; and a magnet housing slidably mounted to the housing such that a magnetic field generating configuration of the magnet housing is movable between a position where it is capable of holding the flapper in an open position and where it is incapable of holding the flapper in an open position. A method for holding open a flapper of a flapper valve. |
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TECHNICAL FIELD
[0001] This disclosure relates to the adjustment of quantities of hydraulic fracturing agents provided to kerogen-rich reservoirs for hydrocarbon extraction.
BACKGROUND
[0002] In some instances, a geologic formation, such as shale, may be fractured to initiate or enhance hydrocarbon production from the formation. Fracturing typically involves pumping a fluid into a wellbore at a particular pressure to break, or “fracture,” the geologic formation. The hydrocarbon fluid may then flow through the fractures and cracks generated by the fracturing process to the wellbore, and ultimately to the surface. In some instances, the fracturing process includes multiple stages of high-pressure fluid circulation into the wellbore, which may involve increased costs and complexities.
SUMMARY
[0003] In general, this document describes the use of hydraulic fracturing agents for hydrocarbon extraction in kerogen-rich unconventional formations.
[0004] In a first aspect, a method for treating a geologic formation includes providing a hydraulic fracture model, providing a first value representative of a volume of kerogen breaker in a fracturing fluid, determining a discrete fracture network (DFN) based on the hydraulic fracture model and the first value, determining a geomechanical model based on the DFN and a reservoir model based on the DFN, determining a hydrocarbon production volume based on the geomechanical model and the reservoir model, adjusting the first value based on the hydrocarbon production volume, and adjusting a volume of kerogen breaker in the fracturing fluid to a hydrocarbon reservoir based on the adjusted first value.
[0005] Various implementations can include some, all, or none of the following features. The method can further include providing a second value representative of an amount of heat to apply to the hydrocarbon reservoir, adjusting the second value based on the hydrocarbon production volume, wherein, determining the DFN can be further based on the second value, and adjusting the amount of heat to apply to the hydrocarbon reservoir is further based on the adjusted second value. The amount of heat can have a heating cost, the hydrocarbon production volume can have a market value, and adjusting the second value can include determining a difference between the market value and the heating cost and adjusting the second value to increase the difference. The method can further include extracting a volume of hydrocarbon from the hydrocarbon reservoir based on the volume of kerogen breaker in the fracturing fluid, and adjusting the second value based on the extracted volume. The volume of kerogen breaker in the fracturing fluid can have a material cost, the hydrocarbon production volume can have a market value, and adjusting the first value can include determining a difference between the market value and the material cost and adjusting the first value to increase the difference. The DFN can be descriptive of one or more of new fractures that are predicted to be created based on the hydraulic fracturing model, modified shale properties predicted to be modified based on the hydraulic fracturing model, and reactivated fractures that are predicted to be reactivated based on the hydraulic fracturing model and the modified shale properties. The hydraulic fracture model can be configured to determine the DFN further based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, injection plans of a fracturing job, heterogeneity in the reservoir formation, elastic stiffness properties of reservoir rocks, plastic strength properties of reservoir rocks, and mechanical properties of heterogeneities, and the DFN can include a number of fractures each characterized by one or more of fracture length, fracture width, fracture height, and fracture orientation. The geomechanical model can be configured to predict the evolution of at least one of stress fields, deformation, and damage in the reservoir based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, rock masses of reservoir layers, the DFN, constitutive models of rock mass that describe stress-deformation-failure processes of reservoirs under loading modes, mechanical properties of rock masses, mechanical properties of fractures, fluid mechanical interaction parameters, and thermal mechanical coupling parameters. The reservoir model can be configured to predict the evolution of multiphase flow and pressure fields in the reservoir based on one or more of reservoir pressure distribution parameters, reservoir temperature distribution parameters, multiphase flow models for fluid flow in rock, multiphase flow models for fluid flow in the DFN, thermal conduction models, thermal convection models, porosity parameters, permeability parameters, saturation parameters, thermal conduction property parameters, thermal convection property parameters, well location parameters, well drawdown plan parameters, and well temperature parameters. The method can also include extracting a volume of hydrocarbon from the hydrocarbon reservoir based on the volume of kerogen breaker in the fracturing fluid, and adjusting the first value based on the extracted volume.
[0006] In a second aspect, a system for hydraulic fracturing includes a hydraulic fracture model configured to determine a discrete fracture network (DFN) based on a first value representative of a volume of kerogen breaker in a fracturing fluid, a geomechanical model based on the DFN and a reservoir model based on the DFN, the geomechanical model and the reservoir model configured to determine a hydrocarbon production volume, and an adjustment module configured to adjust the first value based on the hydrocarbon production volume.
[0007] Various implementations can include some, all, or none of the following features. The system can also include a valve configured to adjust a volume of kerogen breaker in the fracturing fluid to a hydrocarbon reservoir based on the adjusted first value. The hydraulic fracture model can be configured to determine the discrete fracture network (DFN) further based on a second value representative of an amount of heat to apply to the hydrocarbon reservoir, and the adjustment module can be further configured to adjust the second value based on the hydrocarbon production volume. The amount of heat can have a heating cost, the hydrocarbon production volume can have a market value, and the adjustment model can be further configured to adjust the second value based on determining a difference between the market value and the heating cost and adjusting the second value to increase the difference. The system can also include a valve configured to adjust delivery of heat provided to a hydrocarbon reservoir based on the adjusted second value. The volume of kerogen breaker in the fracturing fluid can have a material cost, the hydrocarbon production volume can have a market value, and the adjustment model can be further configured to adjust the second value based on determining a difference between the market value and the material cost and adjusting the first value to increase the difference. The DFN can be descriptive of one or more of new fractures that are predicted to be created based on the hydraulic fracturing model, modified shale properties predicted to be modified based on the hydraulic fracturing model, and reactivated fractures that are predicted to be reactivated based on the hydraulic fracturing model and the modified shale properties. The hydraulic fracture model can be configured to determine the DFN further based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, injection plans of a fracturing job, heterogeneity in the reservoir formation, elastic stiffness properties of reservoir rocks, plastic strength properties of reservoir rocks, and mechanical properties of heterogeneities, and the DFN can include a number of fractures each characterized by one or more of fracture length, fracture width, fracture height, and fracture orientation. The geomechanical model can be configured to predict the evolution of at least one of stress fields, deformation, and damage in the reservoir based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, rock masses of reservoir layers, the DFN, constitutive models of rock mass that describe stress-deformation-failure processes of reservoirs under loading modes, mechanical properties of rock masses, mechanical properties of fractures, fluid mechanical interaction parameters, and thermal mechanical coupling parameters. The reservoir model can be configured to predict the evolution of multiphase flow and pressure fields in the reservoir based on one or more of reservoir pressure distribution parameters, reservoir temperature distribution parameters, multiphase flow models for fluid flow in rock, multiphase flow models for fluid flow in the DFN, thermal conduction models, thermal convection models, porosity parameters, permeability parameters, saturation parameters, thermal conduction property parameters, thermal convection property parameters, well location parameters, well drawdown plan parameters, and well temperature parameters.
[0008] The systems and techniques described here may provide one or more of the following advantages. First, a system can identify amounts of kerogen-reducing or removing agents that have corresponding estimates for volumes of extracted hydrocarbons. Second, the system can increase the efficiency of extracting volumes of hydrocarbons based on predetermined amounts of kerogen-reducing agents to be used. Third, the system can increase the profitability of hydrocarbon extraction processes in kerogen-rich formations where kerogen-reducing agents are in use.
[0009] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a schematic diagram of an example of a well system.
[0011] FIG. 2 is a schematic diagram that shows an example of a control system.
[0012] FIG. 3 is flow chart that shows an example of a process for adjusting kerogen breaker volume values.
DETAILED DESCRIPTION
[0013] FIG. 1 is a schematic diagram of an example well system 10 . The well system 10 includes a fracturing device 45 , through which kerogen breaker in fracturing fluids or heat or both may be applied on a hydrocarbon production field such as a rock formation 42 of a kerogen-rich, unconventional subterranean zone 40 .
[0014] In some instances, in the kerogen-rich shales, the extensive existence of kerogen may have significant influence upon the overall mechanical behavior of the shales. However, due to the micro- or nano-scale of some kerogen volumes, it is impractical to measure the mechanical properties and behaviors of kerogen in conventional geomechanics testing configurations, such as a uniaxial test, a triaxial test, or a Brazilian disc test.
[0015] Generally speaking, kerogens can demonstrate strain-softening, ductile mechanical behavior when subjected to tensile load. An implication of this observation is that kerogen can have a negative impact on the initiation and propagation of fractures and sustainability of fracture opening in kerogen-rich unconventional reservoir formations. In some implementations, these negative impacts can be reduced by adding breaker, heat, or other treatments in the fracturing fluids. The dose of breaker, for example, can determined by the tradeoff between the cost of adding breakers into fracturing fluids and the value of the resulting increase in hydrocarbon (for example, petrochemical, oil) production. In some implementations, the amount of treatment can be determined by a recursive numerical simulation, which takes stress, pressure and mechanical properties of reservoir formation, including kerogen domains, and fracturing fluid properties as inputs and can predict the fracture extension, sustainability, and productivity of the stimulated reservoir. In some implementations, the amount of treatment can be determined in real time by feedback control process, which takes target and actual hydrocarbon extraction rates as inputs and can adjust the amount of treatment to approach the target extraction rate. In some implementations, the feedback control process can take a market value for hydrocarbons and the costs of treatments as inputs, and can adjust the amount of treatment to adjust a net financial gain.
[0016] The fracturing compounds, in some implementations, may decompose or remove at least part of the kerogen domains in the rock formation 42 . For example, exposure of the rock formation 42 to breaker compounds or heat or both can at least partly dissolve kerogen, easing the flow of hydrocarbons through the rock formation 42 to a wellbore 20 .
[0017] As shown, the well system 10 accesses a subterranean zone 40 (which can be a formation, a portion of a formation or multiple formations), and provides access to hydrocarbons located in such subterranean zone 40 . In an example implementation of system 10 , the system 10 can be used for a drilling operation in which a downhole tool 50 can include or be coupled with a drilling bit. In another example implementation of system 10 , the system 10 can be used for a completion, for example, hydraulic fracturing, operation in which the downhole tool 50 can include or be coupled with a hydraulic fracturing tool. Thus, the well system 10 can allow for a drilling or fracturing or stimulation operations.
[0018] The well system 10 also includes a control system 19 , for example, microprocessor-based, electro-mechanical, or otherwise, that can determine or control the amount of breaker compound(s), heat, or both to be applied downhole to fracture the kerogens in the rock formation 42 .
[0019] In hydraulic fracturing implementations, the bottom hole pressures used to initiate fractures around the wellbore 20 are called breakdown pressure (P b ). For impermeable rock P b can be related to in-situ stress and reservoir rock tensile strength, and can be expressed as:
[0000] P b =3σ min −σ max +σ T
[0020] where σ max and σ min are maximum and minimum in-situ effective principal stress, respectively; σ T is the tensile strength of rock; P b is the pressure above the initial in-situ pore pressure that is required to break down the formation.
[0021] In some kerogen rich shales (KRS), the kerogen fibers can be fine but can exist across large volumes. Their presence can be described by widespread distributed “spider webs”. The densely distributed kerogens can have various implications upon hydraulic fracturing. For example, kerogen can add extra strength to the reservoir rock, so KRS can have higher tensile strength than kerogen free shale (KFS), which can result in a higher breakdown pressure being needed to initiate the fracture in KRS. In another example, kerogen can have relatively high tensile strength at high tensile deformation, which can raise fracture propagation pressure to a higher pressure level than fracturing KFS in which the tensile strength usually drops to zero quickly after the initial fracture. In yet another example, after the proppants are placed in the fractures and the bottom hole pressured decreased, the kerogen can bounce back thereby imposing additional confining compressive stress to the proppants in addition to the in-situ stress of reservoir formation, which can cause additional embedment of proppants into the formation resulting in extra reduction of the fracture aperture.
[0022] Kerogen has negative impact on initiation and propagation of fractures, and the sustainability of fracture opening in kerogen-rich unconventional reservoir formations; fracturing fluid shall reverse the negative effect of elastic rebound of kerogen after the initial fracturing opening, including (1) use breaker to decompose, at least partially, or (2) use other materials or methods, to remove at least part of kerogen domains.
[0023] In the oilfield, commonly used oxidizers can include persulfate, bromate, H 2 O 2 , H 2 O 2 -urea, and H 2 O 2 -carbonate complexes. Cl-contained oxidizers can be used as well. In some implementations, persulfate or bromate or both can be good enough to remove all or part of kerogen. In some implementations, iron (Fe) in kerogen can act as a catalyst to speed up reactions. In some implementations, the FeS 2 in pyrite can be oxidized to release Fe ions.
[0024] Two series of tests, each consisting of four tests, were conducted to break kerogen under laboratory conditions. In the first series of tests, the same amount of breaker compound was used to break the same amount of kerogen, but the breaking time was different in each test. In the second series tests, different amounts of breaker compound was used to break the same amount of kerogen with same breaking times.
[0025] In the first series of tests, about 50 mg of kerogen and 500 mg of sodium bromate were added to 20 ml of deionized water in each sample, and placed in a 300 F bath for 8, 16, 32, and 64 hours, respectively. The residue was filtered out, dried, and weighed. The tests show that this type of treatment can be useful to at least partly remove kerogen.
[0026] The testing conditions and results are provided in Table 1.
[0000]
TABLE 1
Weight reduction of kerogen with same amount of
sodium bromate (500 mg) but different time.
Hours at
Kerogen initial
Residue
Weight
300 F. (hours)
weight (mg)
weight (mg)
reduction (%)
8
48.0
22
54
16
49.1
11
78
32
48.8
7
86
64
49.7
7
86
[0027] In the second series of test, around 50 mg of kerogen and 50, 100, 200, or 400 mg, respectively, of sodium bromate were added to 20 ml of deionized water in each sample, and placed in a 300 F bath for 48 hours. The residue was filtered out, dried, and weighed. The testing conditions and results are presented in Table 2.
[0000]
TABLE 2
Weight reduction of kerogen with different amount
of sodium bromate but same time (48 hours).
NaBrO3
Kerogen initial
Residue
Weight
weight (mg)
weight (mg)
weight (mg)
reduction (%)
50.0
50.3
35
30
99.8
50.5
29
43
200.1
50.8
18
65
400.8
50.9
7
86
[0028] In the first series of tests, ˜500 mg of NaBrO 3 caused a kerogen weight reduction of about 86% after sufficient time. So it appears that about 400-500 mg of NaBrO 3 can be used to break about 50 mg of kerogen. In some implementations, it may not be necessary to break down 100% of the organic materials in kerogen. For example, as long as kerogen is weakened to such an extent that it will not significantly affect fracture initiation and propagation, the treatment can be considered to be sufficient.
[0029] FIG. 2 is a schematic diagram that shows an example of a control system 200 . In some embodiments, the control system 200 can be implemented by the example control system 19 of FIG. 1 . As discussed above, kerogen can be at least partly dissolved by chemical means, depending on the amount of breaker (for example, sodium bromate) and treatment time used. However, undertaking such a pre-treatment operation, the time required to perform the operation, and the volume of the breaker material used to perform the operation can add extra cost to the process of extracting hydrocarbons when compared with hydraulic fracturing processes without such pre-treatment. On the other hand, in some implementations, removal or reduction of kerogen domains along the fractures can generate longer and wider fractures in hydraulic fracturing, which can enhance well productivity. In some kerogen treatment designs, the parameters of the pre-treatment operation can be adjusted to increase the net financial gain from the kerogen breaking treatment, based on the difference between the expense of the operation (for example, cost of an amount of breaker compound used) and the value of any additional hydrocarbon that can be extracted as a result. The control system 200 is configured to determine such pre-treatment parameters, apply them to the rock zone 40 of FIG. 1 , and estimate the effect upon the extraction of hydrocarbons out of the wellbore 20 .
[0030] The control system 200 implements a shale stiffness and strength model 205 . In some implementations, the model 205 can be implemented as computer instructions stored on a computer-readable medium and executable by one or more processors. Alternatively or in addition, the model 205 can be implemented in hardware or firmware or a combination of hardware, firmware and software. The model 205 is configured to receive a kerogen breaker volume value 210 and determine a collection of modified shale formation properties. In some implementations, the kerogen breaker volume value 210 can be received from an external source, for example a predetermined startup value provided by a storage system, a startup value provided by a pseudorandom number generator, a value provided by human operator, or any other appropriate source. The kerogen breaker volume value 210 represents a quantity of a selected breaker compound that is to be delivered down hole (for example, to the rock formation 42 ). The shale stiffness and strength model 205 is configured to determine an amount by which a selected kerogen-rich environment such as the rock formation 42 can be affected by the application of a selected volume of kerogen breaker. For example, shale stiffness and strength in the rock formation 42 can be reduced by X % for a Y volume of kerogen breaker. In some implementations, the collection of modified shale formation properties can represent the estimated stiffness and strength of shale in the selected kerogen-rich environment as a result of providing the volume of kerogen breaker represented by the kerogen breaker volume value 210 .
[0031] The shale stiffness and strength model 205 is also configured to receive a bottom hole heat up value 212 to determine the collection of modified shale formation properties. In some implementations, the bottom hole heat up value 212 can be received from an external source, for example a predetermined startup value provided by a storage system, a startup value provided by a pseudorandom number generator, a value provided by human operator, or any other appropriate source. The bottom hole heat up value 212 represents an amount of heat energy that is to be delivered down hole (for example, to the rock formation 42 ). For example, a temperature rise of 50° C. can be selected to at least partly dissipate kerogens. In some implementations, the heat energy can be provided chemically. For example, an acid and a base can both be delivered down hole, and the resulting reaction can create heat that can dissipate kerogen. In some implementations, the heat energy can be provided electrically. For example, microwave or radio frequency energy can be delivered downhole to heat the rock formation 42 . In some implementations, other heating techniques can be used (for example, steam, radiation, vibration, ultrasound, lasers). The shale stiffness and strength model 205 is configured determine an amount by which a selected kerogen-rich environment such as the rock formation 42 can be affected by the application of a selected amount of heat delivered down hole. For example, shale stiffness and strength in the rock formation 42 can be reduced by M % for an N amount of heat energy or temperature rise. In some implementations, the collection of modified shale formation properties can represent the estimated stiffness and strength of shale in the selected kerogen-rich environment as a result of providing the amount of bottom hole heat up represented by the bottom hole heat up value 212 . Without adding breaker, due to the hindrance of rubbery kerogen domains, the breakdown pressure observed during hydraulic fracturing can be larger. However, in examples in which breaker is added, kerogen domains can be at least partially broken and the hindrance can be weakened, resulting in smaller breakdown pressure values.
[0032] The collection of modified shale formation properties determined by the shale stiffness and strength model 205 are received by a hydraulic fracture model 220 . In some implementations, the model 220 can be implemented as computer instructions stored on a computer-readable medium and executable by one or more processors. Alternatively or in addition, the model 220 can be implemented in hardware or firmware or a combination of hardware, firmware and software. In some implementations, the hydraulic fracture model 220 can also be configured to receive additional information about a well system such as the well system 10 . For example, the hydraulic fracture model 220 can accept information including in-situ stresses and pore pressure in the reservoir field, injection plans for a fracturing job, heterogeneity in the reservoir formation, elastic stiffness properties of reservoir rocks, plastic strength properties of reservoir rocks, and mechanical properties of heterogeneities. In some implementations, some of these properties can be measured in a rock mechanics lab and provided for use by the hydraulic fracture model 220 .
[0033] The hydraulic fracture model 220 simulates a main hydraulic fracturing stimulation based on the collection of modified shale formation properties. In the simulation performed by the hydraulic fracture model 220 , some existing natural fractures can be reactivated, new fractures can be created, and proppants can be placed in the created fractures. As a result of this simulation, a stimulated reservoir volume (SRV) consisting of new fractures or reactivated natural fractures (or both) will be determined. The output of hydraulic fracture model 220 is a discrete fracture network (DFN) consisting of a description of a number of fractures, wherein each fracture can be characterized by length, width, height, and orientation.
[0034] The system 200 includes a geomechanical model 230 . In some implementations, the model 230 can be implemented as computer instructions stored on a computer-readable medium and executable by one or more processors. Alternatively or in addition, the model 230 can be implemented in hardware or firmware or a combination of hardware, firmware and software.
[0035] The geomechanical model 230 is configured to receive the DFN and estimate an amount of hydrocarbon production that the rock formation 42 can provide based on the DFN. In some implementations, the geomechanical model 230 can be configured to receive additional information about a well system such as the well system 10 . For example, the geomechanical model 230 can accept information including in-situ stresses and pore pressure in the reservoir field, rock mass of reservoir layers, constitutive models of rock mass that describe the stress-deformation-failure process of reservoir under various loading modes, mechanical properties of rock mass, mechanical properties of fractures, fluid mechanical interaction parameters, and thermal mechanical coupling parameters. In some implementations, some of these properties can be measured in a rock mechanics lab and provided for use by the geomechanical model 230 .
[0036] The system 200 includes a reservoir model 232 . In some implementations, the model 232 can be implemented as computer instructions stored on a computer-readable medium and executable by one or more processors. Alternatively or in addition, the model 232 can be implemented in hardware or firmware or a combination of hardware, firmware and software.
[0037] The reservoir model 232 is configured to receive the DFN and estimate an amount of hydrocarbon production that the rock formation 42 can provide based on the DFN. In some implementations, the reservoir model 232 can be configured to receive additional information about a well system such as the well system 10 . For example, the reservoir model 232 can accept information including initial reservoir pressure distribution information, reservoir temperature distribution information, multiphase flow models for fluid flow in rock, multiphase flow models for fluid flow in the DFN, thermal conduction models, and convection models, rock porosity, rock permeability, saturation levels, thermal conduction properties of rock, convective properties of rock, well location, drawdown plans, and temperature at the production well.
[0038] The geomechanical model 230 and the reservoir model 232 are bidirectionally coupled to each other. For example, the reservoir model 232 can be at least partly driven by a drawdown plan at the well system 10 . In examples such as this, after thermal and fluid flow modeling is performed, updated pore pressure and temperature parameters can be transferred from the reservoir model 232 to the geomechanics model 230 . In such examples the geomechanical modeling can be performed to bring the system to equilibrium, then the estimated deformation, mechanical damage, and failure in the rock formation 42 can be used to estimate updated porosity and permeability parameters, and the deformation of the DFN can be used to estimate the updated aperture or other geometric parameters of the DFN. In such examples, updated geometric or mechanical properties (or both) of rock mass or the DFN (or both the rock mass and the DFN) can then be transferred from the geomechanical model 230 to the reservoir model 232 , and the reservoir model 232 can perform further estimation based on these updated parameters.
[0039] The output of the reservoir model 232 and the geomechanical model 230 is an estimated production value 240 . As an example, the following ideal “Darcy”, steady state, radial flow equation can be used to calculate the inflow performance of a fully penetrating, damaged, vertical, open hole well in a homogeneous formation.
[0000]
q
w
=
0.00708
kh
(
p
r
-
p
w
)
B
μ
[
ln
(
r
e
r
w
)
+
S
]
[0040] where q w is the well flow rate; k is permeability (mD); h is the thickness of reservoir layer (ft); p r is the reservoir pressure (psi); p w is the flowing bottom hole pressure (psi); B is the formation volume factor; μ is the viscosity of reservoir fluid (cp); r e is drainage radius (ft); r w is the well radius (ft); S is the skin factor.
[0041] Shales are anitropic and heterogeneous, and the fluid flow related parameters of shale, such as permeability, skin factor, fluid viscosity, and any other appropriate parameter of shale fluid flow, can all evolve dynamically with the stress state of the rock matrix and fractures. For these types of complex systems, no analytical solutions exist to predict the production rate. Instead, a coupling of geomechanical models and reservoir models can be implemented to make reliable predictions, in which the geomechanical model is used to update the stress and pore pressure based on the updated pore pressure in the reservoir model, while the updated stress and pore pressure are used to update the permeability and porosity of rock matrix (and aperture and pressure distribution along fractures) in reservoir models to be used in the next step of computation in reservoir model.
[0042] The estimated production value 240 represents an accumulated production of hydrocarbon. An adjustment module 250 can then determine an updated kerogen breaker volume value to be provided to the shale stiffness and strength model 205 based on the kerogen breaker volume value 210 and the estimated production value 240 . The adjustment module 250 can also determine an updated bottom hole heat up value to be provided to the shale stiffness and strength model 205 based on the bottom hole heat up value 212 and the estimated production value 240 .
[0043] In some implementations, the system 200 can be run multiple times to approach a selected objective. For example, the adjustment model can be configured to perform a sweep or search of various kerogen breaker volume values 210 or bottom hole heat up values 212 or both to determine a range of resulting estimated production values 240 .
[0044] In some implementations, the resulting estimated production values 240 can be analyzed to identify an estimated production value 240 that approaches a target parameter. For example, the estimated production value 240 having the highest estimated value can be selected, and the kerogen breaker volume value 210 or bottom hole heat up value 212 (or both) that corresponds to the selected estimated production value 240 can be identified and used to configure production in the well system 10 .
[0045] The updated kerogen breaker volume value is also provided as an input to a valve 260 . The valve 260 is configured to receive kerogen breaker volume values and control a flow of kerogen breaker compound that is delivered to the rock formation 42 . For example, if the system 200 determines that 2000 L of a selected breaker is to be delivered down hole, then the valve 260 can be operated to provide 2000 L of the breaker to the rock formation 42 .
[0046] In a similar manner, the updated bottom hole heat up value is also provided as an input to a valve 262 . The valve 262 is configured to bottom hole heat up values and control an amount of heat that is delivered to the rock formation 42 . For example, if the system 200 determines that the rock formation 42 is to be raised 40° F., then the valve 262 can be operated to provide one or more volumes of heat-generating chemical reactants, steam, or other agents corresponding to the identified heat rise to the rock formation 42 . In some embodiments, the valve 262 can be replaced by an electrical or other control mechanism. For example, an electrical switch or amplifier can be used to determine a corresponding amount of electrical, RF, microwave, or other energy to be provided to the rock formation 42 . In another example, a mechanical oscillator or other vibratory mechanism (for example, ultrasound or extremely low frequency—ELF—sound) can be used to create heat energy down hole.
[0047] In some implementations, the breaker compound can have an associated material cost (for example, a per-volume unit cost), and a kerogen breaker compound cost can be determined based on the material cost and the kerogen breaker volume value 210 . For example, if a selected breaker compound cost $0.10 per liter and the kerogen breaker volume value represented 1000 liters, then the kerogen breaker compound cost would be $100.
[0048] In some examples where the bottom hole heat up is provided chemically, the chemical reactants used can have an associated per-unit heating cost (for example, a per unit volumetric cost of the reactants), and a heating cost can be determined based on the per-unit heating cost and the bottom hole heat up value 212 . For example, it may be known that 1000 liters of a selected acid and 500 liters of a selected base cost $0.25/liter each, and therefore a 20° C. rise may consume (1000+500)*20=30000 liters of reactants and have a heating cost of 3000010.25=$7500.
[0049] In some examples where the bottom hole heat up is provided electrically, the electrical power can have an associated per-unit heating cost (for example, a per kilowatt cost for electricity), and the heating cost can be determined based on the per-unit heating cost on the bottom hole heat up value 212 . In some implementations, other heating techniques can be used (for example, steam, radiation, vibration, ultrasound, extreme low frequency—ELF, lasers), and each heating technique can have its own per-unit heating cost that can be used along with the bottom hole heat up value 212 to determine the heating cost.
[0050] In some implementations, the system 200 can be configured to identify values for the kerogen breaker volume value 210 or the bottom hole heat up value 212 or both based on the per-unit costs of the kerogen breaker compound, heating costs, and the per-unit value of the estimated production 240 . For example, the adjustment module 250 can be configured to identify an estimated production value 240 that approaches a maximized difference (for example, profit margin) between the value of the estimated production value 240 and the costs of heating and the volumes of kerogen breaker compound described by the kerogen breaker volume value 210 or the bottom hole heat up value 212 or both corresponding to the identified estimated production value 240 .
[0051] FIG. 3 is flow chart that shows an example of a process 300 for adjusting kerogen breaker volume values. In some implementations, the process 300 can be performed at least in part by the example system 19 of the example well system 10 of FIG. 1 or by the example system 200 of FIG. 2 .
[0052] In the process 300 , a hydraulic fracture model is provided. In some implementations, the hydraulic fracture model can be the example hydraulic fracture model 220 . In some implementations, the hydraulic fracture model can be configured to determine the discrete fracture network (DFN) further based on a second value representative of an amount of heat to apply to a hydrocarbon reservoir, such as the rock formation 42 . In some implementations, the hydraulic fracture model can be configured to determine the DFN further based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, injection plans of a fracturing job, heterogeneity in the reservoir formation, elastic stiffness properties of reservoir rocks, plastic strength properties of reservoir rocks, and mechanical properties of heterogeneities.
[0053] At 320 a first value is provided. The first value is representative of a volume of kerogen breaker in fracturing fluid. In some implementations, the first value can be the example kerogen breaker volume value 210 .
[0054] At 330 a discrete fracture network (DFN) is determined. The example, the DFN is based on the hydraulic fracture model and the first value. For example, the example hydraulic fracture model 220 simulates a main hydraulic fracturing stimulation based on the collection of modified shale formation properties, and the output of the hydraulic fracture model 220 is a DFN consisting of a description of a number of fractures, wherein each fracture can be characterized by one or more of length, width, height, and orientation. In some implementations, the DFN can be descriptive of one or more of new fractures that are predicted to be created based on the hydraulic fracturing model, modified shale properties predicted to be modified based on the hydraulic fracturing model, and reactivated fractures that are predicted to be reactivated based on the hydraulic fracturing model and the modified shale properties.
[0055] At 340 a geomechanical model is determined. The geomechanical model is determined based on the DFN. For example, the geomechanical model can be the example geomechanical model 230 . The geomechanical model is configured to receive the DFN and estimate an amount of hydrocarbon production that the rock formation 42 can provide based on the DFN. In some implementations, the geomechanical model can be configured to predict the evolution of at least one of stress fields, deformation, and damage in the reservoir based on one or more of in-situ stresses in the reservoir field, pore pressures in the reservoir field, rock masses of reservoir layers, the DFN, constitutive models of rock mass that describe stress-deformation-failure processes of reservoirs under loading modes, mechanical properties of rock masses, mechanical properties of fractures, fluid mechanical interaction parameters, and thermal mechanical coupling parameters.
[0056] At 350 a reservoir model is determined. The reservoir model is based on the DFN. For example, the reservoir model can be the example reservoir model 232 . The reservoir model is configured to receive the DFN and estimate an amount of hydrocarbon production that the rock formation 42 can provide based on the DFN.
[0057] At 360 , a hydrocarbon production volume is determined. The hydrocarbon production volume is an estimate based on the amounts of hydrocarbon production estimated by the geomechanical model and the reservoir model for the given first value. In some implementations, the hydrocarbon production volume can be the example estimated production value 240 . In some implementations, the reservoir model can be configured to predict the evolution of multiphase flow and pressure fields in the reservoir based on one or more of reservoir pressure distribution parameters, reservoir temperature distribution parameters, multiphase flow models for fluid flow in rock, multiphase flow models for fluid flow in the DFN, thermal conduction models, thermal convection models, porosity parameters, permeability parameters, saturation parameters, thermal conduction property parameters, thermal convection property parameters, well location parameters, well drawdown plan parameters, and well temperature parameters.
[0058] At 370 , the first value is adjusted based on the determined hydrocarbon production volume. In some implementations the first value can be adjusted by the example adjustment module 250 . For example, the first value can be raised or lowered to effect an increase or decrease in the estimated production value 240 .
[0059] In some implementations, the first value can have an associated monetary cost (for example, the cost of kerogen breaker compound) and the estimated hydrocarbon production value (for example, the market price of crude oil) can have an associated monetary value, and the first value can be adjusted to increase the difference between the costs and resulting estimated value (for example, increase net profit).
[0060] At 380 , a flow of kerogen breaker in fracturing fluid to a hydrocarbon reservoir is adjusted based on the adjusted first value. For example, the example adjusted kerogen breaker volume value 210 can be used as part of a control routine that directs the operation of the example valve 260 . In some implementations, the flow of kerogen breaker in fracturing fluid to the rock formation 42 can be based on an adjusted first value that increases the difference between the value of hydrocarbon expected to be extracted by the well system 10 and cost of the amount of kerogen breaker compound used as part of the extraction process.
[0061] In some implementations, the first value can be adjusted at 370 based on an actual hydrocarbon production volume. For example, as the valve 260 is operated to control the volume of kerogen breaker compound that is delivered to the rock formation 42 , the amount of hydrocarbons extracted from the rock formation 42 may not be the exact amount predicted by the geomechanical model 230 and the reservoir model 232 . In such examples, the actual value of the produced hydrocarbons can be greater or less than the value of the estimated production volume, and the first value can be adjusted to increase the difference between the costs and resulting actual value (for example, increase net profit).
[0062] In some implementations, a second value representative of an amount of heat to apply to the hydrocarbon reservoir can be provided, the DFN can be determined based on the second value, the second value can be adjusted based on the hydrocarbon production volume, and the amount of heat to apply to the hydrocarbon reservoir can be adjusted based on the adjusted second value. For example, the example bottom hole heat up value 212 can represent an amount of heat energy or heat-producing material that can be used to dissipate an amount of kerogen and affect the amount of hydrocarbon produced by the example well system 10 .
[0063] In some implementations, the volume of kerogen breaker in fracturing fluid can have a material cost, the hydrocarbon production volume can have a market value, and adjusting the first value can include determining a difference between the market value and the material cost and adjusting the first value to increase the difference. In some implementations, the amount of heat can have a heating cost, the hydrocarbon production volume can have a market value, and adjusting the second value can include determining a difference between the market value and the heating cost and adjusting the second value to increase the difference.
[0064] For example, the bottom hole heat up value 212 may indicate that $10,000 worth of acid and base would need to be delivered down hole to generate a predetermined amount of kerogen-dissipating heat, and the kerogen breaker volume value 210 may indicate that $5,000 worth of breaker compound would need to be delivered down hole to chemically dissipate a predetermined about of kerogen, and the estimated production value 240 can indicate that $100,000 worth of hydrocarbons could be extracted as a result. This would result in a $−10,000−$5,000+$100,000=$85,000 net gain. The system 200 can, for example, adjust the kerogen breaker volume value 210 to indicate that $6,000 worth of breaker compound could be used to produce an estimated production value 240 having a worth of $110,000, or a $94,000 net gain. In such an example, the system 200 can select the latter kerogen breaker volume value 210 over the first because the latter value provides a greater net return on investment in breaker compounds and heat than the former value (for example, $94,000 versus $85,000, an additional $9,000 return on an additional $1,000 investment).
[0065] In some implementations, the process 300 can include extracting a volume of hydrocarbon from the hydrocarbon reservoir based on the volume of kerogen breaker in fracturing fluid, and adjusting the first value based on the extracted volume. In some implementations, the process 300 can include extracting a volume of hydrocarbon from the hydrocarbon reservoir based on the volume of kerogen breaker in fracturing fluid, and adjust the second value based on the extracted volume. For example, the well system 10 may initially be configured to deliver the $5,000 worth of breaker compound down hole, and extract $100,000 worth of hydrocarbon as a result. The control system 200 can adjust the valve 260 to increase the amount of breaker compound being delivered down hole and detect that an additional amount of hydrocarbon is being produced from the rock formation 42 . In some implementations, the control system 200 can adjust the kerogen breaker volume value 210 , the bottom hole heat up value 212 , or both, based on the increases and decreases in the hydrocarbon volumes that can be extracted as a result, for example, to improve production volumes or profit margins for the amounts of hydrocarbon that can be extracted as a result.
[0066] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described herein may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. As another example, although certain implementations described herein may be applicable to tubular systems (for example, drill pipe or coiled tubing), implementations may also utilize other systems, such as wireline, slickline, e-line, wired drill pipe, wired coiled tubing, and otherwise, as appropriate. As another example, some criteria, such as temperatures, pressures, and other numerical criteria are described as within a particular range or about a particular value. In some aspects, a criterion that is about a particular value is within 5-10% of that particular value. Accordingly, other implementations are within the scope of the following claims. | The subject matter of this specification can be embodied in, among other things, a method for treating a geologic formation that includes providing a hydraulic fracture model, providing a first value representative of a volume of kerogen breaker in a fracturing fluid, determining a discrete fracture network (DFN) based on the hydraulic fracture model and the first value, determining a geomechanical model based on the DFN and a reservoir model based on the DFN, determining a hydrocarbon production volume based on the geomechanical model and the reservoir model, adjusting the first value based on the hydrocarbon production volume, and adjusting a volume of kerogen breaker in the fracturing fluid to a hydrocarbon reservoir based on the adjusted first value. |
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CROSS-REFERENCES TO RELATED APPLICATIONS
This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 103113943 filed in Taiwan, R.O.C. on 2014 Apr. 16, the entire contents of which are hereby incorporated by reference.
BACKGROUND
Technical Field
The disclosure relates to a locking structure, and particularly to a locking structure for fixing the electronic device at a specific position.
Related Art
Along with the invention of the smart phones, tablet PCs are used to replace the notebook gradually. However, either the smart phones or the tablet PCs, are absent from keyboard and have smaller screens than the notebooks have usually; besides, the hardware of these electronic devices are lower leveled than those of the notebooks. Consequently, the electronic devices are externally connected to other apparatuses like monitors, keyboards, or laptop computers to temporarily extend the usage of the electronic devices. Meanwhile, connectors or positioning members are required to connect and fasten the electronic devices with different apparatuses
A conventional fastening structure applies the connector structure to fasten the electronic device with the extension apparatuses; or, a simple pressable buckle is assembled on the conventional fastening structure to connect the electronic device with the extension apparatuses. However, most of the conventional fastening structures are detached from the electronic devices (or the extension devices), easily due to the poor fastening; or, when the buckle is pressed unintentionally, the electronic device is detached from the extension devices. For example, for connecting the tablet PC to the monitor, a connector and a fastening structure are assembled at the front portion of the tablet PC, so that the tablet PC is connected to the monitor via the connector, and the connection between the tablet PC and the monitor is maintained by the fastening structure. However, if the fastening structure is a pressable buckle, when the buckle is pressed unintentionally the tablet PC is detached from the monitor; even more inconveniently, the tablet PC may be broken by its fall to the ground.
SUMMARY
In view of this, the disclosure provides a locking structure, provided for fixing an electronic device. The locking structure includes a body, a worm shaft, a guide rod, a fixing base and a linkage set. The worm shaft is pivotally assembled to the body, and the worm shaft includes a rotating shaft, a guide rail and a locking member. The guide rail is annularly assembled on the rotating shaft, and the locking member is securely assembled at an end portion of the rotating shaft. The guide rod is disposed on the body, and one of two ends of the guide rod slidably assembled to the guide rail of the worm shaft. The fixing base and the linkage set are both pivotally assembled to the body. One end of the linkage set is abutted against the fixing base, and another end of the linkage set is connected to the guide rod. When the electronic device pushes the body to rotate the body by using the fixing base as a rotating center, the worm shaft axially rotates to allow the locking member to rotate from a releasing direction to a securing direction.
Based on this, when the user wants to connect the electronic device with another extension apparatus, the electronic device is assembled to the locking structure to allow the electronic device pushing the locking structure, so that the locking member of the worm shaft is rotated from the releasing direction to the securing direction, so the electronic device connects with the locking structure. Since the locking structure is assembled on the extension apparatus, the electronic device can be fastened with the extension apparatus via the locking structure. Upon detaching the electronic device from the extension apparatus, the electronic device is lifted up to return to the initial position, the locking member of the worm shaft being rotated from the securing direction to the releasing direction so as to detach the electronic device from the locking structure. Based on this, the electronic device is connected to or detached from the locking structure simply and conveniently.
The detailed features and advantages of the disclosure are described below in great detail through the following embodiments; the content of the detailed description is sufficient for those skilled in the art to understand the technical content of the disclosure and to implement the disclosure there accordingly. Based upon the content of the specification, the claims, and the drawings, those skilled in the art can easily understand the relevant objectives and advantages of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will become more fully understood from the detailed description given herein below for illustration only and thus not limitative of the disclosure, wherein:
FIG. 1 is an application schematic view ( 1 ) of a locking structure of a first embodiment of the disclosure;
FIG. 2 is an application schematic view ( 2 ) of the locking structure of the first embodiment of the disclosure;
FIG. 3 is an exploded view of the locking structure of the first embodiment of the disclosure;
FIG. 4 is a partial enlarged view of the locking structure of the first embodiment of the disclosure;
FIG. 5 is a schematic view of parts of the components of the locking structure of the first embodiment of the disclosure;
FIG. 6 is a sectional view of the locking structure of the first embodiment of the disclosure;
FIG. 7 is a sectional view of the locking structure shown in FIG. 2 ;
FIG. 8 is an operational view ( 1 ) of the locking structure of the first embodiment of the disclosure;
FIG. 9 is an operational view ( 2 ) of the locking structure of the first embodiment of the disclosure;
FIG. 10 is an operational view ( 1 ) of a locking member of the locking structure of the first embodiment of the disclosure;
FIG. 11 is an operational view ( 2 ) of the locking member of the locking structure of the first embodiment of the disclosure;
FIG. 12 is a perspective view of the locking structure of the first embodiment of the disclosure; and
FIG. 13 is a schematic view of parts of the components of a locking structure of a second embodiment of the disclosure.
DETAILED DESCRIPTION
Please refer to FIG. 1 and FIG. 2 , which are application schematic views ( 1 ) and ( 2 ) of a locking structure 1 of a first embodiment of the disclosure. As shown, the locking structure 1 is provided for fixing an electronic device 2 on a holder 31 of a screen 3 . When the user wants to assemble the electronic device 2 on the holder 31 of the screen 3 to connect the electronic device 2 with the screen 3 for displaying the information of the electronic device 2 on the screen 3 , the electronic device 2 is firstly engaged with the locking structure 1 assembled on the holder 31 , as shown in FIG. 1 . Next, as shown in FIG. 2 , by using the locking structure 1 as a rotating center, the electronic device 2 is rotated downwardly by gravity, so that the electronic device 2 is fastened at the holder 31 of the screen 3 because of the locking structure 1 . Based on this, the electronic device 2 is connected with the screen 3 via a proper engagement, so that the electronic device 2 is protected from being detached from the screen 3 .
The interior structure and the operational principle of the locking structure 1 are described as following. Please refer to FIG. 3 to FIG. 5 , which are respectively an exploded view, a partial enlarged view, and a schematic view of parts of the components of the locking structure 1 of the first embodiment. The locking structure 1 of the first embodiment includes a body 11 , a worm shaft 12 , a guide rod 13 , a fixing base 14 and a linkage set 15 .
The body 11 is approximately formed as U-shaped. The worm shaft 12 is pivotally assembled to the inner side of the body 11 , so that the worm shaft 12 is self rotatable. The worm shaft 12 includes a rotating shaft 121 , a guide rail 122 and a locking member 123 . The guide rail 1221 is annularly assembled on the rotating shaft 121 . The locking member 123 is securely assembled at an end portion of the rotating shaft 121 . As shown in FIG. 5 , the locking member 123 is a hook portion. In order to allow the worm shaft 12 to self-rotate at the inner side of the body 1 , and to concern about the convenience of the manufacturing, the body 11 includes two positioning portions 111 , and the rotating worm shaft 12 includes two positioning grooves 124 annularly disposed. When the worm shaft 12 is assembled with the body 11 , the two positioning portions 111 are disposed in the two positioning grooves 124 respectively, so that with the positioning between the two positioning grooves 124 and the two positioning portions 111 , the worm shaft 12 is self rotatable in the positioning portion 111 by using the rotating shaft 121 as a rotating center. The number of the positioning groove 124 and the positioning portion 111 are depended according to user requirements, embodiments are not limited thereto.
The guide rod 13 is disposed on the body 1 , and one of two ends of the guide rod 13 is slidably assembled to the guide rail 122 of the worm shaft 12 . As shown in FIG. 4 and FIG. 5 , the body 11 includes a supporting member 113 protruded, and the other end of the guide rod 13 is slidably assembled to the supporting member 113 , so that the guide rod 13 is balanced through the supporting member 113 .
The fixing base 14 and the linkage set 15 are both pivotally assembled to the body 1 . One end of the linkage set 15 is abutted against the fixing base 14 , and another end of the linkage set 15 is connected to the guide rod 13 . As shown in FIG. 4 and FIG. 5 , the linkage set 15 includes a first linkage rod 151 and a second linkage rod 152 . One of two ends of the first linkage rod 151 is connected to the guide rod 13 , and the other end of the first linkage rod 151 is pivotally connected to one of two ends of the second linkage rod 152 . The second linkage rod 152 is pivotally assembled to the body 11 , and the other end of the second linkage rod 152 which is not pivotally connected to the first linkage rod 151 , is abutting against the fixing base 14 . In this embodiment, the second linkage rod 152 is L-profiled, and the second linkage rod 152 is pivotally assembled to the body 11 using the perpendicular portion of the second linkage rod 152 as the pivoting center.
The fixing base 14 includes a fixing plate 141 and an abutting member 142 . The fixing plate 141 is pivotally assembled to the body 11 , and the abutting member 142 is securely assembled to the fixing plate 141 . Additionally, as shown in FIG. 3 , one of two ends of the fixing plate 141 is locked with the holder 31 of the screen 3 , and the second linkage rod 152 of the linkage set 15 is abutting against the abutting member 142 . In this embodiment, since the abutting member 142 is contacted and rubbed with the linkage set 15 frequently, the abutting member 142 is a plastic component; while in order to enhance the strength of the fixing plate 141 , the fixing plate 141 is a metal component. Based on this, screws are applied to fasten the fixing plate 141 with the abutting member 142 . In some implementation aspects, the fixing plate 141 and the abutting member 142 are both made from plastic or metal, and are formed integrally as a whole, so that a locking process is omitted during the manufacturing.
Next, please refer to FIG. 1 , FIG. 2 and FIG. 6 to FIG. 9 , in which FIG. 6 is a sectional view of the locking structure 1 of the first embodiment, FIG. 7 is a sectional view of the locking structure 1 shown in FIG. 2 , FIG. 8 is an operational view ( 1 ) of the locking structure 1 of the first embodiment, and FIG. 9 is an operational view ( 2 ) of the locking structure 1 of the first embodiment. As shown in FIG. 6 , the body 11 includes an engaging groove 112 disposed, and the engaging groove 112 is opposite to the fixing base 14 . The locking member 123 of the worm shaft 12 is protrudingly assembled in the engaging groove 112 . When the electronic device 2 is engaged in the engaging groove 112 , the locking member 123 is correspondingly inserted into the electronic device 2 .
As shown in FIG. 2 , FIG. 7 and FIG. 8 , when the electronic device 2 is engaged with the engaging groove 112 , the electronic device 2 is rotated downward in the presence of gravity; meanwhile, the electronic device 2 pushes the body 11 to rotate the body 11 by using the fixing plate 141 as a rotating center. As shown in FIG. 7 , since the fixing base 141 is secured, when the body 11 rotates counterclockwise, the body 11 drives the second linkage rod 152 which is pivotally assembled to the body 11 ; meanwhile, the second linkage rod 152 with one end thereof abutting against the abutting member 142 , rotates counterclockwise because of the abutting of the abutting member 142 . Next, the second linkage rod 152 pushes the first linkage rod 151 which is pivotally connected thereto, to move toward the electronic device 2 .
As shown in FIG. 8 and FIG. 9 , when the first linkage rod 151 is driven to move toward the Y axis direction indicated in the figures, the first linkage rod 151 pushes the guide rod 13 to move toward the Y axis direction; at the same time, since one end of the guide rod 13 is slidably assembled in the guide rail 122 of the worm shaft 12 , when the guide rod 13 moves toward Y axis direction to abut against the guide rail 122 , the worm shaft 12 is driven to rotate by using the rotating shaft 121 as a rotating center. As shown in FIG. 9 , hence the rotating shaft 121 is rotated clockwise, and the direction of the hook portion of the locking member 123 is changed, from being parallel to the X axis direction to being parallel to the Z axis direction. Here, when the hook portion of the locking member 123 is parallel to the X axis direction, the locking member 123 is defined in a releasing direction; while when the hook portion of the locking member 123 is rotated to be parallel to the Z axis direction, the locking member 123 is defined in a securing direction. When the locking member 123 is rotated to the securing direction, the hook portion of the locking member 123 which is inserted into the electronic device 2 is hooked with the electronic device 2 , so that the electronic device 2 is securely connected with the locking structure 1 .
Please refer to FIG. 10 and FIG. 11 , which are operational views ( 1 ) and ( 2 ) of the locking member 123 of the locking structure 1 of the first embodiment. FIG. 10 and FIG. 11 are illustrated in a direction from the interior of the housing of the electronic device 2 toward the locking structure 1 . The electronic device 2 includes a through hole 21 opened, and the through hole 21 is provided for inserting the locking member 123 . As shown in FIG. 6 , when the electronic device 2 is engaged in the engaging groove 112 , the locking member 123 is correspondingly inserted into the electronic device 2 , and the locking member 123 is in the releasing direction. When the electronic device 2 is rotated downward in the presence of the gravity to drive the locking structure 1 to operate in a manner as mentioned above, so that the locking member 123 is rotated to a state as shown in FIG. 11 ; that is, the locking member 123 is rotated to the securing direction. At this moment, as shown in FIG. 11 , the hook portion of the locking member 123 is hooked with the housing of the electronic device 2 , so that the electronic device 2 is connected with the locking structure 1 securely.
As shown in FIG. 1 and FIG. 3 , in order to protect the components within the body 11 , the locking structure 1 includes a cover 17 provided to enclose the body 11 , to protect the components within the body 11 , and to allow the appearance of the locking structure 1 being more attractive. Please refer to FIG. 3 to FIG. 6 again, in which the fixing plate 141 of the fixing base 14 is passing through the cover 17 to lock with the holder 31 . Based on this, the locking structure 1 is connected with the holder 31 ; when the electronic device 2 is connected with the locking structure 1 securely, the electronic device 2 is fastened on the holder 31 of the screen 3 .
Please refer to FIG. 4 and FIG. 12 , in which FIG. 12 is a perspective view of the locking structure 1 of the first embodiment. As shown, the locking structure 1 further includes a torsion spring 16 disposed on the body 11 . One of two ends of the torsion spring 16 is abutted against the body 11 , and the other end of the torsion spring 16 is abutted against the second linkage rod 152 of the linkage set 15 . When the user tends to detach the electronic device 2 from the locking structure 1 , the electronic device 2 is lifted up to return back to a horizontal position, as shown in FIG. 6 . Meanwhile, the abutting force applied to the second linkage rod 152 of the linkage set 15 is disappeared, and the second linkage rod 152 is recovered to the initial position in the presence of the recovering force provided by the torsion spring 16 .
Please refer to FIG. 9 , in which the second linkage rod 152 drives the first linkage rod 151 to move along a direction opposite to the Y axis direction at the time the second linkage rod 152 is recovered back to the initial position, and the first linkage rod 151 drives the guide rod 13 to move toward a direction opposite to the Y axis direction. At this time, with the interaction between the guide rod 13 and the guide rail 122 of the worm shaft 12 , the worm shaft 12 is rotated counterclockwise by using the rotating shaft 121 as a rotating center, such that the locking member 123 of the worm shaft 12 is rotated from the securing direction to the releasing direction. Therefore, the user can take the electronic device 2 from the engaging groove 112 .
Based on the structure and the operation of the locking structure 1 , when the user tends to connect the electronic device 2 with the screen 3 , the electronic device 2 is inserted into the engaging groove 112 , so that the electronic device 2 drives the body 11 of the locking structure 1 to rotate downward in the presence of gravity, thereby locking the electronic device 2 with the locking structure 1 . Since the locking structure 1 is provided to lock with the holder 31 of the screen 3 , the electronic device 2 is correspondingly assembled to the screen 3 . Based on this, the user connects the electronic device 2 with the screen 3 securely and simply via the locking structure 1 , so that the information of the electronic device 2 is displayed on the screen 3 . When the user wants to detach the electronic device 2 from the screen 3 , the electronic device 2 is lifted up, thereby the electronic device 2 being detached from the screen 3 and the connection between the electronic device 2 and the locking structure 1 being released. Additionally, since the locking structure 1 and the electronic device 2 are connected by the hook portion of the locking member 123 and the hook portion is hooked with the housing of the electronic device 2 , when the electronic device 2 (or the locking structure 1 ) is shaken or pulled forcefully, the connection between the screen 3 and the electronic device 2 is still maintained; that is, the structure of the present invention is steady and the conventional unintentional pressing issue can be avoided.
Please refer to FIG. 13 , which is a schematic view of parts of the components of a locking structure 1 of a second embodiment. The structure of the second embodiment is approximately the same as the first embodiment, except that in the first embodiment, the locking member 123 is the hook portion; while in the second embodiment, the locking member 123 is an anchor shaped hook member. The structure of the anchor shaped hook member allows the engagement between the locking structure 1 and the housing of the electronic device 2 being much secured, and the electronic device 2 is difficult to detach from the locking structure 1 when forced.
While the disclosure has been described by the way of example and in terms of the preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. | A locking structure for securing an electronic device includes a body, a worm shaft, a guide rod, a fixing base and a linkage set. When a user wants to connect the electronic device to another device, the user could insert the electronic device into the locking structure which is set on the device. Then, the user pushes down the electronic device to drive the locking structure and the worm shaft of the locking structure would be rotated from a releasing direction to a securing direction. When the user wants to release the electronic device, the user could push it back to the original position. Then, the worm shaft would be rotated from the securing direction to the releasing direction so the user could release the electronic device from the locking structure. Consequently, it is easy to secure or release the electronic device to another device through the locking structure. |
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BACKGROUND OF THE INVENTION
This application is a continuation in part of patent application Ser. No. 08/177,441 filed Jan. 5, 1994 and now U.S. Pat. No. 5,433,759.
This invention relates to a method for treating turf and soil to control the temperature of the soil and maintain it and the turf in a condition to promote the growth and health of the turf.
The term turf as herein used refers to the upper layer of earth that is exposed to ambient air. The turf may be bare of vegetation or support grass or the like. The term subsoil or subsoil profile as herein used refers to one or more soil layers that are situated immediately below the turf and may be made up of natural or prepared layers of various constituents such as sand, gravel, and mixes containing organic and other substances that might promote the growth and well being of plant life. The term fluid as herein used may refer to either a gas or a liquid or a mixture of the two which is capable of treating soil to control the soil temperature.
In many soil related environments, it is important to maintain the soil and turf temperature at a desired level. One such application involves putting greens found on golf courses. The special grasses used in the construction of these greens are typically temperature sensitive and some grasses cannot tolerate even relatively small changes in temperatures outside of their adaptation range. Bent grasses used on some courses in southern states are native to more northern climates and cannot tolerate high summer temperatures and humidities. As a consequence, the grass will quickly wilt if special precautions are not taken to protect it. One such procedure is to move air over the green surface using rather large and noisy electric fans. Needless to say, the equipment involved is extremely expensive to both procure and operate and detracts from the game itself. Constant watering and syringing of the grass is also employed, however, this procedure is expensive, time consuming and not wholly satisfactory in that it increases the potential for onset and spread of plant disease. Heating the greens during cold periods has proven to be an even greater problem.
There are also other applications where it is important to maintain soil and turf temperatures within a desired range. One such application relates to brooder houses for poultry where the poultry is raised on bare turf. Poultry are susceptible to many diseases and are generally intolerant to climatic changes. Keeping the soil of these brooder houses at a desired temperature has long been a problem. Here again, different types of above and below ground heating systems have been employed with varying degrees of success.
SUMMARY OF THE INVENTION
It is a primary object of this invention to improve systems for treating soil and turf.
It is a further object of the present invention to provide an underground system for heating or cooling soil and subsoil profiles.
A still further object of the present invention is to improve methods for treating the soil of golf course putting greens.
It is a still further object of the present invention to oxygenate the soil profile of a golf course green.
Another object of the present invention is to improve the health of grass areas found on golf courses and outdoor playing fields.
Yet another object of the present invention is to retrofit existing golf course greens with a system for treating the soil of the green.
Still another object of the present invention is to provide a method for utilizing energy from the earth to heat or cool specific soil regions.
While another object of the present invention is to provide a method for heating and cooling golf course green that has the further capability of quickly drawing excess water from the soil of the green.
A further object of the present invention is to provide a method for heating and cooling a grassy area that has the further ability of providing nourishment to the grass.
These and other objects of the present invention are attained by installing a gravel bed beneath the soil and turf of a putting green, said gravel having particles of a size and shape such that interconnected interstices are provided between the particles. Ambient air is pumped into the bed to first fill the interstices with air and then push the air through the soil and turf of the green to uniformly aerate the green. In one form of the invention, oxygen is added to the air moving through the soil and turf.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of these and other objects of the present invention, reference shall be made below to the detailed description of the invention which is to be read in association with the accompanying drawings, wherein:
FIG. 1 is a side elevation in section showing a golf course green embodying the teachings of the present invention for heating or cooling the green;
FIG. 2 is a perspective view in partial section showing a golf course green employing the heating and cooling system of the present invention that is equipped with a horizontally disposed ground source heat exchanger and an auxiliary blower;
FIG. 3 is a further embodiment of the present invention employing a vertically disposed ground source heat exchanger;
FIG. 4 is a further embodiment of the present invention having an alternate ground source circuit for cooling a golf green and a multiple circuit heat exchanger;
FIG. 5 is a still further embodiment of the invention wherein the system is able to nourish the turf and soil of a golf course green; and
FIGS. 6 and 7 show apparatus for reversing the flow of air moving through the treatment system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning initially to FIG. 1, there is shown one form of the invention for heating or cooling a golf course green generally referenced 10. Although the present invention will be explained in detail with reference to the treatment of the turf and subsoil of a golf green, it should be clear that the present invention has wider application and can be used in any type of similar application. Outdoor sports stadiums having grass playing fields are examples of sites where underground soil treatment is desirous. Brooder houses for various types of poultry is a still further application where underground soil treatment is highly desirous for maintaining the health of the housed poultry.
The green depicted in FIG. 1 is one that has been constructed in compliance with the specifications of the United States Golf Association (USGA). The green includes a top layer 11 that supports a grass turf 12. The top layer is about twelve inches deep and contains a mix that is 80% fine sand and 20% organic matter which is typically peat moss. Immediately below the top layer is an intermediate layer 13 that is about two to four inches deep and contains choker sand. Finally, a lower layer 14 of pea gravel about four inches deep is placed directly below choker sand layer.
Typically, buried beneath the subsoil layer of the green is a duct network that is in communication with the pea gravel bed and serves to carry excess water in the subsoil region away from the green. The duct network includes one or more main perforated feeder lines 15 that are interconnected to a series of perforated distribution lines 16--16. The lines are arranged in a herringbone pattern that is dispersed beneath the surface of the green. The lines have openings that permit excess water in the soil to be collected in the lines. The lines are laid in the ground at an angle so that the collected water is gravity fed to the drainage system servicing the golf course. As will be explained in greater detail below, existing duct network can be easily retrofitted to provide an underground heating cooling system, capable of treating the subsoil and turf of the green.
As shown in FIG. 1, the main feeder lines 15 of the present system are connected to a supply ductwork 17 which, in turn, is connected to the outlet side of a blower 19. The horizontal section of the supply duct is buried between four and ten feet below the surface of the ground at a depth wherein the ground temperature is relatively constant and not readily responsive to changes in ambient air temperature.
The length of the horizontal section is such that sufficient energy is exchanged between the ground and the air moving through the ductwork to bring the air temperature close to the ground temperature. The horizontal section of the ductwork thus acts as a ground source heat pump to either heat or cool the air moving through the ductwork, depending upon the temperature of the ambient air that is drawn into the blower.
The blower can be located some distance from the green, preferably mounted below ground level to deaden any blower noise which might be distractful to golfers playing on the course. The blower is adapted to draw in ambient air and deliver it through appropriate lines to the duct network under the green. The air is pumped at relatively low pressure and at a high volume to prevent undue heating of the air and is distributed into the gravel bed by means of openings contained in the duct lines. The gravel in the bed is of a size and shape to provide interconnected interstices between the particles. Air is pumped into the bed at a predetermined pressure such that the interstices are completely filled with high pressure air before the air is driven upwardly through the overlying soil and turf layers. Tests have shown that the air entrapped in the gravel bed will be passed upwardly through the soil and turf and will eventually escape to the surrounding atmosphere to uniformly aerate the green. The system acts much like a balloon in that the balloon cavity (gravel bed) must be completely filled before outward pressure is exerted on the balloon envelope (the soil and turf layers). In this case, however, the soil is porous and the air penetrates the envelope before the envelope can expand.
In the event the ambient air temperature is relatively high, the air will be cooled as it moves through the heat exchanger section of the system thus providing cooling to the green. If the ambient air temperature is relatively low, the air moving through the system will be warmed by the ground effect thus providing heating to the green.
A prototype system was built and tested which proved that air moving through a system of the type herein described could be pushed upward through the subsoil profile of a green constructed in accordance with USGA specifications. An air tight housing five feet long, three feet wide and two feet nine inches deep was constructed and a four inch diameter feeder line was seated in the bottom of the housing. One end of the feeder line was blocked and the other attached to a blower. The feeder line was a typical drain pipe used in association with most existing greens. The line was covered with pea gravel and the gravel layer brought to about four inches over the top of the pipe. A three-and-one-half inch layer of choker sand was placed over the pea gravel and the choker sand covered with the twelve inches of an 80-20 USGA mix. The edge region between the walls of the housing and the layers of material were sealed to prevent air from flowing along the housing walls. The subsoil profile was watered and compacted.
The blower (New York Blower Model No. 1406A-3) was driven by a three horsepower Lesson motor (Cat. No. 13126300) and was attached to the four inch feeder line that was in communication with the subsoil profile by means of a four to six inch supply line. The top of the housing was closed by a cover frame surrounding a plastic film. The edges of the cover frame were then sealed.
The blower motor was started and ambient air discharged by the blower was metered into the four inch feeder line by opening a control valve in the supply line. Perched water that collected in the subsoil was observed through a window in the housing. The plastic film in the sealed cover became inflated clearly indicating that air from the blower was flowing freely through the subsoil profile. A colored fragrance was sprayed into the ambient air being drawn into the pump. The fragrance was clearly detected at the top of the soil profile and on the plastic film. Removal of a block in the end of feeder line further showed that positive pressure air was moving through the line.
Visual observations of the perched water showed that water did not impede the flow of air through the soil profile.
Temperature measurements of the subsoil were also taken during the test. Ambient air temperature was 38° F. The initial choker sand temperature was 45° F. and the USGA mix temperature was 41° F. at the mid depth level. After a short operating time, the temperature of the choker sand and the USGA mix equalized at about 40° F. showing that the soil profile was being cooled by the ambient air moving through the system. The test was repeated showing similar results.
FIG. 2 illustrates another embodiment of the invention wherein like numbers depict like elements as those described in reference to FIG. 1. Here again, air from a blower 19 is delivered to the feeder and distributing line 15 and 16 situated beneath the green by means of a supply line 17. A flat horizontally disposed heat exchanger coil 20 is connected between the supply line and the blower discharge. The coil is again buried at least four feet below ground level and provides a sufficient heat transfer surface so that the temperature of the air moving through the line will approach that of the earth surrounding the line. An auxiliary blower 22 is connected into the supply line downstream from the heat exchanger coil and serves to help push the treated air through the supply line. The auxiliary blower preferably is situated below ground to minimize heat loss and to suppress blower noise.
FIG. 3 illustrates a further embodiment of the invention wherein a vertically disposed heat exchanger 25 is operatively connected between the supply line 17 and the discharge side of the blower 19. The heat exchanger is a U-shaped line that is sunk to a depth well below that of the supply line into cooler regions of the earth for more efficient heat transfer. A four-way reversing valve unit 27 is positioned between the discharge line 28 of the blower and the heat exchanger for reversing the flow of air through the system.
As illustrated in FIGS. 6 and 7, the reversing valve unit 27 contains four control valves 30-33 that are mounted in a bridge configuration. The entrance to the bridge is connected into the discharge line 28 of the blower. One pair of the bridge legs are connected to the heat exchanger 25 while the opposing pair of legs are connected to ambient air inlet by line 35. The exit to the bridge is connected to a return line 29 connected to the blower inlet. FIG. 6 depicts the valve positioning when the blower is providing cooling or heated air to the duct network under the turf. At this time valves 30 and 32 are closed and valves 31 and 33 are opened. Ambient air is delivered to the blower via the air inlet line 35 and the blower air discharge is pushed through the heat exchanger and the duct network.
Reversing the valve positions as shown in FIG. 7 places the inlet in communication with the heating and cooling system and its discharge in communication with ambient air. This in turn causes the blower to draw ambient air downwardly through the green soil profile. Any excess moisture or water in the subsoil is thus pulled into the duct network beneath the green. The network is arranged to drain into a sump 37 via a drain line 38 from which it is exhausted into the main drainage system servicing the golf course. A valve 40 is mounted in the drain line 38. The valve is closed when air is being pushed from the blower, and opened when the blower operation is halted.
Turning now to FIG. 4, the outlet of blower 19 is connected to a multiple circuit heat exchanger 40. Each circuit 42--42 is a vertically disposed double helix line with the circuits being buried about ten feet below ground level. The circuits are connected in parallel flow relationship and each circuit is connected to a condensate drain sump 45. The outlet of the exchanger is coupled to the under green duct network via supply line 17 to provide heating or cooling to the soil profile.
An auxiliary pipe line 47 surrounds the periphery of the green and includes a series of spaced apart pop-up heads 50--50 of the type typically used around golf courses for distributing water above ground. The auxiliary line sprinklers are attached to the normal irrigation supply line 48 by a one-quarter inch fluid line 49 servicing the course. The heads are designed to be elevated by the air pressure and distribute air/water mist over the green surface.
A valve 53 is provided in the fluid line 49 that is operable to isolate the auxiliary pipe line 47 from the normal irrigation line 48. The auxiliary pipe line is coupled to the blower supply line 17 by a shunt line 55. A valve 56 is mounted in the shunt line and a second valve 57 is similarly mounted in the supply line downstream from the shunt line. The valves 56 and 57 can be cycled to deliver air from the blower to the pop-up head which can be modified to also distribute air as well as water over the surface of the green. Valve 53 can be opened at this time to supply both water and air to the heads. This, in turn, causes a fine mist to cover the green surface thus providing for more effective green cooling. A drain system 58 is tied into the under green duct network and functions as explained above to carry away excess moisture collected in the duct network.
FIG. 5 illustrates a heating and cooling system that is similar to that described with reference to FIG. 1. Here again, the blower 19 pushes air through the supply line 17 into the under green duct network whereupon the air is forced upwardly through the soil profile. A pressurized tank 60 is mounted adjacent to the green and is connected into the supply line by means of a delivery line 61. A metering valve 62 is mounted in the delivery line. The tank may be used to store either gaseous or liquid materials for feeding and/or fortifying the soil or destroying unwanted pests and thus promote the growth and/or health of the grass. Opening the metering valve introduces the material into the air flow which, in turn, carries it upwardly through the subsoil profile where it is efficiently absorbed into the soil.
As should be evident from the disclosure above, the present system provides an effective means for treating subsoil regions to maintain the soil temperatures at desired levels. At the same time, the system can be utilized to promote drainage in these regions as well as providing for subsoil feeding and aeration. The system can be easily retrofitted to existing golf greens or other similar underground drainage systems or incorporated into new construction.
While this invention has been explained with reference to the structure disclosed herein, it is not confined to the details set forth and this invention is intended to cover any modifications and changes as may come within the scope of the following claims: | A method of treating the soil and turf of a golf course putting green that includes installing a gravel bed beneath the green and pumping air into the bed at a pressure such that the pressurized air is first distributed uniformly throughout the bed and then forced upwardly through the soil and turf of the green to treat the soil and turf. |
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FIELD OF THE INVENTION
The present invention relates to modular enclosure assemblies, and more particularly to a toothlike or denticulated flange construction enabling enclosures to be quickly assembled, without special tools.
BACKGROUND OF THE INVENTION
In the construction of optic baffles to enclose a light beam path, fixed enclosures having inlet and outlet ports are frequently employed. Alternately, modules may be constructed utilizing fasteners for securing the various panels of a baffle together. This prior art approach is expensive and time consuming when baffles must be constructed with fasteners and tools.
BRIEF DESCRIPTION OF THE PRESENT INVENTION
The present assembly is a modular approach for constructing enclosures, such as rectangular boxes and cubes of different sizes. One particular example of such a structure is an optics enclosure with internal baffles to permit unobstructed light beam paths. The size may be easily configured on a customized basis. The panels of the enclosures may be made of light, rigid material, such as poster board or tinted acrylics and can be assembled without tools, fasteners, or adhesives. In certain applications panels made of heavier materials, such as plywood or metal sheets, could be used. The panels of the completed enclosure form overlapping edges to restrict light and air currents. However, inlet and outlet ports may be formed in the panels to provide access as required.
Denticulated strips are provided for securing the edges of the panels together, thereby forming enclosures. The various lightweight panels may be held in place in the strips by push pins or equivalent fasteners to enhance rigidity, which allow simple and rapid assembly, as well as disassembly.
These denticulated strips may be made from a metal (e.g., aluminum) or a variety of plastics, machined easily with a single cutter and sliced into as many individual strips as needed. For large quantities, injection molding may be practical. A completed three-dimensional structure may be used on any flat surface or on various types of optical bench guide rails which are prevalent in optics laboratories. They may also be directly bolted to a platform or optical bench having threaded holes or a portable test platform may be the support surface--where the assembly must be moved from place to place. As will be appreciated from the following discussion, arrangements for a wide margin of strip adjustments are allowed together with a wide choice of enclosure designs. Accordingly, the present invention is particularly well suited for optical enclosures and baffles.
The present invention is also particularly well suited as a means to alleviate optical disturbances due to air currents and unwanted light leaks.
The modular enclosure assembly of the present invention provides for a lightweight and durable structure which can be utilized for a variety of functions. The present invention provides a means for the construction of a variable size configuration in which the parts therefor are inexpensive to manufacture on a production basis. Specific uses for the present invention range from the construction of modular offices and temporary cover structures to containers for field experiments in which the wind and/or sun need be blocked. The modular enclosure assembly of the present invention is designed in such a manner and constructed from materials such that the apparatus is highly transportable and easy to assemble.
BRIEF DESCRIPTION OF THE FIGURES
The above-mentioned objects and advantages of the present invention will be more clearly understood when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view illustrating the basic components of the present invention;
FIG. 2 is a perspective view illustrating the disposition of a particular denticulated strip on an apertured support surface;
FIG. 3A is a top plan view of a denticulated strip designed as a telescoping member;
FIG. 3B is a front elevational view of the strip shown in FIG. 3A;
FIG. 4 is a perspective view illustrating a number of enclosures positioned in a preselected aligned configuration to form optic baffles for a light beam;
FIG. 5 is a perspective view illustrating a denticulated strip with projections along its entire length.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures and more particularly FIG. 1 thereof, the modular enclosure of the present invention is generally indicated by reference numeral 10 and is seen to include six panels 20, 22, 24, 26, 28, 29 held in place with four denticulated strips indicated by reference numerals 12, 14, 16, and 18. The strips receive the edge portions of top and bottom panels 20 and 22, side panels 28 and 29, and end panels 24 and 26. In some cases a bottom panel 20 may not be needed. Reference numeral 30 indicates push pins or fasteners which secure the various panels to the denticulated strips, which would be used in moving the setup from one location to another.
The use of the denticulated strips 12, 14, 16, and 18 in the parallel position shown in FIG. 1 permits a six-sided enclosure to be formed. Each strip may include an elongated recess such as 52 (FIG. 1) for receiving a top or bottom panel in flush mounted relationship with the strips.
FIG. 2 illustrates another design of the denticulated strips, such as strip 12, in greater detail. The base 32 of the strip supports an orthogonally oriented denticulated flange 34 having individual parallel separated projections 36. A second, preferably deeper, flange 38 arises perpendicularly from base 32 with a second set of denticulated projections 40 which are respectively aligned with the projections 36 of flange 34. The end projections 42 and 42A overlap the confronting, adjacent projections 43, 45. The channel 44 is created between projections 42 and adjacent projections 43, 45, thereby receiving the edge portion of a panel such as 24 (FIG. 1). Holes 46 are formed in the projection 42 and 43 for receiving the push pins or equivalent fasteners 30, shown in FIG. 1, which serve as fasteners for the assembly. Note, that the push pins 30 serve only as temporary securing devices.
The channel 48 (FIG. 2) extends longitudinally between the projections on flanges 34 and 38. This elongated channel permits the insertion of a bottom edge portion of a side panel 28, as shown in FIG. 1.
The end panel 24, as illustrated in FIG. 1, is received within channel 44A (FIG. 2). Holes 50 formed along flange 34 serve to receive push pins 30, as shown in FIG. 1--for temporarily securing end panel 24 to the denticulated strip 12.
In FIG. 2, strip 12 is seen to rest against a support surface 54, for example, an optical bread board, having threaded holes 56. Threaded fasteners 58 pass through a slot or openings 60 (view occluded) existing along a non-denticulated section 61 of strip 12.
FIGS. 3A and 3B illustrate a further embodiment of the present invention wherein the length of each denticulated strip may be easily altered due to the telescoping nature of each strip. In FIGS. 3A and 3B, a recess 62 is formed within the left end portion of a strip while the right end portion includes an elongated tabular section 64. A step-down section 38A of the left end portion includes a longitudinally extending slot 66 aligned with perpendicularly oriented openings 68 formed in the section 64. Threaded fasteners 70 are received within threaded openings 68 in the section 64 for adjusting the telescoping length of the strip. Accordingly, openings 68 should be tapped, i.e. threaded, for receiving the threaded fasteners 70. It should also be noted that the openings 68 need not be individual holes, but rather a continuous longitudinal opening for ease of adjustment. Foreshortened channel 52A separates the forward and rearward projections of the left-hand section and receives the lower edge of a panel. The channel 52A exists on the right-hand section of the strip for also receiving a correspondingly positioned portion of a panel. In FIG. 3B recess 51A receives a lower panel 20 (FIG. 1) in flush relationship as previously mentioned. The ability to clamp the two sections with threaded fasteners 70 and tapped openings 68 is of use when the surface on which the enclosure is to rest provides no threaded holes.
In FIG. 4 a number of enclosures are assembled and positioned adjacent to one another to form optic baffles having inlet and outlet ports 72 formed in certain panels to allow passage of a light beam 74 through the baffles as illustrated. The reflective surfaces or mirrors 76 would incorporate mirror or beam splitters in conventional fashion.
An alternate embodiment of present invention shown in FIG. 5 is envisioned to include denticulated strips having projections along the entire length thereof--to allow utilization flexibility if it is required. The completed assembly is intended to form overlapping edges to restrict light leaks and/or air currents within an enclosure so that it is very well adapted as an optical enclosure and baffle. The assembly itself may be designed to rest against a flat surface or may be adapted to rest against an optical guide rail assembly.
As will be appreciated from the above-described invention, a modular enclosure may be quickly assembled or disassembled--without the necessity of special tools. This not only affords an efficient means for constructing enclosures but the reusability offers an economical advantage.
Features of the invention are: (a) modular concept accommodates various enclosure sizes, shapes, and materials; (b) panels and strips can be custom made for a particular application; (c) alternately, a selection of standard size panels and strips can be created; (d) access openings can be included in panels for input and output ports and internal baffles; (e) overlapping edges restrict light leakage and air currents; and (f) provisions for fasteners can be included in the strip and panel designs if needed.
It should be understood that the invention is not limited to the exact details of construction shown and described herein for obvious modifications will occur to persons skilled in the art. | Denticulated strips receive orthogonally disposed panels to form rectangular or cube enclosures of desired sizes. They are quickly assembled utilizing push pins. The panels are designed to have overlapping edges so that they minimize light/air leakage--making them particularly adaptable as optic baffles. |
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional Patent Application No. 61/681,536 filed Aug. 9, 2012, entitled COMBINATION CABLE RESET MECHANISM which is incorporated herein by reference.
BACKGROUND
The disclosed embodiments generally pertain to locks, and particularly to combination cable reset mechanisms.
SUMMARY
A resettable lock assembly is provided having features that indicate when the lock is in reset mode or normal-use mode.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
Embodiments of the invention are illustrated in the following illustrations.
FIG. 1 illustrates a first embodiment of a lock assembly in a normal-use mode.
FIG. 2 depicts the lock assembly of FIG. 1 in a reset mode.
FIG. 3 shows a reset knob of the lock assembly of FIG. 1 .
FIG. 4 shows a reset knob spacer as used in conjunction with the reset knob of FIG. 3 .
FIG. 5 depicts a detent system on a plastic reset knob.
FIG. 6 depicts a detent system on a die cast reset knob.
FIG. 7 is a cross-sectional view of a first embodiment of a lock assembly in reset mode.
FIG. 8 is a cross-sectional view of the lock assembly in FIG. 7 in a normal-use mode.
FIG. 9 illustrates a second embodiment of a lock assembly.
FIG. 10 is a cross-sectional view of a second embodiment of a lock assembly in a reset mode.
FIG. 11 is a cross-sectional view of the lock assembly in FIG. 10 in a normal-use mode.
DETAILED DESCRIPTION
Referring now to FIG. 1 , an embodiment of a lock assembly 100 is shown in normal-use mode with the reset knob 102 in a first position and the outer dials 104 and knob spacer 106 tight to the lock body 108 . Referring to FIG. 2 , the lock assembly 100 is shown in reset mode with the reset knob 102 in a second position and the outer dials 104 and knob spacer 106 moved away from the lock body 108 exposing a colored indicator 110 between the outer dials 104 and lock body 108 .
Referring now to FIG. 3 , the reset knob 102 is provided with outer ramps 112 and inner ramps 114 . The reset knob is also provided with detent tabs 116 to provide feedback to the user. Referring now to FIG. 4 , the knob spacer 106 is provided with knob ramps 118 that interact with the outer ramps 112 on the reset knob 102 . This interaction is explained in greater detail herein.
Referring to FIGS. 5 and 6 , detent systems are shown that provide feedback to the user to affirm whether the lock has been fully switched between normal-use and reset modes. In FIG. 5 , an elastic tab 116 on a plastic reset knob 102 is provided to interact with a recess on an inner lock post 120 . Similarly in FIG. 6 , a spring mechanism 122 on a die cast reset knob is provided to interact with recesses on an inner lock post 120 .
Referring now to FIGS. 7 and 8 , cross-sectional views of a lock assembly 100 are shown in reset and normal-use modes, respectively. The lock assembly 100 is provided with outer dials that are biased to the right of FIGS. 7 and 8 by an outer dial spring 126 . The assembly 100 is further provided with inner dials 124 that are biased to the right of FIGS. 7 and 8 by an inner dial spring 128 . The assembly 100 further comprises a reset slide 130 and a spring spacer 132 . The spring spacer 132 is also provided with the colored indicator 110 shown in FIG. 1 .
As shown in a reset mode in FIG. 7 , the reset knob 102 on the lock assembly 100 is in a first rotational position. In this first position, the outer ramps 112 on the reset knob 102 are disengaged from the knob ramps 118 on the knob spacer 106 . This allows the outer dials 104 to be biased by the outer dial spring 126 and translate to the right of the Figure exposing the colored indicator 110 . With the reset knob in the same position, the inner ramps 114 on the reset knob 102 are engaged with the reset slide 130 . This pushes the inner dials 124 against the bias of the inner dial spring 128 and translates the inner dials 124 to the left of the Figure. Accordingly, the outer dials 104 and inner dials 124 are disengaged allowing the user to reset the lock combination.
As shown in normal-use mode in FIG. 8 , the reset knob 102 on the lock assembly 100 is in a second rotational position. In this second position, the outer ramps 112 on the reset knob 102 are engaged with the knob ramps 118 on the knob spacer 106 . This allows the outer dials 104 to overcome the bias of the outer dial spring 126 and translate to the left of the Figure hiding the colored indicator 110 . With the reset knob in the same position, the inner ramps 114 on the reset knob 102 are disengaged from the reset slide 130 which allows the inner dial spring 128 to bias and translate the inner dials 124 to the right of the Figure. Accordingly, the outer dials 104 and inner dials 124 are engaged allowing the user to use the lock.
As shown in FIGS. 7 and 8 , the reset knob 102 moves from a first position to a second position by rotational movement.
Another embodiment of a lock assembly 200 is shown in FIGS. 9-11 in which the outer dials 204 are linearly fixed. Referring to FIG. 9 , the outer dials 204 are tight to the lock body 208 regardless of whether the lock assembly 200 is in normal-use or reset mode. To indicate to a user which mode the lock assembly 200 is in, the knob spacer 206 is provided with an indicator window 210 to visually see a colored indicator 211 on the reset knob 202 .
As shown in reset mode in FIG. 10 , the reset knob 202 on the lock assembly 200 is in a first rotational position. In this first position, inner ramps 214 on the reset knob are engaged with a reset slide 230 . This pushes the inner dials 224 against the bias of an inner dial spring 228 and translates the inner dials 224 to the left of the Figure. Accordingly, the outer dials 204 and inner dials 224 are disengaged allowing the user to reset the lock combination.
Referring now to FIG. 11 , the lock assembly 200 is shown in normal-use mode. The reset knob 202 on the lock assembly 200 is in a second rotational position. In this second position, inner ramps 214 on the reset knob 202 are disengaged from the reset slide 230 which allows the inner dial spring 228 to bias and translate the inner dials 224 to the right of the Figure. Accordingly, the outer dials 204 and inner dials 224 are engaged allowing the user to use the lock.
As shown in FIGS. 10 and 11 , the reset knob 202 moves from a first position to a second position by rotational movement. While the reset knob 202 is in the reset mode, a colored indicator 211 on the reset knob 202 shows through an indicator window 210 on the knob spacer 206 .
The foregoing written description of structures and methods has been presented for purposes of illustration. Examples are used 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 examples are not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and many modifications and variations are possible in light of the above teaching. Features described herein may be combined in any combination. Steps of a method described herein may be performed in any sequence that is physically possible. The patentable scope of the invention is defined by the appended 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 languages of the claims. | A resettable lock assembly is provided having features that indicate when the lock is in reset mode or normal-use mode. The lock assembly may include a reset knob operable in a first rotational position and a second rotational position. When the reset knob is in the first rotational position, the lock assembly is in a reset mode and a visual indicator is visible. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to safety valves and devices used within a wellbore.
[0003] 2. Description of the Related Art
[0004] In the oil and gas industry, subsurface safety valves are used as a means of stopping the production of hydrocarbons in the event of an unexpected catastrophe or a planned shut down of a well. Most subsurface safety valves are hydraulically controlled from the surface facility by connecting a hydraulic control line to surface pumping equipment. Application of pressure at the surface is transmitted to the safety valve to open the device. Subsurface safety valves are typically installed into the well as a part of the production tubing string. Accordingly, these safety valves are typically referred to as tubing retrievable safety valves (TRSVs). In the event that the TRSV fails or stops functioning properly, it is possible to install a smaller safety valve into the interior diameter of the existing TRSV by running the smaller valve into the production tubing on wireline. The smaller installed valve is referred to as a wireline insert safety valve (WLSV). The WLSV operates off of the hydraulic pressure of the TRSV. Before running the WLSV into the TRSV, it is necessary to create a communication chamber between the TRSV and the wellbore. Several tools or methods can be used to accomplish fluid communication with the hydraulic chamber of the TRSV. Once communication is established, the WLSV is landed into the TRSV. A set of seals located on the upper portion and the lower portion of the WLSV land above and below the TRSV. The seals prevent the hydraulic fluid from escaping into the wellbore and allow the WLSV to operate off of the hydraulic control line of the TRSV.
[0005] It is problematic to utilize a wireline insert safety valve where the TRSV uses electrical power rather than hydraulic power to be actuated. There is no mechanism for transmitting hydraulic power to the wireline insert valve. In addition, if the WLSV is electrically powered, it is difficult to transmit electrical power to the WLSV in a reliable manner. Downhole environments are filled with debris and are extremely corrosive environments. Solids can build up on exposed areas of a downhole valve, including electrical contacts. An electrical plug or port for electrically mating the TRSV and WLSV would likely become exposed and filled with debris to make an electrical connection difficult, if not impossible.
SUMMARY OF THE INVENTION
[0006] The invention provides methods and devices for utilizing an electrically-actuated wireline insert safety valve and for delivering power to an electrically actuated WLSV without the use of wired contact. In a preferred embodiment, inductive charging is used to deliver actuating power from a TRSV to a WLSV. There are preferably no exposed metallic contacts to corrode, and the electronic compartments are preferably sealed to prevent water corrosion or physical damage from debris within the wellbore.
[0007] In a described embodiment, an electrically-powered tubing-run safety valve is provided with an induction charging coil that is sealed within the valve housing. A wireline-run insert safety valve is also provided with an induction charging coil that is operably interconnected with a valve actuator assembly that is operable to cause a safety valve member, such as a flapper member, to be operated within the safety valve.
[0008] In an aspect of the present invention, the WLSV may be selectively inserted into the production tubing string which carries the TRSV. The WLSV is preferably landed within a landing profile associated with the TRSV. When landed, the induction charging coils of the TRSV and WLSV become substantially aligned to form an inductive coupling. Energizing the induction charging coil of the TRSV will transmit electrical energy to the coil of the WLSV. The transmitted electrical energy is used to actuate the WLSV valve actuator assembly and safety valve. In an alternative embodiment, the transmitted electrical energy is preferably stored within a charge storage device in the WLSV, and the stored electrical energy is thereafter used to actuate the WLSV valve actuator assembly and safety valve.
[0009] In certain embodiments, the WLSV may be actuated from the surface by a wireless signal to a wireless receiver that is operably interconnected with the WLSV valve actuator assembly. In this instance, the wireless transmitted will command the WLSV to remain in the open position, and the WLSV valve member will move from the closed position to the open position. Thereafter, current supplied to the WLSV from the induction charging coil in the TRSV will retain the WLSV in the open position. The WLSV can be closed by deenergizing the induction charging coil in the TRSV.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
[0011] FIG. 1 is a side, partial cross-sectional view of an exemplary wellbore containing a production string with subsurface safety valves constructed in accordance with the present invention.
[0012] FIG. 2 is a side, cross-sectional view of an exemplary tubing-retrievable safety valve, in accordance with the present invention, with the valve in an open configuration.
[0013] FIG. 3 is a side, cross-sectional view of the tubing-retrievable safety valve shown in FIG. 2 , now in a closed configuration.
[0014] FIG. 4 is a side, cross-sectional view of an exemplary wireline insert safety valve constructed in accordance with the present invention.
[0015] FIG. 4 a is an enlarged side cross-sectional view of portions of the wireline insert safety valve shown in FIG. 4 .
[0016] FIG. 5 is a side, cross-sectional view of the wireline insert safety valve inserted within the tubing-retrievable safety valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] FIG. 1 illustrates an exemplary wellbore 10 that has been disposed within the earth 12 from the surface 14 and down to a hydrocarbon-bearing formation 16 from which it is desired to obtain hydrocarbon production fluid. The wellbore 10 is lined with metallic casing 18 in a manner known in the art. Perforations 20 are formed through the casing 18 and into the formation 16 .
[0018] A production tubing string 22 is disposed within the wellbore 10 , and an annulus 24 is formed between the production tubing string 22 and the casing 18 . A central axial flowbore 23 is defined along the length of the production tubing string 22 for flow of fluids therethrough. The production tubing string 22 may be made up of a number of threaded production tubing string segments, in a manner known in the art. Alternatively, the production tubing string 22 may be formed of coiled tubing. The production tubing string 22 includes a ported production nipple 26 , of a type known in the art, which is located within the wellbore 10 proximate the perforations 20 . Packers 28 isolate the production nipple 26 within the wellbore 10 .
[0019] The production tubing string 22 also includes an electrically-powered tubing-retrievable safety valve assembly (TRSV) 30 above the production nipple 26 . An electrical power supply cable 32 extends from the valve assembly 30 to the surface 14 wherein it is operably associated with a power source 34 . The safety valve assembly 30 is preferably a flapper-type safety valve which is operable between open and closed positions to selectively block fluid flow through the production tubing string 22 . The TRSV 30 includes a tubular outer housing 36 which defines a central axial valve bore 38 which is aligned with the flowbore 23 of the production tubing string 22 . The valve bore 38 contains a landing profile 40 . In addition, seal bores 42 , 44 are located within the valve bore 38 . The seal bores 42 , 44 are smooth bore portions that for packing stacks of seals on a component disposed inside the valve bore 38 to seal against the seal bores 42 , 44 .
[0020] The housing 36 of the valve assembly 30 includes an induction charging coil 46 which is preferably fully enclosed within the housing 36 and separated from the valve bore 38 . The induction charging coil 46 is operably associated with the power supply cable 32 so that the coil 46 may be energized from the surface 14 . The power supply cable 32 is also operably associated with a flapper valve actuator, which is depicted schematically at 48 . The valve actuator 48 is interconnected with valve piston assembly 50 . The valve piston assembly 50 includes a piston cylinder 52 and a piston member 54 that is movably disposed within the cylinder 52 . The piston member 54 is interconnected with a flow tube 56 which controls the position of pivotable flapper member 58 , in a manner known in the art. The flapper member 58 is a known device which is moveable about pivot point 59 between an open position, illustrated in FIG. 2 , wherein fluid may pass through the valve bore 38 , and a closed position, illustrated in FIG. 3 , wherein fluid flow through the valve bore 38 is blocked by the flapper member 58 . As is known, the flapper member 58 is biased by a torsional spring toward the closed position. The flow tube 56 is moveably disposed within a radially enlarged bore portion 60 of the valve bore 38 . The flow tube 56 is biased toward the closed position by a compressible power spring 61 , of a type known in the art. This spring bias provides for the valve assembly 30 to have a fail-safe mode such that, in the event of loss of a control signal from the surface (e.g., an electrical signal via cable 32 ), the power spring 61 will lift the flow tube 56 (see FIG. 3 ) and allow the flapper member 58 to rotate to its closed position. When the flow tube 56 is in a lowered position within the bore portion 60 , as depicted in FIG. 2 , the flow tube 56 retains the flapper member 58 in the open position. When the flow tube 56 is moved to an upper position within the bore portion 60 , the flapper member 58 moves to its closed position against valve member seat 62 , as depicted in FIG. 3 . The flapper valve actuator 48 may be a fluid pump, a motor, an electromagnetic solenoid, or an-electro-hydraulic actuator device which is operable to cause movement of the piston member 54 within the piston cylinder 52 . One suitable electro-hydraulic valve actuator is described in U.S. Pat. No. 6,269,874 issued to Rawson et al. U.S. Pat. No. 6,269,874 is owned by the assignee of the present invention and is hereby incorporated in its entirety by reference.
[0021] FIG. 4 illustrates an exemplary wireline insert safety valve 70 which is insertable into the production tubing string 22 and securable within the tubing run safety valve 30 in the event that the tubing-run safety valve 30 fails to operate. The wireline insert safety valve 70 includes a tubular valve housing 72 which is shaped and sized to fit within the valve bore 38 of the tubing run safety valve 30 . An axial flowbore 74 is defined along the length of the valve housing 72 . The valve housing 72 is secured by release pins 76 to a wireline running tool 78 . The housing 72 carries a plurality of latching keys 80 which are biased radially outwardly by compression-springs 82 . A flapper member 84 is also located within the flowbore 74 and is pivotable about pivot point 86 between open and closed positions within the flowbore 74 . As with the flapper member 58 , the flapper member 84 is biased toward a closed position by a torsional hinge spring. An axially moveable flow tube 88 is retained within a radially enlarged portion 90 of the flowbore 74 . The flow tube 88 is spring-biased by an axially compressible power spring 91 (see FIG. 4 a ) toward a position that would lift the flow tube 88 and allow the flapper member 84 to be closed. The flow tube 88 serves the same purpose in controlling the flapper member 84 as the flow tube 56 does in controlling the configuration of the flapper member 58 . A pair of external fluid seals 93 radially surrounds the valve housing 72 (see FIG. 4 ).
[0022] An electric flapper member actuating assembly, generally indicated at 92 , is preferably housed within the housing 72 of the valve 70 . The flapper member actuating assembly 92 includes an induction charging coil 94 which is preferably sealed within the housing 72 so as to not be in contact with either the flowbore 74 or the radial outer surface of the tool 70 . The induction charging coil 94 is operably interconnected with a charge storage device 96 , such as a rechargeable battery. The charge storage device 96 is operably interconnected with a valve actuator, shown schematically at 98 . In an alternative embodiment, the coil 94 is directly connected with the valve actuator 98 such that energizing the coil 94 will cause the valve actuator 98 to be operated. In one preferred embodiment, the valve actuator 98 also includes a wireless receiver that is operable to receive a wireless signal from a surface-based wireless transmitter 99 and, in response to receipt of such a signal, will generate a command to actuate the associated valve piston assembly 100 . The valve actuator 98 is interconnected with valve piston assembly 100 . The valve piston assembly 100 includes a piston cylinder 102 and a piston member 104 that is movably disposed within the cylinder 102 . The piston member 104 is interconnected with the flow tube 88 which controls the position of pivotable flapper member 84 . When the valve actuator 98 is actuated, the spring bias provided by the power spring 91 is overcome by the actuator 98 . The valve actuator 98 may be a fluid pump, a motor, an electromechanical solenoid, or an electro-hydraulic actuator device which is operable to cause movement of the piston member 104 within the piston cylinder 102 . Upon loss of power to the valve actuator 98 , the valve member 84 will be closed due to the fail-safe spring bias of the power spring 91 .
[0023] FIG. 5 depicts the WLSV 70 landed securely within the valve bore 38 of the TRSV 30 so that the keys 80 of the WLSV 70 are latched into the landing profile 40 of the radially surrounding TRSV 30 . When the keys 80 are latched into the landing profile 40 , the induction charging coil 94 of the WLSV 70 is in proximity to the induction charging coil 46 of the TRSV 30 such that electrical energy can be effectively transferred from the coil 46 to the coil 94 via induction charging. It can be seen from FIG. 5 that, when the wireline insert valve 70 is landed within the landing profile 40 , the induction charging coil 94 of the WLSV 70 is preferably generally aligned with the induction charging coil 46 of the TRSV 30 to form an inductive coupling. Energizing the coil 46 of the TRSV 30 will cause the coil 94 to be energized via inductive charging. When the WLSV 70 is landed within the landing profile 40 , the fluid seals 93 on the outer radial surface of the WLSV valve housing 72 form a seal against the seal bores 42 , 44 of the TRSV 30 .
[0024] In operation, the WLSV 70 may be used as a back-up valve in the event that the TRSV 30 fails to operate. When the TRSV 30 fails, the WLSV 70 is affixed to the wireline running tool 78 and is run into the tubing string 22 . The WLSV 70 is lowered through the production tubing string 22 until the keys 80 of the WLSV 70 become latched into the landing profile 40 . Following landing, electrical power is transmitted from the surface through the cable 32 to the induction coil 46 of the TRSV 30 to energize the coil 46 . Via induction charging, electric charge is transmitted from the outer coil 46 to the induction charging coil 94 of the WLSV 70 . The transmitted electrical charge is stored in the storage device 96 or, alternatively, used to directly retain the flapper member in the open position.
[0025] When a sufficient amount of electrical charge has been transmitted to the WLSV 70 , the WLSV 70 may be selectively actuated to move the flapper member 84 between its open and closed positions. In one preferred embodiment, the WLSV 70 is run into the production tubing string 22 in the closed position. Once sufficient electrical charge has been transmitted to the induction charging coil 94 , the valve actuator 98 causes the piston member 104 to be moved axially within the cylinder 102 so that the flow tube 88 is moved axially downwardly within the housing 72 , resulting in the flapper member 84 being moved to the open position. In the event of a loss of power to the charging coil 94 , the flapper member 84 would rotate to the closed position as the power spring 91 moves the flow tube 88 upwardly.
[0026] Use of the wireless transmitter 99 to operate the WLSV 70 is preferred when used in connection with a charge storage device 96 . In this instance, the WLSV 70 would be again run into the production tubing string 22 in the closed position. Transmission of power from the surface to induction charging coil 94 will then store electrical charge within the storage device 96 . When it is desired to open the WLSV 70 , a wireless command is transmitted from the transmitter 99 to the valve actuator 98 .
[0027] The WLSV 70 may alternatively be actuated to close the flapper member 84 by transmitting a wireless signal from the transmitter 99 to the valve actuator 98 . The valve actuator 98 causes the piston member 104 to be moved axially within the cylinder 102 . As the piston member 104 is moved within the cylinder 102 , the flow tube 88 is moved axially upwardly with respect to the surrounding housing 72 to allow the flapper member 84 to rotate to its closed position, thereby blocking fluid flow through the flowbore 74 of the housing 72 . Due to the seal formed between the seals 42 , 44 of the TRSV 30 and the housing 72 of the WLSV 70 , any fluid flow through the flowbore 38 of the TRSV 30 and production tubing string 22 is thereby blocked by the flapper member 84 .
[0028] The TRSV 30 and WLSV 70 collectively form a safety valve arrangement that will allow the flowbore 23 of the production tubing string 22 to be selectively closed off to fluid flow even in the event that the TRSV 30 becomes inoperable and is no longer able to close off fluid flow through the flowbore 23 .
[0029] 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 those 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. | Methods and devices for utilizing an electrically-actuated wireline insert safety valve (WLSV) and for delivering power to an electrically actuated WLSV via inductive charging and without the use of wired contact. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a grille shelter and particularly to a grille shelter capable of moving from a closed position for use in storing a grille to an open position that allows a user to use the grille for cooking while the grille remains positioned inside the grille shelter.
[0003] 2. Discussion of Related Art
[0004] Barbecue grilles are a popular cooking device used to prepare and cook food outdoors. Typically, they are stored outdoors due to their style and weight, and to make them convenient for use. To reduce the grille's exposure to the weather, many types of covers are available. Some grille covers are made of nylon, canvas or other suitable fabric material. Unfortunately, these types of covers often tear or become damaged after prolonged exposure to the effects of sun, rain or snow. Other types of grille covers are constructed with rigid materials such as plastic or other suitable materials to provide a more robust and weather resistant cover. Although more durable, they tend to be heavy and difficult to lift and place over a grille for storage and to remove from a grille for use.
[0005] In addition to the aforementioned shortcomings of grille covers currently available in the art, there are no known covers capable of providing a storage facility for a grille that will also allow for use of the grille while positioned within that storage facility. When a user desires to use the grille for cooking, he or she must either remove the cover from the grille, or remove the grille from its storage location. Often, even when a grille is covered with a grille cover, the user must also move the grille to a suitable location for use in order to accommodate for smoke and heat that is generated when cooking on a grille.
[0006] Thus, there is a desire and need in the art to provide a grille cover or storage facility configured to provide for storage and protection of the grille while not in use, and with the ability to allow for use of the grille while it remains located within the grille storage facility.
SUMMARY OF INVENTION
[0007] Accordingly, the present invention provides a grille shelter configured to store an outdoor cooking device, such as a barbecue grille, to protect it from the effects of weather and other damaging elements while providing an aesthetically pleasing appearance. The grille shelter of the present invention is also configured to allow for use of the grille to cook food while the grille remains positioned within the grille shelter.
[0008] In one embodiment of the present invention, a grille shelter includes a housing comprising a rear wall, a first side wall and a second side wall. A roof member is pivotally connected to a top edge of the housing. At least one pivoting panel is pivotally connected to at least one of the first side walls and is moveable between a first position, wherein a user may access the grille within the shelter, and a second position wherein the shelter conceals a grille contained therein.
[0009] In another embodiment of the present invention, a grille shelter includes a rear wall, a first side wall and a second side wall connected to opposing ends of the rear wall. A roof member is pivotally connected to a top edge of the rear wall and at least one pivoting panel is pivotally connected to at least one of the side walls. The roof member is moveable between a first position and a second position. The pivoting panel is moveable between a first position and a second position.
[0010] Other features of the present invention will become more apparent to persons having ordinary skill in the art to which the present invention pertains from the following description and claims taken in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The foregoing features, as well as other features, will become apparent with reference to the description and figures below, in which like numerals represent like elements, and in which:
[0012] FIG. 1 is a front perspective view of a grille shelter of the present invention in a first position;
[0013] FIG. 2 is a perspective view of a housing of the present invention;
[0014] FIG. 3 is a side view of a grille shelter of the present invention in a first position;
[0015] FIG. 4 is a front perspective view of a grille shelter of the present invention in a second position;
[0016] FIG. 5 is a top view of a grille shelter of the present invention in a first position with the sides fully pivoted outward;
[0017] FIG. 6 is a front perspective view of an embodiment of a grille shelter of the present invention; and
[0018] FIG. 7 is a top view of the embodiment shown in FIG. 6 .
DETAILED DESCRIPTION
[0019] The present invention provides a grille shelter configured to store a barbecue grille to protect it from the effects of weather and other damaging elements and provide an aesthetically pleasing appearance. The grille shelter of the present invention includes one or more moveable panels and a moveable roof, which allow the user to reconfigure the grille shelter between a first (open) and second (closed) position to permit use of the grille to cook food while the grille remains positioned within the grille shelter.
[0020] Referring to FIGS. 1-4 , in one embodiment of the present invention, a grille shelter 20 may include a frame assembly 22 , a rear wall 24 , a first side wall 26 , and a second side wall 28 forming a housing 32 , and a roof member 30 . Frame assembly 22 may include a plurality of frame members constructed with conventional materials such as steel, aluminum, fire retardant wood beams or other suitable structural framing materials. Frame assembly 22 may be bolted, nailed, threadably fastened together, or connected by any other suitable attachment method known in the art. Depending on the type of material used to construct the various walls of grille shelter 20 , frame assembly 22 may not be necessary. In such a configuration, the walls 24 , 26 and 28 of grille shelter 20 may be connected directly to each other and the roof member 30 may be connected directly to one or more of the walls 24 , 26 and 28 . Alternatively, rear wall 24 and first and second side walls 26 and 28 may be formed as one unit. These alternative embodiments may work best with sheet metal, plastic or other strong light-weight material. Such materials may be provided with a decorative surface layer, for example, wood grain or decorative enamel.
[0021] It is also noted that the embodiment of grille shelter 20 illustrated in the figures envisions a grille shelter 20 constructed primarily of wood. It is to be understood, however, that grille shelter 20 may alternatively be constructed of other materials such as masonry, steel or plastic. Other materials may be desired to achieve a specific aesthetic appearance, but will not affect the functional benefits provided by the present invention.
[0022] For the illustrated embodiment, rear wall 24 and first and second side walls 26 and 28 may be connected to frame assembly 22 such that first and second side walls 26 and 28 are positioned on opposite ends and adjacent to rear wall 24 . As stated, rear wall 24 and first and second side walls 26 and 28 may be constructed of wood or any other suitable material such as plastic or steel. In the embodiment shown in the figures, rear wall 24 and first and second side walls 26 and 28 may be connected to frame assembly 22 utilizing a variety of attachment methods, such as a threaded connection using screws or bolts, nails, straps, pins or any other variety of known attachment means. As shown in the figures, first and second side walls 26 and 28 only extend forwardly to about the middle of the width of the grille shelter.
[0023] A first pivoting panel 34 and a second pivoting panel 36 may be pivotally or hingedly attached to first and second side walls 26 and 28 respectively with first hinged attachment 27 as shown in FIG. 1 . If a relatively small grille is to be sheltered, a single pivoting panel may suffice. First and second pivoting panels 34 and 36 may include a first section 38 and second section 40 configured to enclose the front corners of grille shelter 20 as shown in FIG. 4 . First and second sections 38 and 40 may alternatively be pivotally or hingedly connected at the corners to allow for even more flexibility when opening grille shelter 20 as shown at connection 39 in FIGS. 6 and 7 . In an embodiment where the housing 32 is formed with the walls 24 , 26 and 28 as a single sheet, panels 34 and 36 may be attached to the forward edges thereof.
[0024] First and second panels 34 and 36 allow grille shelter 20 to be repositioned from a first position as shown in FIG. 1 , to a second position as shown in FIG. 4 . In the second position, first and second pivoting panels 34 and 36 form the front corners of grille shelter 20 and come together at a location in the front of grille shelter 20 as shown in FIG. 4 . A latch assembly 42 may be used to securely connect first and second pivoting walls 34 and 36 in the second position. A variety of latch assemblies known and available in the art may be incorporated and used as latch assembly 42 . Latch assembly 42 may also be configured to accept a conventional lock to further secure the grille within grille shelter 20 . As many grilles available in the art are very expensive, it may be desirable to protect the grille or other items placed within the grille shelter from potential theft.
[0025] A cover such as roof member 30 may be pivotally or hingedly attached to frame assembly 22 , adjacent to rear wall 24 with a third hinged attachment 29 as shown in FIGS. 1 and 3 . Other suitable attachment methods may be utilized that allow roof member 30 to pivot upwardly and rearwardly above rear wall 24 and side walls 26 and 28 . At least one support member 44 may be connected to the housing 32 as shown in FIGS. 1 and 3 to hold roof member 30 in the first/second position. Support member 44 may include a typical hydraulic or pneumatic cylinder similar to those used to hold the hood of a vehicle in an open position. Roof member 30 may alternatively be hingedly attached directly to one of the walls 24 , 26 and 28 in an embodiment where no frame assembly 22 is utilized. Likewise, support member 44 may alternatively be connected to first and second side walls 26 and 28 as opposed to frame assembly 22 .
[0026] To place first and second pivoting panels 34 and 36 in the first position, the user may move first and second pivoting panels 34 and 36 outwardly away from each other to the desired open position as shown in FIGS. 1 and 5 . The pivoting relation between first and second pivoting panels 34 and 36 and side walls 26 and 28 allow first and second front pivoting panels 34 and 36 to be easily moved to the first position. The first position may include any of a variety of configurations of first and second pivoting panels 34 and 36 depending on the needs of the user. In one embodiment, pivoting panels 34 and 36 may be moved to a fully opened position to allow the greatest possible access to the grille as shown in FIG. 5 . This type of positioning may be desirable to provide additional space for persons working with the grille or standing nearby, particularly in situations such as parties and cookouts. Also, in an embodiment where first and second sections 38 and 40 are pivotally or hingedly attached to one another, pivoting panels 34 and 36 may be positioned in a variety of additional orientations.
[0027] With roof member 30 and pivoting panels 34 and 36 moved to the first position, a user may access the barbecue grille contained inside grille shelter 20 and use the grille for cooking. Thus, the user may access the grille for cooking purposes without having to move the grille out of its stored position. The positioning of roof member 30 in the first position may be specifically designed to meet standard clearance requirements to protect grille shelter 20 from damage due to smoke and heat.
[0028] Other components may be attached to grille shelter 20 to further add to its functionality and convenience. As shown in FIG. 1 , a platform 48 may be connected to frame assembly 22 (or to side walls 26 and 28 and rear wall 24 when no frame assembly is used) to provide a floor for which the grille may be positioned within grille shelter 20 . Platform 48 is configured to attach to housing 32 whereby the grille shelter 20 is secured from toppling in adverse weather or during use of the grille as shown in FIG. 4 . In addition, grille shelter 20 may include a at least one accessory item mounted to an interior surface of the grille shelter 20 , such as one or more hooks 54 mounted on side panel 28 as shown in FIG. 1 . Hooks 54 may be used to hang barbecue tools, cooking aprons or other desired tools. One or more shelves 60 may also be mounted on the interior surface of grille shelter 20 as shown in Figure 1 to provide further storing capabilities within grille shelter 20 .
[0029] Another feature that may be included on grille shelter 20 is a handle 58 as best shown in FIGS. 1 and 4 . Handle 58 may be constructed of a variety of different materials including, but not limited to, wood, metal or plastic, and may be attached to roof member 30 by any of a variety of attachment means known in the art. Handle 58 provides a firm grip location to assist the user with opening and closing roof member 30 . A pull cord 52 may also be connected to roof member 30 to further assist the user in moving roof member 30 between the first and second positions as shown in FIG. 3 . Pull cord 52 may alternatively attach to handle 58 as shown in FIG. 1 . Pull cord 52 may include a section of chain (as shown in the figures), a rope, strap, or other suitable component configured to attach to roof member 30 (or handle 58 ) to assist an individual who may be unable to reach handle 58 when roof member 30 is in the first position.
[0030] While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the present invention attempts to embrace all such alternatives, modifications and variations that fall within the spirit and scope of the appended claims. | A grille shelter includes a housing comprising a rear wall, a first side wall and a second side wall. A roof member is pivotally connected to a top edge of the housing and at least one pivoting panel is connected to one of the first side wall and second side wall. The pivoting panels are moveable between a first (open) position, wherein a user can access the grille within the shelter, and a second (closed) position, wherein the shelter conceals a grille contained therein. The roof member is also moveable between a first and second position. The grille shelter is configured to allow use of the grille while the grille remains positioned within the grille shelter and may optionally include a floor platform and other accessories to assist the user. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. The Field of Invention
This invention relates in general to vacuums and animal waste and in particular to vacuums that use a disposable container and pickup tool. The emphasis here is on a potable hand held powered device that uses a vacuum airflow to remove animal waste and in the process collect it in a disposable container which along with the pick up tool can easily be removed from the device and disposed of cleanly with ease.
2. The Description of Related Art
In order to provide background information so that the invention may be completely understood and appreciated in its proper context, reference may be made to a number of prior art patents. Their patent numbers will be listed below when the item is patented. However, there are processes in use which are not necessarily patented whose description and use sheds light on the existing problems of which this new invention solves.
There is a problem for people in using lawn or grassy areas, or sidewalks where animals such as dogs have been. This problem is widespread, especially, but not limited to, dog owners backyards and city streets in crowded metropolitan areas. These animals leave behind their waste. This is particularly obnoxious to people when they are walking, playing or servicing the area and they happen to step in the waste or roll over the waste with the wheels or some other part of their equipment. The problems also extends to health considerations and surface deterioration/discoloration from the natural deterioration of this waste. People have solved this problem by picking up the waste using various tools however each device has its own drawbacks which I will be pointing out, and of which my invention solves.
There is in use a little, garden shovel which is used to scoop up the waste and deposit it in a bucket lined with a disposable bag. But the problems here are stooping or bending repetitively, getting close to the smelly waste, and getting debris on the shovel. My machine is operated from a standing position with no bending or stooping and there is no cleaning of the tools as they are immediately disposed of.
Some dog walkers carry with them plastic baggies which they use to wrap around the waste with their hands, or use a tool to push the waste into. This brings the owner terribly close to the waste and if a tool is used in the process, some waste is left on the tool which must later be cleaned. Not only is this process obnoxious but embarrassing as well as neighbors can see what the owner is carrying. My device keeps the owner at a comfortable distance from the waste and since the waste goes directly into a container no one is embarrassed by onlookers and since the pickup tool and container are disposable there is no cleanup. Just a simple slide out from the machine and a toss into a trash container and they are done.
Another tool is similar to two shovels at the end of long sticks connected midway down the poles as a pair of scissors. This tool keeps the person at a distance from the waste but the problem of bending is replaced with teaming to effectively wield the long handled device to pick up the waste and then dispose of it in another container. But this tool still needs to be cleaned after its use and this is a particularly disgusting task. My hand held machine collects the debris in a long disposable intake lube which is hand controlled for ease of collection and no cleaning is required. All places that come into contact with the debris are disposed of after each use.
Another invention, U.S. Pat. No. 4,549,329, is a vacuum which will intake the debris through a tube. This machine is self cleaning in that after each use it puts down a puddle of water to be vacuumed up and this little mount of water is supposed to dissolve the waste that stuck to the interior of the tube. This device is not as clean as it proposes. The little mount of water that it deposits is not sufficient to clean some waste. It is also a disgusting process in that it must be emptied when filled up and then the waste is more fluid and obnoxious that before. This tool also requires the person to get somewhat close to the smelly obnoxious waste or debris, by stooping or bending to use the tool. My invention, although it used the concept of a long tube as a pickup device is better since it is disposable, and never needs cleaning. It is also better in that the intake tube/container port is easily pointed m and brought near the waste for pickup.
Still another group of tools am the blower/vacuum devices. Please refer to the following U.S. Pat. Nos. 4,325,163, 4,644,606, 4,461,055, 4,870,714 and 5,222,275. These machines are either electric or gas powered blower/vacuums. The blower portion works because an air flow is created with an impeller (fan) connected to the motor/engine, Air is sucked into the machine by the impeller, across the blades of the impeller and pushed out the blower tube. A vacuum is created at the intake end. When the vacuum portion is desired to be used a switch of equipment puts a bag on the blower end and a long tube is put on the intake end. Waste is sucked into the machine via the intake tube, across the impeller and out the blower end and into the bag. However, these types of machines will not work as animal waste vacuums as the waste and debris is smashed and crunched when it rams into the impeller or cut by a mulching blade and this would make a severe mess and clog up the machine. My machine collects the debris before the debris reaches the impeller. The container allows the waste to collect outside of the air flow path and before it gets to the impeller.
There is also another group of portable vacuums, please refer to these U.S. Pat. Nos., 4,325,162, 4,570,286 and 4,944,065 that use a long intake tube and a portable vacuum. These vacuums do not use the combination of disposable pickup tools and disposable storage containers and as pointed out earlier with other devices cleaning these pieces of equipment after each use would be problematic.
Whatever the precise merits, features and advantages of the above cited references, none of them achieves or fulfills the purposes of the current disposable intake tube and container of the present invention.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide a vacuum operated device and tool with characteristics that will enable the user to pick up waste and debris with less bending and less stooping.
It is also another principal object of the present invention to provide a vacuum operated device with a disposable intake tube and disposable container which connects and disconnects easily to the vacuum source.
It is also another principal object of the present invention to provide a vacuum operated device with a disposable intake tube and disposable container which are made and marketed at a very low cost so as to allow the user to dispose of the tube and container after each use.
It is another principal object of the present invention to provide a vacuum device with a disposable pick up tube and disposable storage container which are used to pick up noxious waste and debris and be more recyclable, more biodegradable, easier to dispose of, and more environmentally friendly than existing tools or methods.
It is another principal object of the present invention to provide a way to pick up waste and debris using a vacuum source with a disposable intake tube and container in which it is believed that the air pressure in the container portion of the device is sufficiently less then the air pressure in the other portions of the device so as to create an air pressure drop which allows other forces to act on the waste and thereby directing the movement of the waste.
It is another principal object of the present invention to provide a vacuum device with a disposable pick up lube and disposable storage container that will pick up waste and debris in a much cleaner and less noxious manner and allow disposal to be quicker and easier than with existing methods.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container that is comfortable and easy to use so that the user simply walks around the area to be cleaned and by simple hand motions points the tip of the pick up tool at base of the waste and the waste is sucked up into and through the pick up tool and stored in either container or in the pick up tool itself depending upon the version the user has chosen to use.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container which is portable and can be operated on its own self-contained power supply or can be plugged into a conventional electrical outlet.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container having the aforementioned described advantageous objects which is lightweight and simple in construction, easy to use and maintain and can be made and sold at a reasonable cost.
Still another principal object of the present invention is to provide a superior vacuum device with a disposable pick up tube and disposable storage container that is both lighter in weight and more convenient to use and which functions in a more efficient manner for picking up animal waste and debris than any previous art.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container in which the debris and waste are efficiently captured while directing the major portion of the exhaust air flow, and any entrained particles away from the user.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container having sufficient power and light weight to provide a system well-suited for its intended use.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container where the volume of the container, it is believed, is large enough compared to the intake tube and while considering the force of the vacuum to allow sufficient pressure drop in said container to allow the incoming debris and waste to be directed into and stored in said container.
Still another principal object of the present invention is to provide a vacuum device with a disposable pick up tube and disposable storage container whose pick up tool is sufficiently large enough to pick up animal waste and debris.
The invention is a hand held portable vacuum with at least three different configurations and all are specially designed with low cost intake tubes and containers which are intended to be disposed of after each and every use and they are designed to be used for the purpose of cleanly and easily picking up animal waste and other debris. The vacuum is sourced from a fan connected to but not limited to an electric motor, or an internal combustion engine which produces a sufficient amount of vacuum to draw the waste from its location through the pick up tube and into the storage container. The pick up tube is constructed from a suitable material whose characteristics meet the needs as intended and the material is to be either recyclable or biodegradable and environmentally friendly.
The present invention advantageously provides a vacuum system which provides a compact power unit that can accept and pass the full range of expected debris and waste from the pick up tube to the container and which directs the major portion of the exhaust air including entrained dust particles away from the user. Other objects and further scope of applicability of the present invention will become apparent from the detailed description to follow, taken in conjunction with the accompanying drawings in which like parts are designated by like reference characters.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the complete unit of Version A of the present invention;
FIG. 2 is a perspective view of the complete unit of Version B of the present invention;
FIG. 3 is a perspective view of the complete unit of the vacuum version of Version C of the present invention;
FIG. 4 is a perspective view of the complete unit of the blower version of Version C of the present invention;
FIG. 5 is a top elevational view of the complete unit of Version A of the present invention;
FIG. 6 is a side elevational view of the complete unit of Version A of the present invention;
FIG. 7 is a front elevational view of the complete unit of Version A of the present invention;
FIG. 8 is an enlarged detail perspective view of the keeper device, item #7, of the present invention;
FIG. 9 is a representative view of the weave of the high porosity mesh suitable for use as item #16 of the present invention;
FIG. 10 is a side elevational view of the complete unit of Version B of the present invention;
FIG. 11 is an enlarged detail representative view taken along line 10--10 of the stopper of FIG. 10;
FIG. 12 is a top elevational view of the complete unit of Version B of the present invention;
FIG. 13 is a from elevational view of the complete unit of Version B of the present invention;
FIG. 14 is a side elevational view of the complete unit of the vacuum configuration of Version C of the present invention;
FIG. 15 is a top elevational view of the complete unit of the vacuum configuration of Version C of the present invention;
FIG. 16 is a back elevational view of the complete unit of the vacuum configuration of Version C of the present invention;
FIG. 17 is a front elevational view of the complete unit of the vacuum configuration of Version C of the present invention;
FIG. 18 is a perspective view of the debris collecting bag, #19 used in the vacuum configuration of Version C of the present invention;
FIG. 19 is a front view of the rubber grommet, #13, used in Version C of the present invention;
FIG. 20 is a side view of the rubber grommet, #13, used in Version C of the present invention;
FIG. 21 is a side elevational view of the complete unit of the blower configuration of Version C of the present invention;
FIG. 22 is a top elevational view of the complete unit of the blower configuration of Version C of the present invention;
FIG. 23 is a front elevational view of the complete unit of the blower configuration of Version C of the present invention;
FIG. 24 is a rear elevational view of the complete unit of the blower configuration of Version C of the present invention;
FIG. 25 is a side elevational view of the pick up tube used in Version C of the present invention;
FIG. 26 is and end view of the pick up tube used in Version C of the present invention.
FIG. 27 is a perspective view of a representative flexible sheet.
FIG. 28 is a perspective view of the storage container and the inlet hole for an alternate embodiment using the flexible sheet.
FIG. 29 is a perspective view of a representative sturdy cover to secure the flexible sheet to the storage container in the flexible sheet embodiment.
DETAILED DESCRIPTION
In view of the above mentioned objects and others, refer now to FIG. 1 for an overall drawing of one of the preferred embodiments of the invention, Version A. This version of the present invention, as dram in farther detail in FIGS. 5, 6 and 7, comprises a vacuum device having a power unit 5 with a rotatably mounted fan 2 of for inducing an air flow from an inlet 6 to an outlet 4. The unit is guided and directed by using the hand held handle 3. The pick up tube 1 of this vacuum device having sufficient diameter relative to the waste and debris to be picked up is connected to the vacuum source by simply slipping it into the inlet 6 of the power unit 5 which pulls the debris into and along the pick up tube 1. The pick up tool of Version A comprises a tube open at both ends with the exception of a keeper device 7 at the pick up end and a filtering device 16 at the air flow exit end. This keeper device 7 comprises a plastic ring that attaches to the end of the tube and this plastic ring has approximately 4 long finger-like tabs which come close together at a point just inside the end of the pick up tube. These tabs are made of a suitable material, such as a light weight plastic, that allows them to flex from their base to open at their tips to permit the waste and debris to pass and then close afterward to keep any waste or debris from passing through in the reverse direction. There is sufficient space between these tabs to allow a sufficient amount of vacuum to pass by the edges of these tabs to pick up the intended waste and debris and pull it into the tube 1 and continue moving the waste and debris through these tabs as the tabs flex open but not so much space between the tabs that any of the intended waste and debris may pass through the tabs when they are closed. In another embodiment this keeper device 7 is an integral part of the pick up tube 1. In this alternate embodiment the flexible tabs will still flex open and closed as waste and debris passes through, however they will be constructed as a continuation of the pick up tube end and they will be bent and inserted into the interior of the pick up tube. This embodiment works well if constructed using a cardboard tube. The filtering device 16 at the air flow exit end of the pick up tube 1 is designed in such a way that it will stop the intended waste and debris from passing any farther and entrap it in the tube 1 while allowing the air flow caused by the vacuum created by the motor 5 and fan 2 to continue and pass through the motor and fan to the outside. This Version A is designed to store the amount of waste picked up in one use and then it is intended to be disposed of. The pick up tube 1 and its components are made of recylable or biodegradable materials, such as plastic, paper or cardboard, and are environmentally friendly so that the daily use of these items will not cause an environmental hazard. This Version A of the present invention in intended to pick up a small mount of waste and debris and it's recommended use is for people to take with them when they take their pets for a walk. Version B and Version C are intended for uses where larger amounts of waste will need to be picked up.
Refer now to FIG. 2 for an overall drawing of another of the preferred embodiments of the invention, Version B. This version of the present invention, as drawn in further detail in Figs. 10, 12 & 13, comprises a vacuum device having a power unit 5 with a rotatably mounted fan 2 for inducing an air flow from an inlet 6 to an outlet 4. The pick up tube 17 of this vacuum device having sufficient diameter relative to the waste and debris to be picked up opens into and passes through the storage container 24 and is connected to the inlet 6 of the power unit which pulls the debris through the pick up tube 17 and into the storage container 24. The section of the pick up tool which passes through the storage container 24 comprises a cut out of most of the lower portion of the back half section of said tube 22 and a deflector tab 21 as seen in FIG. 11. Both the cutout 22 and the deflector tab 21 are sufficiently sized to accept and direct the expected range of waste and debris. There is also a filtering stopper device 16 which completely filters the air as is passes around the deflector 21 and through the remaining tail section of the pick up tube 17 and into the fan 2 and motor section 5. The debris passes through the intake tube 17 being carried by the vacuum air flow caused by the motor 5 and fan unit 2 until it hits the deflector 21 as seen in FIG. 11, at which time, it is believed, because of the lower air pressure in this section and the interruption in the inertia of the waste and debris the gravitation force of the earth pulls the waste and debris through the opening in the intake tube 22 and into the storage container 24. The remaining portion of the portion of the intake tube 23 which passes through the storage container, this is the first portion that is inside the storage container, keeps the waste and debris that has already been picked up from going back into the incoming pathway. Any smaller particles that bypass this container section are caught by the filter 16 in the tail section of the pick up tube 17. It is in the enlarged container space 24 of Version B that a larger amount of waste and debris can be collected. A typical place where this version would be used is in cleaning up a pet owners backyard.
Refer now to FIGS. 3 and 4 for two overall drawings of another of the preferred embodiments of the invention, Version C. This version of the present invention, as drawn in further detail in FIGS. 14, 15, 16 and 17 for the vacuum function and FIGS. 21, 22, 23 and 24 for the blower function. Both functions are created using a power unit 18 with a rotatably mounted fan 18 for inducing an air flow from an inlet 25 to an outlet 15. Said motor is cooled by air brought in through the openings 11. The inlet 25 is the source of the vacuum and the outlet 15 is the source for the blower. This power unit housing 10 easily mounts on top of the storage container 9 and has the means for locking in place by pressing the flange 26 of the base of the housing 10, to which the motor 18 and fan 18 are mounted to, onto and around the lip of the open top of the storage container 9 or any arrangement whereby the motor base and open portion of the container have the means for a lockable connection and an airtight seal. The pick up tube 14 for the vacuum function, FIGS. 14, 15, 16 and 17, having sufficient diameter relative to the waste and debris to be picked up is inserted into and through the upper side wall of the storage container 9 via a rubber grommet 13 which creates an airtight seal between the container 9 and the pick up tube 14. This storage container 9 may or may not have, at the discretion of the operator, a sealed flexible wailed storage filtering bag 19. This bag will fit neatly inside the storage container 9 and will have an opening to accept the intake tube 14. The opening of this filtering bag 27 is of sufficient size to accept the intake tube 14 and seal around the exterior of the tube and is reinforced at the opening with a more rigid support 10. This bag 19 is of sufficient porosity so as to entrap the expected range of waste and debris and still allow a sufficient amount of air flow through the porous walls, into the solid walled container 9 and out through the opening 25 which leads to the intake of the fan 18 and motor 18. The storage container 9 is connected to the power unit 18 which generates a vacuum which pulls the debris through the pick up tube 14 and into the storage container 9 and if so desired by the operator, into the bag 19. In an alternate construction, the rubber grommet 13 may be replaced with another setup, FIG. 27, comprising a flexible sheet, 18 with a hole in it's center 29. This hole 19 in the flexible sheet 28, is aligned over the hole 30 in the storage container, FIG. 28, in such a manner as to allow the end of the pick up tube 14 to pass through the flexible sheet 28 and into the storage container 9 while making an airtight seal between the pick up tube 14 and the storage container 9. This flexible sheet 28 is held in place by a sturdy cover 31, FIG. 29 which also has a similarly sized hole 32 in it's center. This sturdy cover 31 with it's centered hole 32 is also aligned over the two other holes 29 and 30 and also allows the pick up tube 14 to pass through it as well. This sturdy cover 31 is held in place and holds the flexible sheet 28 in place by suitable means. Still in another embodiment the sealed flexible walled storage filtering bag 19, may be replaced with the same bag and opening and support but have an opened top, or in yet another embodiment this bag may be any type of open top bag so as to allow the waste to fall into the bag and the air to flow to the vacuum intake 15. However, in such an embodiment as this, an air filter located inside the opening at the vacuum intake 15 will be necessary to entrap any remaining airborne waste. It is believed that the porousness of the bag becomes obsolete once the top is opened as the air flow would not longer be restricted.
For the blower function of Version C, FIGS. 21, 22, 23 and 24, the pick up tube 14 is removed from the rubber grommet 13 and is inserted into the fitting 15 for the exhaust air and directs the exhaust air through the end of the tube 14. This tube 14 in this position is now called the discharge tube 14.
The handle 12 is aligned in the same plane as the pick up tube or the discharge tube. This alignment aids the user in aiming the pick up tube for either function. The foregoing descriptions of these preferred embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | The present invention advantageously provides a vacuum system which provides a compact power unit that can accept and pass the full range of expected debris and waste from the pick up robe to the container and which directs the major portion of the exhaust air including entrained dust particles away from the user. The invention discloses disposable pick up tubes and storage containers which are low cost and easy to use which achieve their purposes of picking up, storing and disposing of waste and debris simply and easily. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of applicant's application Ser. No. 08/655,988, filed on May 31, 1996, now U.S. Pat. No. 5,803,196, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improved subterranean drill bits and abrasive cutter elements for application with such bits. More specifically, the present invention is directed to a stabilized drill bit including an improved cutting element incorporating enhanced wear characteristics.
2. Description of the Prior Art
Diamond cutters have traditionally been employed as the cutting or wear portion of drilling and boring tools. Known applications for such cutters include the mining, construction, oil and gas exploration and oil and gas production industries. An important category of tools employing diamond cutters are those drill bits of the type used to drill oil and gas wells.
The drilling industry classifies commercially available drill bits as either roller bits or diamond bits. Roller bits are those which employ steel teeth or tungsten carbide inserts. As the name implies, diamond bits utilize either natural or synthetic diamonds on their cutting surfaces. A "fixed cutter", as that term is used both herein and in the oil and gas industries, describes drill bits that do not employ a cutting structure with moving parts, e.g. a rolling cone bit.
The International Association of Drilling Contractors (IADC) Drill Bit Subcommittee has officially adopted standardized fixed terminology for the various categories of cutters. The fixed cutter categories identified by IADC include polycrystalline diamond compact (pdc), thermally stable polycrystalline(tsp), natural diamond and an "other" category. Fixed cutter bits falling into the IADC "other" category do not employ a diamond material as any kind as a cutter. Commonly, the material substituted for diamond includes tungsten carbide. Throughout the following discussion, references made to "diamond" include pdc, tsp, natural diamond and other cutter materials such as tungsten carbide.
An oil field diamond bit typically includes a shank portion with a threaded connection for mating with a drilling motor or a drill string. This shank portion can include a pair of wrench flats, commonly referred to a "breaker slots", used to apply the appropriate torque to properly make-up the threaded shank. In a typical application, the distal end of the drill bit is radially enlarged to form a drilling head. The face of the drilling head is generally round, but may also define a convex spherical surface, a planar surface, a spherical concave segment or a conical surface. In any of the applications, the body includes a central bore open to the interior of the drill string. This central bore communicates with several fluid openings used to circulate fluids to the bit face. In contemporary embodiments, nozzles situated in each fluid opening control the flow of drilling fluid to the drill bit.
The drilling head is typically made from a steel or a cast "matrix" provided with polycrystalline diamond cutters. Prior art steel bodied bits are machined from steel and typically have cutters that are press-fit or brazed into pockets provided in the bit face. Steel head bits are conventionally manufactured by machining steel to a desired geometry from a steel bar, casting, or forging. The cutter pockets and nozzle bores in the steel head are obtained through a series of standard turning and milling operations. Cutters are typically mounted on the bit by brazing them directly into a pocket. Alternatively, the cutters are brazed to a mounting system and pressed into a stud hole, or, still alternatively, brazed into a mating pocket.
Matrix head bits are conventionally manufactured by casting the matrix material in a mold around a steel core. This mold is configured to give a bit of the desired shape and is typically fabricated from graphite by machining a negative of the desired bit profile. Cutter pockets are then milled into the interior of the mold to proper contours and dressed to define the position and angle of the cutters. The internal fluid passageways in the bit are formed by positioning a temporary displacement material within the interior of the mold which is subsequently removed. A steel core is then inserted into the interior of the mold to act as a ductile center to which the matrix materials adhere during the cooling stage. The tungsten carbide powders, binders and flux are then added to the mold around the steel core. Such matrices can, for example, be formed of a copper-nickel alloy containing powdered tungsten carbide. Matrices of this type are commercially available to the drilling industry from, for example, Kennametal, Inc.
After firing the mold assembly in a furnace, the bit is removed from the mold after which time the cutters are mounted on the bit face in the preformed pockets. The cutters are typically formed from polycrystalline diamond compact (pdc) or thermally stable polycrystalline (tsp) diamond. PDC cutters are brazed within an opening provided in the matrix backing while tsp cutters are cast within pockets provided in the matrix backing.
Cutters used in the above categories of drill bits are available from several commercial sources and are generally formed by sintering a polycrystalline diamond layer to a tungsten carbide substrate. Such cutters are commercially available to the drilling industry from General Electric Company under the "STRATAPAX" trademark. Commercially available cutters are typically cylindrical and define planar cutting faces.
The cutting action in prior art bits is primarily performed by the outer semi-circular portion of the cutters. As the drill bit is rotated and downwardly advanced by the drill string, the cutting edges of the cutters will cut a helical groove of a generally semicircular cross-sectional configuration into the face of the formation.
Bit vibration constitutes a significant problem both to overall performance and bit wear life. The problem of vibration of a drilling bit is particularly acute when the well bore is drilled at a substantial angle to the vertical, such as in the recently popular horizontal drilling practice. In these instances, the drill bit and the adjacent drill string are subjected to the downward force of gravity and a sporadic weight on bit. These conditions produce unbalanced loading of the cutting structure, resulting in radial vibration.
Prior investigations of the effects of the vibration on a drilling bit have developed the phraseology "bit whirl" to describe this phenomena. One solution proposed by such investigations is the utilization of a low friction gauge pad on the drill bit.
One known cause of vibration is imbalanced cutting forces on the bit. Circumferential drilling imbalance forces exist to some degree on every drill bit. These imbalance forces tend to push the drill bit towards the side of the bore hole. In the example where the drill bit is provided with a normal cutting structure, the gauge cutters are designed to cut the edge of the borehole. During the cutting process, however, the effective friction between the cutters near the gauge area increases. When this occurs, the instantaneous center of rotation is translated to a point other than the geometric center or longitudinal axis of the bit. The usual result is for the drill bit to begin a reverse or backwards "whirl" around the borehole. This "whirling" process regenerates itself because insufficient friction is generated between the drill bit gauge and the borehole wall, regardless of bit orientation. This whirling also serves to change the bit center of rotation as the drill bit rotates. Thus, the cutters travel faster, in the sideways and backwards direction, and are subjected to greatly increased impact loads.
Another cause of bit vibration is from the effects of gravity. When drilling a directional hole, the drill string maintains a selected angle vis-a-vis the vertical. The drill string continues to maintain this vertical deflection even during a lateral drilling procedure. The radial forces inducing this vertical deflection can also result in bit "whirl".
Steering tools also result in bit vibration. One such cause for vibration in a steering tool occurs as a result of a bent housing. Vibration occurs when the bent housing is rotated in the bore hole resulting in off center rotation and subsequent bit whirl. Bit tilt also creates bit whirl and occurs when the drill string is not properly oriented vis-a-vis the center of the borehole. In such occasions, the end of the drill sting, and thus the drill bit, is slightly tilted.
Yet another source of bit whirl results from stratification of subsurface formations. When drilling well bores in subsurface formations it often happens that the drill bit passes readily through a comparatively soft formation and strikes a significantly harder formation. In such an instance, rarely do all of the cutters on a conventional drill bit strike this harder formation at the same time. A substantial impact force is therefore incurred by the one or two cutters that initially strike the harder formation. The end result is high impact load on the cutters of the drill bit, vibration and subsequent bit whirl.
Whatever the source of the vibration, the resulting "whirl" generates a high impact on a few of the cutters against the formation, thereby lessening drill bit life.
A number of solutions have been proposed to address the above and other disadvantages of prior art bits associated with vibration and subsequent bit "whirl". Some of these solutions have proposed the use of various geometries of the bit cutters to improve their resistance to chipping. Other proposed solutions have been directed at the use of gauge pads and protrusions placed behind the cutters.
None of these proposed solutions, however, has disclosed or suggested the use of discrete stabilizing elements whose contact face is disposed at an exaggerated angle of attack or contact vis-a-vis the formation. Quite the contrary, conventional wisdom in the drilling industry has taught that the use of exaggerated cutting angles would detrimentally impact the penetration rate of the drill bit.
Still other solutions have involved the use of shaped cutters to PDC bits to prevent bit whirl. It was traditionally believed that a shaped cutter served as a stabilizing element at any depth of cut.
Disadvantages associated with the use of traditional shaped cutters as a stabilizing element include limited wear life. In this connection, while the shaped cutter in an unsharpened condition acts as a constant stabilizing element, the nature of the cutter changes as it begins to wear. When the depth of the cut is excessive or wear removes the chamfer, the shaped cutter acts as an unchamfered cutter, and therefore loses its effectiveness as a stabilizing element in the borehole.
SUMMARY OF THE INVENTION
The present invention addresses the above and other disadvantages of prior art drill bits and is directed to an improved drill bit to minimize drill bit vibration and decrease cutter wear.
In one embodiment, the drill bit of the present invention defines a shank disposed about a longitudinal axis for receiving a rotational drive source, a gauge portion extending from the shank portion and a face portion disposed about the longitudinal axis and extending from the gauge portion. This face portion typically includes a number of blades arranged in a symmetrical configuration. In alternate embodiments, the cutter face may include a smaller diameter cutting zone, usually referred to as a pilot section, which extends coaxially from a larger diameter cutting zone.
A plurality of cutting elements are disposed on the bit face about the longitudinal axis. Interposed among these cutting elements are stabilizing elements placed on one or more blades of the bit. These stabilizing elements are radially situated on the bit face so as to achieve a sufficient depth of cut to aid in stabilizing the bit. Furthermore, these stabilizing elements are disposed at an exaggerated cutting angle vis-a-vis the formation.
These stabilizing elements are preferably formed of polycrystalline diamond carbide or some other hard compound, e.g. carbide, adapted to cut rock.
The present invention also addresses the above and other disadvantages of prior art shaped cutters which may be used to minimize drill bit vibration.
In a another embodiment, the cutter of the present invention includes a body and a polycrystalline diamond cutting face which are bonded together using conventional techniques. The body is comprised of a cemented tungsten carbide which includes a chamfer cut at a selected angle, e.g. forty-five degrees. Polycrystalline diamond is bonded to the body so as to create a diamond table having an enhanced depth of diamond and to define a constant and enhanced diamond thickness along the length of the rake land. In such a fashion, the diamond cutting surface is strengthened as a result of increased and consistent thickness throughout its length.
The cutter system of the present invention presents a number of advantages over the art. One such advantage is decreased bit whirl and vibration through even highly stratified formations.
A second advantage is the strengthening of the cutting elements themselves as a result of the modified wear surface, thereby enhancing bit wear life.
Another advantage is increased wear life of the cutter created as a result of the increased length of the rake land.
Increased wear life of the cutter is also increased as a result of increased and consistent thickness of polycrystallic diamond along the rake land.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 graphically illustrates a typical cutter drilling profile highlighting cutter height versus bit radius.
FIG. 2 graphically illustrates the contact angle of a cutter versus the formation.
FIG. 3 illustrates a bottom view of one embodiment of a drill bit made in accordance with the present invention which includes stabilizing elements manufactured in accordance with the present invention.
FIG. 4A-C illustrates several embodiments of the stabilizing element of the present invention.
FIG. 5A-B illustrates a side, cross sectional view of prior shaped cutters.
FIG. 6 illustrates a side view of an embodiment of a drill bit made including stabilizing elements made in accordance with the present invention.
FIG. 7 illustrates a bottom view of the drill bit illustrated in FIG. 6.
FIG. 8 illustrates a side, cross sectional view of one embodiment of the shaped cutter illustrated in FIG. 4A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 6 and 7 represent one embodiment of a drill bit 60 manufactured in accordance with the methodology of the present invention. By reference to the figures, the drill bit 60 comprises a threaded portion 40 for attachment to the drill string or other rotational drive source and disposed about a longitudinal axis "A", a shank portion 42 extending from the gauge 40, and a face portion 44 extending from the gauge portion 42. As illustrated, shank portion 42 may include a series of wrench flats 43 used to apply torque to properly make up the thread 40.
In a typical embodiment, bit face 44 is defined by a series of cutting blades 50 which form a continuous linear contact surface from axis "A" to gauge 42. When viewed from the bottom, blades 50 may describe a generally helical or a linear configuration. (As shown in FIGS. 6 and 7) Blades 50 are provided with a number of cutting elements 39 disposed about their surface in a conventional fashion, e.g. by brazing or force fitting. The number of these elements 39 is typically determined by the available surface area on blades 50, and may vary from bit to bit.
A series of stabilizing elements 2 are disposed on the bit face 44 in a selected manner to stabilize bit 60 during operation (See FIG. 3). The methodology involved in the placement of these elements 2 is as follows: A geometrical analysis is made of the bit face 44 by creating a array of spatial coordinates defining the center of each cutter 39 relative to the longitudinal axis "A". A vertical reference plane is next created, which plane containing the longitudinal axis. Coordinates defining the center of each cutter 39 are then rotated about this axis "A" and projected onto the reference plane to define a cutter profile such as those illustrated in FIG. 1. In this connection, the cutter profile illustrated in FIG. 1 represents an aggregate pictorial side section of each of the cutters 39 on bit 60 as the bit is revolved about axis "A".
FIG. 1 illustrates a typical cutter profile of a drill bit made in accordance with the above described methodology where the x axis is taken along the longitudinal axis "A". As illustrated, drill bit face 44 defines an arc intercepting the bit gauge indicated by line 52. As illustrated in FIG. 1, the cutters 39 positioned in the intermediate zone 70 are more widely spaced and therefore experience a greater depth of cut into the formation.
Zone 72 defines a segment of the cutter arc between 0 and 60 degrees as measured from a line normal to the longitudinal axis "A". Elements 2 are preferably placed within the 60 degree arc of this zone 72 to achieve maximum stability of the drill bit during operation. It has been discovered that elements 2 placed within this arc afford the greatest stabilizing benefits while minimizing any negative impact on the penetration rate of the bit 60.
Positions for stabilizing elements 2 are selected on the bit face 44 so that such elements 2 remain in substantially continuous and constant contact with the formation. Cutter positions are determined on the basis of the need for a stabilizing force on the bit. The need for this stabilizing force is in turn determined by drilling conditions. The stabilizing elements are preferably placed on consecutive cutters.
By reference to FIG. 1, this optimum position for element 2 falls within the zone 72 identified earlier. To further stabilize bit 60, it is desirable to position elements 2 in a substantially symmetrical fashion among blades 50. In this connection, any radial reactive force imported by a given element 2 will be offset by a corresponding element 2 placed on corresponding blades 50. Stabilizing elements 2 may be positioned between two or more of the typical cutters 30. In selected areas of the cutter profile, several elements 2 are preferably placed in adjacent positions on the cutter blade 50 so as to ensure substantially continuous contact with the formation.
Various embodiments of the stabilizing element 2 of the present invention may be seen by reference to FIGS. 4A-C. While the illustrated stabilizing elements 2 include chamfered or rounded cutting edges, it is contemplated that any cutter which includes a "less sharp" cutting edge, when compared to those other cutters as the drill bit may be employed. "Less sharp" as used herein relates to the condition of a cutter which cannot effect as much penetration into the formation as an adjacent cutter, weight on bit and angle of attack being equal.
FIG. 4A illustrates a stabilizing element 2 of the present invention comprising a cutter body 4, a cutting face 6 and a cutting edge 7. Cutting face 6 is preferably comprised of a polycrystalline diamond compact (PDC) which is fabricated in a conventional manner. Face 6 is integrally formed with body 4. Alternatively, other hard compounds, e.g. thermally stable polycrystalline diamond or carbide, may also be used to achieve the objectives of the present invention.
By reference to FIGS. 2 and 3, the use of elements 2 as a stabilizing force depends both on their positioning on the cutter blade 50 to ensure continuous contact with the formation 80, as described above, and on the their contact angle with the formation 80. To achieve the stabilizing objectives of the invention, these elements should be disposed at a contact angle "C" in the range of 5-55 degrees as measured from a plane defined by the formation. As illustrated, this contact angle is achieved by the combination of a selected back rake angle BR and a beveled or arcuate cutting edge BA on each stabilizing element 2. Back rake angle BR is measured from a line normal to the formation. Bevel angle BA is measured from a line normal to the face 6 of the stabilizing element 2. The back rake angle BR contemplated to be used in the present invention is in the range of 10-30 degrees. The bevel or radii angle BA contemplated for use with elements 2 is from 10-75 degrees. (See also FIG. 4B) The linear dimension of the beveled cutting edge 7 is measured as a function of the projected depth of cut of the formation 80 for a element 2 at a selected position on the blade 50. This depth of cut may be ascertained from the following formula: ##EQU1## To achieve the stabilization required from elements 2, this bevel dimension "W" is substantially equal to or greater than 100% of the depth of cut projected for the radial position of that element 2 on the cutter face 44. For a conventional cutting element measuring some three eighths to three fourths of an inch in diameter, this bevel is greater than or equal to 0.030 inches. Alternatively, cutting edges 7 may be provided with a radius instead of a beveled cutting edge, where such edge 7, again for a cutter having a diameter between three eighths and three quarters of an inch, is greater than 0.030 inches. (See FIG. 4C)
Stabilizing elements 2, when applied to a drill bit in accordance with the present invention, prevent the initiation of bit whirl in the following manner. When the drill bit is rotated in the borehole, an imbalanced force is created for the reasons earlier identified. The presence of a discrete number of elements 2, arranged about the bit face 44 at a contact angle C, acts as a self correcting force to prevent conventional cutters 39 from cutting too deeply into the formation 80. Since these elements are positioned in the 60 degree arc as measured from a line perpendicular to the longitudinal axis "A", the penetration rate of the bit 60 is only nominally affected.
The Stabilizing Cutter
A side cross-section of a conventional stabilizing element 83 may be seen by reference to FIG. 5 and includes a body 84 and a superabrasive layer or diamond table 86 bonded thereto about an interface 80 and defining a cutter face 82, a cutter edge 85 and a rake land 87.
In the illustrated embodiment, stresses encountered during both the manufacture and field application of elements 83 are partially relieved by use of a series of alternating grooves 90 and ridges 92 disposed in the body about interface 80, where such stresses are concentrated at a point designated "S." An example of the use of such grooves and ridges is seen in U.S. Pat. No. 5,007,207 as issued to Phaal. Notwithstanding such efforts, however, element 83 is prone to wear and failure as a result of, among other factors, the lack of a constant thickness of the polycrystalline diamond layer in selected areas and the dimension of the rake land 86.
The thickness of diamond table 86 may be measured at a variety of locations about stabilizing element 83. One such location is along a line parallel to the longitudinal axis "A" and normal to the plane defined by the cutter face 82, designated in FIG. 5 as T 1 . A second measurement may be taken along a line normal to the plane defined by the rake land 87, designated T 2 .
Also significant to the performance and use life of stabilizing element 83 is the length of the rear boundary of the cutter face 82 trailing said cutting edge 85. In FIG. 5, this length is designated D 1 . In prior embodiments, this distance is frequently no more than 0.010 inches.
By reference to FIG. 3, the following are examples of the performance of drill bits constructed in accordance with the foregoing methodology.
EXAMPLE 1
A 105/8" pilot hole encompassed an interval from 6060 ft. to 12499 ft. MD. The directional objective for this interval was to drill a vertical hole to the kickoff depth at 6100 ft., build angle at 3.00°/100 to 48.89° at 7730 ft. with a direction of S18.40E, then maintain this angle and direction to 12499 ft. MD. The secondary objective was to drill the entire interval with a "MT33M" PDC bit and steerable BHA.
The BHA consisted of a "MT33M" PDC bit, 13/4° Sperry 8" steerable motor, xo sub, 101/4 stab., 63/4" LWD, 63/4" MWD, float sub, 101/4 stab., 6 jts. Hevi-wate, jars, 23 jts. hevi-wate. This BHA was used to drill from 6060 ft. to 12322 ft. in 82.5 drilling hours. The kickoff, from 6120 ft. to 7760 ft., built angle from 0.57° to 49.2°. The average slide section was 38 ft./100 ft., and resulted in an average build rate of 3.12°/100 ft. The tangent interval, from 7760 ft. to 12322 ft., had an average angle of 49.32° with an average direction of S17.54E. The average slide section for the tangent interval was 10 ft./200 ft., resulting in an average dogleg severity of 0.40°/100 ft. The slide sections were mainly devoted to counteracting a slight angle dropping tendency of 0.38°/100 ft. The BHA was pulled out of the hole at 11155 ft. to replace the MWD collar. The same bit and BHA configuration was rerun and it drilled to TD at 12322 ft.
The "MT33M" PDC bit is of a conventional design with 8 blades, with 8 mm. cutters. The back rake of the cutters was 20°. Each blade incorporated one shaped cutter and one reverse bullet. The gauge pads were reduced to 2 in. in length.
This new design bit proved to be very effective in the reduction of the reactive torque associated with the mud motor. The slide intervals during the kickoff and the tangent section of the well demonstrated a 75% reduction in the reactive torque. The bit produced about the same amount of reactive torque as a rock bit. The well was control drilled at an instantaneous penetration rate of 100 ft./hour. This resulted in an average penetration rate of 75.9 ft/hour. The bit weights varied from 5K to 20K while rotary drilling and sliding. Slide intervals were drilled as fast as rotary drilling intervals without encountering any excessive reactive torque. This bit design proved to be very effective in eliminating all of the problems associated with drilling directional wells in highly laminated shales and ratty sand formations.
FIG. 3 illustrates a bottom view of the embodiment of the drill bit described in Example 1. By reference to FIG. 3, stabilizing elements 2 positioned within zone 72 are indicated by asterisks. The angel θ of at which these elements 2 is identified below for the eight blades of the bit.
______________________________________Blade A 24° Blade E 14° Blade B 11° Blade F 24° Blade C 18° Blade G 18° Blade D 21° Blade H 11°______________________________________
EXAMPLE 2
In a standard drill bit, an hourly rate of penetration of 47.8 ft/hr and a rate of penetration of 573.6 inches per hour was desired for 190 revolutions per minute. Given these operating parameters the depth of cut is calculated as follows: ##EQU2##
In this example, the projected depth of cut will be 0.05 inches. Therefore, a bevel greater than or equal to 0.050 inches is preferable to achieve the desired objectives of the invention to optimize efficiency where each individual cutter is assumed to take a full depth of cut.
EXAMPLE 3
In a drill bit a rate of penetration of 78.4 ft/hr (940.8 in/hr) was desired for 150 rpm (9000 rph). Given the above parameters, a depth of cut of 0.105 inches was projected, thereby requiring a preferred bevel of greater than or equal to 0.105 inches to optimize efficiency where each individual cutter is assumed to take a full depth of cut.
EXAMPLE 4
In a drill bit a rate of penetration of 66.7 ft/hr (800.4 in/hr) was desired for 150 rpm (9000 rph), yielding a projected depth of cut of 0.089 inches. Therefore, a bevel dimension greater than or equal to 0.089 inches is preferred to optimize efficiency where each individual cutter is assumed to take a full depth of cut.
EXAMPLE 5
In a standard drill bit, a penetration of 75.8 ft/hr (909.6 in/hr) was desired at 160 rpm (9600 rph), yielding a projected depth of cut of 0.095 inches. Therefore, a bevel dimension greater than equal to 0.095 inches is preferred to optimize efficiency where each individual cutter is assumed to take a full depth of cut.
EXAMPLE 6
In a prophetic example necessitating a ROP of 33.8 ft/hr at 210 rpm, a depth of cut of 0.032 is calculated. A bevel dimension of at least 0.032 inches is preferred to optimize efficiency where each individual cutter is assumed to take a full depth of cut.
Imbalance forces acting on a drill bit change with wear, the particular formation in which the bit is operating and operating conditions within the borehole. The magnitude and direction of these imbalance forces can vary significantly. The use of an exaggerated contact angle for cutting edge 7 provides the advantage of being relatively immune to formation inhomogenities and downhole operating conditions. (See FIG. 4A)
FIG. 8 illustrates a side cross-section of the stabilizing element 13 of the present invention as illustrated in FIG. 4A. By reference to FIG. 8, body 34 defines an interface or boundary 23 which includes a plurality of grooves 24 and ridges 26 running in a direction generally parallel to the line of contact defined between cutting edge 43 and the borehole (not shown). Such grooves and ridges aid in the relief of hoop stresses formed during the manufacturing phase and further addresses impact stresses encountered during operation.
In the embodiment illustrated in FIG. 8, the thickness of the diamond table 25 at cutting face 43 is designated T 1 . In this embodiment, T 1 is substantially thickened to enhance the wear life of element 13 and is preferably between 0.020 and 0.060 inches in depth. Also in the illustrated embodiment, the thickness T 2 of the polycrystalline diamond disposed along rake land 45 is constant for its entire length. In a preferred embodiment, this thickness, when measured along a line normal to the plane defined by rake land 45, is between 0.020 and 0.060 inches.
As a result of the increased thickness of the polycrystallic diamond, the length of the rear boundary T 3 from cutting edge 43, as measured along the longitudinal axis, is between 0.010 and 0.060 inches. By way of comparison, the prior art cutter 81 illustrated in FIG. 5b includes no diamond 80 on the surface which contacts the formation, thereby shortening the life of the cutter by removal of the substrate 82. The prior art cutter of FIG. 5a includes more diamond to address the abrasion of the substrate, yet nevertheless demonstrates an abbreviated wear life. By using a specialty cutter with an increased thickness, an amount of diamond comparable to premium quality pdc cutters can be positioned on the surface of the cutter so as to be in contact with the formation. By enhancing the wear life of the stabilizing cutters to a point equivalent to that of the other cutters on the bit, an increase in the effective life of the bit is obtained.
Although particular detailed embodiments of the apparatus and method have been described herein, it should be understood that the invention is not restricted to the details of the preferred embodiment. Many changes in design, composition, configuration and dimensions are possible without departing from the spirit and scope of the instant invention. | A drilling tool operational with a rotational drive source for drilling in a subterranean formation where said tool comprises a body defining a face disposed about a longitudinal axis, a plurality of cutting elements fixedly disposed on and projecting from said tool face and spaced apart from one another, and one or more stabilizing elements disposed on the tool face and defining a beveled surface. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present utility patent application claims the benefit of provisional application No. 61/459,895 filed Dec. 20, 2010.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] Field of the Invention
[0004] The present invention relates to disaster prevention system for offshore oil wells and in particular to a supplemental disaster preventive system to provide means to insure human, equipment and environmental safety and associated cost avoidance during the offshore well drilling process under all conceived/feasible accidents/failures conditions. The overall system design concept, related procedures/processes and many associated system components to provide major cost reduction benefits for the entire life cycle (drilling, completion, production and abandonment) for both accident/failure and normal/uneventful operations.
[0005] Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 Shortly after the 2010 offshore oil well catastrophe in the Gulf of Mexico, it became obvious that British Petroleum (BP), the entire oil industry, and/or the US Government were unprepared to effectively stop the gushing oil or the means to clean it up. Throughout the first two plus months of the disaster numerous re-sealing, capturing, clogging, killing and capping techniques were unsuccessfully attempted and several high risk/cost ‘normal’ well drilling processes were brought to light.
[0006] The successful 20 July re-seal, capture and cap ‘Rube Goldberg’/‘Kluge’ (said with admiration) was a simplistic but effective temporary solution for the catastrophic symptoms of the problem—where the primary operative phrase is ‘temporary solution for the catastrophic symptoms’.
[0007] The enormous somewhat/sometimes unquantifiable costs of the (or of a future) incident includes:
[0008] Human life,
[0009] Environment,
[0010] Drilling platform,
[0011] Well (the equipment and the associated labor and its potential production),
[0012] Equipment and labor associated with the numerous re-seal, capture, and cap ‘quick fixes’,
[0013] Equipment and labor associated with the relief/kill wells,
[0014] Gulf clean-up,
[0015] Tourist and fishing industry,
[0016] Local community,
[0017] Public opinion relating to the oil industry & the government and
[0018] Nation and international financial markets
[0019] The prior art ‘blowout prevender’ (BOP) is intended to close off the well in case of an uncontrolled/emergency condition (blowout). It's a multi mega-buck, multi-ton device installed on the seafloor having various means/methods, with the design intent of closing a well. The most technically difficult is if/when a pipe and/or pipes (drill, casing, etc.) are within the well. The BOP must ‘ram’ through the pipe(s) and close off the well. That seems difficult, but add the extreme water pressure and low temperatures, the more extreme oil pressure and high temperatures and the prior art BOP is likely not going to work. After the Macondo's well was finally closed, the BOP was pulled up and evaluated—it was functional but did not do the job.
[0020] As offshore oil drilling/production continues in the future it seems only rational that the government as well as oil industry itself would demand, as a prime priority the development of improved equipment/systems and processes.
[0021] Whatever the cause(s) (human neglect/error, equipment failure, etc.) of the 2010 oil well disaster and whatever means are developed to insure no such similar failure and/or related impacts reoccurs, there are potentially more likely and more damaging events—specifically natural disasters and (accidental or deliberate) human intervention that must also be addressed.
[0022] The focus of the ‘quick fix’ was to stop/control the symptoms of the immediate catastrophe—the gushing oil.
[0023] What is needed is an overall systems design and implementation approach that provides the means to reduce/eliminate the causes and impacts of any conceived/realistic threats to oil wells in the future and further provides more reliable, practical and cost effective means to accomplish the oil well drilling task.
BRIEF SUMMARY OF THE INVENTION
[0024] The primary design objective of the present invention was to provide an offshore oil well improvement system using an overall systems design and implementation approach that provides the means to reduce/eliminate the causes and impacts of any conceived/realistic threats to oil wells in the future and further provide more reliable, practical and cost effective means to accomplish oil well drilling.
[0025] As the present invention design evolved it became apparent that many related procedures/processes and many associated system components provide major cost reduction benefits for the oil well's entire life cycle (drilling, completion, production and abandonment) in either problem or normal operations.
[0026] The present invention is composed of two functional and physically integrated subsystems, the Multi-Function Well Subsystem (MFWS) and the Intrusion Detection and Response Subsystem (ID&RS).
[0027] The MFWS is presented in two basic configurations, the ‘Fundamental’ & the ‘Advanced’. Both configurations modify the sea-floor and in-well equipment to provide maintenance access and unique tools to provide the means to: cap the well, seal/re-seal the well, drill/re-drill the well, kill the well from the top, improve BOP reliability, add BOP functional redundancy, improve the cementing process, incorporate a sea-floor pressure relief/diversion function and improves the well's life cycle safety.
[0028] The Advanced MFWS includes a unique dome top cylindrical sidewall structure enclosing the well's sea-floor equipment providing improved structural strength as well as passive protection from natural/human induced disasters.
[0029] The ID&RS provides the means to detect, track and classify the 3D aspects of air/surface/sub-surface objects about a specific oil well or group of oil wells and provides the means to evaluate and eliminate threats.
[0030] As all elements are based on existing simplistic proven technology, the development cost risk is minimum.
[0031] As the system design includes a major focus on the physical implementation and operation, the implementation and operational cost risk is minimum
[0032] Considering the pure human and environmental safety, the pure dollar and cents (or multi-million/billion dollar) cost avoidance and/or the potential cost savings/reductions (for any or all such reasons) it is a significant understatement to suggest that features of the present invention should be integrated with other planned improvements, and incorporated on all oil wells.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0033] These and other details of the present invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention.
[0034] The drawings are intended to provide an introductory overview of major system/system elements that along with other unique system supporting devices are comprehensively defined in the ‘Detailed Description Of The Invention’.
[0035] FIG. 1 is a diagrammatic cross-sectional view of the Fundamental Multi-Function Well Subsystem (MFWS) showing a typical oil well's sea-floor equipment of a Stud ( 3 ), Marine Riser ( 4 ), BOP ( 5 ), Production Valve Assembly ( 6 ) and Well Pipe/Casing ( 2 ) sitting on the Sea-Floor ( 1 ). Connected to this ‘typical’ equipment is a ‘Normal’ Capture Valve & Associated pipe ( 11 ) going to a surface capture platform and a well drill & return pipe ( 9 ) ‘typically connected to ( 6 ) going to a surface drilling platform. The drawing further depicts the addition of two additional items, an Adjunctive BOP/Valve Assembly (AVA) ( 7 ) and a Platform to Well Interface Assembly (P-WIA) ( 8 ) in series with the ‘typical’ well's interface of ( 6 ) & ( 9 ). These two units are further shown on FIGS. 3A & 3B and FIG. 4 . These units provide functional redundancy of the BOP (using alternative, simplistic technology) to seal/close the well. Unit ( 8 ) provides the means to seal the drill pipe's exterior wall return flow path while unit ( 7 ) closes the entire well's flow path when there no obstruction (drill pipes, casings etc.) within the valve area of unit ( 7 ). Note the drawing does not depict the drill pipe, drill bit or various casings that may be going into the well from the drill platform during the drilling stage. When in use these would be feed through items ( 9 , 8 , 7 , 6 , 5 , 4 , 3 & 2 ). It is further noted that the full ‘functional redundancy of the BOP’ is not yet complete in that the BOP can (by intent but with poor reliability) ram through an obstruction and close the well. The full ‘functional redundancy’ is provided by one of two alternate means. The first is the Enclosed Pipe Cutter within ( 7 ) and the second is the remote Pipe Coupling/De-Coupling device as shown on FIG. 6 . In either case the cut or de-coupled pipe must be extracted from the valve area of unit ( 7 ). Such would be accomplished via the drill platform or a Remote Operated Vehicle (ROV) lifting the pipe/casing or the addition of an internal pipe lifting device (not shown). FIG. 1 further shows a Pressure Relief/Diversion Valve & Pipe/Tube ( 10 ) on a parallel well output port of unit 6 . This provides an input to the Pressure Relief/Diversion Assemble as shown on FIG. 5 . This provides the means to safely protect a problem well & platform, the means to safely capture the well output and the means to safely reduce/eliminate the disastrous effects on the environment.
[0036] FIG. 2 is a diagrammatic cross-sectional view of the Advanced Multi-Function Well Subsystem (MFWS) in a similar fashion to FIG. 1 . FIG. 1 begins showing a ‘typical’ oil well's sea-floor equipment of a Stud ( 3 ), Marine Riser ( 4 ), BOP ( 5 ) & Sea-Floor ( 1 ) (as identified on FIGS. 1 as 1 , 2 , 3 , 4 , & 5 ).
[0037] The Advanced MFWS differs by replacement the Production Valve Assembly with a unique manifold Domed Assembly (DA) structurally enclosing—reinforcing the well's sea-floor equipment. The DA consists of a Dome Cylindrical Sidewall ( 21 ), a Dome Top ( 22 ), and the Dome Interior Plate ( 23 ). The DA's lower section further includes Leveling Devices ( 24 ), Floor/Footing ( 25 ), & Vent Pipes ( 26 ). The Dome Top ( 22 ) includes parallel well outputs for the Normal Capture Valve & Pipe ( 11 ) & the Pressure Relief/Diversion Valve & Pipe ( 10 ) (functionally identical to 11 & 10 on FIG. 1 ). The DA upper section further includes a large ROV Access Port ( 27 ) that can be converted to the smaller port size of a normal BOP feed thru access by installing the Access Port Adaptor (APA) ( 28 ). Two sets of AVA's ( 8 ) & P-WIA' s ( 7 ) are provided in series with the Normal Well Drill & Return Pipe ( 9 ). One set is connected to the BPO ( 5 ) via the BOP Output Adaptor (OPA) ( 32 ) and a Pipe Mounting Adaptor (PMA) ( 31 ). The other set is connected to the APA ( 28 ). The Dome Interior Plate ( 23 ) includes a Cable/Tube Access Hole and an associated Cable/Hole Sealer ( 29 ) (further shown on FIG. 3A ). The interior area between the Dome Top ( 22 ) & Dome Interior Plate ( 23 ) and further enclosed by 28 , 29 , 31 , 32 , 10 & 11 is the Reservoir Area ( 30 ) sealed form the exterior sea water and is capable of holding well pressure.
[0038] FIG. 3A is a diagrammatic cross-sectional view of the Adjunctive BOP/Access Valve Assembly (AVA)-Housing with an Enclosed Pipe Cutter (EPC).
[0039] The Housing ( 41 ) includes a physical area ( 42 ) below the Access Valve ( 43 ) that incorporates the EPC. The mechanical aspects of the EPC are shown on FIG. 3B . As a general reference the BOP Access Area ( 44 ) is shown as dashed lines. As a specific reference to the Advanced MFWS relating to the lower (ref. FIG. 2 ) AVA ( 7 ) & P-WIA ( 8 ), the Dome Interior Plate ( 23 ), PMA ( 31 ), OPA ( 32 ), Cable/Tube Access Hole & associated sealer ( 29 ) and AVA, P-WIA & DA control & monitor cables/tubes ( 45 ) are shown. In the case of the Fundamental MFWS the AVA ( 7 ) is directly connected to the Production Valve Assembly ( 6 ) and the upper set of AVA ( 7 ) & P-WIA ( 8 ) of the Advanced MFWS directly connects to the APA ( 28 ) (ref. FIG. 2 ).
[0040] FIG. 3B is diagrammatic cross-sectional top view, at the EPC elevation depicting the mechanical aspects of the Adjunctive BOP/Access Valve Assembly (AVA) with EPC. Item 51 is a flat circular/donut shaped turn-table connected to the AVA housing via ball bearings. Item 52 (in dashed lines) reference the BOP's access area depicting the required centered opening of item 51 . Item 53 is the turn-table motor assembly consisting of a motor, gearing, encoder & associated housing. The motor housing is attached to the AVA housing. The motor shaft, gearing & encoder interface with the turn-table. An item 54 (in dashed lines) represents the AVA housing under the turn-table.
[0041] Item 55 ′s are six Lateral Drive Devices.
[0042] Items 56 are three circular saw blades each including a motor & tachometer. Items 57 are three wedges. Items 58 & 59 are details of items 55 . Item 58 is the fixed member of item 55 . It is affixed to the turn-table and includes a lateral drive motor, an encoder, slides & gearing. Item 59 is the lateral sliding member of item 55 and includes slides & gearing. The dashed lines at item 59 indicate this member at its extended position.
[0043] FIG. 4 is a diagrammatic cross-sectional view of the Platform to Well Interface Assembly (P-WIA).
[0044] Item 61 depicts the housing. Item 62 depicts the return flow opening/path. Item 63 is the remotely controlled by-pass valve allowing (return) flow around a sealed pipe outer wall to return. Items 64 are remotely controlled expandable ‘o’ ring gaskets capable of closing the area between the interior pipes outer sidewall and the AVA's housing (the return path). The dashed lines at items 64 show the said gasket expanded. Item 65 is a sample pipe within the P-WIA. Item 66 is a reference to the Normal Well Return Pipe going to the drill platform. This reference is applicable to the Fundamental MFWS & the upper P-WIA of the Advanced MFWS. The lower P-WIA of the Advanced MFWS is opened to the Reservoir. Item 67 (in dashed lines) is a reference to the BOP's access feed-thru area. FIG. 5 is a diagrammatic cross-sectional view of the Pressure Relief/Diversion Assembly. Item 71 is the Containment/Separator Tank. Although not shown it is assumed internal elements would provide enhanced oil-water-mud-gas separation beyond that obtained by a simplistic internally opened tank. Item 72 is the Ballast required to stabilize the tank to the Sea-Floor ( 1 ) as the tank takes on different elements (initially filled with sea water and latter replaced with mud, oil & gas). Items 10 & 11 are references to the Pressure Relief/Diversion Valve and the pipe/tubing coming from the well as seen on FIGS. 1 & 2 . This pipe/tube extends horizontal from the well's sea-floor equipment to a safe area where any possible release of oil/gas from the well will not impact the safety of the surface equipment or personnel. Item 73 is a composite of numerous controls and internal tank monitoring/sensors interfacing with the surface equipment. Items 77 are pipes/tubes to further divert and/or capture the tank's separated holdings. It is assumed the different separated outputs would go to different places (such as oil to a surface containment area or capture vehicle while the gas may be diverted to a further safer area father away from the oil containment/capture area). Items 74 , 75 & 76 are remotely controlled valves. Item 74 is the Sea Water/Mud Valve and would initially be opened in conjunction with the Pressure Relief/Diversion Valve to allow the tank to extract its initial sea water and accept the wells output. As sensors indicate the tank no longer contains sea water/mud the valve would be closed. Item 75 is the Gas Valve. If gas is sensed within the tank this valve would be opened. Item 76 is the Oil Release Valve. As oil is sensed within the tank this valve would be opened.
[0045] FIG. 6 is diagrammatic perspective & cross-sectional views of a matching/mating pair of the Coupling/De-Coupling Pipes.
[0046] Items 81 are the upper end & lower end of the upper & lower coupling pipes. These ends have standard pipe to pipe coupling means. Item 82 (in dashed lines) indicates the inside wall. Item 84 is the smaller diameter upper pipe coupling surface that fits within the lower coupling pipe as indicated by the dashed lines of Item ( 90 ). Item 89 depicts a tapered the bottom portion of item 84 allowing it to initially align/fit into the lower section. Item 83 is the upper pipe's mounting flange & gasket that mates to the lower pipes mounting flange item 91 . Item 92 is a unique threaded element in the interior sidewall of the lower pipe. The ‘unique’ threads have a stepping characteristic as shown on Detail ‘B’ item 93 . The widths of the individual steps are slightly larger than the width of the remote controlled Spring Loaded Grabbing Device (SLGD), item 85 . Items 85 are installed on the upper coupling pipe via Pivots ( 87 ) and normally extend out from the sidewall via its internal spring. When compressed the SLGD fits into the pipe's sidewall per item 88 . Detail ‘A’, item 94 indicates a sloped mating (mating the slope of item 93 ) of the SLGP. As the upper & lower sections are joined the SLGDs compress into the sidewall and springs in & out of the different levels of the stepped threaded element. When the mounting flanges bottom-out the upper pipe is turned clockwise (where it ratchet into, further tightens and locks into the threaded-stepped element. The pipes de-couple via energizing the SLGD remote control mechanism, item 86 where the SLGD is pulled into its sidewall unlatching/freeing the two pipe sections.
DETAILED DESCRIPTION OF THE INVENTION
[0047] The system of the present invention comprises two functional and physically integrated subsystems, the Multi-Function Well Subsystem (MFWS) and the Intrusion Detection and Response Subsystem (ID&RS).
[0048] Both MFWS configurations (Fundamental and Advanced) utilize ‘other’ (not shown on Figures) unique support devices including: Production Hard Cap (PHC) Remote Monitor and Control Unit (RM&CU) Re-Case End Pipe (R-CEP) Re-Case Pipe (R-CP) Bottom Kill End Pipe (BKEP) Kill Pipe (KP) Modified Conversion Float Valve (MCFV) Modified Casing (MC) Modified Reamer Shoe/Drill Shaft (MRS/DS) Modified Drill Bit (MDB)
[0049] The Production Hard Cap (PHC) is a simplistic device. It is round as viewed from the top and has a mounting surface compatible with both the Production Valves and the Production Ports. The PHC is utilized to provide means to cap each individual unused Production Port and/or Valve.
[0050] The Remote Monitor and Control Unit (RM&CU) is a platform mounted specialized device associated with the Multi-Function Well Subsystem (MFWS).
[0051] The RM&CU will provide the surface platform to sea-floor and in-well equipment man-machine monitor & control interface. The RM&CU will include processing capability to provide operator recommendations and warnings, as well as an automatic mode to control the sea-floor and in-well equipment for critical/emergency situations. Although specific operational displays, modes, functions or controls are not specified in detail at this time, it is assumed the RM&CU equipment (such as monitors, computers and interface devices) matching/exceeding the system requirements are commercially/off-the-shelf available. The Re-Case End Pipe (R-CEP) is a pipe section smaller in diameter than the installed well pipe/casing in need of repair when the drill pipe is not in the well. It will have a remotely controlled initially closed bottom end valve, a remotely controlled expandable ‘o-ring’/gasket around its outer circumference near the closed end. It will further have a remotely controlled sidewall gate valve located slightly above the said gasket. Prior to installing the R-CEP the number of sections of Re-Casing Pipe (R-CP) required to repair the well must be determined. At a point above where the existing well pipe is in need of repair but below the BOP, a pair of remotely controlled Coupling/De-Coupling Pipes shall be joined, followed by additional sections of R-CP from above the bottom of the BPO to the surface platform. The R-CEP and R-CP would be lowered through the ‘normal outer/return drill pipe’ to the desired location. The R-CEP gasket would be energized sealing/closing/choking the pipe to pipe area. The sidewall remotely controlled gate valve will be opened and mud followed by concrete would be pumped directly into the re-casing pipe. The mud/concrete flows through the opened gate valve and into the pipe/casing in need of repair to seal the pipe to pipe/casing area. The concrete will flow through said area until cement is detected in the pipe to pipe area above the last (highest) section of well pipe that needed repair. The concrete pumping will stop, the sidewall gate valve will be closed and the concrete will be removed from the interior of the Re-Case Pipe. The bottom remotely controlled closed end valve will then be opened. The concrete is let to set between the pipe to pipe areas. The Re-Case Pipe (below the BOP and above the well pipe that require repair) will be uncoupled via the Coupling/De-Coupling Pipe (or will be cut and extracted).
[0052] The Re-Case Pipe (R-CP) is similar to the lowest section of the installed faulty well pipe/casing except: [ 0051 ] Smaller in diameter. Selected sections (the uppermost as a minimum) shall incorporate remotely monitored exterior pressure, oil, water, mud and concrete sensors.
[0053] The Bottom Kill End Pipe (BKEP) is similar to the R-CEP except: The ‘initially’ closed bottom end will also have a permanently closed section above it. The volume between the initially and permanently closed portions will contain pre-loaded ‘junk’, along with a remotely controlled means to open the bottom and release the ‘junk’. The ‘junk’ will be of various size material, flexible, buoyant (in oil) and capable of withstanding well pressures and temperatures, will not include the remotely controlled circular hydraulic controlled gasket around its outer circumference near the closed end, but instead will include a large expandable remotely controlled end plug (similar to an expandable pipe plug). The ‘large’ plug will be capable of expanding to the diameter of the well bore. The large plug will be set below the well casing and the plug would be expanded. The initially closed bottom end will be opened releasing the junk further sealing/clogging/choking the well. Mud followed by concrete would be pumped through KP in a similar manner as the Re-Case Pipe except the concrete will also flow into the well bore and the concrete will not be evacuated from the pipes interior. The upper sections of pipe will be removed in a similar manner as the Re-Case Pipe.
[0054] The Kill Pipe (KP) is similar to the R-CP except the ‘selected sections’(the uppermost as a minimum) shall incorporate remotely monitored interior (as well as exterior) pressure, oil, water, mud and cement sensors.
[0055] The Modified Conversion Float Valve (MCFV) changes the release method/mechanism from the present dropped ball, semi obstructing the flow through a pipe holding the valve opened causing a delta pressure. When/if the delta pressure and flow meet a pre-selected criterion, the said pipe releases and converts the device to a one-way valve.
[0056] The modification converts the valve to an electrical remote controlled device—activating a solenoid. The opening valve will further be spring loaded and its opening will be sensed and reported and remotely monitored as flow-rate.
[0057] The Modified Casing (MC) incorporates remote controlled sidewall gate valves near the top of the casing. Although the MC is primarily intended for the lower most casing, it could be desirable for other casing sections as well. The said valves would be initially being held closed. Upon command the valves will allow one-way flow, from the pipe into the well-bore. This will allow cementing from the top of the casing to the bottom, reducing the required pressure and further provides a more positive void/bore fill.
[0058] The Modified Reamer Shoe/Drill Shaft (MRS/DS) modifications combine the functional elements of the R-CEP and the BKEP with the following alterations: The ‘large’ ‘plug’ element of the BKEP is incorporated on the lower part of the shaft/collar slightly above the shoe or drill bit to seal/clog/choke the well bore to drill shaft/collar incorporates a remotely controlled gate valve device internal to the pipe, just above the drill bit to restrict flow through the drill bit. The remotely controlled ‘o-ring’ pipe to pipe sealing gasket around the pipes circumference incorporated on the R-CEP shall be re-located to above the controlled gate valve. The intent of the MRS/DS is: Similar to the BKEP by providing the means to kill the well below the last pipe in the well bore, but with the reamer/drill shaft in the well. Similar to the R-CEP by providing reliable means to re-case (specifically the pipe to pipe cementing process), but with the drill shaft/collar and/or the Reamer Shoe in the well to provide improved reliable means to cement the last pipe to the well bore.
[0059] The ‘Fundamental’ MFWS provides maintenance access, redundancy, sea-floor pressure relief/diversion means and utilizing common unique and in-use apparatus and tools, used in conjunction with a newly devised oil well access to provide the means to: Cap the well, Seal/re-seal the well, Drill/re-drill the well, Kill the well (at the bottom from the top), Improve BOP(s) reliability and Improve means to end casing
[0060] The ‘Advanced’ MFWS includes all the features of the above, and further includes a unique dome top, cylindrical sidewall assembly/structure enclosing the well's sea-floor equipment providing improved structural strength and protection from natural/human induced disasters.
[0061] Either the Fundamental or Advanced MFWS configurations could be modified to include an additional Adjunctive BOP/Access Valve Assembly (AVA) installed below the BOP providing further redundancy.
[0062] MFWS Detail Design Notes/Information
[0063] The dome's size is determined by the wells characteristics. The primary factor is the height of the wells above sea-floor equipment (Marine Riser and BOP and newly installed adaptors/assemblies—OPA, PMA, and AVA and P-WIA) followed by the margin of safety associated with the: lateral stability of the DA (diameter to height ratio), sidewall strength beyond that required to support the top members—where the ‘beyond’ is the strength to compensate for falling objects/underwater blasts, height and width of the required maintenance area (ROV workspace). The overall ‘Dome Assembly’ size shall be as small as possible but its sidewall height shall be greater than the existing wells sea-floor equipment (Marine Riser and BOP)—(generic/ball-park height >60′). The sidewall diameter will provide lateral stability of the Dome Assembly and have a surface area compatible with all required dome top ports. (>two third the height, generic/ball-park diameter >40′) The initial (pre-cementing) weight of the Dome Assembly shall be slightly greater than the weight to sink it to the sea-floor, But if prior to its installation, the well head is opened and under pressure and can not be controlled/stopped, then weight must be added to overcome the well pressure. The added weight shall be determined assuming all top ports/valves opened (the said ports/valves would be opened during the normal installation/setting process). The top domed member (dome top and interior plate forming the reservoir) shall be made of material and joined in a manner to withstand greater than two times the wells' anticipated pressure. The cylindrical sidewall of the dome is fabricated with material and supporting braces capable of supporting the top (domed) structure and act as a concrete form to structurally connect the dome top section to a concrete floor pad. The center interior will include installation positioning/guide braces about the locations of Marine Riser, BOP and BOP Output Pipe Adaptor. The sidewall may be made of two or more vertical separable sections enabling sea-floor equipment changes for the completion-production phases (if/as desired). The exterior of the sidewalls will include a minimum of three horizontally extending ‘L’ brackets. The brackets will support remotely controlled leveling jacks capable of lifting/leveling the pre cemented Dome Assembly. The dome top to sidewall mechanical interface shall include lifting hooks/eye-bolts and shall be capable of supporting the DA's initial (pre-cemented) weight. After the DA is set (positioned and leveled) on the sea-floor, pressure relief vent pipes (approximately 3-4 feet long) will be vertically set in the sea-floor having the vent pipes be semi-evenly spaced in the floor and encompassing an area approximately five percent of the total sea-floor area, and a concrete floor (approximately 3 feet deep) will be poured (structurally connecting the Well Stud to the sidewall). The cylindrical sidewall will include an opening the size compatible with passing through a ‘typical’ off-shore oil well's ROV. The opening will be enclosed by a door. The door will include pressure relief/venting means allowing higher internal pressure to be released, while sealing the interior from higher external pressure. The center of the dome top will house a large access port. ‘Large’ is defined as the area capable of passing through a device the size of an ROV. The port will be initially used to access the interior of the dome during installation and latter for repair/replacement on assemblies within the dome. The exterior of this port area will include guide-pins and bolt studs to mechanically secure an Access Port Adaptor (APA). The APA reduces the port size and is used to connect various assemblies/adaptors for well pipe drilling, sealing repair and abandonment processes (killing), Off-center of the access port will include several production sized ports. The exterior of these ports will include the means to secure a Pressure Relief/Diversion Valve, Production Valves or Production Hard Caps. These mounting elements (pins and bolt studs) shall be identical (size, spacing and pattern) on all Production Ports. These ports/valves will be initially opened (as well as the Access Port) during the Dome Assembly (DA) installation (lowering and positioning). The ports/valves are initially used for pressure relief/venting and latter used for production—or will be capped. The Dome Assembly will include numerous standard (non-unique) remotely monitored/controlled equipment such as: Levels, Internal and external closed circuit T.V. (s) and associated lights, Pressure sensors, Oil, water and gas detectors All assemblies/adaptors/tools shall include the following where applicable: Be made of material capable of withstanding greater than twice the well's pressure Supporting means compatible with lifting, lowering and positioning the unit from the surface platform and ROV(s) Top and bottom mounting surfaces' compatible (size and shape) with the units they physically interface with Top and bottom mounting hardware (bolt studs, guide-pins) and compatible (size and pattern) holes and captivated securing components with the units they physically interface with:
[0064] Mounted gaskets compatible with the size and shape of the unit and the unit it physically interface with the means to remotely remove and replace all internal functional elements by a ROV(s). Remotely controllable devices shall be designed using electrical, fiber-optics, mechanical, hydraulic and/or pneumatic means with connections compatible with a ROV(s) capability to install/remove. There are many different ‘working’ pipe sizes and the expandable seals of the P-WIA will likely not be capable of handling, therefore different sized P-WIA s′ or inserts must be provided. Varying levels of pressure could be applied to the P-WIA's seals allowing for a fully opened, to fully a hard sealed, as well as intermediate levels allowing for rotating and vertical pipe movement as well as sequencing the said pressure from the upper & lower seals as the pipe joints pass thru the unit. The functionally/performance of numerous MFWS unique equipment/tools require or would be enhanced with the addition of an ‘in-well’ monitoring & control interface. Numerous interface structures could be employed to provide this function. Although the intent of this document is to provided a ‘system level’ design the following is provided as design information/specifications/requirements for this interface as follows:
[0065] Design.
[0066] Embedded Fiber-Optic (FO) cable within the drill pipe sidewall, Compression pipe to pipe FO connections, directly connect sensors and controlled devices attached to the drill pipe to the said cable. Sensors and controlled devices not directly attached to the drill pipe interface via non-physical contact means of coded Light/IR/RF and/or acoustic interface devices (such as a garage door opener or ‘Easy-Pass’ type device). Sensor and controlled devices powered by batteries. Controlled devices using hydraulics would use battery power to activate (in-well) pumps with initial pressure equalization means. Notes/Requirements: The FO bandwidth is orders of magnitude greater than required (but provides a convenient bi-directional capability). The sensors will include addresses (digital/frequency codes) capable of any future conceivable need. The following define the minimum required simultaneous functionally, which basically defines/limits the requirements of the controlling/monitoring unit. 25 discretes—yes/no (such as sensed gas), 15 levels indicators with ten to the 5.sup.th dynamic range (such as well pressure), 15 controls (such as turn on/off), 15 control status/feedback.
[0067] The sequence of operations of the Pipe Cutter Mechanism will be initiated by an operator at the Remote Monitor and Control Unit (RM&CU). In the automatic operational mode, after being ‘initiated’, an embedded micro-processor and program in the RM&CU will control and perform the cutting process described below. In a manual mode the operator will perform the steps below: 1. An operator at the RM&CU will initiate a pipe cut defining a given size pipe. 2. The Circular Saws and Lateral Drive Devices drives, with minimum torque contacts the pipe to confirm the designated pipe size. If different informs the operator. 3. If the pipe designated is confirmed the proper size, the saw motors are turned on and laterally driven into the pipe until either the thickness of the pipe-wall is penetrated or the saw motor speed decreases greater than 20%. If the latter occurs see * (below). 4. When the pipe-wall is penetrated, the Turn-Table Motor turns on and continues to cut the pipe until either the Turn-Table turns to where the pipe is cut by each saw 110 degrees or the saw motor speed decreases greater than 20%. If the latter occurs see * (below). 5. When three saws have cut the pipe 110 degrees, Circular Saws and Lateral Drive Devices retract the saw blades and: The Turn-Table is positioned at 120 degrees. 6. The Wedges' Lateral Drive Devices is activated pressing the wedges into the pipe cut. 7. The Circular Saws' Lateral Drive Devices is again activated to drive the saw blade towards the pipe until either the thickness of the pipe-wall is penetrated and the pipe is fully cut or the saw motor speed decreases greater than 20%. If the latter occurs see * (below). 8. Once the pipe is fully cut it must be extracted. If another pipe needs to be cut, the first pipe must be pulled clear of the pipe cutting lateral drive mechanism.
[0068] *If any of the saws speed decreases greater than 20% from its unloaded speed, the appropriate drives will be backed-off until the no-load speed is obtained. The drives will then proceed to the continuing cutting process.
[0069] The heart the pressure relief, diversion, capture and recovery subsystem is the unique seabed containment/separator tank supported with its primary interfaces devices (manifold, remote controlled valves and offset/diversion piping) providing the means to vent and/or capture oil/gas.
[0070] This continuation-in-part application incorporates a new capture device (a Containment Balloon) as an additional option to venting into the sea or capturing in a surface containment device (floating opened top -closed sidewall area or tanker(s)).
[0071] This continuation-in-part subsystem description further identifies various means (pipe/tank thermal insulation, heaters and/or anti-freeze chemical injection) incorporated in the pressure relief, diversion, capture and recovery flow path to guard against potential freezing—blocking gases.
[0072] The objective of the Intrusion Detection and Response Subsystem (ID&RS) is to protect the surface and underwater oil well elements from deliberate human intervention. It is assumed a 3D restrictive zone will be established about an individual or group of oil wells.
[0073] The ID&RS provides the means to detect, track and classify the 3D aspects (bearing, range, and depth) of air/surface/sub-surface objects about a specific oil well or group of oil wells. It also provides the means to evaluate potential threats and ‘Hard and/or Soft Kill’ threats.
[0074] The ID&RS elements are identified in four categories as follows:
[0075] 1. Major existing military type platform equipment that provides short range AAW, ASUW and ASW capability including such items as: Radars (search and fire control), IFF, ESM, Sonar, Active and Passive Decoys (Acoustic, RF and IR), Hard Kill Weapons (guns, missiles, torpedoes and depth charges). 2. Major existing military/commercial type equipment such as: LAMPS Helicopter and ROV s. 3. Unique equipment such as:
[0076] Array(s) of sea surface tethered remotely controlled RF and IR generators/decoys, Array(s) of below sea tethered remotely monitored Passive Acoustic Sensors (PAS) and a platform mounted PAS, Remotely controlled acoustic generators/decoys and remotely controlled acoustic corner reflectors, Interface, Processing and Display Monitor and Controls 4. Trained Operator(s).
[0077] Many of the terms such as ‘short range’ and ‘weapons’ are quite subjective and since the primary threat is considered to be quite rudimentary the following are identified as design guidance: A Radar (search, fire control and integrated IFF) capability such as the MK92 CAS, Weapons such as the Standard Missile, Harpoon and Mk46 Torpedoes would work but have a significant over kill for the anticipated threat, Hard Kill weapons could include such items as a MK15 CIWS, a 3 ″ gun, SUBROC and Helicopter launched depth charges and shoulder type fire and forget anti-air and anti-surface missiles.
[0078] ID&RS Detail Design Notes/Information
[0079] The acoustic sensors and arrays are conceptually based on USN ASUW and ASW detection and processing techniques. The subsurface piggy-back depth angle sensor and the related arrays depth determination is unique but based on the triangular processing of the bearing and range. It is anticipated the sensed ‘depth angle’ will be compromised by sea-floor and surface reflections/bounce, but it is assumed that integrating over time and averaging the three differently located sensors data will provide tangible results. The tracking, classification, threat analysis and threat response recommendations are also based on USN processing.
[0080] The RF, IR and acoustic generators and corner reflector(s), and their associated array, are conceptually based on USAF and USN air tactical counter-measures (stand-off jammers and gate stealers) and USN submarine counter-measures (decoys).
[0081] The Light Airborne Multi-Purpose System (LAMPS) operations are based on the USN LAMPS MK111 ASW and ASUW techniques.
[0082] The following describe a single well installation utilizing a USN or USCG Ship for the ‘Major existing military type platform equipment that provides short range AAW, ASUW and ASW capability’.
[0083] It is assumed alternative interfaces, operations and array configurations could be derived for well platform based equipment and/or multiple well implementations.
[0084] The Radar and associated IFF and Electromagnet (passive detection) Sensor (EMS) are the ‘eyes’ for above the surface, while the passive acoustic sensors are the ‘eyes’ for below the surface.
[0085] The acoustic sensor array provides subsurface and surface detection data and the means required to triangulate the sensors detections to determine Bearing, Range and Depth. The outputs of the acoustic sensors* and control signals for all generators (RF, IR and acoustical) interface with (via cable) an Array Distribution Unit (ADU). The ADU (data/controls) interfaces (via cable) with to the Data and Signal Formatter (D&SF). D&/SF on a (oil well) platform digitizes and serializes the signals. The digitized and serialized signal is sent to the platforms RF Data Link and then the ship's RF Data Link. The data is then sent to the Processor where is processed for display monitoring and display interface, detection support (bearing, range and depth determination for acoustic contacts) and tracking, classification, threat analysis and related recommendations, as well as historical storage for air, surface and subsurface contacts.
[0086] The processed data and information is then sent to the Display Monitor and Control Unit. A trained Operator views/reviews the data and information and determines and initiates appropriate actions.
[0087] The processing will include an operator selectable auto threat-quick reaction ‘soft-kill’/decoy mode, allowing the program to automatically control the RF, IR, acoustical generators and corner reflectors.
[0088] The controls are sent to the appropriate selected unit(s) (specific sensor and/or generator) via the Processor, RF Data Link, Data Formatter, Array Distribution Unit and then to the appropriate unit. LAMPS Helicopter interfaces via its own data link.
[0089] If ROV actions are required, a stand alone interface, monitor and control system identical to the existing ROV's will be used.
[0090] If the Ship has a sonobuoy receiver system compatible with the number and type of sonobuoys in the array the sensors could directly (via RF) interface with the ship.
[0091] It is assumed the sensor (RADAR, IFF, and ESM etc.) and weapons on a USN or USCG Ship identified as short range AAW, ASUW and ASW capable would well serve this mission, particularly as supplemented.
[0092] The RF and IR Generators/Decoys are standard simplistic active noise or repeater source similar to numerous such devices used by the USN and USAF. The device shall be externally stimulated and controlled by the Processor to produce outputs capable of:
[0093] Being totally silent, Producing broadband continuous wave frequencies over the entire spectrum of anticipated homing devices, at power levels greater than the anticipated homing device's transmitter, Producing a controlled variable delayed pulsed repeater outputs compatible with the pulse-width and spectrum of an anticipated active pulsed homing device. The controlled variable delay shall have a minimum range from; <1 us to greater than 10 ms. The repeater will further have controlled power levels from a maximum equaling the anticipated power of a homing device's transmitter, to minimum power level of zero.
[0094] The Passive Acoustic Sensor (PAS) is derived from a modification of the standard AN/SSQ 53 Directional Frequency Analysis and Recording (DIFAR) Sonobuoy.
[0095] The low-tech modifications include: Providing an external power source via cable (vs. internal battery power), Removing the antenna output interface and utilize output via cable interface format, Mounting two unit's piggy back on different axis (one producing bearing angle and the other depth angle),Increase buoyancy to insure unit with attached cable (and attached Acoustic Generator has significant positive buoyancy.
[0096] The Acoustic Generator (AG) is a simplistic active acoustic noise source similar to numerous such devices used by the USN.
[0097] The device shall be externally stimulated and controlled by the Processor to produce outputs capable of: Being totally silent, Emulating the acoustic signature of an oil well's sea-floor and platform, with power levels equal to ten times the said well, Producing broadband continuous wave acoustic frequencies over the entire spectrum of anticipated homing devices, at power levels greater than an anticipated homing device's transmitter, Producing a controlled variable delayed pulsed repeater output compatible with the pulse-width and spectrum of an anticipated active pulsed homing device. The controlled variable delay shall have a minimum range from; less than 10 us to greater than 10 ms. The repeater will further have controlled power levels from a maximum equaling the anticipated power of a homing device's transmitter, to a minimum power level of zero. The Acoustic Corner Reflector (ACR) is a simplistic passive decoy type device. It is basically composed of two flat acoustical reflective crossing plains (crossing in the center) at 90 degrees that reflects an acoustical signal back in the same angle it was received. The ACR further includes a remote controlled element that rotates (from the center) one of the plains to form a dual flat surface. The ACR is deployed with weighs on the sea-floor and/or tethered at different depths.
[0098] The PAS and AG units will be connected (via cable or be physically joined) and typically deployed in functional sets of three or four typically @ equal distance from each other and equal distance about a specific well (or in other functional sets about a group of wells).
[0099] Each of the PAS, AG and/or ACR units will be tethered from the sea-floor to pre-determined depths. The RF & IR generators will be tethered to the sea surface.
[0100] The said tethered cables could include various combinations of sensors/decoys. The sea-floor will hold the tethered cable with weights capable of insuring it does not change its position (depth, lat. and long.). The cable length from the tethered weight to the sea-floor to platform shall be the planned distance plus about one and a half times the sea depth (for future recovery/maintenance). A single (non-joined) AG will be mounted on the underside of the surface platform providing the means to calculate (via the processor) the exact position and aspect of the joined PAS and AG devices.
[0101] The ROV(s) is identical to such devices used by the oil industry for deep off-shore drilling but this unit's interface cables will be lengthened so it can travel greater than two miles from the platform. The ROV(s) provide the means to view, evaluate and move delayed fused under-sea explosives.
[0102] The Array Distribution Unit (ADU) function only acts as a convenient physical wire/cable distribution center.
[0103] The Data and Signal Formatter (D&SF) is an active electronic data and signal formatting device located on the platform.
[0104] The ‘formatting includes: Analogue to Digital conversion, Digital to Analogue conversion, Multiplexing and De-multiplexing into and from a single serial digital data interface cable. The D& SF will have the minimum through-put capacity (bandwidth) to simultaneously handle: From Sensors: Acoustic outputs of eight type AN/SSQ-53 Sonobuoys. Plus 50% (control, feedback, status, etc.). To Sensors and Generators: Approximately 25% of the ‘from sensors’ bandwidth
[0105] It is assumed devices matching/exceeding these requirements are available ‘off-the shelf’ (from Industry/US Government). The RF Data Link is a common device used by industry and the government. The device converts serial (cable media) electronic data/signals to RF for transmission to another location via an antenna and likewise receives RF and converts it to serial electronic data/signals.
[0106] The capacity (bandwidth) must be compatible with the required data/signals of the system, as identified for the D&SF.
[0107] It is assumed devices matching/exceeding these requirements are available ‘off-the shelf’ (from Industry/US Government).
[0108] *The above assumes a separate in-place ship to helicopter (LAMPS) data link.
[0109] The Processor includes a computer and specialized computer programs. The Processor provides critical functions related to the surface/sub-subsurface objects: Detection, Position, Tracking, Classification, Threat Analysis and related recommendations The processor also provides interface for the Display Monitor and Control Unit. The processor further provides for sensor position and aspect calibration, operator training via simulation and historical operational recording.
[0110] It is assumed the computers are in-place on the ship, or a computer matching/exceeding the required process capacity and speed are available ‘off-the shelf’ commercially. The ‘specialized computer programs would have to be developed, but the USN utilizes similar functional software for their AAW, ASUW and ASW mission. If such were made available the development (time, cost and risk) would be reduced by an order of magnitude.
[0111] The Display Monitor and Control Unit (DM&CU) provides for the operator to system interface.
[0112] The Light Airborne Multi-Purpose System (LAMPS) is identical to that used by the USN for surface and sub-surface detection, localization and engagements.
[0113] Although specific operational displays, modes, functions or controls are not specified in detail at this time, it is assumed the DM&CU is in-place on the ship or a unit matching/exceeding the requirements is commercially available—large touch-screen monitor would well serve the all requirements.
[0114] It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed. | The parent patent—The Oil Well Improvement System—incorporates and integrates several different unique assemblies and subsystems that provides a cost effective disaster preventive system for offshore oil wells while concurrently providing the means to reduce the cost of the drilling processes.
The system modifies the sea-floor, in-well and platform equipment and processes.
This divisional patent—The Pressure Relief, Diversion Capture & Recovery Subsystem—acts in concert with the Oil Well Improvement System to provide an additional and/or interim means to control a blown out well by providing an alternate/safe low resistance flow path along with the means to capture and recovery oils/gases. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to efficient means for the generation of electrical power utilizing energy from geothermal sources and, more particularly, relates to arrangements for suspending and sealing in operating relation hot geothermal water pumping equipment in deep, hot water wells for the transfer of thermal energy to the earth's surface.
2. Description of the Prior Art
A prior art advance in the art of extraction and use of geothermal energy is reflected in the H. B. Matthews U.S. Pat. No. 3,824,793 for a "Geothermal Energy System and Method," issued July 23, 1974 and assigned to Sperry Rand Corporation. This prior Matthews invention provides means for efficient power generation employing energy derived from geothermal sources through the generation of dry, super-heated steam and the consequent operation of sub-surface equipment for pumping extremely hot well water at high pressure upward to the earth's surface. Clean water is injected at a surface station into the deep well where thermal energy stored in hot solute-bearing deep well water is used at a deep well station to generate super-heated steam from the clean water. The resultant dry, super-heated steam is used at the well bottom for operating a turbine-driven pump for pumping the hot solute-bearing well water to the earth's surface, the water being pumped at all times in the system at a pressure sufficient to prevent flash steam formation. The highly energetic water is used at the surface power station in a binary fluid system so that its thermal energy is transferred to a closed-loop surface-located vapor generator-turbine system for driving an electrical power alternator. Cooled, clean water is regenerated by the surface system for re-injection into the well for operation of the steam turbine therein. Undesired solutes are pumped back into the earth via a separate well in the form of a concentrated brine.
In the H. B. Matthews U.S. Pat. No. 3,967,448 for a "Geothermal Well Casing Seal," issued July 6, 1976 and also assigned to Sperry Rand Corporation, there is described an improvement facilitating ready installation and reliable operation of such geothermal systems; according to that invention, there are provided means for the support of the deep well geothermal pump system within the well casing from the earth's surface by the pump-driven turbine exhaust steam conduit. In view of the differential expansion effects on the relative lengths of the casing extending downward from the earth's surface and the exhaust steam conduit contained therein, a particular flexible seal arrangement was provided between the suspended geothermal pump system and the well pipe casing. A first element of the improvement provided a vertical, smooth cylindrical sealing surface at the desired location for the deep well apparatus by means itself previously sealed to the well casing pipe. A second element assured easy assembly of a second seal interfacing the cylindrical sealing surface and suspended from the hot water pump so as to permit sliding motion of the seal in the prevailing hostile environment.
It is necessary to provide an efficient seal of some kind between the brine pump and the well casing; otherwise, a differential pressure would never be built up across the brine pump impeller. While the seal of the prior Matthews patent has certain established advantages for this purpose, it is complex and expensive. This expensive design will seal against very high differential pressures and is effectively leak-proof, while some leakage may actually be permitted. The packer used in the prior arrangement requires a large-diameter casing, whereas casings of more conventional dimensions are less expensive and evidently preferred. The prior art fixed packer is relatively expensive to buy and to insert, adding considerably to the time required for deployment of the equipment in the geothermal well. The fixed packer must be drilled out when it is to be removed.
SUMMARY OF THE INVENTION
The invention is an improvement facilitating ready installation and reliable operation of geothermal systems, including geothermal energy retrieval systems of the kind described in the aforementioned H. B. Matthews U.S. Pat. No. 3,824,793. The invention affords ready and less expensive installation of deep well geothermal apparatus. The deep well apparatus is supported within the well casing pipe from the well head at the earth's surface by the pump-driving turbine exhaust conduit. Alternatively, the working fluid conduit may serve as the suspension. Differential expansion effects are accommodated by a novel sealing arrangement mounted on the geothermal pump itself before it is lowered into the well and having seal interfaces directly mating with the interior surface of the well casing when deployed at the well bottom. An arrangement is provided for protecting elements of the flexible seal during lowering of the pump and its associated seal system into the well and then for automatically deploying the seals in their operating condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view, mostly in cross section, of the suspension arrangement for the deep well geothermal pumping apparatus.
FIG. 2 is an elevation view, mostly in cross section, of the deep well geothermal pump apparatus and of the novel sealing arrangement.
FIGS, 3, 4, and 5 are fragmentary views in cross section showing the seal arrangement in three successive states and apparatus for deploying the seal.
FIG. 6 is a partial development, partly in cross section, of the seal when in the state shown in FIG. 4.
FIG. 7 is a partial plan view of an alternative arrangement for deploying the seal.
FIG. 8 is a partial elevation view, partly in cross section, of the structure shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate the general structure and characteristics of a geothermal energy extraction system a portion of which is immersed in a deep well extending into strata below the surface of the earth, preferably being located at a depth where a copious supply of extremely hot water is naturally available, the active pumping structure being located adjacent the hot water source and within a generally conventional well casing pipe 20. The configuration in FIG. 1 is seen to include a well head section 1 located above the earth's surface 21 and a main well section 25 extending downward from well head section 1 below the earth's surface 21. In a geothermal system such as that illustrated in the aforementioned Matthews U.S. Pat. No. 3,824,793, for example, the main well section 25 joins a steam or other vapor generator input section 33 near the source of hot, geothermal brine. As is explained in the Matthews patent, the steam generator section 34, the steam turbine section 35, a rotary bearing section 36, and a hot water pumping section 37 follow in close cooperative succession at increasing depths. At the lowest or seal section 65, the input to the pump section 37 is sealed with respect to the inner wall of well casing pipe 20, as will be further described.
Referring again particularly to FIG. 1, the well casing pipe 20 extends downward from the well head section 1 in preferably concentric relation about an innermost conduit 2 for supplying a flow of relatively cool pure water at the bottom of the well. A second relatively large conduit 10 surrounding conduit 2 is also provided within well casing 20, extending from well head 1 to the energy conversion and hot water pumping system at the bottom of the well and permitting turbine exhaust steam to flow to the surface of the earth.
The clean water injection pipe 2 passes through a fitting 3 mounted on the apertured capping plate 4. In a similar manner, the exhaust steam return pipe 10 passes through a fitting 15 mounted on a second apertured capping plate 16. While these generally concentric structures may be integrated to a degree, it is intended that the exhaust steam pipe 10 furnish the main support for the deep well apparatus, though conduit 2 may be used alternatively. For this purpose, a ring collar 11 is affixed about the exhaust steam pipe 10 immediately below its tee branch 10a. Ring collar 11 normally rests on a suitable horizontal platform 18 which may, in turn, be supported by braces 14, 17 from associated vertical support beams 18 and 19. The latter are fixed in the earth, for example, by suitable concrete foundation elements (not shown) that may take entirely conventional form. In this manner, the weight of the conduits within the well casing pipe 20 and the weight of the deep well geothermal pump apparatus itself are primarily suspended from the exhaust steam return pipe 10 by platform 18.
It will be seen from FIGS. 1 and 2 that relatively clean cool water is pumped by pump 5 through pipe 2a into the vertical injection pipe 2 down to the pressure regulator and input section 33 (FIG. 2). As in the aforementioned Matthews U.S. Pat. No. 3,824,793, the water flow in pipe 2 is then divided for further downward flow in two branching pipes (not shown). A first branch path supplies the clean water for lubricating a system of bearings within the bearing section 36. The second branch path feeds clean water through a pressure regulator in the steam generator input section 33 and via other distribution pipes to an input manifold of the steam generator in section 34. Accordingly, high pressure steam is delivered to a steam turbine located within turbine section 35.
The function of the turbine located at section 35 and supported on bearings located within bearing section 36 is to drive a hot water pump located at section 37. Hot well water is thus impelled a high pressure upward by the rotating pump blades 39 between the rotating conical end 40 of the pump and an associated stationary shroud 41; the hot water is pumped upward at high velocity in the annular conduit between pipes 10 and 20, thus permitting use of the thermal energy it contains at the earth's surface. More important, the hot water is pumped upward to the earth's surface 21 at a pressure preventing it from flashing into steam and thus undesirably depositing dissolved salts at any point of flashing.
Accordingly, it is seen that the extremely hot, high-pressure well water is pumped upward, flowing in the annular region defined between pipes 10 and 20. Heat supplied by the hot well water readily converts the clean water flowing into the steam generator section 34 into highly energetic, dry, super-heated steam. The clean water, before flowing into the pressure regulator of input section 33, is at a very high pressure due to its hydrostatic head and also because of the action of the surface-located pressure pump 5 so that it may not flash into steam. The pressure regulator at location 33 controls the pressure of the clean water flowing therethrough so that it may be vaporized and superheated in the steam generator in section 34. The highly energetic steam drives the steam turbine at section 34 and is then redirected to flow upward to the earth's surface 21 after expansion as relatively cool steam flowing within the annular conduit defined between pipes 2 and 10. Thermal energy is recovered at the earth's surface primarily from the hot, high pressure water flowing upward between pipes 10 and 20, but may also be retrieved at the earth's surface from the turbine exhaust steam, if desired.
As described in the aforementioned Matthews U.S. Pat. No. 3,824,793, the hot, high pressure water within well casing 10 is fed by pipe 20a to a conventional surface thermal power plant 22, which latter may include in the usual manner a vapor generator system in which a major part of the energy in the hot geothermal fluid is converted into energy in high pressure vapor for driving an alternator supplying electrical energy on power lines 24. The cooled geothermal fluid is pumped by pump 31 back deep into the earth via re-injection well 32. Thus, the geothermal fluid flow loop is effectively completed and the fluid and its dissolved mineral salts are returned into deep strata of the earth.
Still referring to FIG. 1, a representative closed loop for injecting clean water into the deep well geothermal system will be described. The steam exhausted upwardly from the driving turbine at section 35 of that well is conveyed by pipes 10 and 10a to a heat exchanger element 7 of a conventional heat exchanger 8, and, after condensation therein, flows through the normally operating pressure pump 5. Heat exchanger 8 may be operated by supplying cooling water in a third loop including a conventional cooling tower (not shown) to pipe 6 connected through heat exchanger element 8 and output pipe 13 back to the same fluid cooling tower. Alternatively, known expedients may be employed for extraction of additional energy during the condensation process for use by power plant 22. The clean water condensate is pumped by the conventional pump 5 for re-injection into the deep well pipe 2 at a pressure substantially above that of the pumped hot well water. Replenishment of the clean water may be supplied from the normally inactive source 12.
As previously noted, the steam turbine driven-hot water pump system is to be suspended at the bottom of the well from a conduit such as the turbine exhaust steam pipe 10. The suspended apparatus includes sections 33 through 37 of the geothermal pump system. After the assembly of sections 33 through 37, the geothermal pump system is lowered into the well casing pipe 20, to its operating level by the gradual lowering of the steam exhaust pipe 10 as the latter is assembled. The clean water injection pipe 2 may be similarly introduced as the assembly is lowered and therefore also lowered into its operating position with the geothermal pump system using conventional oil well technology.
Before the geothermal pump system is put into its operating position, an annular seal system must be provided below the intake shroud 41 of the pump. In its operating location, the cooperating pump seal will translate axially with respect to the inner surface of casing 20 because of the effects of thermal expansion. The geothermal pump system, hanging as it does from a long pipe such as the steam exhaust pipe 10, may move up or down by many inches, so that a slippable seal interface is required between pump section 37 and the well pipe casing 20. The inner wall of the casing pipe 20 will normally be rough and will vary in diameter and roundness, so that a flexible sealing element is required.
According to the invention, and as seen generally in FIG. 2, the deep well sealing section 65 is supported from a generally conventional pump shroud 41 supported, in turn, from the pump section 37 by a plurality of welded radially spaced vanes 38. In this manner, an annular passageway provides smooth flow of the brine upward from the production pipe 54, through the expanding annulus between shroud 41 and the rotary pump cone 40, and upward toward the earth's surface within well casing 20.
The production pipe 54 also serves as a mounting device for a system of one or more annular cup-shaped piston seal devices 50. As is seen in FIG. 2, where the device 50 is represented in operation position, each seal system includes a tubular metal collar piece 55 affixed to a portion of the outer wall of production pipe 54. At its bottom, collar piece 55 has an apertured metal disk 59 supporting, in turn, at its periphery a short cylindrical metal flange 58. Elements 55, 58, and 59 may be formed integrally of corrosion resistant alloy and they constitute a support for the resilient or flexible element of seal 50.
The cup-shaped seal devices 50 are composed of a molded flexible material adapted to withstand the severe thermal and caustic nature of the environment in which they are to be used. There is available in the market a variety of materials for the construction of molded seals and other bodies for use in the oil fields and in other such severe environments, including various well known elastomer compositions. For relatively low temperature wells, certain ethylene-propylene compositions widely used in industry are suitable. For general and high temperature use, a molded composite of asbestos fibers and solid polymerized fluorocarbon resin materials is found useful. Other suitable compositions known to those skilled in the art are additionally selectable according to the character or the well.
In general, each annular seal device 50 may include an annular mounting base part 60 bonded to apertured plate 59 at interface 61 and to the inner surface of annular flange 58 at interface 57. Extending upwardly from base part 60 is an elastic cup-shaped element 56 forming a slidable seal at interface 52 between its outer surface and the inner surface of casing 20. It is seen in FIG. 2 that at least one metal loop 53 protrudes from the inner surface of seal device 50; a circular array of many such loops will normally be used, as will be further explained. Only one such loop 53 of the array for seal device 50 is shown in FIG. 2 for the convenience of providing an uncluttered drawing, since the loop 53 in the situation of FIG. 2 is in its purely passive state, seal device 50 having been deployed against casing 20. Abutting at interface 51' is a second seal device 50' having elements 51' to 61' corresponding to elements 51 to 61 of seal device 50. Two or more such seals, as needed, may be affixed in serial fashion to production pipe 54.
FIGS. 3, 4, and 5 illustrate a form of the seal device 50 in successive stages of use. In FIG. 3, the annular piston shaped seal device 50 is seen mounted with respect to production pipe 54, as before, on elements 55, 58, and 59, this time being held in position by a conventional fastener, such as a bolt 72 running through aligned clearance holes in plate 59, base part 60, and a washer or plate 71, and correperating with a nut 70. The piston seal device 50 has been mounted on the geothermal pump preparatory to inserting the latter into its well. Such is indicated by the presence in the view of the production pipe 54, the well casing 20 being absent. To prepare each seal device 50 for lowering into the well, further apparatus shown in FIGS. 5 and 6 is used, it being understood that FIG. 6 is a developed or "un-rolled" view of FIG. 4.
In FIGS. 4 and 6, the use of a tie back cable, cord, tape, rope, or other flexible connector 73 is shown, element 73 being passed through each of the plurality of loops 53, as a tension means to pull the mating surface 52 inward to a stowed or retracted position so that it may avoid contact with and abrasion by the inner surface of casing 20 while the pump is being lowered into the well. The flexible connector element 73 of the tension means having been passed through all loops 53, its ends 73a, 73b are pulled together and tied. The re-shaped seal device 50 will then be distorted to have a diminished diameter substantially the same, for example, as that of annular flange 58 and is thus protected from damage by casing 20. The apparatus as seen in FIG. 4, including the geothermal pump, may then be safely lowered to its operating position in the geothermal well by pipe 2 or 10. In place of tying the ends of cable or rope 73, its ends 73a, 73b may be held under tension in a suitable clamp indicated at 74.
Tie-back or flexible connector element 73 pulls inwardly against the flexible wall portion 56 of seal 50, whose spring characteristics may be augmented as shown in FIG. 6 by the inclusion within the body of the wall 56 of a comb-like structure comprising a flexible metal sheet with a base 76 and a plurality of spaced spring fingers 75. The metal base 76 is seen to extend into the inert base part of the flexible seal 50. As further illustrated in FIG. 5, each flexible finger 75 forms a convenient element to which a corresponding tie-back loop 53 may be fastened. Thus, the spring-like nature of the seals is enhanced and a convenient way of attaching the tie-back connector loops 53 is afforded.
The state of the seal device 50 in its operating position deep in the well is illustrated in FIG. 5, which figure also contributes in an apparent manner to a visual understanding of the function and disposition of the spring fingers 75 at that time. In FIG. 5, the seal has been deployed, rope 73 having been removed, and the flexible sealing face 52 is now firmly held against the interior surface of well casing 20 in part by spring fingers 75.
Before use, the geothermal pump and its seal section 65 are lowered into the well to the pump's operating station with the seals retracted, as in FIG. 4, by a flexible connector or tie-back element 73 providing tension means. In this manner, the seals 50, 50' reach their operating site without abrasion by rubbing against the inner surface of casing 20 and without other damage due to local roughness of that inner surface. At the operating location, hot brine fills the production pipe 54 and also fills the annular cavities in which the elastic seals 50, 50' are located. The tie-back or flexible connector element of the tension means is thus immersed in the hot caustic brine.
So that the seal cups 50, 50' may then be deployed, the flexible tie-back connector 73 may be composed of a material that will stretch, relax, dissolve, or otherwise disintegrate within a reasonable time period in the hot caustic brine. The disintegration process employed may be the consequence of any of several known physical or chemical interactions between the material of the tie-back element or tension means and the hot brine, or combinations thereof. Since the geothermal pump can be lowered to its operational position in a matter of an hour or so, and since ten or so hours are then required to prepare cooperating equipment at the earth's surface before the geothermal pump is turned on, it is reasonable to use a tie-back or flexible connector element 73 which will require several hours to relax or dissolve and thus finally to deploy the seals 50, 50' into their operating positions against the inner surface of casing 20.
It will be apparent that the flexible connector element 73 may be composed of a water soluble elastomeric tape or cord. It may be constructed in a conventional manner of many short fibers such as paper or asbestos fibers or bonded together in the form of a cord or rope by a water soluble adhesive, such as water glass, a polyvinal alcohol, polyethylene glycol, or ethyl-methyl cellulose or hydroxy cellulose, for example. Alternatively, the tie-back element 73 may be a conventional cable or cord immune to the brine and the clamp 74 of FIG. 6 may be made of a hot-brine soluble or otherwise disintegratable material whose strength will degenerate due to heat or to the caustic nature of the geothermal brine. The clamping element 74 may itself consist, for instance, of two parts clamped together about the ends of cable 73 by screws 74a, the two parts being constructed of a low melting alloy. Other such clamping configurations constructed to release tie-back 73 by melting will be readily envisioned by those skilled in the art. An abundance of ternary and binary alloys fusible in the range of 200° to 400° F, for instance, are available for use in clamp 74 or as parts of cable 73.
An alternative system for release of the seal 50 is shown in FIGS. 7 and 8. In this arrangement, a permanent metal cable 73 is drawn through the loops 53 at the inner surface 80 of seal element 50. The cable end 73b is equipped with an element 90 swaged to cable end 73b and fitted with a threaded portion 89 mating with interior threads within a bore in the eye piece 88. An eye 87 is integral with piece 88. The effective length of cable 73 is adjusted at the time of its installation by manually rotating parts 88, 89 with one respect to the other.
To the cable end 73a is swaged a plate 83 having a hole 85. There is also supplied a trip lever 81 having an enlarged, generally spherical end 91 that is provided with oppositely extending pins 84, 86. In the condition in which the seal system is ready to be lowered into the well, pin 86 projects as shown in FIG. 8 through the hole in eye 87, while pin 84 projects through hole 85 in the cable and plate 83. In that condition, the end of trip lever 81 opposite sphere 91 lies along side of cable end 73a and is bound thereto by a soluble or otherwise disintegratable binding or cord 82. When the geothermal system is lowered into the well, binding 82 is destroyed or relaxed, and the forces provided in part by the spring fingers 75 of FIGS. 5 and 6 pull the trip lever, rotating it about hole 85. Consequently, eye 87 slips off of pin 86, releasing the seals so that they expand and make the desired sealing contact with the inner wall of casing 20.
Accordingly, it is seen that the invention is a significant improvement over the prior art, facilitating the ready and inexpensive installation and reliable operation of geothermal systems; according to the invention, there is provided means for the support of a deep well geothermal pump system within the well casing from the earth's surface by the pump-driving turbine exhaust or other conduit. In view of the differential expansion effects on the relative lengths of the casing pipe extending downward from the earth's surface and the exhaust or other conduit contained therein, an improved flexible seal is provided between the suspended geothermal pump system and the well casing. The seal is made a part of the pump before the latter is lowered into the well. Protective elements prevent damage to the seal during the latter event. The seal is automatically deployed upon the pump reaching its operating site. The geothermal pump system may be subsequently removed from the well without concern for consequent damage to the seal, since the flexible seal elements may themselves readily be replaced at the earth's surface at nominal cost. No time or money must be expended for the introduction or removal of a conventional packer.
It will be understood by those skilled in the art that the invention is readily adaptable to use in other types of geothermal energy extraction systems. For example, it finds utility in the improved geothermal well pumping system shown in the H. B. Matthews, K. E. Nichols, U.S. Pat. No. 3,910,050 for "Geothermal Energy System and Control Apparatus," issued Oct. 7, 1975 and assigned to Sperry Rand Corporation, and elsewhere. It may additionally be employed, for example, in the gravity head type of geothermal system that is the subject of the H. B. Matthews U.S. patent application Ser. No. 674,243 for a "Geothermal Energy Conversion System," filed Apr. 6, 1976 and also assigned to Sperry Rand Corporation.
While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than of limitation and that changes within the purview of the appended claims may be made without departure from the true scope and spirit of the invention in its broader aspects. | A geothermal energy transfer and utilization system makes use of thermal energy stored in hot solute-bearing well water to generate a thermal working fluid from an injected flow of clean fluid. The working fluid is then used for operating a turbine-driven pump near the well bottom for pumping the hot solute-bearing water in liquid state to the earth's surface, where it is used by transfer of its heat content to a closed-loop generator-turbine alternator combination for the beneficial generation of electrical power. The deep well pump system is supported within the well casing pipe from the earth's surface by a turbine exhaust conduit. In view of the effects of differential expansion on the relative lengths of the well casing pipe and the exhaust conduit, a novel flexible seal is provided between the suspended turbine-pump system and the well casing. Furthermore, an arrangement is provided for protecting elements of the flexible seal during initial lowering of the deep well pump and its associated seal system into the well and then for automatically deploying the seals in their operating condition at the well bottom. |
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FIELD OF THE INVENTION
This invention relates generally to overhead doors, and in particular, to an overhead door with stacking panels.
BACKGROUND OF THE INVENTION
Overhead doors are utilized to provide security and access control in institutional, industrial and commercial buildings. They fall into two general design categories: coiling doors and segmented panel doors. Each have their advantages and disadvantages making one better suited for a given design application.
Often times a segmented panel door is better suited for a particular application but cannot be used due to the increased space requirement needed to house the panels once the door is opened. Various attempts have been made to reduce the profile of the opened door, such as stacking the panels as taught in U.S. Pat. No. 4,460,030 to Tsunemura et al. and in U.S. Pat. No. 5,685,355 to Cook et al.
The stacking design of those two patents, as do all other known panel stacking designs, maintain a connection point between the panels such as a hinge, or otherwise link the opened panels, for example, with chains, to support the weight of the panels during opening.
Having to maintain a connection point between the panels presents many disadvantages such as placing limitations on the ease of repair of damaged panels and requiring higher energy consuming operators to open the door. Accordingly, there is still a continuing need for improved stacking panel overhead door designs. The present invention fulfills this need and further provides related advantages.
BRIEF SUMMARY OF THE INVENTION
The following disclosure describes a stacking panel overhead door design wherein the panels are independent of one another.
One advantage of unconnected stacking panels is the spring torque to door weight ratio is easy to control. The weight of the door decreases as the door is lifted and a panel disengages completely from its adjacent panel as it reaches the stacked position. This allows for a linear spring torque to door weight relationship requiring a smaller motor compared to existing designs to provide the lifting torque necessary to operate the door, thereby providing concomitant energy savings. Chart A represents the spring torque to door weight ratio.
A second advantage of independent stacking panels is the ease of replacement or repair of a damaged panel.
Other features and advantages of the present design will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention.
Chart A represents an ideal spring torque curve.
FIG. 1 is a front view of the overhead door system.
FIG. 2 is a perspective view of a panel.
FIG. 3 is an end view of a panel without the end cap.
FIG. 4 is a side view of two engaged panels without the end cap.
FIG. 5 is a front view of an end cap with the roller assemblies.
FIG. 6 is a side view of stacked door panels in the open position.
FIG. 7 is a perspective view of the drive mechanism.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate by way of example the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed 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 to variously employ the present invention. Where possible, like reference numerals have been used to refer to like parts in the several alternative embodiments of the present invention described herein.
Turning now to FIG. 1 , in a preferred embodiment, the overhead door 2 comprises a plurality of unconnected panels 4 which operatively travel at each end within a first 6 and second 8 track ( FIG. 6 ).
As shown in FIGS. 2 and 3 , each panel 4 comprises an outer 10 and inner 12 surface with preferably an insulating material 14 in-between. A top 16 and bottom 18 edge each comprise a geometry that allows for engagement and disengagement of its adjacent panel during operation.
Turning to FIG. 5 , end caps 46 are fastened at each panel end. While end caps 46 in and of themselves are not required for operability, the end caps 46 provide esthetic advantages, operative engagement advantages, and fewer panel component parts. When the panels 4 are stacked, the end caps 46 contact each other, not the panels 4 , thereby limiting the bumping and disfigurement of the panels 4 . Instead of the time consuming task of separately mounting a first 26 and second 28 positioning assembly, activation engagement member 34 , and panel guide 38 (described in detail below) to each panel 30 , a prefabricated end cap 46 containing those components is fastened to each panel end 30 . The end caps 46 are preferably molded of high impact plastic.
All panels 4 , including the bottom panel 48 are interchangeable to allow for easy removal of a damaged panel and replacement. The bottom panel 48 ( FIG. 1 ) includes a removably attached weather seal and/or sensing edge 50 affixed to its bottom edge 18 that is removed and reattached to the replacement bottom panel. The end caps 46 of the bottom panel 48 are operatively engaged to a drive mechanism 64 ( FIG. 7 ), for example a cable, chain, belt, or piston.
When the drive mechanism 64 is a cable, the cable arrangement provides the cable 64 an effective operative cable geometry that will allow the cable 64 to operatively wrap on a cable drum 66 . As shown in FIG. 7 , to achieve this, in a preferred embodiment, the cable 64 is positioned vertically from the panel cable attachment 68 , around a first pulley 70 mounted to a vertical pulley bracket 78 , and then around a second pulley 72 mounted to a horizontal pulley bracket 80 and positioned about 15 inches to about 17 inches, optimally about 16 inches behind a wall attachment 82 before the cable 64 wrap on the cable drum 66 .
Turning to FIGS. 3 and 4 , for the top edge geometry a lip 20 is angled in relation to outer panel surface 10 forming angle α. Likewise, trough 22 is angled in relation to inner panel surface 12 forming angle β. For the bottom edge geometry the lip 20 is angled in relation to inner panel surface 12 forming angle α. Trough 22 is angled in relation to outer panel surface 10 forming angle β. When two panels 4 are fully engaged ( FIG. 4 ) the lip 20 of the first panel nests intimately within the trough 22 of its adjacent panel. The lip 20 /trough 22 geometry allows adjacent panels to nest and prevents engaged panels from separating, thereby insuring security, improving the wind load rating, and providing added weather protection. Preferably, a thermal break piece 24 , shown in FIG. 3 , is attached to each panel 4 . Multiple points of contact between the panel top edge thermal break piece 54 and panel bottom edge thermal break piece 56 increase the surface area of the joint to provide a more complete air infiltration seal. In the preferred embodiment, top and bottom thermal break pieces 54 , 56 are fabricated from PVC.
To insure proper panel engagement/disengagement during door closing and opening and to prevent water from traveling from the outside environment to the inside environment, angles α and β are about 10 degrees to about 25 degrees, preferably about 15 degrees to about 20 degrees and optimally about 18 degrees.
While the following elements may be attached directly to a panel 4 , for the advantages described above, in a preferred embodiment they are fabricated as part of the end cap 46 . As shown in FIG. 5 , a first 26 and second 28 positioning assembly, for example, bearing assemblies, are attached to each end 30 of panel 4 . The first positioning assembly 26 comprises a first engagement member, for example, a bearing 32 , extending outward from panel outer surface 10 to operatively engage the first track 6 . An activation engagement member, for example, an activation bearing 34 , is positioned to operatively engage the panel guide 38 of the adjacently superior panel during opening and closing of the door 2 .
Activation engagement member 34 aids in engaging/disengaging the lip 20 and trough 22 of adjacent panels by riding on the panel guide 38 around the panel bottom edge radius 40 to nest the panels in the fully engaged (door closed) position. Bearing 34 remains in contact with panel guide 38 in the stacked position, the fully closed position, and throughout the panel engagement/disengagement operation.
The second positioning assembly 28 comprises an engagement member, for example, a bearing 36 , extending inward from the panel inner surface 12 to operatively engage the second track 8 .
Although optional panel stiffeners may be added to the panel 4 , the present design does not require any stiffeners to be operatively effective, providing additional benefit over known sectional door designs which require stiffeners to achieve equivalent wind load ratings. In a preferred embodiment the insulating material 14 comprises an expandable foam injected between the outer 10 and inner 12 panel surface. While bearings have been used as exemplars for the engagement members, any low friction member, for example, PTFE pads are also contemplated.
Turning now to FIG. 6 , each set of first 6 and second 8 tracks are fixed to both sides of a door opening frame member 76 in known fashion. In a horizontal section 42 of tracks 6 , 8 , the tracks 6 , 8 are separated by a distance equal to the width of a panel 4 . In a vertical section 44 of tracks 6 , 8 , the tracks 6 , 8 are separated by a distance equal to the thickness between the first engagement member (bearing) 32 and the second engagement member (bearing) 36 . The transition between the horizontal section 42 and the vertical section 44 is accomplished through radii γ and δ. Ideally, the radii γ and δ are sized to support only two panels 4 simultaneously. The ideal spring torque curve indicated by Chart A is most closely achieved by having as few panels simultaneously engage radii γ and δ as possible. Since effective disengagement of adjacent panels will not occur if radii γ and δ are sized to only accept one panel, two panels is optimum.
The optimal sizing of the radii γ and δ allows for the advantageous reduced force required to operate the door 2 . Larger radii would require increased initial force to hold the panels, thereby causing the spring torque to door torque to become out of balance near the closed position as those panels are no longer traveling within the radii. Larger radii would also increase the height of the stacked panels 4 above the door opening creating the need for additional overhead space. In the preferred embodiment, the radii γ and δ are about three inches to about five inches, and optimally, about four inches. Along with providing the optimal spring torque to door torque ratio, the optimal radii allow the footprint of the panel stack 58 to fit within the current requirements for a typical rolling steel door construction, thereby allowing easy retrofit.
In operation of a preferred embodiment, to close the overhead door 2 a motor 60 turns a shaft 62 in a direction to unwind a cable 64 from a cable drum 66 attached to the shaft 62 . The bottom panel 48 gravity closes as the cable 64 unwinds. The bottom panel 48 maintains the panel immediately superior to it in the panel stack 58 until the point of transition to the engaged position. As the lip 20 and trough 22 of adjacent panels 4 become engaged, the process begins again as the newly engaged panel maintains its immediately superior panel in the panel stack 58 until the point of transition to the engaged position. The process repeats until all of the panels necessary to close the opening are in place.
To open the door 2 , the opposite occurs. As the motor 60 turns the shaft 62 winding the cable 64 onto the cable drum 66 the bottom panel 48 is raised thereby raising all the panels above it. As a panel 4 travels through the radii γ and δ, the activation bearings 34 located at each panel end disengage the lip 20 and trough 22 of adjacent panels as the activation bearings 34 ride on the panel guide 38 around the panel bottom edge radius 40 . As each succeeding panel is disengaged it pushes the preceding panel into and forms the panel stack 58 .
In this manner, the weight of the door 2 decreases as each panel 4 disengages and joins the panel stack 58 . This allows for easier control of the spring torque to door weight ratio. This linear relationship (indicated by Chart A) requires a much smaller motor to provide the lifting torque necessary to operate the door when compared to known technology where the panels cannot separate from one another.
Because the panels 4 are independent from and unconnected to one another, repair or replacement is easily and quickly accomplished. Returning to FIG. 6 , in the door open position each independent stacked panel 4 can be slid out the rear of the stack until the damaged panel is retrieved. Once repaired or replaced, the removed panels 4 are easily and quickly replaced within the track. No time is lost to removing hinges or otherwise disconnecting and reconnecting one panel to adjacent panels as required with existing technology.
Although the present design has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present design is capable of other variations and modifications within its scope. For example, although a cable lifting mechanism has been described, any motion that provides for raising and lowering the bottom panel is contemplated. These examples and embodiments are intended as typical of rather than in any way limiting on the scope of the present design as presented in the appended claims. | An overhead door system featuring independent, unconnected panels is described. Each panel end is operatively carried within a pair of parallel tracks. The weight of the door decreases as the door is lifted and each panel completely disengages from its adjacent panel as it reaches the stacked position. This allows for a linear spring torque to door weight relationship requiring a very small motor compared to existing designs to provide the lifting torque necessary to operate the door. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/331,281, entitled “VERTEX BUILDING SYSTEM”, filed on May 4, 2010, and the specification and claims thereof are incorporated herein by reference.
COPYRIGHTED MATERIAL
[0002] ©2010 Chuck McCune. A portion of the disclosure of this patent document contains material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention (Technical Field)
[0004] The present invention relates to building construction methods and structural components.
[0005] 2. Description of Related Art
[0006] Setting up buildings is inherently time consuming, expensive, and dangerous. In the aftermath of disasters, response time is of utmost concern, high cost translates into limited response in providing significant disaster resistant structures, and adverse conditions in a disaster area contributes in many ways to even more dangerous building conditions. Disasters also require both temporary and permanent buildings for response and recovery. Additionally the skills, materials and resources necessary to build response and recovery buildings and shelters is nonexistent or in limited supply. The general building industry is fraught with many of these problems as well. The present invention embodies the design and construction of buildings, related building components, materials and methods, for, but not limited to, general building industry and disaster response, recovery, preparedness and mitigation, for temporary and permanent construction.
[0007] The present building system, by storing and shipping in stacks of light weight, flat panels, solves the problem of inefficient storage of emergency building assets for disaster preparedness (i.e., FEMA trailers), addresses slow recovery efforts with a system of fast deployment for response to the shelter requirements for businesses, government agencies, and survivors affected by disasters. Many logistics problems are solved by the building system, specifically but not limited to building quickly under adverse weather or disaster obstacles, with lack of electrical power or skilled construction labor force. The building is designed to be deployed and erected by limited skilled persons, some of whom may be survivors of a disaster, and having safety built into the methods and materials in that no worker need be off the ground more than about 3 or 4 ft to complete the building. The roof is completed without anyone having to get onto the roof. Further, delivery logistics problems due to obstructed routes for large trucks are solved due to the small overall size of the building package. The buildings can be brought to a site with a small truck, on the roof of a car or any other vehicle and even carried in by hand. Building construction generally requires a diverse array and large number of tools. The present building requires only a conventional manual material lift mechanism, cordless or corded screwdrivers and step ladders to construct the buildings. What is shown is a building assembly method and apparatus comprising a number of laminated panels of any shape and size with structural end caps of any shape size and thickness, connected by connector struts and hinged hub assembly permitting the building to be up and provide cover in as little as 2½ hours, with final installation of all connectors and fastening within a few hours. The building is Category 5 Hurricane and Earthquake resistant. The building may be temporary or permanent, can be disassembled to re-locate in 1 hour, with no worker off the ground more than 3 or 4 feet during construction. No cutting or tools are required beyond a manual material lift, cordless screw guns and a step ladder. Lightweight individual pieces can be handled easily by one or more persons.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention is a building having a plurality of vertically upright wall panels enclosing a defined space. The wall panels are linked together to form a stable structure. A plurality of roof panels cover the enclosed space and are affixed to the wall panels. Also included is a method of providing an emergency shelter. The method includes the steps of erecting a plurality of vertically upright wall panels to enclose a defined space. Then, the wall panels are linked together to form a stable structure. The method includes raising a plurality of roof panels over the defined space and fastening the roof panels to the wall panels.
[0009] Objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings FIGS. 1-11 , and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] 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:
[0011] FIG. 1 is a perspective view of one configuration of the building.
[0012] FIG. 2 is a perspective view of another configuration of the building.
[0013] FIG. 3 is a cross section view of a wail panel of the building.
[0014] FIG. 4 is a cross section view of a roof component of the building.
[0015] FIG. 5 is a plan view of a roof hub assembly for the building.
[0016] FIG. 6 is a cross section view of the roof hub assembly and hub assembly lifter.
[0017] FIG. 7 is a perspective view of a panel connector strut.
[0018] FIG. 8 is an enlarged perspective view of the contact flange for the connector strut.
[0019] FIG. 9 is a perspective view of the connector struts in place on wall panels.
[0020] FIG. 10 is a perspective view showing the overlap of connector strut contact flanges.
[0021] FIG. 11 is a perspective view of a third configuration of the building.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 is a perspective illustration of one of many possible shapes, designs or configurations of the panel building system herein using, in this illustration, a plurality of rectilinear, vertically upright, wall panels 1 , placed in a circular configuration of any diameter, and a plurality of triangular, wedge shaped roof panels 2 , to form a conical shape roof on a circular building floor plan. Vent hole/hub location 3 is shown in FIG. 1 .
[0023] FIG. 2 is a perspective illustration of another configuration using the building system. In this illustration, a plurality of rectilinear wall panels 4 , placed in a combination of rectilinear and circular configuration utilizing a plurality of triangular wedge shaped roof panels 5 to form a conical shape wall/roof, of any radius on two halves of a circular building floor plan, separated by rectilinear shaped roof assembly insert 6 , of a given length or width, and rectilinear wall assembly insert 7 , of a given length or width.
[0024] FIG. 3 is an illustration of wall panel 1 assembly 8 . Panel assembly 8 includes exterior skin 13 covering panel insulation fill 14 , completing the laminated panel assembly 8 .
[0025] FIG. 4 is a cross section detail of a roof or wall panel connection 9 , with cap flashing component 10 , having insulation fill 11 under cap 10 , including Structural C component wall end caps 12 .
[0026] FIG. 5 is a plan view illustration of hub assembly 18 . In this illustration, a circular arrangement, including a number of hinging mechanisms 19 is arranged in a polar or linear array, to affix roof panels 2 to hub assembly 18 by, but not limited to, fasteners such as adhesive, screws, bolts, weldment, or rivets, allowing a roof placement of any angle, with void 20 of any size or shape in the center as a vent hole and receptor for adapter hub sleeve 24 (see FIG. 6 ), necessary for lifting the hub and roof assembly to its final elevation and location. Layout lines 21 are provided for ease of alignment. Hub 18 may be left in place as part of final structure or removed if the panel fastening method allows. Embodying a plurality of hinging mechanisms 19 provides the ability to fasten all roof panels 2 in this building in proper alignment relative to the walls for a simultaneous lift of the roof assembly in its entirety to its final raised location, at any height or roof pitch angle, in as little as 30 seconds with the workers on the ground. Hinging hub assembly 18 also provides for the transfer of imposed and opposing forces in the roof assembly.
[0027] FIG. 6 is a cross section illustration of hub assembly 18 , and hub adapter, 23 , made of any material capable of supporting the necessary weigh and force of the assembly process. Also shown is sleeve 24 for insertion into hub assembly void 20 . Threaded adjustment shaft 26 is provided with locking nuts or other locking device 28 to adjust elevation or rotation of hub assembly 18 . Hub support platform 27 supports hub assembly 18 during placement and lifting of the roof/hub assembly and is fitted with sleeves 29 to mount laser pointers of any common size or brand for the purpose of aligning the roof panel apex and panel hinging mechanism 19 with the corresponding wall panel whereby the matching roof panel is properly aligned perpendicularly or otherwise to the wall panel at a predetermined angle or placement. Tube structure 31 of hub adapter 23 can be mounted on any material lifting equipment at attachment point 32 , with a sleeve, flange, bolt(s), weldment, rivet(s), or any other fastening capable of withstanding the forces of lifting hub and roof assembly. Hub adapter 23 , is designed to allow any material lifting system to safely and properly lift hinging hub assembly 18 and roof panels 2 and to adjust alignment of the system and subsequently easily removed after securing the roof and hub assembly in its final position.
[0028] FIG. 7 is a perspective view of a stabilizer/connector strut shown 33 , used to fasten wall and/or roof panels to each other at any angle and to be located at any elevation in any number, interior or exterior, for the purpose of registering panels to and with each other to create the floor plan shape of the building without the necessity to measure angles or distances. Once placed, connected and registered, tightening of fasteners of any type is completed to make a rigid structure. Strut 33 includes shaft 34 of a selected size, section shape or length, depending on the size and shape of the building. Registration slotted or drilled holes 35 are formed in contact flange or contact area 36 . Flange 36 may be bent or straight to match the angle(s) or average angle of wall or roof panel assembly junctions.
[0029] FIG. 8 is an enlarged perspective view of stabilizer/connector strut 33 , illustrating shaft 34 , contact flange 36 and fastener/registration slots 35 .
[0030] FIG. 9 is a perspective view showing connector struts 33 inner connecting wall panels 1 . In FIG. 10 , it can be seen that connector struts 33 overlap one another as do flanges 36 and their registration slots 35
[0031] FIG. 11 is a perspective illustration of a possible building shape embodied by a plurality of wall panels 1 and roof panels 2 , in a circular floor plan. This building includes a plurality of windows 43 and at least one door 44 .
[0032] To assemble the building, as seen in FIG. 1 or FIG. 12 , the site should be level or leveled prior to set up. Although not necessary, it is helpful to set up a center reference point prior to beginning. Setup can occur on a foundation, in a trench, on an elevated site, or on ground surface. A lifting mechanism affixed with hub adapter 23 and hinging hub assembly 18 is placed in the center of the building location. Erection of the walls is started by determining where door panel 44 will be located. Since it is the heaviest panel in the building, it is suggested but not necessary to stand it up first with braces, then start fastening 2 wall panels 1 together stabilizer/connector strut 33 , at both top and bottom. Then, stand the assembled walls up and brace temporarily. If there is no wind, bracing is not necessary if subsequent panels are to be added right away and if a worker can keep a hand on the standing walls until more wall panels are added, using the same repeated sequence of wall placement and strut fastening. The more of the circle completed, the more stable the assembly.
[0033] A plurality of stabilizer/connector struts 33 are placed in an array alternating every other two panels at approximate top and bottom, of the wall assembly as walls are placed. Fasteners in registration slots 35 are only gently tightened until the entire wall assembly is complete and located properly and then all strut fasteners are tightened completely. A perforated compression strap is then applied to the outside top of wall assembly surrounding the building perimeter and fastened to each wall panel. The lifting mechanism is then positioned in proper position for lift of roof assembly 2 or 5 , 6 . Hub adapter 23 is then fitted with a laser pointing device in sleeves 29 , under hub adapter platform 27 to align the hinging mechanism and roof panel apex precisely with its corresponding wall panel edge by rotating the assembly on threaded shaft 26 and locking into proper position using locking mechanism 28 . This ensures the entire roof assembly will arrive at the top of the lift in the proper alignment so that adjustment of the entire weight will not be necessary.
[0034] A plurality of roof panels 2 , with attached roof cap 10 on one side to mate with adjacent roof panel, are positioned singly or in multiples around the perimeter walls in the interior space with the exterior end of the roof panel leaning against the top of each corresponding wall panel, exterior facing in or up. Each roof panel is then lifted into alignment with corresponding hinging mechanisms 19 on hinging hub assembly 18 and fastened to the hinging mechanism with a number of fasteners.
[0035] Upon completion of fastening roof panels to hinging hub assembly, preassembled vent cap flashing 45 is affixed to the top of hinging hub assembly 18 arranged to overlap the apex of the assembled roof panels. The apex is then raised by the lifting mechanism affixed with hub adapter 23 atop and fitting to hinging hub assembly void 20 . Lifting continues until the roof panels are in place at the proper elevation and abutting the adjacent roof panel for closure under roof cap 45 , allowing the roof panels to be raised as a unit. After the roof assembly of panels 2 has been raised to its final location, workers then proceed to fasten roof panels 2 to corresponding wall panels 1 with angle clips, plates, or any other approved connector with drill screws or any other approved fastener.
[0036] Additional fasteners are placed in strut registration slots 35 at extreme ends of slots to prevent any movement and eliminate the ability for struts 33 to slide on the fasteners. Each roof panel is bolted or otherwise fastened to its adjacent roof panel. A worker or workers then fastens roof cap 10 from a step ladder or other working platform as far up on the roof as is practicable or easily reached. Lifting mechanism or equipment is then lowered and removed, leaving the completed roof with hinging hub assembly in place with the roof assembly at the proper height. No support of hub 18 is necessary after final fastening of all hinging mechanisms 19 , struts 33 , plates, connectors, straps, wall and roof caps 10 , flashings 45 and panels 1 , 2 or 4 , 5 , 6 . Once completed, the building may be secured to a foundation by brackets or other hold down devices attached to wall panels 1 .
[0037] To disassembly and relocation the building, reposition lifting mechanism affixed with hub adapter 23 under hinging hub assembly 18 and raise to the mating position with hub adapter sleeve 24 inserted into void 20 of hinging hub assembly 18 . Then, raise the assembly until weight bearing and then in reverse order of the above sequence, remove roof fasteners, connectors plates cap flashing fasteners until the roof assembly is disconnected from the wall assembly, then lower to remove individual roof panels. The disassembly of the wall panels is the same. The door panel assembly should be braced, then remove panels/struts in sequence until all are removed. Stacking or palletizing for storage or relocation is accomplished as each roof and wall panel is removed. Struts and connectors and all miscellaneous parts are packaged or boxed to remain with the panel components.
[0038] 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. | A building structure. A plurality of vertically upright wall panels enclose a defined space. The wall panels are linked together to form a stable structure. A plurality of roof panels cover the enclosed space and are affixed to the wall panels. |
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a modular window well egress and a method of installing the same. More specifically, though not exclusively, the invention relates to a modular egress window well with modular walls that are structurally identical and providing a simple means of installing a window well egress below ground level that is also easy to manufacture.
[0002] As land prices have increased, homeowners have looked for means of better utilizing a building's footprint. To do so, building owners have turned to using basement or below grade level space as living space. This raises several issues, such as being able to quickly exit the building in case of an emergency. To allow egress from the basement, building designers have incorporated means of exiting through a basement window into window well designs. These designs have included window well walls with built in steps, hand grips, and other devices that facilitate exiting through the basement window.
[0003] Many different designs have been used to create basement window wells. Early designs incorporated window wells into foundations of the building or home. The well was lined with bricks and then capped with additional bricks, wood or iron plating. This was done in an attempt to retain soil and increase the amount of light that entered into the below ground living space. The window was also used to allow the passage of materials, typically coal, into the basement without having to carry the material through the house. These early designs had to be incorporated at the beginning of construction and were nearly impossible to install after the building was formed.
[0004] The next step in the design evolution was to create a structure that could be manufactured separately from the foundation of the building. Still in use today, this design typically involves using corrugated and galvanized sheets of metal bent into a generally U-shaped structure that was then attached to the exterior of a building's foundation. The galvanized metal resisted the elements better than previous materials and was easily manufactured. Unfortunately, the galvanized material is unsightly and unattractive to an individual looking out the window. Further, the unitary design increases the difficulty of handling and installing the galvanized metal well structure.
[0005] For relatively shallow window wells, there was no need for the window well to incorporate devices or structures that would assist an individual in exiting through a basement window. But with increased building code regulations, the size of a basement window has increased to facilitate egress from within the basement. With this increase in window size, came the requirement for window wells to become deeper. With a deeper window well, there is a need for a structure within the well itself to facilitate exiting the window well. The first solution was the incorporation of a ladder structure outside of the confines of the window well that had to be lowered in. Later designs incorporated recesses and protrusions in the surface of the window well itself. Because the wells were typically constructed of galvanized corrugated sheet metal, the steps and handles were difficult to form and slippery when wet.
[0006] U.S. Pat. No. 3,999,334 to Webb discloses a basement escape window structure with a one-piece unit that has a hinged top that serves as an escape hatch from the basement. It also discloses a device with a plurality of steps that allow for easily ascending from the basement in order to escape from an opening in a basement wall. Because of the unitary design, the system is difficult to install. Further because of the lid, the device does not allow sunlight into the basement and completely obstructs the view that might have been afforded with the use of a more traditional window well.
[0007] The most recent development in egress window well design is a modular approach as demonstrated in U.S. Pat. Nos. 5,107,640 to 5,657,587 to Gefroh. Instead of the structure being constructed as a single unit, it is instead comprised of multiple parts and modules. The modular design allows for ease of construction, either during the original construction of the building or as a later addition. The modular concept also allows for the replacement of damaged and weathered parts without complete removal and disposal of the entire egress structure. The current designs are deficient in that they are comprised of multiple components of various sizes and shapes.
[0008] The variance in the modular pieces increases the cost of manufacturing a complete modular egress window well structure. Multiple tool sets are required to be used in the production of the individual walls. A greater number of individualized components cause a manufacturer's boxing and shipping system to be more complex to ensure that the correct components are shipped. The variance in shapes and size of the components also increase the number of shipping containers necessary to transport the entire system to the final destination. Further, because of the variety of necessary components, a retailer must stock many more components than is necessary to meet on demand needs.
[0009] Therefore, there is a need for an improved egress window well structure that consists of a limited number of components that can be easily manufactured. This structure should consist of components that are sightly yet constructed of material that are durable to environmental elements.
FEATURES OF THE INVENTION
[0010] A general feature of the present invention is the simplification of the construction of a below ground modular window well egress.
[0011] A further feature of the present invention is the provision of a modular window well egress with walls that are structurally identical.
[0012] An additional feature of the present invention is the provision of window well egress walls that interlock with one another.
[0013] Yet another feature of the present invention is the provision of a wall termination strip that interlocks with a window well egress wall.
[0014] Another general feature of the present invention is the provision of a rigid step that is placed between two non-parallel window well egress walls.
[0015] Still another feature of the present invention is the ability to stack the window well egress walls one on top of another to vary the depth below ground of the window well.
[0016] Still yet another feature of the present invention is the provision of a rigid wall for a modular egress window well structure that is easy to mass produce.
BRIEF SUMMARY OF THE INVENTION
[0017] The present invention generally comprises a method and apparatus for installing an egress window well. This structure consists of structurally identical walls that interlock via a system of protruding tenon and recessed notch. The pattern of protruding tenon and recessed notch could consist of any multiple number of tenon and notches such that one end pattern is the reciprocal of the other. Further, the walls are constructed of any material rigid enough to retain soil away from a below ground window. The space created allows the admittance of light and further allow the window to be used as an egress from the interior of a building. The walls are secured to the foundation of the building via interlocking termination strips.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of an embodiment of the invention.
[0019] FIG. 2 is an exploded view of the embodiment shown in FIG. 1 .
[0020] FIG. 3 is a perspective view of another embodiment of the invention.
[0021] FIG. 4 is an exploded view of the embodiment shown in FIG. 3 .
[0022] FIG. 5 is a perspective view of an embodiment of a modular wall section.
[0023] FIGS. 5A and 5B is a perspective view of another embodiment of a modular wall section.
[0024] FIG. 6 is a perspective view of an embodiment of the invention including a rigid step.
[0025] FIG. 7 is a perspective view of another embodiment of the invention comprising multiple layers of wall components.
[0026] FIG. 8 is a cross-sectional view of a building foundation and the surrounding soil.
[0027] FIG. 9 is a cross-sectional view of a building foundation in a hole excavated adjacent to the foundation.
[0028] FIG. 10 is a perspective view of a section of the building foundation with a first and second interlocking strip mounted thereon.
[0029] FIG. 11 is a perspective view of FIG. 10 with a first interlocking wall section joining with the first termination strip.
[0030] FIG. 12 is a perspective view of FIG. 11 with a second interlocking wall section joining with the second termination strip.
[0031] FIG. 13 is a perspective view of FIG. 12 with a third interlocking wall section interlocking with the first and second wall sections.
[0032] FIG. 14 is a perspective view of FIG. 13 with multiple layers of wall components.
[0033] FIG. 15 is a perspective view of FIG. 14 with soil back filled around the egress window well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described embodiment. It is intended that the invention cover all modifications and alternatives, which may be included within the spirit and scope of the invention. In a preferred embodiment, the modular egress window well is constructed as three identical planar structures that interlock and connect to a building foundation via termination strips.
[0035] Now, referring to the drawings, FIG. 1 illustrates the preferred embodiment as a modular egress window well 10 having a first side wall 14 , a second side wall 18 , and a front wall 22 . FIG. 1 illustrates the first side wall 14 and second side wall 18 attaching to termination strips 24 . As shown in FIG. 2 , the front wall 22 interlocks with the first side wall 14 and second side wall 18 .
[0036] FIG. 3 illustrates another embodiment of a modular egress window well 10 having a first arcuate side wall 16 and a second arcuate side wall 20 . FIG. 3 illustrates that two arcuate walls 16 , 20 attaching to termination strips 24 that attach to the foundation of a building. Further, the arcuate side walls 16 , 20 interlock to form a solid barrier to form a space about a below ground window. The two embodiments described disclose a planar and arcuate rectangular wall to form the necessary side walls to create an egress window well. Other shapes and sizes are contemplated, including shapes with an upper surface 26 and a lower surface 28 that is sinusoidal, scalloped, triangular, and/or of any other fanciful design that can have the reciprocal image formed along the opposite surface (see FIGS. 5, 5A , 5 B).
[0037] As shown in FIG. 5 , the generic modular egress window well wall 12 has an interior surface 30 , exterior surface 32 , upper surface 26 , and a lower surface 28 . The wall 12 further has a first end 34 and second end 36 that consist of a pattern of tenon 38 and notch 40 . The first ends 34 pattern of tenon 38 and notch 40 is the reciprocal of the second ends 36 pattern of tenon 38 and notch 40 . The pattern created by the tenon 38 and notch 40 can vary both by the number of each and the spacing between and still be effective so long as the two ends 34 , 36 have a reciprocal pattern that facilitates the wall 12 interlocking with each other.
[0038] A further feature is depicted in FIG. 6 . A rigid step 42 is shown to be spanning two non-parallel walls 18 , 22 . The rigid step 42 rests upon the upper surface 26 and engages the interior 30 and exterior 32 surfaces of the two walls 18 , 22 . The rigid step 42 provides further rigidity to the egress window well 10 as well as provide a stepping surface for providing escape from deeper window wells.
[0039] To provide for deeper window wells, the modular walls 12 can be stacked on top of one another. FIG. 7 depicts multiple walls 12 stacked one on top of another to create a deeper well. Depending upon the design of the upper surface 26 and lower 28 surface, the stacked walls 12 may interlock vertically as well as horizontally.
[0040] FIGS. 8-15 relate to a method of installing a modular egress window well. FIG. 8 depicts a cross-section of a building foundation 44 and the soil 46 that is adjacent to the foundation 44 . FIG. 9 shows a hole 48 dug in the soil 46 adjacent to the foundation 44 . FIG. 9 shows the preferred method of installation. Another method would be the installation of the modular egress window well 10 before soil 46 is placed against the foundation 44 and hence there would be no need of a hole 48 . The size and dimension of the hole 48 is dependent upon the size of the window within the foundation 44 and the desired size of the window well.
[0041] FIG. 10 is a perspective view of a foundation 44 . Two termination strips 24 are secured to the foundation 44 separated by a space. The first termination strip 24 is secured by glue, nails, screws or other suitable methods to foundation 44 . The second termination strip 24 is also secured to the foundation 44 with the opposite orientation of the tenon 38 and notch 40 pattern. The two termination strips 24 are parallel to each other and are horizontally level with the bottom edge of each aligning with the other.
[0042] The termination strips 24 can be constructed of any material that provide sufficient rigidity to be formed into a tenon 38 and notch 40 pattern and secure the modular wall 12 to the foundation 44 . Examples of material that could be used to form the termination strip 24 include aluminum and high density plastic.
[0043] FIG. 10 further depicts a foundation 44 without a window. The egress window well 10 can be installed before or after installation of a window into the foundation 44 .
[0044] FIG. 11 shows the installation of the first side wall 14 onto the termination strip 24 . The modular wall 12 is constructed of a material sufficiently rigid to retain soil 46 and to be formed with tenon 38 and notch 40 . The walls 12 are constructed of high density plastic in the preferred embodiment but also may be made of high density polyethylene skin in a linear low density polyethylene core.
[0045] FIG. 12 further illustrates the installation of an egress window well 10 with an insertion of a second side wall 18 into a termination strip 24 . FIG. 13 shows a front wall 22 interlocking with the first side wall 14 and a second side wall 18 . FIG. 14 shows a second layer of wall sections 12 having been stacked on top of the first layer of wall sections 12 and terminated unto additional termination strips 24 . FIG. 15 depicts the egress window well 10 having been backfilled around, thus creating a space within the structure that can be used as an egress in conjunction with a window.
[0046] A general description of the present invention as well as a preferred embodiment to the present invention has been set forth. Those skilled in the art which the present invention pertains will recognize and be able to practice additional variations in the method and systems described which fall within the teachings of this invention. Accordingly, all such modifications and additions are deemed to be within the scope of the invention which is to be limited only by the claims appended hereto. | A modular egress window well structure which is constructed of structurally identical walls that interlock and attach to the foundation of a building via a termination strip. The identical wall members allow for ease of manufacturing and installation of the egress window well. The method of installation comprises removing soil away from the foundation of a building, securing the termination of strips to the foundation, assembling the egress window well and then backfilling the soil around the structure. |
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims priority to U.S. Patent Application No. 62/314,716 to Martin Augustyniak entitled “Transparent Composite Material as Cladding Material for Architectural Features in Building Construction” and filed on Mar. 29, 2016 and to U.S. Provisional Patent Application No. 62/247,564 to Robert Comeau entitled “Composite Films for Architectural Applications” and filed Oct. 28, 2015, both of which are incorporated by reference herein.
FIELD OF THE DISCLOSURE
[0002] The instant disclosure relates to composite materials. More specifically, portions of this disclosure relate to transparent composite materials with sufficient strength for use as building materials.
BACKGROUND
[0003] A roof or façade of a building are visually prominent aspects of a building. These parts of a building are thus areas of great interest by architects in shaping the appearance of the building. Of particular interest are transparent materials for use as a building enclosure. The building enclosure may cover areas of importance that are the basis of the transparent composite cladding. The building enclosure is responsible for structural performance, durability, reliability, security, aesthetics, value, constructability, and maintainability, water and moisture resistances, light control, fire performance, and blast resistance. Transparent materials allow natural light to penetrate an interior of a building, reducing the need for artificial light in the space. Transparent materials also allow colored lighting to be projected throughout the building to enhance the visual effect. One conventional material frequently used as cladding material for a building enclosure is Ethylene tetrafluoroethylene (ETFE).
[0004] ETFE is a transparent polymer material with strong weatherability, but has limited tensile strength and is prone to creep. The ETFE is conventionally manufactured as pillows or cushions to improve the structural stability of the material, and the pillows or cushions are installed on buildings. ETFE cushions add significant cost to the cladding system as they double and triple the amount of ETFE material needed within the coverage area, require expensive extruded aluminum clamping systems, and require expensive air handling and ductwork systems to maintain inflation. An example of ETFE cushions on a building is shown in FIG. 1A . FIG. 1A is a perspective view of a building constructed with ETFE cushions according to the prior art. Architects may be interested in the visual capabilities of ETFE, but are constrained by the requirement to package the ETFE in the cushion shape.
[0005] ETFE can also be used in a single layer application, but the system is limited to a span of less than 1 meter and must incorporate a grid of steel or cables to distribute loads imposed on the ETFE. Single layer ETFE applications add significant cost to construction in the form of substructure support in the form of steel or cables and the additional manufacturing and labor required to install the steel or cable load carrying system and link the system to the ETFE cladding. FIG. 1B is an illustration of a building constructed with single-layer ETFE 112 supported by a cable grid 114 . The cable grid 114 is both expensive to construct and a distracting architectural feature.
SUMMARY
[0006] A composite material may provide better functionality for use as a building enclosure or in other aspects of a building. The composite material may include two or more materials, in which a first material provides desirable qualities of durability, reliability, aesthetic, constructability and maintainability and a second material provides desirable qualities for strength, durability, reliability, aesthetic, constructability and maintainability or other characteristics desirable of a building material. In some embodiments, the composite material may include a first material for exterior protection and a second material for strength. The second material may be part of a support carrier on which the first material is attached. Each of the first material and the second material may be transparent, such that the composite material is also transparent. In one embodiment, the material for exterior protection may be ETFE and the material for strength may be PET. Using a support carrier for the ETFE may allow use a thin ETFE layer for protection from external forces, e.g., improved weatherability, compared to the thicker single ETFE layer for weatherability and strength of conventional structures described above. The thinner ETFE layer can still adequately protect other materials within the composite, such as the support carrier. The thinner ETFE layer may also allow for increased clarity of the composite, compared to a thicker ETFE layer of the prior art. Furthermore, the support carrier may provide sufficient strength to allow construction of much larger panels, and thus allow an architect to design outside of the limitations of the conventional ETFE pillows or conventional single-layer ETFE with 1 meter×1 meter cable grid required of the prior art.
[0007] The composite material may be organized as a support carrier including one or more strength layers and/or functionality layers surrounded on one or more sides by a protection layer that provides the desired durability, reliability, aesthetic, constructability and maintainability aspects. The support carrier enables the use of the protection layer as an exposed feature in a building without requiring the protection layer to meet the strength and engineering requirements of the structure. Thus, the protection layer's desirable qualities may be obtained for the building. When such a protection layer has undesirable qualities, such as low strength, the support carrier can supplement the protection layer regarding those undesirable qualities. That is, the composite material may include different layers for different functions, such as solar control solar harnessing, digital imaging, and/or lighting. An outside layer facing the environment and that is visible to individuals may be selected for architectural aspects. A support carrier for that outside layer may be selected based on strength requirements by an engineer for the building. Certain layers may be transparent for aesthetic effect. In some embodiments, all layers may be transparent to enhance the aesthetic effect. In some embodiments, the support carrier may be a single adhesive layer affixing a protection layer to another protection layer to provide strength, and the single adhesive layer may provide other functionality such as IR reflectance. In other embodiments, the support carrier may be a polymer layer, and attached to one or more fluoropolymer protection layers by an adhesive or other sealing mechanism. For example, the protection layer may be bonded to the support carrier.
[0008] Some embodiments of composite films made from layering polymeric materials may provide the designer with materials that provide high strength (e.g., tensile strength), transparency (e.g., VLT %), high durability (e.g., weatherability), and/or high cost performance (e.g., lower cost materials and construction than industry standard conventional materials). In one embodiment, one or more layers of the composite films may include one or more fluoropolymers, such as ETFE, ECTFE, PVF, PVDF, PTFE, PCTFE, PFA, and/or FEP. Further, in some embodiments of the composite films, additional features can be provided through the composite film that could not be implemented in conventional materials, such as solar control, light spectrum manipulation, tinting, shading, solar harnessing, digital imaging, and/or lighting. In embodiments using PET as the strength layer, the PET may be treated to prevent UV and hydrolysis degradation during its service life. Further, the PET may be configured to crystalize when it is exposed to flame to reduce or eliminate dripping, such as to pass the UL94, NFPA 701, ASCM E108, and/or other standards. For example, the PET or other transparent polymer material may be configured to crystalize when exposed to flame to prevent drip, such as by treating the polymer material during manufacturing.
[0009] According to one embodiment, an apparatus may include a first substantially transparent material; a second substantially transparent material of a different material than the first substantially transparent material; and/or a first adhesive that attaches the first substantially transparent material to the second substantially transparent material.
[0010] According to another embodiment, a composite material for building construction may include a first material configured to allow at least some visible light transmission and configured to face towards an exterior environment around the building construction; a second material configured to allow at least some visible light transmission and configured to provide strength to the composite material to allow use of the composite material in the building construction; and/or a first adhesive attaching the first material to the second material.
[0011] According to another embodiment, a method may include attaching a first substantially transparent material to a second substantially transparent material different from the first substantially transparent material to form a substantially transparent composite material for building structures. The step of attaching may include depositing a first adhesive on the first substantially transparent material and/or coupling the second substantially transparent material to the first adhesive.
[0012] The foregoing has outlined rather broadly certain features and technical advantages of embodiments of the present invention in order that the detailed description that follows may be better understood. Additional features and advantages will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those having ordinary skill in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same or similar purposes. It should also be realized by those having ordinary skill in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. Additional features will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended to limit the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the disclosed system and methods, reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
[0014] FIG. 1A is a perspective view of a building constructed with ETFE cushions according to the prior art.
[0015] FIG. 1B is an illustration of a building constructed with single-layer ETFE supported by a cable grid.
[0016] FIG. 2A is a cross-sectional view of a transparent composite material for building construction according to one embodiment of the disclosure.
[0017] FIG. 2B is a cross-sectional view of a transparent composite material for building construction according to another embodiment of the disclosure.
[0018] FIG. 2C is a cross-sectional view of a transparent composite material for building construction according to a further embodiment of the disclosure.
[0019] FIG. 3 is a graph illustrating stress-strain of a composite material formed according to embodiments of this disclosure compared to a single-layer ETFE of the prior art.
[0020] FIG. 4 is a graph illustrating light reflectance for a support carrier with an IR reflectance layer according to one embodiment of the disclosure.
[0021] FIG. 5A is a perspective view of an extrusion for connecting a composite material with a support carrier to a perimeter structural support according to one embodiment of the disclosure.
[0022] FIG. 5B is a perspective view of an extrusion for connecting a composite material with a support carrier to an intermediate structural support according to one embodiment of the disclosure.
[0023] FIG. 6 is a cross-sectional view of a manufactures lap joint for joining panels of composite material with a support carrier according to some embodiments of the disclosure.
[0024] FIG. 7 is a cross-sectional view of a manufactured butt joint for joining panels of composite material with a support carrier according to some embodiments of the disclosure.
[0025] FIG. 8 is a cross-sectional view showing a perimeter edge of a panel of composite material with a support carrier according to some embodiments of the disclosure.
[0026] FIG. 9 is a cross-sectional view showing a structural cable connection to a panel of composite material with a support carrier according to some embodiments of the disclosure.
DETAILED DESCRIPTION
[0027] FIG. 2A is a cross-sectional view of a transparent composite material for building construction according to one embodiment of the disclosure. A composite material 200 may include a combination of two or more materials. In some embodiments, the two or more materials are each substantially transparent, at least to visible light. The composite material 200 may include a first material 202 and a support carrier 210 comprising a second material 204 . The second material 204 may be attached to or affixed to the first material 202 by an adhesive 206 . The first material 202 may face towards an exterior environment around the building construction. The first material 202 may be selected to provide protection to the support carrier 210 , such as from external forces that may affect the support carrier 210 . For example, the first material 202 may be selected for its ability to withstand weather, such as rain, hail, snow, ice, etc., and thus protect the support carrier 210 that may not be as durable when exposed to the environment as the first material 202 . Other examples of materials for the first material 204 include PVDF or other fluoropolymers. In one embodiment, co-extruding particles and materials may be included within material 202 or 204 .
[0028] In some embodiments, such as shown in FIG. 2A , the second material 204 is sealed on one side by the first material 202 . In other embodiments, the second material 204 may be sealed on both sides by protective materials, such as shown in the embodiment of FIG. 2B . FIG. 2B is a cross-sectional view of a transparent composite material for building construction according to another embodiment of the disclosure. A composite material 250 may include a first material 252 A attached to a support carrier 260 having a second material 254 and adhesive 256 A. The first material 252 A may face towards an exterior environment and provide protection for the material 254 from the exterior environment. Adhesive 256 A may attach the support carrier 260 to the first material 252 A. A third material 252 B may be attached to the second material 254 by adhesive 256 B. The materials 252 A and 252 B may be the same materials, or in some embodiments the materials 252 A and 252 B may be different materials. For example, the materials 252 A and 252 B may both be ETFE. Likewise, the adhesives 256 A and 256 B may be similar or dissimilar adhesives selected, for example, to match the materials 252 A and 252 B and/or the target application for composite material 250 .
[0029] The thicknesses of the materials 252 A, 252 B, and 254 and adhesives 256 A and 256 B may be selected, in part, based on an intended application of the composite material 250 . For example, a thickness of the second material 254 may determine, in part, a strength of the composite material 250 . Because second material 254 is the strength material, increasing the thickness of the second material 254 may increase a weight loading capability of the composite film 250 . As another example, a thickness of the first material 252 A and 252 B may be selected, in part, based on the expected exterior environment around the second material 254 . For example, in harsh climates or rainy climates, a thickness of the first material 252 A may be increased to withstand additional wear on the composite material 250 . In one embodiment, a thickness of materials 252 A and 252 B may each be approximately 10-125 microns, or more particularly approximately 25 microns, a thickness of adhesives 256 A and 256 B may add up to approximately 25 microns. In some embodiments, a thickness of the second material 254 may be approximately 10-1000 microns, or 25-250 microns, or more particularly 125 microns. In some embodiments, the composite material is formed into a large transparent composite architectural panel by heat sealing manufactured composite materials together to form a building envelope and configured for installation on a building. Such building envelope composite panels may be several hundred feet long, and have an unsupported width or length between approximately 3 and 30 feet.
[0030] In some embodiments, the second material 254 may be a PET or other transparent polymer that is chemistry treated to prevent UV degradation. In some embodiments, the PET may be modified from stock formulations. For example, PET is a useful high strength material, however PET materials drip in fire. Thus, when the composite material 250 is used for building structures (e.g., a roof or other enclosure), the PET may be modified to prevent drip when exposed to flame. One example of such a modification is to modify the PET such that the PET crystalizes at high temperature to prevent dripping of the PET during a fire.
[0031] In some embodiments, the second material 254 may comprise multiple layers. For example, the second material 254 may include two layers of like or different materials attached together by an adhesive. Some materials have limits to the available thickness. Multiple layers of such materials may be adhered together to form a stronger second material 254 , when desired for certain applications.
[0032] In addition to providing strength, the support carrier may include materials or designs to provide additional features to the composite material. For example, additional features may be added to a composite material by inserting particles and/or nanoparticles with certain characteristics to the composite material. In some embodiments, the particles and nanoparticles may be incorporated into one or more adhesive layers of the composite material, such as shown in FIG. 2C . FIG. 2C is a cross-sectional view of a transparent composite material for building construction according to a further embodiment of the disclosure. The composite material 250 of FIG. 2C is similar to the composite material 250 of FIG. 2B , but includes particles 258 embedded in the adhesives 256 A and 256 B. Although particles 258 are shown in both adhesives 256 A and 256 B, the particles 258 may be present in only one of the adhesives 256 A and 256 B. Further, the nanoparticles may be present when there is only one adhesive, such as adhesive 206 in FIG. 2A .
[0033] The particles 258 may have a chemistry selected to obtain desired functionality. For example, the particles 258 may be selected to obtain tinting or shading, such as by partially blocking visible light, either the entire spectrum of visible light (e.g., shading) or a portion of the spectrum of visible light (e.g., tinting). Other example uses of particles 258 may include other spectral manipulations, such as to reflect infrared (IR) radiation or to absorb infrared (IR) radiation. Although nanoparticles have been described as embedded in an adhesive layer, the nanoparticles may alternatively or additionally be embedded in other portions of the support carrier.
[0034] Other functionality may be integrated into layers of the support carrier or as additional layers of the support carrier. For example, micro light emitting diodes (micro LEDs) and associated circuitry and wiring may be incorporated in the support carrier. The LEDs may be configured to provide lighting and/or to produce digital imaging capability within a composite material or in an array of panels. For example, many panels of composite material may be connected to form a roof or building façade and incorporate digital imaging technology into the support carrier of the material used to display images like a television or scoreboard. In some embodiments, a liquid crystal layer, similar to that of liquid crystal displays (LCDs), or an organic LED (OLED) layer, may be included in the support carrier and configured to couple to electronics that control the liquid crystal or OLEDs to generate a digital image. As another example, solar harnessing materials may be built into the support carrier. Solar concentrating materials may include additives to layers of the support carrier or a specific layer of the support carrier that redirects light impinging on the support carrier towards a collection point. A photovoltaic cell, or other device for converting light to electricity, may be located at that collection point to convert light received across the entire support carrier to electricity. As a further example, a photovoltaic layer may be integrated with the support carrier and configured to generate electricity from light impinging on the apparatus. As still a further example, an electrochromatic layer may be integrated with the support carrier and configured to provide a variable tint in the apparatus. Electronics, such as wires and control circuitry, may be attached to the electrochromatic layer to apply a variable tint or color to the support carrier. When a composite material with the support carrier is used as a roof, the electrochromatic layer may be controlled to darken during sunny days and lighten during cloudy days. As a further example, a heat reflectance layer may be integrated with the support carrier and configured to reflect a heat to reduce solar heat gain during the day and be switched off at night to allow heat to radiate out of the space. Some circuitry is described as supporting functionality for certain features in the support carrier layers, and similar circuitry may be configured for other feature layers included in the support carrier.
[0035] As yet another example, a layer may be added to the support carrier and configured to reflect infrared (IR) radiation. An example spectral characteristic of a support layer with such an IR reflection layer is shown in FIG. 4 . FIG. 4 is a graph of reflectance versus light wavelength, which shows nearly 100% reflectance of light in the IR spectrum from approximately 760 nm to 1100 nm while allowing nearly 80% transmission of light in the visible spectrum from approximately 400 nm to 750 nm. In some embodiments, such an IR reflectance layer may be a thin metal layer, and the support carrier may be modified through sputter or evaporation techniques to adhere one or more metals to the support carrier to reflect infrared (IR) radiation and maintain visible light transmission.
[0036] Embodiments of the composite materials described above have been tested and the results of the tests are shown in FIG. 3 . FIG. 3 is a graph illustrating stress-strain of a composite material formed according to embodiments of this disclosure compared to a single-layer ETFE of the prior art. Line 302 illustrates a stress-strain curve for a conventional single-layer ETFE material. Line 304 illustrates a stress-strain curve for an enhanced ETFE material by incorporating a support carrier with the ETFE as a protective layer. As shown in FIG. 3 , embodiments of the composite material using a support carrier may have stress-strain results significantly better than conventional single-layer ETFE materials. Thus, embodiments of the composite material may be useful in applications requiring high strength materials, such as enclosures or other architectural aspects for buildings.
[0037] The higher strength of the support carrier-based composite material shown by the stress-strain graph allows for more architectural freedom when designing and constructing a building. For example, the grid of steel or cables to carry load imposed on the ETFE material as described in the background may be eliminated or fewer cables may be required to support the cladding and resist snow and wind loads. Elimination of some or all of these cables provides freedom to the architect or engineer in the design of the building and provides improved aesthetic appearances. In the case of a cushion configuration, higher strength material allows the designer to increase the size (e.g., width) of a cushion and increase the internal pressure within the cushion to resist extreme snow and wind loads.
[0038] A composite film may be formed from the support carrier and one or more protection layers. The composite film may be formed into a flexible membrane and have a lighter weight than equivalent glass materials, which are also conventionally used as a transparent cladding material. A decrease in weight may allow the composite films to be supported by less building substructure than glass. The increase in strength of the composite film from the support carrier may allow additional flexibility in the sizing of panels of the composite material. An increase in size of the panels may allow new architectural designs not possible with conventional glass or ETFE films.
[0039] Some techniques for building construction with composite films having a support carrier are described with reference to FIGS. 5-9 . In some embodiments, the composite films may be attached to a rod-like structure, such as an EPDM chord, a nylon rod, or a rope. The rod-like structure may be used to connect composite panels to a building substructure. FIG. 5A is a perspective view of an extrusion for connecting a composite material with a support carrier to a perimeter structural support according to some embodiments of the disclosure. An extrusion 500 may include a holder 502 for holding a rod-like structure attached to the composite film. Supports 504 A, 504 B press against the composite film attached to the rod that fits in the holder 502 . Attachment mechanism 506 attaches the extrusion 500 to a building substructure. For example, the extrusion 500 may hold composite panels on a top or side of a building to serve as a transparent roof. The extrusion 500 may be used at perimeters of an architectural area, such as a perimeter of a roof, to support installation of the composite material panels.
[0040] An extrusion may alternatively be used to connect composite material to an intermediate structural support as shown in FIG. 5B . FIG. 5B is a perspective view of an extrusion for connecting a composite material with a support carrier to an intermediate structural support according to some embodiments of the disclosure. A holder 512 of extrusion 510 may receive a rod-like structure attached to composite film. The extrusion 510 may connect the composite materials to upstands 516 and/or substructure 518 . In some embodiments, a birdwire may be attached to the extrusion 510 to assist in preventing wildlife damage to the composite material panels. The extrusion 510 may be used in the middle of an architectural area, such as portions of the roof away from a perimeter, to support installation of the composite material panels on a left and right side of the extrusion 510 .
[0041] In some embodiments, panels of composite material may be directly connected as shown in FIG. 6 . FIG. 6 is a cross-sectional view of an attachment of panels of composite material with a support carrier according to some embodiments of the disclosure. A first panel 602 and a second panel 604 may each be a composite material panel with a support carrier as described in embodiments above. A bottom surface 602 A of the first panel 602 and a top surface 604 A of the second panel 604 may be attached in overlapping region 606 to form a lap seal. For example, a heat seal may be formed, an adhesive may be applied, and or a tape may be applied to attach the first panel 602 to the second panel 604 . In some embodiments, the overlap width w may be between 0.375 inches and 2 inches.
[0042] In some embodiments, panels of composite material may be indirectly connected through a butt joint to a secondary material as shown in FIG. 7 . FIG. 7 is a cross-sectional view of a manufactured butt joint for attaching panels of composite material with a support carrier according to some embodiments of the disclosure. A first panel 702 and a second panel 704 may be attached through secondary material 706 . The first panel 702 may be attached to the secondary material 706 in overlapping region 702 A; the second panel 704 may be attached to the secondary material 706 in overlapping region 704 A. In some embodiments, a width of the overlapping regions 702 A and 704 A may be approximately 0.375 to 2 inches, although the two widths of regions 702 A, 704 A do not need to be identical. In some embodiments, a total overlapping width, or the width of the secondary material 706 , may be between 0.75 and 4 inches. The widths of the various overlaps and sizes of the panels may be selected to obtain desired architectural characteristics and to meet necessary strength requirements for support of the building.
[0043] Panels of the composite films may be attached to rod-like structures for attachment to extrusions as shown in FIG. 8 and FIG. 9 . FIG. 8 is a cross-sectional view showing an edge of a panel of composite material with a support carrier according to some embodiments of the disclosure. The perimeter detail shown in FIG. 8 may be received by an aluminum extrusion such as shown in FIG. 5A and FIG. 5B . The extrusions may be bolted to a structural frame like that in a glass mullion. A composite film 802 may be rolled at an edge around a rod-like structure 804 , such as an EPDM chord, a nylon rod, or a rope. The rod-like structure 804 may provide rigidity to a formed panel from the composite material 802 and/or provide a means for attaching the panel to a building substructure or intermediate structure through extrusions. A seal 806 may be made between the composite material 802 and a curled edge of that same material sheet. An overlapping region 808 , or seal width, may be approximately 0.375 inches to 2 inches, although the amount of overlap may be determined specifically for each application of the panels. In FIG. 8 , a first portion of the composite material 802 is wrapped around the rod-like structure 804 and sealed 806 to a second portion of the composite material 802 .
[0044] FIG. 9 is a cross-sectional view showing a structural cable connection to a panel of composite material with a support carrier according to some embodiments of the disclosure. A film 902 may be attached to film 906 at seals 910 A and 910 B to attach the film 902 and 906 to a rod-like structure 904 , such as a cable. The seals 910 A and 910 B may be, for example, heat seals, adhesive seals, or tape seals. An overlapping width 908 A and 908 B, or seal width, may be approximately 0.375 inches to 2 inches, although the amount of overlap may be determined specifically for each application of the panels. Either or both of the materials 902 and 906 may be a composite material with a support carrier and one or more of the functionalities described in embodiments above. In FIG. 9 , the composite panel 906 is attached to the rod-like structure by a material sheet 902 wrapped around the rod-like structure 902 and sealed 910 A, 910 B to the composite material 906 on opposite sides of the rod-like structure 902 .
[0045] Although architectural applications for the composite material are described, the composite material may be used for other applications. For example, the composite materials may be used to build flexible electronic devices, outdoor weather-resistance electronic devices, flexible toys with integrated electronic functionality, among other applications. The composite material may be used as a replacement technology for any device conventionally constructed between, for example, rigid glass panels.
[0046] Although the present disclosure and certain representative advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. For example, although many single layer embodiments of the composite material with support carrier are provided, the composite material with support carrier may also be formed into cushions for installation in architectural applications. As another example, where a “layer” is referred to, the “layer” may include one or more materials in a layer and may include one or more layers within the “layer.” Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | A composite material may be used as a building material to provide desirable visible aesthetics, such as in a roof or facade. The composite material may include two or more materials, wherein a first material provides desirable qualities for appearance and a second material provides desirable qualities for strength or other characteristics desirable of a building material. Each of the first material and the second material may be transparent, such that the composite material is also transparent. The first material may be Ethylene tetrafluoroethylene (ETFE) and the second material may be Polyethylene terephthalate (PET). |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ventilators and deodorizers for toilet bowls.
2. Prior Art
In the prior art, there are a wide number of various ventilators for home and industrial toilets. Some of these also use activated charcoal as a filtering element for removing odors. U.S. Pat. No. 3,087,168 to M. A. Huso illustrates a filter unit that mounts, in one form, on the interior of the toilet tank, and also in another form on the exterior of the tank, and which includes a fan for ventilating the toilet bowl and passing the air through an acitvated charcoal filter. U.S. Pat. No. 3,781,923 illustrates a ventilating system which is mounted into a hollow cover which replaces the standard cover on the tank of a water closet or toilet. In this device electrical controls also can be included for flushing the toilet.
U.S. Pat. No. 3,626,554 shows a suction hood directly mounted onto the overflow pipe on the interior of the toilet tank, which hood is connected to an external blower. U.S. Pat. No. 2,881,450 shows a blower unit mounted directly to an overflow pipe of a toilet with electrical controls, and apparently there is a holding circuit which is under control of floats in the tank which opens to disable the blower unit when the water level rises.
U.S. Pat. No. 3,763,505 shows a ventilating unit mounted inside a tank in a special housing, utilizing the overflow pipe for ventilation of the toilet bowl in one form of the invention, and includes battery power for driving the motor for the fan together with a timer switch for operation.
U.S. Pat. No. 2,591,817 includes a damper mounted on the overflow pipe which controls the flow of vapor from the water tank into the bowl when the water in the closet rises during filling.
U.S. Pat. No. 3,939,506 shows a ventilator that has an exhaust conduit connected to the upper portion of the water tank of the toilet to withdraw air from the toilet bowl through the overflow pipe, with a fan located in the attic of a house in which the device is used.
SUMMARY OF THE INVENTION
The present invention relates to a small compact unit for ventilating water closets or toilets, which mounts onto the overflow pipe, and is contained, except for the activating switch assembly, entirely within the water supply tank. This makes the unit unobtrusive, and yet it is easy to install. Means are included for securely wedging the main housing onto the upper edge of the overflow pipe when the unit is installed so that it is securely held without any external fasteners. The interior unit is small enough so that it can be positioned in a desired location to avoid interfering with any other mechanism in the water supply tank.
The timer switch is used for operating a battery powered fan, used for safety purposes, and the batteries are positioned inside the tank but adjacent to the switch so that the batteries can easily be replaced.
The time delay device is made to be operated on a pneumatic principle using molded parts that fit together to provide the necessary pneumatic time delay orifice.
The entire device can be installed without any special tools. The blower is simple to make because of the small volume that is required to be moved, when removing air only from the toilet bowl. Battery life is adequate and the time delay avoids excessive battery drain that can result from leaving the unit on for an unnecessary length of time. The low voltage batteries are safe to use, and no high voltage power is necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a typical toilet tank illustrating a ventilator made according to the present invention installed thereon;
FIG. 2 is a sectional view taken as on line 2--2 in FIG. 1;
FIG. 3 is a sectional bottom view taken as on line 3--3 in FIG. 2; and
FIG. 4 is a sectional view of an activating switch and time delay mechanism and the battery housing used with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a standard toilet tank 10 is connected to a toilet bowl in the normal manner, and includes flushing controls 11, which are used for flushing the toilet and refilling the tank with water, which is indicated generally at 12. The flushing controls are operated through an exterior handle 13. Reference can be made to the prior art for further detailed showings of toilets. The toilet tank overflow pipe 14, which is provided on all standard toilets leads directly to the toilet bowl (not shown) through a rim around the edge of the bowl so that water can overflow from the tank into the bowl if the refill mechanism and float do not work properly. Further, a refill jet or orifice discharges water through this passage to the bowl to refill the trap of the bowl after flushing, as the tank is refilled. The overflow pipe provides an air passage indicated generally at 15 to the toilet bowl. The normal refill pipe normally passes over the edge of the overflow pipe 14 into the passage 15 for refilling the trap in the toilet bowl.
In the device of the present invention, the blower and filter assembly illustrated generally at 20 includes a support housing 21, which is of size to fit over and be spaced from the overflow pipe 14, and a refill nozzle 27 is molded into one side of the housing 20 and fastened securely thereto. The refill nozzle 27 has a rectilinear cross section, as shown in FIG. 3, and the back wall 28 of the nozzle, which is adjacent one of the walls of the mounting housing 21 is also positioned adjacent and centered between a pair of ribs 24,24 which are fastened to one wall of the housing 21 as shown also in FIG. 3. These ribs 24 then serve to wedge the back wall 28 of the refill nozzle 27 against the overflow pipe 14 so that the upper portion of the overflow pipe is pinched between the ribs 24 and the back wall 28 of the nozzle. In this way the tapered back wall 28 will clamp or wedge down on the overflow pipe and securely hold the housing 21 on the overflow pipe. A refill tube 30 can then easily be installed onto the refill nozzle 28 from the provided refill orifice of the flushing control. The refill tube 30 leads from the flush control mechanism 11 as shown in FIG. 1.
The housing 21 is open at is lower end as shown, and skirt portions of the housing are spaced from the overflow pipe 14, but are below the water level when the refill tank is full. At the upper end of the housing 21 there is a passageway 31 formed in which a small fan motor 32 is mounted, with a fan blade 33 that is of size to fit within and rotate within the passage 31 with a small amount of clearance. When the fan motor 32 is operating, the air will move up through the overflow pipe 14 and past the fan blade 33, and over into a filter compartment 34. The passageway 31 leads to a chamber 35 that is above a perforated or apertured dividing wall 36, and below which a filter material 37 such as activated charcoal or other known odor removal material is packed. A lower perforated wall 38 leads to the exterior of the filter compartment. It should be noted that the upper wall 39 of the filter compartment 34 is sealed so that the air drawn by the fan must pass through the filter 37 into the interior of the water tank. The fan motor 32 is fixed to the wall 39.
After refilling water in the tank so the lower edge of housing 21 is below the water the only passage for air to the fan is through the passageway 15. Also, the spacing of the skirt or wall of housing 21 from the overflow pipe permits water to flow from the tank into the overflow pipe if necessary, even after the ventilator has been installed.
The fan motor 32 is operated from a battery source in a holder indicated generally at 41, which is mounted in turn on the interior of the water tank 10 and is mounted onto a clip 42 that fits over the top lip of the tank. The clip is thin enough to pass under the tank cover without substantial dislocation of the cover. Batteries indicated generally at 43, for example two D cell flashlight batteries, are mounted in the battery holder 41 and are connected through suitable clips and a switch to power wires 44 and 45. Wire 45 is connected to a switch indicated generally at 46 which includes spring loaded contacts on arms 53 and 54.
The switch 46 is a time delay switch and as shown, the clip 42 supports an outer housing 47 which has a center aperture 48, and which defines an interior chamber 49. The clip 42 also has an annular or cylindrical neck 50 that extends outwardly from the wall of the tank and from the back wall 51 of the clip to define a cylindrical interior chamber 52. A first switch spring contact 53 is mounted on the wall 51 inside the chamber 52, and a second switch spring contact arm 54 is also mounted to wall 51. Arm 54 is spring loaded away from the contact on arm 53, as shown in FIG. 4. The contact arm 54 is to the exterior of the contact arm 53. Contact arm 53 is connected to wire 55 that leads from one end of the batteries. Contact arm 54 is connected to wire 45 so that a circuit is completed across the batteries through the contact arms 53 and 54 when the end contacts are touching.
A flexible, molded elastomeric diaphragm and push button member illustrated generally at 60 includes an outer rim 61 that has interior threads indicated generally at 62 to provide a frictional gripping on the exterior surface of the collar 50, and at the same time provide a controlled air leakage past the seal. The diaphragm has a pushbutton portion 62A that extends through opening 48. A boss portion 63 is positioned on the interior of wall 47 and is adjacent to and touches contact arm 54. The central boss 63 and the pushbutton 62A are attached to the rim 61 by a flexible sealing wall 64.
The diaphragm assembly therefore encloses and seals the chamber 52 with a flexible wall.
The diaphragm portions 64 are flexible, and permit the button 62 to be pressed inwardly into the interior chamber 52 defined by the collar 50. Because the chamber 52 is sealed by the diaphragm, when the button is depressed the air in chamber 52 will be compressed. This will cause discharge of air out through a flapper valve assembly 66 that covers a small aperture 67 in the wall 51. The flapper valve is a one way check valve, that permits air to be discharged from chamber 52 but prevents air from being drawn back into the chamber through the aperture 67. When the diaphragm button 62A is depressed the contacts 53 and 54 will be pushed together to complete the circuit to the fan motor 32. The spring contact arms 53 and 54 will urge the diaphragm outwardly from the chamber 52, but in order to move out, replacement air must be drawn in. Air is drawn into chamber 52 past the threads 62 on the rim 61 as the diaphragm moves out. The amount of thread, the tension of the rim 61 and the characteristics of the outer surface of the collar 50 can be controlled so that a delay in return of the diaphragm to its condition shown in FIG. 4 with the contact arm separated can be caused. Approximately a three minute delay from the time of depressing button 62A and starting motor 32 until the contacts open and motor 32 stops is utilized in the present device. Running the fan for three minutes has been found to be satisfactory for deodorizing purposes.
Thus, a simple pneumatic time delay device is utilized and the delay does not require electrical power. This means that the power from the batteries 43 is used entirely for driving the fan motor. The fan will only be on for limited periods of time each time the button 62A is depressed.
It can be seen that the battery and switch holder can easily be slipped over the tank wall and the batteries can easily be replaced because they are positioned adjacent the front edge of the tank.
The filter housing 34 can be mounted in alternate locations. In other words, the filter unit 34 can be reversed in direction of extension from pipe 14 from that shown and extend over toward the flush controls 11 if desired.
The device is easy to make, easy to install, relatively low in cost and inherently safe. It is unobtrusive and because of low power consumption and insurance that the fan will not continue to run, the batteries last a substantial time. | A timed ventilator for toilets which mounts entirely within the toilet tank, and which operates from a battery power source to remove air from the toilet bowl and move the air through a charcoal filter for deodorizing. An external control includes an automatic time delay which will hold the fan on for a desired amount of time necessary to change the air in the small volume of the toilet bowl. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of provisional patent application serial No. 60/308,365 filed Jul. 27, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to methods and devices for providing a stress-relieving joint between a riser and the keel of a floating platform.
[0004] 2. Description of the Related Art
[0005] Deep water floating platforms use risers to communicate production fluid from the sea floor to the floating production platform. Floating platforms have a portion that lies below the surface of the sea. For stability of the platform, it is desired that there be a very deep draft. The spar, for example, is a popular style of floating platform that has an elongated, cylindrical hull portion which, when deployed, extends downwardly a significant distance into the sea. The lowest portion of the submerged hull is referred to as the keel. Currents in the sea tend to move the floating platform laterally across the sea surface. Despite the presence of anchorages, the platform imparts bending stresses to the riser during lateral movement. Localized, or point, stresses are particularly problematic for risers.
[0006] One known joint arrangement for use with risers and floating vessels is described in U.S. Pat. No. 5,683,205 issued to Halkyard. Halkyard describes an arrangement wherein a joint means is positioned within a keel opening in the floating vessel to reduce the amount of stress upon a pipe passing through the keel opening. The joint means consists of a radially enlarged sleeve member with an elastomeric annulus at either end that is in contact with both the sleeve member and the pipe. Halkyard's intent is to reduce stress upon the pipe that is imposed by lateral movement of the floating vessel upon the sea. In order to reduce stress, Halkyard contacts the pipe at two points with an elastomeric annulus, which is described as providing a resilient, somewhat yieldable connection. Unfortunately, Halkyard's arrangement is problematic since it permits almost no angular movement of the pipe within the sleeve member. While point stresses upon the pipe are reduced, they are still significant. Further, the pipe is required to bend within the confines of the sleeve. This bending, together with the induced point stresses at either end of the sleeve, place significant strain on the pipe.
[0007] The present invention addresses the problems in the prior art.
SUMMARY OF THE INVENTION
[0008] Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel. The assemblies of the present invention greatly reduce the amount of stress and strain that is placed upon the riser, as well. The present invention describes keel joint assemblies that provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening.
[0009] In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 illustrates an exemplary riser extending upwardly from the sea floor and through a spar-type floating platform.
[0011] [0011]FIG. 2 is a schematic side, cross-sectional view of a first exemplary keel joint assembly constructed in accordance with the present invention.
[0012] [0012]FIG. 3 is a schematic side, cross-sectional view of a second exemplary keel joint assembly constructed in accordance with the present invention.
[0013] [0013]FIG. 4 is a schematic side, cross-sectional view of a third exemplary keel joint assembly constructed in accordance with the present invention.
[0014] [0014]FIG. 5 is a schematic side, cross-sectional view of a fourth exemplary keel joint constructed in accordance with the present invention.
[0015] [0015]FIG. 6 is a schematic side, cross-sectional view of a fifth exemplary keel joint assembly constructed in accordance with the present invention.
[0016] [0016]FIG. 7 is a schematic side, cross-sectional view of a sixth exemplary keel joint assembly constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] [0017]FIG. 1 generally illustrates a subsea wellhead 10 that has been installed into the sea floor 12 . A riser 14 is connected to the wellhead 10 and extends upwardly through the waterline 16 to a floating platform 18 . The riser 14 is used to transmit production fluids or as a drilling conduit from the wellhead 10 to production facilities (not shown) on the floating platform 18 . The riser 14 is used to provide a closed conduit from the wellhead 10 to the floating platform 18 . The floating platform 18 shown is a spar-type floating vessel that carries production equipment (not shown) on an upper deck 20 . The hull 22 of the platform 18 is a cylinder having flotation chambers within and a central, vertically-oriented passage 24 through which the riser 14 is disposed. It is noted that the configuration for a passage used in floating platforms varies from platform to platform. Sometimes the passage is lined by a cylindrical wall that extends substantially the entire length of the hull. In other platforms, the passage is partially lined by such a wall, and in still other platforms, there is essentially no lining for the passage. The keel 26 is located at the lower end of the hull 22 . A keel joint, indicated generally at 28 , is used to permit axial upward and downward motion as well as angular deflection of the riser 14 with respect to the keel 26 . It is desired that the keel joint 28 be constructed to preclude localized bending stresses in the riser 14 that could damage it, resulting in structural failure of the riser 14 .
[0018] Referring to FIG. 2, there is shown a first, and currently most preferred, exemplary keel joint arrangement 30 that can be used as the keel joint 28 to support the riser 14 . The keel joint arrangement 30 includes a stiff cylindrical can 32 that radially surrounds a portion of the riser 14 . The can 32 is retained within and disposed away from the walls of the keel opening or passage 24 by supports or guides 34 that are securely affixed with the hull 22 . While there are only two upper and two lower supports 34 shown in FIG. 2, it should be understood that there are actually more such supports 34 , perhaps four or more upper and four or more lower supports 34 and that the supports are located to surround the circumference of the riser 14 . The supports 34 have rounded, non-puncturing ends 36 to contact the outer wall of the can 32 . It is noted that the supports 34 are not affixed to the can 32 , thereby permitting the can 32 to move upwardly and downwardly within the passage 24 . The keel joint arrangement 30 maybe thought of an “open can” arrangement since the can 32 is affixed to the riser 14 by a stress joint (straight or tapered) 38 proximate the lower end of the can 32 while the upper end 40 of the can 32 is not secured to or maintained in contact with the riser 14 . The exemplary stress joint 38 illustrated consists of a pair of radially enlarged collars 42 that surround the riser 14 and are affixed to the inner radial surface of the can 32 . The collars 42 are shown to be fashioned of metal. However, the collars 42 may also be fashioned of a suitable elastomeric material. The collars 42 may be substantially rigid so as to permit a small amount of angular movement of the riser 14 with respect to the can 32 . Alternatively, the collars 42 may be relatively flexible to permit additional angular movement.
[0019] In operation, the riser 14 can move angularly to a degree within the can 32 under bending stresses. Illustrative directions of such relative angular movement are shown in FIG. 2 by arrows 33 about rotation point 35 . During such angular movement, the outer walls of the riser 14 are moved closer to or further away from the inner walls of the keel opening 24 . The stress joint 38 forms a fulcrum. The can 32 is stiff enough that it transfers stresses directly from the stress joint 38 to the supports 34 , thereby preventing any significant stresses from being seen by the upper portion of the riser 14 . Generally, this arrangement allows the upper portion of the riser 14 to have a smaller cross section than the stress joint 38 .
[0020] [0020]FIG. 3 illustrates an alternative embodiment for a keel joint arrangement 50 that is useful as a keel joint 28 . In the keel joint arrangement 50 , a heavy walled wear sleeve 52 radially surrounds a portion of the riser 14 . The wear sleeve 52 may or may not be secured to the riser 14 in a fixed relation, such as by the use of welding or retaining rings such as are known in the art. A central portion of the wear sleeve 52 has an external annular ring 54 that extends radially outwardly and forms the portion of the sleeve 52 having the largest exterior diameter. The ring 54 presents an outer radial surface that is vertically curved in a convex manner. The outer radial surface of the ring 54 may also be frustoconical in shape. Below the annular ring 54 is a lower inwardly tapered portion 56 . Above the ring 54 is an upper inwardly tapered portion 58 . A partially-lined passage, designated as 24 ′, in the hull 22 of the floating vessel 18 has an open upper end 60 that is outwardly flared for installation purposes. The flare of the upper end assists in guiding the sleeve 52 and ring 54 into place when lowering the riser 14 through the hull 22 . The lower end of the passage 24 has an annular recess 62 that is sized and shaped for the annular ring 54 to reside within. The recess 62 presents an inner surface that is vertically curved in a concave manner so that the outer convex surface of the annular ring 54 can be matingly engaged. If the outer radial surface of the ring 54 is frustoconical in shape, however, the inner surface of the recess 62 will be made complimentary to that frustoconical shape.
[0021] In operation, the keel joint arrangement 50 helps to prevent damage to the riser 14 from bending stresses. The wear sleeve 52 is located at the keel 26 where the primary bending stresses are imparted to the riser 14 and, therefore, is designed to absorb most of those stresses and prevent them from being imparted directly to the riser 14 . The interface of the ring 54 and the recess 62 provides a fulcrum wherein the riser 14 can move angularly with respect to the hull 22 . In addition, the elongated upper tapered portion 58 will tend to bear against the length of the passage 24 ′, thereby reducing or eliminating localized, or point, stresses.
[0022] Referring now to FIG. 4, there is shown a keel joint arrangement 70 , which is a second alternative embodiment that is useful as the keel joint 28 . The keel joint arrangement 70 employs centralizer assemblies 72 that are secured within the passage 24 of the hull 22 . Preferably, the centralizer assemblies 72 are spaced angularly about the circumference of the passage 24 . In a preferred embodiment, the centralizers 72 comprise hydraulically actuated piston-type assemblies, the piston arrangement being illustrated schematically by two 72 a , 72 b . In practice, the two arms 72 a , 72 b would be nested one within the other in a piston fashion and would be selectively moveably with respect to one another. In an alternative embodiment, the centralizer assemblies 72 comprise hinged assemblies wherein the two arms 72 a , 72 b are hingedly affixed to one another at hinge point 72 c . Actuation of the centralizer assembly in this case would move the arm 72 a angularly with respect to the arm 72 b about the hinge point 72 c , thereby permitting the arm 72 a to be selectively moved into and out of engagement with the riser 14 . The centralizers 72 are energized via hydraulic lines (not shown) to urge the riser toward the radial center of the passage 24 to resist contact between the riser 14 and the passage 24 . The centralizers 72 have rounded, non-puncturing tips 74 that bear upon the riser 14 . Preferably, the non-puncturing tips comprise either wear pads or rollers for engagement of the riser 14 . It is noted that the piston-type centralizer assemblies 72 may be actuated mechanically rather than hydraulically. Also, the centralizer assemblies' attachments to the passage 24 may be softened, such as through use of springs or rubber, in such a way as to decrease bending stresses by yielding to riser deflection. In a further alternative embodiment, the centralizers 72 will comprise members that have a hinged attachment to the passage 24 .
[0023] [0023]FIG. 5 depicts a third alternative embodiment for the keel joint 28 . Keel joint assembly 90 includes a riser collar 92 that surrounds a portion of the riser 14 proximate the keel 26 . The collar 92 is not affixed to the riser 14 but instead permits sliding movement of the riser 14 upwardly and downwardly through the collar 92 . The collar 92 is generally cylindrical but includes a bulbous central portion 94 and two tapered end portions 96 , 98 . A guide sleeve 100 radially surrounds the collar 92 and features an interior rounded profile 102 that is shaped and sized to receive the bulbous portion 94 of the collar 92 . An exterior landing profile 104 is located at the lower end of the guide sleeve and is shaped and sized to form a complementary fit with a landing profile 106 formed into the keel 26 . The passage 24 ′ is constructed identically to the passage 24 ′ described earlier in that it has an open upper end with an outward flare.
[0024] To assemble the keel joint arrangement 90 , the collar 92 and guide sleeve 100 are assembled onto the riser 14 . Then the riser 14 is run through the passage 24 ′ and the landing profile 104 of the guide sleeve 100 is seated into the matching profile 106 in the keel 26 . In operation, the riser 14 can slide upwardly and downwardly within the collar 92 as necessary to compensate for movement of the floating platform 18 . Rotation of the platform 18 with respect to the riser 14 is permitted between the riser 14 and the collar 92 as well as between the collar 92 and the guide sleeve 100 . Angular movement of the riser 14 with respect to the platform 18 is accommodated by rotation of the bulbous portion 94 within the rounded profile 102 of the guide sleeve 100 . Alternatively, a rubberized flex joint of a type known in the art (not shown) might be used to accommodate angular rotation.
[0025] A fourth alternative exemplary embodiment for the keel joint 28 is shown in FIG. 6. Keel joint assembly 110 incorporates a flexible cage assembly to permit relative movement between the riser 14 and the floating vessel 18 . A flexible cage assembly 112 is formed of an inner riser sleeve 114 and an outer keel sleeve 116 . A central cage 118 adjoins the two sleeves 114 , 116 . The cage 118 includes an upper ring 120 , a central ring 122 , and a lower ring 124 . There are a series of upper spokes 126 that radiate upwardly and outwardly from the central ring 122 to the upper ring 124 . There are also a series of lower spokes 128 that radiate outwardly and downwardly from the central ring 122 to the lower ring 124 . The upper and lower spokes 126 , 128 are each arranged in a spaced relation from one another about the circumference of the central ring 122 . The spokes 126 , 128 are fashioned from a material that is somewhat flexible yet has good strength under both tension and compression. It is currently preferred that the spokes 126 , 128 are fashioned of a steel alloy, although other suitable materials may be used. The spokes 126 , 128 are elastically deformable as necessary to allow the riser 14 to move angularly within the passage 24 ′. Angular deflection of the riser 14 results in non-uniform deflection of upper spokes 126 and lower spokes 128 . The upper ring 120 affixes the upper spokes 126 to the outer keel sleeve 116 . The lower ring 124 is not affixed to the outer keel sleeve 116 .
[0026] The outer keel sleeve 116 is seated within the passage 24 ′ by means of a landing profile 130 that is shaped and sized to be seated within a complimentary seating profile 132 at the lower end of the passage 24 ′. Locking flanges 134 are secured onto the lower side of the keel 26 to secure the outer keel sleeve 116 in place. In a manner known in the art, the locking flanges 134 may be selectively disengaged, or unlocked, and subsequently retrieved by upward movement of the riser 14 with respect to the passage 24 ′, i.e., by pulling upwardly on the riser string.
[0027] During operation, the cage 118 holds the riser 14 in a semi-rigid manner that permits some flexibility. The riser 14 can move angularly with respect to the hull 22 due to the flexibility of the spokes 126 and 128 of the cage 118 . Loading from movement of the riser 14 is transferred by the upper spokes 126 to the keel sleeve 116 which, in turn transfers the loading to the hull 22 . Because the keel sleeve 116 engages the passage 24 ′ of the hull 22 along substantially its entire length, point loading is avoided.
[0028] [0028]FIG. 7 depicts a fifth alternative embodiment for use as the keel joint 28 . Keel joint arrangement 130 includes an open top can structure, which is shown incorporated into the riser 14 as a sub 132 at is affixed at either end to other riser sections 134 , 136 . The can sub 132 includes a pair of concentric tubular members. The inner tubular member 138 has the same interior and exterior diameters as a standard riser section. The outer tubular member, or can, 140 is coaxial with the inner tubular member 138 and is affixed to the inner tubular member 138 by a flange adapter, or stress joint, 142 that joins the two pieces together proximate the lower end of the sub 132 . While FIG. 7 shows the flange adapter 142 to be an annular metallic collar that is integrally formed into both the inner and outer tubular members 138 , 140 , it might also comprise a separate collar or elastomeric member as well as a flexible casing.
[0029] A cylindrical guide sleeve 144 radially surrounds the open top can sub 132 . The guide sleeve 144 is securely affixed to the outer tubular member 140 by, for example, welding. Supports 146 are used to secure the guide sleeve 144 within the passage 24 of the hull 22 . The supports 146 maintain the guide sleeve 144 a distance away from the wall of the passage 24 so that the guide sleeve 144 is substantially radially centered within the passage 24 . The supports 146 are preferably formed of structural beams. The supports 146 are arranged in two tiers, an upper tier and a lower tier, and each tier surrounds the circumference of the passage 24 . The outer tubular member 140 is stiff enough that it transfers stresses directly from the flange adapter 142 to the guide sleeve 144 . Because the guide sleeve 144 and the outer tubular member 140 are affixed along substantially their entire length, point stresses are avoided. In addition, the supports transmit loads or stresses from the guide sleeve 144 to the passage 24 walls. The length of contact between the outer tubular member 140 and the guide sleeve 144 allows for a longer vertical riser stroke than arrangements wherein there is less contact area, such as the arrangement 30 shown in FIG. 2.
[0030] While described in terms of preferred embodiments, those of skill in the art will understand that many modifications and changes may be made while remaining within the scope of the invention. | Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel and greatly reduce the amount of stress and strain that is placed upon the riser, as well. Keel joint assemblies described provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening. In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening. |
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This is a continuation of application Ser. No. 413,195, filed Nov. 6, 1973, now abandoned.
BACKGROUND OF THE INVENTION
Grabsticks for picking up litter as used by personnel on public grounds such as state parks and the like should be capable of picking up a wide range of litter as for example jars and cans which represent rather large articles and ranging down to very small objects such as matches and the like. These devices should also be of lightweight construction and should require a minimum of physical effort on the part of the user firmly to grip the object being picked up and should otherwise be convenient to use and of effective and efficient operation.
BRIEF SUMMARY OF THE INVENTION
It is therefore of primary concern in connection with the present invention to provide an improved type of grab stick which is of light weight, is fully effective to pick up a wide range of litter and which incorporates a pistol grip type of action which makes the device easy to operate and to manipulate.
Essentially, the present invention incorporates a grab stick in which a support column is provided with a pistol grip type of member at its upper end and a trigger-like pull rod assembly which is characterized by its ease of action and firm gripping mechanical connection to the swing leg of the grab stick. The grab stick incorporates a channel-shaped support column in which the lower end of the column is flattened to provide a gripping jaw portion of large surface area. The swing leg is attached to the support column on the side opposite to the pistol grip and likewise is of channel configuration flattened at its end to provide the cooperative gripper jaw portion. A control link member is pivotally connected to the support column and has triangularly related pivotal connections respectively to the trigger pull rod, the support column and to a pull rod which projects through the support column into pivotal connection with the swing leg. The arrangement is detailed in design such that a spring acting between the support column and the control link member normally positions the swing leg in wide open position and causes the control link to seat against the support column. The triangular disposition of the pivot points effects a minimum of trigger movement between the full open and full closed positions of the gripper jaws and effects a positive gripping action.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a perspective view showing the preferred embodiment of grab stick according to the present invention;
FIG. 2 is a rear elevational view of the lower end of the grab stick as is indicated by section lines 2--2 in FIG. 1; and
FIG. 3 is a longitudinal section of the assembly shown in FIG. 2 as indicated by the section lines 3--3 in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
As will be seen by reference to FIG. 1, the grab stick according to the present invention consists essentially of a support column indicated generally by the reference character 10 and provided at its upper end with a laterally protecting pistol grip portion 12 and presenting at its lower end a gripper jaw portion 14. Associated with the pistol grip portion 12 is a trigger 16 which operates a control line 18 and the latter of which is connected through a pull rod 20 to the swing leg assembly indicated generally by the reference character 22. The swing leg assembly is pivotally connected at 24 to the support column and its lower end presents a gripper jaw portion 26 cooperative with the aforementioned gripper jaw portion 14 of the support column.
The swing leg 22 is of channel shaped configuration presenting the bight portion 28 and the parallel legs 30 and 32 and the gripper jaw portion 26 thereof is formed by flattening this channel configuration as shown so that its tip 34 presents a wide gripping jaw and is mildly curved as is evident from FIG. 3 so as to conform more readily to various objects to be picked up and to provide when closed a relatively narrow gripping area engagement with the gripper jaw portion of the support column.
The support column is also of channel configuration to present the bight 36 and the parallel legs 38 and 40 and it, too, is flattened at its lower end to present the gripper jaw portion 14, substantially as is shown. However, the flattened area of the gripper jaw portion 14 of the support column is of somewhat lesser axial length than is the flattened portion 34 of the swing leg so as to be of somewhat greater rigidity than is the gripper jaw portion of the swing leg. This permits the flattened gripper extremity or tip of the swing leg to flex flatwise against the gripper jaw tip 42 of the support column.
The opposed surfaces of the gripper jaw portions 14 and 26 preferably are provided with pads 44 and 46 of roughened, resilient material adhesively contacted thereto so as to provide for a firmer grip on the objects being picked up.
The trigger is in the form of an elongate rod 48 formed into a loop 50 at its upper end, which loop as well as the pistol grip portion 12 may be coated with resilient material 52, as shown. The pull rod 48 and the tip 54 of the trigger loop are guided within suitable openings in an L-shaped bracket 56 secured to the inner surface of the bight 36 of the support column and secured in place by a suitable fastener such as that indicated by the reference character 58. The lower extremity of the trigger pull rod 48 is pivotally connected to the control link 18 and the pivotal connections between the control link 18 and the support column 10, between the control link 18 and the trigger pull rod 48, and between the control link 18 and the pull rod 20 are, as indicated by reference characters A, B and C disposed in triangular relation. These pivot points and the lengths of the pull rod 20 in conjunction with the location of the pivot point 24 of the swing leg 22 are detailed in design so that in the full line position shown in FIG. 3 which is the extremity of swing leg opening position, a line passing through the points A and B is at an angle of not more than 135° with respect to the axis of the support column 10 and such that when the trigger rod is fully retracted, a line passing through the pivot point C and the pivot point D between the other extremity of the pull rod 20 and the swing leg 22 lies closely adjacent to the pivot point A, in which position the gripper jaws will be firmly interengaged. This arrangement allows a powerful gripping action throughout the range of operation and, at the same time, achieves this through a minimum of travel of the trigger assembly.
A torsion spring 60 is disposed in the bights 36 and 62 of the support column 10 and the control link 18 normally to urge the swing leg 22 to the full open position as is shown in FIG. 3.
The control link preferably is constructed of a deep channel member whose legs 66 and 68 are essentially triangularly shaped and which are disposed between the legs 38 and 40 of the support column in close adjacency to the inner sides thereof as shown in FIG. 2. The control link is fastened pivotally between legs 38 and 40 of the support column by a member 70, which in the preferred embodiment comprises a pivot pin which passes through apertures in legs 66 and 68, is suitably widened at the outer edges of the support column legs 38 and 40, and around the central portion of which pin is wrapped the coil of the torsion spring 60. Two other pivotal members 72 and 74 receive the respective ends of the trigger rod 48 and the pull rod 20 and pivotally connect them to the control link. The member 72 is provided with a transverse smooth bore receiving the end of the trigger pull rod 48 in a slip fit. Member 48 is secured in place by means of an end cap screw and/or an allen head set screw. The pivot member 74 is provided with a smooth transverse bore to receive the end of the pull rod 20 in a "slip" fit. The pull rod 20 may be secured in said bore by means such as a set-screw provided in one end of the pivot member 74 located along its main axis. A similar type of connection member 80 is provided for the opposite end of the pull rod 20. In any event, in the preferred embodiment, the opposite ends of the member 74 effect a stop action against the edges of the legs 38 and 40 to establish the wide open position of the swing arm 22 as reflected by the spring 60 so that the control link member 18 normally bears against the support column under the action of the spring 60.
A member 82 suitably mounted on the support column 10 provides both mounting for the swing leg 22 and guidance for said leg during use so as to avoid significant lateral motion thereof. The member 82 in the preferred embodiment comprises a short channel-shaped member, the upper leg 84 of which has been curved around the pivot pin 24 in the swing leg 22, providing mounting of the swing leg in an offset relationship sufficiently far from bight 36 so as to allow the gripper jaw portions 34 and 42 to engage in the fully closed position. The member 82 is slightly less wide than the distance between the legs 30 and 32 of the swing leg, and the lower leg 66 of said member forms a finger-like projection which is straddled by flanges 30 and 32 of the swing leg 22 to provide a guide for limiting motion of said swing leg perpendicular to its intended plane of motion. The position of the finger guide 86 near the pivot 24 allows effective function of the guide throughout the swing of the swingleg 22 in spite of the limitation in length imposed on the guide 86 by the necessity of allowing complete closure of gripper jaw portions 34 and 42. The leading edge of the finger guide 86 may be suitably curved or faceted so as to provide smooth engagement of the swing leg 22 around the guide 86 as closing is initiated from a fully open position. | A lightweight grab stick incorporates a hand grip with trigger pull action. The support column and swing leg are of channel form and the trigger rod is connected to a control link member. The tips of the support column and swing leg are flattened to provide gripper jaws. The control link member is pivoted at triangularly spaced points respectively to the support column, the trigger rod and a pull rod which is connected to the swing leg. The control link and swing leg are on opposite sides of the support column and the pull rod protects through the support column. A guide prevents lateral motion of the swing leg. |
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to building construction methods, particularly to a method and unit that provides energy efficiency and structural soundness in buildings through a foam layer shell application.
Background Art
“Light framing” construction is a known construction mode using many small and generally closely spaced members that are assembled by nailing/screwing, and the mode includes balloon, platform and light-steel framing. Light framing building techniques are commonly used, especially in the USA, to erect residential, small commercial or light industrial structures. Light-frame construction using standardized dimensional lumber has become the prevailing light construction method in North America. Use of relatively minimal structural material allows builders to enclose a large area with minimal cost, while achieving a wide variety of architectural styles.
In light platform framing, each floor is framed separately, each floor level being framed as a separate unit or platform. Freed from the need to use heavy timbers (e.g., as with a post-and-beam system), platform framing offers ease of construction. Builders first fabricate a floor, which consists of wood joists and subflooring. The floor often serves as a working platform on which the stud wall frames are fabricated in sections and then lifted into place. A second floor, or the roof, is constructed atop the first-floor wall frame sections. The roof is formed of rafters (e.g., sloping joists) or wood trusses. The standard interior wall sheathing is gypsum board (drywall), which provides fire-resistance, stability, and a surface ready for interior finishing. Light framed structures traditionally have been constructed individually at each construction site; today many of the framing elements are mass-produced elsewhere and assembled on-site.
Modern light-frame structures typically obtain strength from rigid panels (plywood and/or other plywood-like composites such as oriented strand board (OSB) used to form all or part of wall sections). Until recent years, builders often employed any of several types of diagonal bracing techniques to stabilize framed walls. Diagonal bracing remains a vital interior part of many roof systems, and in-wall wind braces are required by building codes in many municipalities or by individual state laws in the USA. Special framed shear walls also are sometimes required to promote building structural strength, especially to foster compliance with earthquake engineering and wind engineering codes and standards.
Thus in commercial and residential construction, walls typically are framed up using vertical wooden or steel studs, to which an interior wall panel made of gypsum drywall (e.g., SHEETROCK® panel), fiberboard, traditional plaster, or the like is attached. Thereafter, exterior wall sheathing is used to enclose the wall and building and provide a surface for application of exterior finish materials, such as stucco, brick façade, shingles, aluminum or vinyl siding, etc. Insulating material, such as fiber glass, rock wool or cellulose, normally is sandwiched between the interior wall panel and exterior wall sheathing in order to thermally insulate the rooms and spaces of the building. Using this traditional method, there disadvantageously is little or no insulation present where the entire length of the vertical stud contacts the interior wall panel on one side, and exterior wall sheathing on the other side, providing a conduit for heat to readily escape the interior rooms, through the studs, to the outside environment.
The present invention solves this thermal insulation problem and also requires significantly less materials to achieve a highly energy efficient and structurally sound building. The presently disclosed method and system offers advantages of structural strength (potentially compliant with many building codes respecting wind and earthquake resistance) using fewer materials and less labor intensive methodology compared to fully conventional light framing construction. Less materials and ease of construction yields benefits of faster construction and reduced construction costs.
The present invention contemplates constructing a building using wall and ceiling panel assemblies that are made up of many traditional framing materials, but which are then coated with an insulating and strengthening foam. The foam layer initially is applied as viscous flowable foam, which may be sprayed in place. After controlled application, the foam layer then hardens into an enveloping shell which provides not only thermal insulation to the completed structure, but which also lends substantial structural strength. Moreover, because the foam shell substantially seals the interior of the structure against exterior weather, an exterior sheathing and an exterior façade are optional. A structure erected according to the present invention may be, if desired, substantially air tight and water tight (except where deliberately provided with doors, windows, vents, and the like). As the structure also is structurally sound and thermally insulated, the only reason to install an exterior sheath or additional roofing material is for aesthetic purposes.
While there are examples in the prior art of applied-foam insulating wall panels, none offer the advantages of the present invention.
SUMMARY OF THE INVENTION
The present invention is a unit and method of residential and commercial building construction. The construction unit is a structure comprised of closed cell polyurethane foam and portions of traditional light framing materials, such as studs, inner wallboard, roof trusses, and inner ceiling wall board. Standoffs are installed on a wall stud or roof truss that creates a gap between the stud/truss and the wall board which allows the foam to more completely coat the wall board. Once it is hardened, the wall board, standoff, stud/truss and foam become a structurally sound, highly insulated, building. The only purpose for the outside wall sheathing materials and roofing (e.g., shingles, tiles) are for aesthetic—not structural—reasons.
The building construction unit and method of the present invention includes arranging two or more (normally a substantial plurality) panel assembly units adjacent to each other to form the walls, ceilings and floors of a building. This erection and arranging of panel assemblies is performed mostly according to known light framing techniques, but once the light framing is realized, the interior panels (e.g., gypsum board are attached to the inside of the framed walls/roof. The framed walls and roofs need not be provided with conventional exterior coverings such as brick or siding. Insulation such as fiberglass batting or blown-in cellulose need not be sandwiched between interior panels and exterior sheathing. Rather, the framed structure, including the installed interior panels, is covered with insulating foam.
Each panel assembly preferably is made of a number of studs with standoffs spaced along one side of the stud and an interior panel. For instance, where a panel assembly is being used as a wall, a number of studs are installed in the upright position a certain distance apart (this distance being calculated to provide adequate structural support for the building), and the standoffs are attached the studs so that the standoffs are between the studs and an interior wall panel. This creates gaps or spaces between the studs and the wall panel where the standoffs are not located. When the insulating foam is applied, it will fill these spaces providing more insulation for the room that is defined by the panel assembly than would be provided by the traditional method of attaching the wall panel directly to the studs.
Not only does the insulating foam provide thermal insulation, it also provides structural support so that an exterior wall panel or sheathing is not required. In a traditional building, an external panel would be attached to the exterior side of the stud, or the opposite side from the standoffs. This exterior panel would cover the studs and foam so that they could not be seen from outside the building, providing additional structural support to the building. In the present invention however, these exterior walls are not required since this method of construction provides enough structural support. Therefore, the exterior walls of a building using this method could have the appearance of insulating foam and the protruding exterior sides of the wall studs. Because this may be unattractive, the user of this method may desire to cover the exterior of the building with some material, but that material would not need to provide any structural support. The material would be for aesthetics only, for instance, the material could be made of solar panels, fabric, wood planks, reflecting material, anything, or nothing.
A combination of the studs with standoffs attached can be pre-fabricated. Further, the stud/standoff combination can be used in conventional construction methods. While not providing the structural support offered by the preferred embodiment of the present invention, the stud/standoff combination can be used such that the exterior sheathing is attached to the studs rather than an interior wall panel. Insulating foam is then sprayed on the interior side of the exterior sheathing so that the foam covers the sheathing and fills the gaps created by the standoffs prior to the installment of the interior wall panel.
In the preferred embodiment of the invention, the insulating foam is a closed-cell spray polyurethane foam (SPF) and is sprayed on such that when hardened, the foam layer is between about 2.0 inches and about 5.0 inches thick, and more preferably approximately 2.5 inches thick on wall panels and approximately 4.0 inches thick on ceiling panels. Preferably, the SPF layer hardens to a medium density (preferably between approximately 1.5 lbs/ft 3 and approximately 4.0 lbs/ft 3 , most preferably approximately 2.0 lbs/ft), and is closed-cell to provide structural strength. The SPF layer is applied to the arranged panel assemblies as continuously as practically possible, and so provides continuous coverage at the junction between panel assemblies. When panel assemblies are used as walls, the studs preferably are of 2×4 or 2×6 wood or steel construction. When panel assemblies are used as ceilings, the ceiling joists or roof trusses are of conventional design. A panel assembly preferably is constructed such that the space or gap between the exterior face of a panel (e.g., gypsum board) and the interior side of the stud is, preferably, a minimum of one-half inch, i.e., the depth of a standoff is at least 0.5 inch—although this dimension may vary depending upon particular design requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several 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 selected embodiments of the invention, and are not to be construed as limiting the invention. Further, all dimensions or proportions seen in the drawings are exemplary and not limiting of the scope of the invention. In the drawings:
FIG. 1 is a perspective view of a portion of a building construction unit erected according to the present invention;
FIG. 2 is an enlarged cross-sectional side-view of a portion of a building construction unit according to the present invention, taken in the vicinity of a juncture of a first panel abutting adjacent to a portion of a second panel where any two panel assemblies adjoin one another;
FIG. 3 is a perspective view of the exterior side of a single stud with standoffs, according to the present invention;
FIG. 4 is a perspective view of the interior side of the stud with standoffs;
FIG. 5 is a perspective view of a plurality of studs according to the present invention, showing the standoffs on interior sides of the studs;
FIG. 6 is a perspective view of a plurality of studs, showing the exterior sides of the studs;
FIG. 7 is a perspective view of a representative panel assembly according to the present invention, the exterior face of a panel being visible, with standoffs defining spaces between the panel and the interior sides of the studs;
FIG. 8 is a perspective view of the representative panel assembly seen in FIG. 7 , after a layer of insulating foam has been applied to the exterior face of the panel and filling the spaces defined by the standoffs and between the interior sides of first studs and the exterior face of the panel;
FIG. 9 is a perspective view of a second stud in the form of, or included within, a roof truss;
FIG. 10 is a perspective view of the building construction unit according to the present invention, in which second studs are in the form of roof trusses;
FIG. 11 is a perspective view of a portion of a self-supporting building construction unit according to the present invention, in which a vertical third panel assembly is provided parallel to a vertical first panel assembly and with a second panel assembly disposed horizontally and perpendicularly between the first and third panel assemblies;
FIGS. 12A-D are perspective views of a construction unit as it appears at successive stages of erection according to the present invention;
FIG. 13 is an enlarged view of the construction unit seen in FIG. 12C , showing an arrangement of three panel assemblies in a possible juxtaposition according to the present invention;
FIG. 13A is an enlarged view of a portion of the construction unit depicted in FIG. 13 , the portion generally identified at “A” in FIG. 13 ;
FIG. 13B is an enlarged view of a portion of the construction unit depicted in FIG. 13 , the portion generally identified at “B” in FIG. 13 ; and
FIG. 13C is an enlarged view of a portion of the construction unit depicted in FIG. 13 , the portion generally identified at “C” in FIG. 13 .
Like label numerals are used to denote like or similar elements throughout the various views.
DESCRIPTION OF PREFERRED EMBODIMENTS
There is disclosed hereafter a method for erecting a structure, and a construction unit erected thereby. Initial steps of erection may be similar to known techniques, including for example the provision of foundation components such as reinforced poured concrete footings and/or stem walls. The method and structure of the inventive method also may be practiced upon conventional concrete masonry unit (CMU) substructures. Conventional subflooring may be installed generally according to known techniques, including the pouring of concrete slab-on-grade, and/or the installation of truss-supported subflooring upon supporting substructure. The present invention exploits and then improves upon basic processes borrowed from light framing construction.
As used herein, certain terms have the following definitions:
A “stud” is a metal or wood post used in the framework of a structure for supporting interior wall panels such as wallboard or similar material. A stud also provides structural support for a ceiling panel or roof top in the form of a ceiling joist, rafter, roof truss, or the like.
A “panel assembly” is a portion of the building construction unit, namely, a plurality of studs, and standoffs, and a panel attached to the studs, as shown generally in FIG. 7 .
Where the subscript “n” is used, “n” equals a positive integer and refers to the “nth” element of the apparatus and system that includes a plurality of such elements of indefinite number “n,” (e.g., “nth” wall panel assembly in a construction unit having a plurality of panel assemblies).
The disclosed method, and a construction unit according thereto, is intended to provide an airtight envelope that completely surrounds the habitable spaces within residential structures and/or temperature and environmentally controlled portions of commercial structures, including high rise buildings. The airtight characteristic of the envelope is subject mainly to deliberate apertures and openings in the envelope, such as doors, vents, stacks, windows, and the like, which may be disposed through/in the envelope.
Reference first is made to FIGS. 1, 4, and 7 , showing an example portion of a building construction unit 12 ( FIG. 1 ) and a simple panel assembly 42 ( FIG. 7 ) erected according to an embodiment of the present invention. There is provided a plurality of first studs 13 , 13 n which in a preferred embodiment are disposed substantially vertically. Each of such first studs has an interior side 14 , 14 n ( FIGS. 4, 7 ) and an exterior side 15 , 15 n (also shown in FIG. 7 ). The studs 13 , 13 n may be composed of metal or preferably wood, generally according to conventional light frame construction.
A plurality of first standoffs 16 , 16 n are attached (e.g., with adhesive or nails) to the interior side 14 of each first stud 13 . The first standoffs 16 may be composed of wood, plastic, or composite, but preferably constitute a generally rigid yet thermally insulating material. Each panel assembly according to this disclosure includes a panel, and panel assembly 42 features first panel 17 . The panels of panel assemblies, including the first panel 17 , have a first (e.g., upper) end 18 , and second (e.g., lower) end 19 , an interior face 20 (see FIGS. 1, 2 ) and an exterior face 21 . The exterior face 21 of the first panel 17 is attached to the first standoffs 16 to define spaces 22 between the exterior face 21 of the first panel 17 and the interior side 14 of the first studs 13 .
Combined reference is made to FIGS. 1 and 2 . For illustrative purposes in FIGS. 1 and 2 , the first panel assembly is shown in the vertical plane and the second panel assembly is shown in the horizontal plane, the first panel assembly being attached at a right angle to the second assembly. Despite this illustrative representation, any number of panel assemblies, connected or arranged at any of various angles (but most typically orthogonally), are contemplated and their arrangement in various constructive configurations is within the capability of a person skilled in the art.
FIG. 2 is a vertical cross section of portions of adjoining first (e.g. vertical) and second (e.g., horizontal) panel assemblies, in the vicinity where they come together, showing single first stud 13 and single second stud 53 . There thus also are provided a plurality of second studs 53 , the second studs 53 having an interior side 54 and an exterior side 55 . The second studs are similar in general configuration to first studs 13 , but may serve as beams/joists and thus more preferably and likely have larger moments of inertia, or are integrated as the bottom chord in a truss (see stud 53 n in FIG. 9 ). The second studs 53 thus may be disposed substantially horizontally and may be, or be a part of, a roof joist system. A plurality of second standoffs 56 are attached to the interior side 54 of each second stud 53 of the plurality of second studs, similarly as described and shown for the first studs 13 .
FIGS. 1 and 2 also illustrate that a second panel 57 (similar to panel 17 , such as a gypsum board) is arranged adjacent to the first panel 17 . The second panel 57 has a first end 58 , a second end 59 , an interior face 60 and an exterior face 61 . The exterior face 61 of the second panel 57 is attached to the second standoffs 56 to define spaces 62 between the exterior face 61 of the second panel 57 and the interior side 54 of the second studs 53 . A first end 58 of the second panel 57 preferably is in contact with a portion of an upper edge of the first panel 17 . A layer of insulating foam 30 is applied to cover the exterior face 61 of the second panel 57 and the exterior face 21 of the first panel 17 , filling the spaces 22 defined between the exterior face 21 of the first panel 17 and the interior side 14 side of the first studs 13 , also filling the spaces 62 defined between the exterior face 61 of the second panel 57 and the interior side 54 of the second studs 53 . The foam layer 30 thus contacts and adheres to both the exterior faces 21 , 61 , as well as to the interior sides 14 , 54 of the studs to constitute a shell-like layer incorporating the studs.
FIG. 2 offers an enlarged, cross-sectional, diagrammatic view of the connection of a first panel assembly (including first studs 13 , first standoffs 16 , first panel 17 , and first spaces 22 ), with a second panel assembly (including second studs 53 , second standoffs 56 , second panel 57 , and second spaces 62 ), with the layer of insulating foam 30 also shown. This corner connection is at the joist band area of a framed construction, where the ends of roof joists (e.g., second studs 53 ) rest atop the top plate (not shown for sake of simplicity of illustration) that typically runs horizontally along the top ends of vertical wall studs (e.g., first studs 13 ).
FIG. 3 illustrates that multiple standoffs 16 n preferably are attached to the interior side 14 of a representative single first stud 13 n , where n equals a positive integer and refers also to the nth element in a multiplicity of studs usable in a building construction unit according to this disclosure; description of a single stud serves substantially to describe a plurality of similar studs. The exterior side 15 is the side to which a first panel 17 is affixed. FIG. 4 shows the single first stud 13 n with standoffs 16 n attached the stud's interior side 14 . The standoffs may be composed of polymers, wood, high density expanded polystyrene, or a wood-polymer composite. Each first stud 13 n has a top end 68 that ordinarily connects to a top plate (not shown, but generally according to light framing convention), and a bottom end 69 that connects to a toe plate (not shown, but also generally according to convention). FIG. 5 illustrates that there is a plurality of the single first studs 13 n (with standoffs 16 n on the studs' interior sides 14 n ) while FIG. 6 is a view of the plurality of studs 13 n with standoffs 16 n extending from the studs' exterior sides 15 n . Each panel assembly (e.g. assembly 42 in FIG. 7 ) includes a plurality of spaced studs 13 n .
Specific reference is made to FIG. 7 , which depicts a representative panel assembly 42 according to the present disclosure. A plurality of panel assemblies are interconnected and juxtaposed as walls and roofs to erect a construction unit (e.g., unit 12 of FIG. 1 ) having two or more walls and a roof. Doors and windows can be defined as desired in any given panel assembly. Any particular panel assembly 42 preferably includes a panel 17 n , with the exterior face 21 of the panel attached to standoffs 16 , which standoffs are in turn attached to the interior sides 14 of a plurality of studs 13 n . Space 22 n is defined in one direction between adjacent standoffs, and (in a second direction) between the exterior face 21 of the panel 17 n and the interior side 14 n of the studs 13 n .
Attention is invited to FIG. 8 , showing the representative panel assembly 42 n seen in FIG. 7 , but after the application of a layer of insulating foam 30 to cover the exterior face 21 n of a panel 17 n and also to fill the spaces 22 n defined between the exterior face 21 n of the panel 17 n and the interior sides 14 n of the studs 13 n . The foam layer 30 preferably is polymer foam (e.g., an aromatic isocyanate) that is applied by spraying. The layer 30 preferably is sprayed into place (using known spray application systems) as viscous foam, but cures to a hard layer of medium density (e.g., approximately two pounds per cubic foot). FIG. 8 also indicates that the foam layer 30 contacts and adheres to the lateral sides of the studs 13 n , as well as to the interior sides of the studs. There accordingly is defined a structural shell that includes a structural integration of the studs 13 n with a panel 17 n , with the standoffs and spaces 22 n enhancing thermal insulation between the studs and panel without compromising structural integrity. The polymer foam preferably is applied so as to compile a layer that cures substantially integrally, preferably to define a layer 30 that is generally continuous over the exterior face 21 of a single panel assembly (but between the studs 13 n ), as well as wrapping around the junctures (near/along wall corner stanchions, and near/along wall top plates) between adjacently juxtaposed panel assemblies.
A person skilled in the art recognizes that the mutual orientation of the studs and panel can be substantially reversed, that is, to turn the arrangement “inside out” with the studs on the inside of the construction unit and the panel on the outside. In such an alternative embodiment, the interior face of a panel faces outward with respect to the interior of the construction unit, and the spaces are defined by the spacers between the panel and the studs, whose interior sides also face inward toward the enclosed space of the structure. Thus the representative panel assembly 42 n seen in FIG. 7 , is merely flipped, and the layer of insulating foam is applied to cover the exterior face 21 n of the panel 17 n (but now facing the opposite direction) also to fill the spaces 22 n defined between the exterior face 21 n of the panel 17 n and the interior sides 14 n of the studs 13 n .
FIG. 9 depicts a single second stud 53 n in the form of, or being a chord of, a roof truss, with multiple second standoffs 56 n attached to the interior side 54 n of the second or roof truss stud 53 n . FIG. 9 is best considered in combination with FIG. 10 , illustrating a building construction unit 12 according to this disclosure and as suggested by FIG. 1 . The construction unit 12 of FIG. 10 is shown covered with the foam layer 30 and having second studs 53 arranged the form of a roof truss.
Taking reference to FIG. 11 , it is seen that an example self-supporting building construction unit 32 according to this disclosure features a unit similar to the unit 12 of FIG. 1 . The construction unit 32 provides a third panel assembly disposed, for example, as a wall parallel to the first (wall) panel assembly and perpendicular to the second (roof) panel assembly. However, it is to be understood that a third panel assembly could be disposed or arranged orthogonally with respect to the first and second panel assemblies, i.e., to “close” the open end of the structure of FIG. 11 , with all three panel assemblies mutually perpendicular in three dimensions to define a 3-D corner. A foam layer 30 is in such a case applied to substantially integrate into a structural shell all three juxtaposed panel assemblies.
The third panel assembly includes a plurality of third studs 73 , each of the third studs 73 having an interior side and an exterior side, a plurality of third standoffs attached to the interior side of each third stud 73 , generally in accordance with those elements and features as described hereinabove for first plurality of studs 13 and second plurality of studs 53 , as well as the first and second panels 17 , 57 . Likewise, a third panel 77 is provided, the third panel 77 having a first upper end, a second lower end, an interior face 80 and an exterior face, the exterior face being attached to the third standoffs in a manner like unto that previous described above for the first and second panels. There also are side or lateral end edges to the third panel. Spaces are defined between the exterior face of the third panel 77 and the interior side of the third studs 73 . The first or upper end of the third panel 77 is adjacent to, preferably abuts, at least a portion of the second end 59 of the second panel 57 (see also FIG. 1 ).
And again, as seen in FIG. 11 a layer of insulating foam 30 is provided on the exterior face of the third panel 77 , the layer 30 substantially covering the exterior face of the third panel 77 , and filling the spaces defined between the exterior face of the third panel 77 and the interior sides of the third studs 83 . FIG. 11 thus depicts three of the representative panel assemblies 42 of FIG. 7 arranged as two parallel walls and a roof. There is a substantially continuous layer of insulating foam 30 , the layer 30 covering the exterior faces of all the panels, and filling the spaces defined between the exterior faces of the panels and the interior sides of all the studs, and bonding together the studs and panels.
It accordingly is understood that, although not depicted, according to the disclosed method two panel assemblies 42 may have their respective side ends placed together and with the planes of the panels disposed to define an angle (typically 90 degrees) between them, so to define two walls of a construction unit. The side ends of the panel assemblies may be connected structurally at a corner stanchion according to known principles of light framing. However, the respective side edges of the panels (e.g., a pair of panels 17 ) of the respective panel assemblies preferably are adjacent, preferably abutted together, to define a vertical juncture that can be covered with an applied foam layer 30 .
A construction unit 32 according to the present disclosure can be self-supporting, even with only the three panel assemblies depicted in FIG. 11 , due to the structural integrity and enhancement provided by the cured foam layer 30 —potentially even in the absence of diagonal bracing within the walls and at the corners of two walls, as commonly required in the art. The foam layer 30 adheres securely to all the panels and all or substantially all the studs and, when cured, with the studs and panels defines a generally integrated thermally insulating shell or envelope of the construction unit.
Still referring to FIG. 11 , it is noted that there is a first juncture 90 defining the corner (generally in the vicinity of the joist band) whereat the first panel 17 and the second panel 57 come substantially adjacently together or in actual abutment. Similarly, the construction unit 32 of FIG. 11 has a second juncture 91 (in the vicinity of the joist band) along a corner defined where the second panel assembly 57 and the third panel assembly 77 preferably abut adjacently together. Referring also to FIG. 2 , and as described further hereinafter, a construction unit 32 according to the present disclosure has the advantageous feature that the layer of insulating foam 30 is applied to wrap continuously over the outside of the junctures 90 , 91 , to cover that juncture and all other junctures similarly defined between other panels throughout a construction unit. The insulating layer 30 is applied substantially continuously between the first studs 13 , and between the second studs 53 , and between the third studs 73 as well as over the junctures 90 , 91 running perpendicular to the studs. As mentioned, the insulating foam 30 also is applied so to fill all the spaces (provided by the use of the standoffs, e.g., 16 , 56 ) defined between the exterior faces (e.g., 21 , 61 ) of the several panels (e.g., 17 , 57 , 77 ) and the interior sides (e.g., 14 , 54 ) of the studs 13 , 53 , 73 . When a plurality of panel assemblies are joined to erect a construction unit (typically to enclose a hollow interior habitation special volume), the application of the insulating foam layer 30 thereby constitutes a mostly continuous, unbroken (i.e., accounting yet for doors, windows, and other intended structural and functional openings) envelope which seals the interior of the structure from significant penetration by weather, including moisture and air.
It is readily understood by a person skilled in the art that fourth and fifth panel assemblies (substantially the same as those described) could be arranged with and against the first three panel assemblies seen in FIG. 11 , to close the open ends of the structure, and thereby to compose a five-sided construction unit enclosing an open hollow interior, the overall construction unit defining a generally parallelepiped shape. All the junctures (including, e.g., junctures 90 , 91 ) at the abutments of adjacent panels of adjoining panel assemblies preferably are covered with the layer of foam 30 . The layer 30 thus is essentially seamless where adjacent panel assemblies come together (i.e., at and along wall corner stanchions where to wall panel assemblies are connected, and along joist bands at the top plates where wall panel assemblies connect to a roof panel assembly.
FIGS. 12A through 12D serve to illustrate further a method of erecting a construction unit structure in accordance with the present disclosure. It is noted that some initial steps of the method are similar to erecting a structure according to known light framing construction techniques, such as conventional frame-on-slab construction. Known techniques may be adapted to accommodate the more specific disclosure of the inventive method as described herein.
There is installed a foundation generally according to convention, which may be footings with stem walls 40 (e.g. reinforced concrete) as shown in FIG. 12A . A concrete slab 41 or other floor is provided. FIG. 12A shows that first studs 13 are provided, the first studs each having an interior side and an exterior side ( FIGS. 3 and 4 ), and may be provided vertically to define partially a wall. The first studs 13 with other framing elements may, according to convention, define window/doors, as suggested in FIG. 12A . First standoffs ( FIGS. 5 and 6 ) are attached to the interior sides of the first studs 13 . Second studs 53 also are provided, the second studs likewise each having an interior side and an exterior side. In FIG. 12A the second studs 53 are disposed horizontally to define partially a roof, and optionally may be part of a roof trussing system ( FIGS. 9, 10 ). Second standoffs ( FIG. 9 ) are attached to the interior sides of the second studs 53 . FIG. 12A also shows that third studs 73 are provided, the third studs each having an interior side and an exterior side ( FIGS. 3 and 4 ); the third studs 73 may be provided vertically to define partially a wall. Third standoffs ( FIGS. 5 and 6 ) are attached to the interior sides of the third studs 13 .
FIG. 12B shows that a first panel 17 is provided, the first panel having a first end, a second end, an interior face and an exterior face. The second panel 57 also is provided, the second panel having a first end, a second end, an interior face and an exterior face. A first panel assembly thus is provided by connecting the exterior face of the first panel 17 to the first standoffs on the first studs 13 to define spaces between the exterior face of the first panel and the interior sides of the first studs 13 . The first panel assembly may define a vertical wall, and includes the first studs 13 , the first standoffs, and the first panel 17 . Similarly, a second panel assembly is provided by connecting the exterior face of the second panel 57 to the second standoffs to define spaces between the exterior face of the second panel 57 and the interior sides of the second studs 53 . The second panel assembly thus may define a horizontal roof, and includes the second studs 53 , the second standoffs, and the second panel 57 . A plurality of third studs 73 preferably was provided. A third panel 77 accordingly is provided, the third panel likewise having a first end, a second end, an interior face and an exterior face. As with the provision of the first and second panel assemblies, a third panel assembly thus is provided by connecting the exterior face of the third panel 77 to third standoffs attached on the third studs 73 to define spaces between the exterior face of the third panel 77 and the interior sides of the third studs 73 . The third panel assembly may define a vertical wall, and includes the third studs 73 , third standoffs, and the third panel 77 .
Reference to FIGS. 12B and 12C indicate generally the step of adjoining together the first two panel assemblies (i.e., panel assemblies 42 , 44 of FIG. 13 ), of what may eventually be a plurality of panel assemblies that are positioned with ends adjacent and adjoined together. A first panel assembly (for instance, wall panel assembly including studs 13 and panel 17 ) and second panel assembly (for instance roof panel assembly including studs 53 and panel 57 ) are adjoined end to end. The adjoining may be by generally conventional means, such as by nailing or framing anchors, with/to a corner stanchion (between two wall panel assemblies) or a top plate (to join a wall panel assembly to a roof panel assembly). The step of adjoining two panels assemblies preferably includes placing the first end of a first panel 17 adjacent to the first end of a second panel 57 to define a first juncture 90 , and applying continuously the layer of insulating foam 30 over the first juncture. Application of the foam layer 30 includes covering the exterior face of the first panel 17 and covering the exterior face of the second panel 57 , and filling the spaces defined between the exterior face of the first panel 17 and the interior sides of the first studs 13 , and filling the spaces defined between the exterior face of the second panel 57 and the interior sides of the second studs 53 , and with the same continuous application also wrapping the layer of insulating foam 30 over the first end of the first panel and over the first end of the second panel to cover the first juncture 90 .
By these steps a sealing envelope comprised of the foam layer 30 covers the first panel assembly and the second panel assembly. The method also preferably includes placing the first end of the third panel 77 adjacent to a second end of the second panel 57 to define a second juncture 91 , as also seen in FIG. 12C . Thereafter, the step of applying continuously the layer of insulating foam 30 preferably further comprises covering with the foam layer the exterior face of the third panel 77 , filling with the foam layer the spaces defined between the exterior face of the third panel 77 and the interior sides of the third studs 73 , and wrapping the layer of insulating foam over the first end of the third panel 77 and over a second end of the second panel 57 to cover the second juncture 91 . In this manner a sealing envelope or shell covers the first panel assembly, the second panel assembly, and the third panel assembly. This forgoing process can be successively or simultaneously repeated to juxtapose and join additional fourth, fifth, sixth or more panel assemblies (e.g. elements 42 n , 44 n , 46 of FIG. 13 ) to erect a construction unit of practically any desired layout or configuration.
FIG. 12D illustrates that any of a variety of suitable exterior sheathings 33 may optionally then be installed, e.g., to the exterior sides of the various studs, to aesthetically cover the structure and/or provide a surface for application of exterior finish materials, such as stucco, brick façade, shingles, aluminum or vinyl siding, etc. However, the installation of exterior sheathings in the inventive method and structure is optional, and primarily for aesthetics; the sealing envelope provided by the application of the continuous foam layer 30 in the process described provides for a sealing of the space within the structure against the weather, sound, vermin, etc.
The method of the present disclosure is further explained by reference to FIG. 13 , which is an enlarged view of the construction unit of FIG. 12C . A construction unit completed according to the basic steps of the inventive method includes a plurality of panel assemblies arranged and connected to comprise the construction unit; there are at a minimum a first panel assembly 42 , a second panel assembly 44 , and a third panel assembly 46 erected and configured as explained hereinabove, and as seen in FIG. 13 . Fourth and fifth panel assemblies are not depicted in FIG. 13 for the sake of simplicity, but may be provided to close the sides appearing to be open in the figure. The panel assemblies 42 , 44 , 46 are adjoined end-to-end and situated on the foundation 40 . The foam layer is visible in all three panel assemblies 42 , 44 , 46 on the exterior faces of the first panel 17 between the first studs 13 , and on the exterior face of the second panel 57 between the second studs 53 . Although not explicit in FIG. 13 , it is readily understood that the foam layer also coats the exterior face of the third panel 77 between the third studs 73 .
FIG. 13A is an enlarged vertical sectional view of a portion, designated generally at “A” in FIG. 13 , of a construction unit according to a substantially completed method of the present disclosure. FIG. 13A is similar to FIG. 2 , but offers additional detail regarding advantageous features of the method and system of the invention. The FIG. 13A configuration typifies the connections between wall panel assemblies (e.g., panel assemblies 42 , 46 of FIG. 13 ) and associated roof panel assemblies (e.g., panel assembly 44 of FIG. 13 ) throughout a construction unit according to the present disclosure. Perceived instead as a horizontal sectional view, FIG. 13A also suffices to illustrate generally the configuration at the connections between adjacent vertically oriented wall panel assemblies (i.e. at a wall corner stanchion where two wall panel assemblies 44 are adjoined) in this construction unit.
FIG. 13A shows a first stud 13 , with a couple of its first standoffs 16 attached to its interior side. The exterior face of the first panel 17 is attached to the first standoffs 16 to space the panel 17 apart from, but about parallel to, the first stud 13 . Spaces 22 are between the interior side of the first stud 13 and the exterior face of the first panel 17 . FIG. 13A also indicates a second stud 53 resting atop the top end of the first stud 13 (e.g., with top plate there between). The exterior face of the second panel 57 is attached to the second standoffs (not seen in FIG. 13A ) to space the second panel 57 apart from, but about parallel to, the second stud 53 . A space thus also is between the interior side of the second stud 53 and the exterior face of the second panel 57 .
The top edge of the first panel 17 is closely adjacent to and preferably abuts an edge of the second panel 57 at the first juncture 90 . The foam layer 30 is applied substantially continuously to the exterior faces of panels 17 , 57 , so to fill the spaces defined between the panels and the studs 13 , 53 . Significantly and as shown in FIGS. 13A and 13B , the foam layer 30 also wraps around the exterior side of the juncture 90 where the panels abut, thereby provided a seamless seal where the panels come together. So doing at all junctures between adjoining panels provides a sealing envelope which substantially encases the exterior faces of all the panel assemblies of the construction unit to supply benefits of the invention. FIG. 13B , for example, illustrates that the foam layer 30 is seamless and continuous as it covers both a vertical first panel and a horizontal second panel as it envelopes the junction of the panels. A third panel assembly adjoining the first two seen in FIG. 13B likewise is enveloped seamlessly and continuously by the same application of the foam layer 30 .
The foundation 40 seen in FIG. 13 is seen in the enlarged view of FIG. 13C . In an embodiment of the invention, the foundation includes a vertical stem wall 92 having an exterior face. In this alternative embodiment, the foam layer 30 is applied substantially continuously to coat and cover not only the exterior face of a first panel on the studs 13 , but also the top of a toe or sole plate 93 and the face 94 of the stem wall as well, thereby to seal and encapsulate the connection between the first panel assembly (e.g., panel assembly 42 ) and the foundation of the construction unit structure.
Whereas the figures and description have illustrated and described the concept and preferred embodiment of the present invention, it should be apparent to those skilled in the art that various changes may be made in the form of the invention without affecting the scope thereof. The detailed description above is not intended to limit the broad features or principles of the invention, or the scope of patent monopoly to be granted. Thus 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. | A building construction unit and a method of constructing a building using wall and ceiling panel assemblies that are made up of traditional framing materials, such as studs and interior walls, coated with insulating foam, except that the typical exterior sheathing is optional. Because the panel assembly is structurally sound and thermally insulated, the only reason to install an exterior sheath or additional roofing material is for aesthetic or practical purposes. |
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FIELD OF THE INVENTION
This invention generally pertains to methods and apparatus for the installation of cable in ducts and tubing, and particularly to the installation of such cable utilizing the injection of a fluid under pressure, and more particularly a method and apparatus for the installation of such cable utilizing the pressure of liquid foam under pressure.
BACKGROUND OF THE INVENTION
As used herein, the term "cable" means any manner of wire or cable, now known or later developed, including cable for the conduction of electromagnetic and/or optical energy such as, fiber optics, electrical conductive wire or other flexible material. The term "duct" means any enclosed canal, conduit, duct, tubing or other enclosed stricture that may be scaled and in which cable may typically be inserted or laid.
There exists a need for an economical and efficient process for installing cables of 3,000 feet or more in length in vertical ducts and in tubing previously installed in pipelines and well casings in gas, oil and geothermal fields. The cable typically provides means for monitoring the conditions at distant locations or in wells at significant depths below the surface. There are various methods that have been used to install cable in ducts. One such method is to cause a fluid such as water to flow through the duct, placing a drogue on the cable, then inserting the cable into the fluid flow such that such fluid flow will propel the cable through the duct by means of pressure against the drogue. Typically such methods are employed to insert the cable in horizontal duct where the cable will exit from a duct at a location downstream from the entry point. In situations where is desirable to insert the cable into a well casing installed in a gas, oil, or geothermal well, it is not uncommon for weights to be attached to the distal end of the cable in order to counter the pressure opposing the insertion. A problem with this method of insertion is that the larger the size of the cable, and the more weight is required in order to overcome the opposing pressure in the well, which weights can affect the structural integrity of the cable.
U.S. Pat. No. 5,156,376 describes a method of installing cable in pipelines, the cable having a syntactic foam pressure resistance sheath, inlet and outlet tubes in the pipeline, the cable having flexible cup members which provide viscous drag on the cable, and then extracting the cable from the downstream outlet. The foam surface of the cable is intended to provide a surface that would provide some dragging force with the flow of fluid, however, the major impetus for the cable in the pipeline being the viscous drag on the cup members by the fluid flowing in the pipeline.
Another example of the prior art for well casing applications is described in U.S. Pat. No. 5,503,370 wherein a cable is inserted into a reel coiled tubing by means of a capstan drive within a pressure housing. The tubing is then attached to other tubing being installed in a well casing, or fed down independently into the casing. The major drawback to this method is that insertion of the cable occurs on the surface, and the method does not demonstrate any advantages over the prior art in inserting cable in a duct or tube previously installed in a well casing wherein there exists a pressure within the well casing opposing the insertion of the cable.
None of the prior art or referenced patents disclose a method and apparatus for economically and efficiently inserting a flexible cable in a duct or tube wherein there is a pressure in the tube from opposing forces.
SUMMARY OF THE INVENTION
The present invention describes a method and apparatus for inserting a cable, in a duct, tube, or other hollow, elongated structure which can be sealed at the point of insertion of the cable to create a pressure housing. The invention comprises positioning a tube in the well, positioning a source of cable adjacent the well, and inserting the cable through a pressure housing into the tubing by means of a foam mixture under pressure. A mechanical force may be employed on the fiber optic to overcome any resistance at the pressure housing. The foam is in the form of a concentrate, which, when mixed with a liquid source and air, expands significantly when injected into the capillary tubing. Due to such expansion, the foam adheres to the surface of the cable, creating a viscous drag against the cable in the direction of pressure flow.
The invention may be better understood by reference to the drawings and the detailed description of the invention that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the apparatus of the invention.
FIG. 2 is a cut-away view of the insertion apparatus of the preferred embodiment.
FIG. 3 is a cut-away view of a second insertion means of the preferred embodiment.
DETAILED DESCRIPTION
For the purposes on the preferred embodiments, the invention will be discussed in terms of inserting a fiber optic strand, or fiber optic bundle, (hereinafter, for the purposes of the inventions both strand and bundle simply referred to as a "fiber optic"), in a capillary tube. The capillary tube may be on a cable reel, laid out on the surface, laid horizontally in a conduit, or the capillary tube may previously have been installed vertically in the casing of a wellbore. A cable foam injection system can be described by reference to FIG. 1, which depicts a fluid container 2 for containing the fluid that mixes with a foam agent prior to injection. Foam agent container 4 stores a selected amount of a foaming agent. High-pressure pump 6 withdraws both fluid and foam agent from their respective containers (2, 4) and provides the pressure to insert the fiber optic 12 in capillary tubing. High-pressure hose 8 carries the mixture of loam agent and fluid under pressure to injection head 10. Injection head 10 defuses the high-pressure mixture of fluid and foaming agent prior to injection of the fluid into the tube. Fiber optic 12 is pulled from its source 1 by means of a power drive 14, drive motor 20 and gear box 22. The power drive 14 impels the cable into lubricator 16, and thereby into pressure housing 18. Upon injection into injection head 10, the fluidized foam expands in volume, adhering to the surface of fiber optic 12. The pressure of injection is in the order of 20,000 psi. As fiber optic 12 is impelled into capillary tubing 24, sealingly attached to injection head 10 by pressure fitting 26, the pressurized foam mixture adheres to the surface of fiber optic 12 and pulls it along the length of lubricator 16 and into capillary tubing 24.
The invention is more particularly described by reference to FIG. 2, wherein a fiber optic 12 of 0.1 mil diameter is inserted through lubricator 16 into pressure housing 18 wherein it is directed around a variable speed capstan drive 28. Capstan drive 28 serves to remove opposing force against fiber optic 12, allowing the fiber to free-flow into injection head 10. Pressure housing 18 is threaded to receive 1/2 inch bulkhead bushing 30, which sealingly mates with a similarly threaded flange 32 in injection head 10. Injection head 10 is a 1/2 inch tee, cylindrical in shape, the interior of which defines a mixing chamber 34, extending the length of injection head 10. Injection head 10 provides a pathway for injection lubricator 31, constructed of 0.094 inch outside diameter stainless steel tubing, and fiber 12. Injection head 10 also provides a pathway for receipt of pressurized foam from pump 6. Bulkhead bushing 30 is formed to have pressure equalizing ports 36 to equalize pressure between chamber 34 and pressure housing 18, thereby facilitating the travel of fiber 12 along the length of lubricator 16 and through mixing chamber 34. Pressure tubing 38, constructed of a 1/4 inch stainless steel, transverses the length of injection head 10, sealingly mating with bulkhead bushing 30 and with high-pressure connector crossover 40, providing a pathway for injection lubricator 31 and fiber optic 12, and through which high-pressure connector crossover 40, the foam mixture will be injected into capillary tubing 24. Pressure tubing 38 has at least one access port 42 providing a pathway for the foam mixture from mixing chamber 34 into pressure tubing 38. Injection lubricator 31 extends through bulkhead bushing 30 and traverses the length of injector head 10, terminating at a point interior to capillary tubing 24, in to which tubing 24 fiber optic 12 is lo be inserted.
Capillary tubing 24 is fed through 1/4 inch high-pressure connector 26, which sealingly, threadedly mates to 1/4 by 1/2 inch high-pressure connector crossover 40. High-pressure collector crossover 40 threadedly mates to 1/2 inch injection bushing 44, which in turn threadedly mates to flange 46 of injection head 10.
A third orifice 48 in mixing chamber 34 is adapted with a pressure fitting 52 for receipt of high pressure hose 8 and provides a pathway for the foam agent/fluid mixture into mixing chamber 34. Pressure fitting 52 sealingly, threadedly mates with flange 54 in injection head 10. In this exemplary embodiment, a 10 horsepower pump 6, producing up to 10,000 psi is used to mix fluid and the foaming agent and to pump such mixture through hose 8 to the mixing chamber 34. Injection head 10 diffuses the foam mixture and the foam mixture is forced through access holes 42 into pressure tubing 38. The foam mixture is directed into capillary tubing 24 through which fiber optic 12 is being directed. The foam mixture expands around fiber optic 12, with the adhesive properties of the foam creating a positive drag force against the surface of fiber optic 12 and propelling fiber optic 12 through capillary tubing 24 to a selected depth, or to a selected distance into a duct. The high-pressure connectors used in this exemplary embodiment are of standard manufacture and use in the industry. In this instance Swedgelock connectors were employed, however, any equivalent high-pressure connectors could be equivalently be used.
In some installations where the pressure opposing insertion of a fiber optic is greater, it may be advantageous to use an injection leader to facilitate the injection of the fiber optic. The injection leader will ensure that there is enough foam in contact with the surface of the fiber optic to pull the fiber optic into the capillary, or along a duct. Referring to FIG. 3, the apparatus of FIG. 2 is similarly employed, except that instead of capillary tubing 24 feeding directly into high-pressure connector 26, injection leader 56 is sealingly fed into high-pressure connector 26. At its distal end, injection leader 56 sealingly mates with injection high-pressure coupler 58, which in turn sealingly mates with capillary tubing 24, thereby creating a pathway for fiber optic 12 and the injected liquid foam.
Injection leader 56 is selected to have a length l, which length l is selected based on the relative friction of the capillary tube into which the fiber optic is to be inserted. The more the friction in capillary tubing 24, the longer the length of injection leader 56, which may vary from 5 feet to over 200 feet. Length l may be calculated by those of ordinary skill in the art once the friction of the tube and the injection pressures are known.
In the preferred embodiment, a capstan drive is employed to impel fiber optic 12 if an insertion force is required to overcome the pressures from the lubricator opposing such insertion. Other means of impelling fiber optic 12 may similarly be employed, such as caterpillar drive, or rollers, and such other means known in the industry.
Differing cables have various surface coatings, requiring the appropriate selection of a foam that will adhere to a particular surface. The surface of fiber optic cables differ based on the environment to which the fiber optics is to be subjected. For example, fiber optics used in low temperature, low corrosion applications, in the region of 0° F. to 150° F. are typically coated with Acralate. Fiber optics for environments with temperatures in the range of 150° F. to 400° F. are coated with Teflon, and fiber optics for environments with temperatures in the range of 400° F. to 800° F.+ are coated with Polyamide.
Its has been determined that a fiber strand, when injected by the process of the invention, tends to remain in the center of the capillary based on the principle of center core flow due to the higher viscous drag of the foam against the interior surface of the capillary. This phenomenon suggests many benefits, not previously obvious, that may be achieved by selection the appropriate foam agent. One of such benefits is the capability of constructing a specialized, encapsulated cable on site. It is now possible, with the concepts of the invention, to select a particular duct, or tubing, and type of cable, fabricate the cable on site, and insert the cable in a wellbore by any conventional means. For instance, it may be desirable to fabricate an electrical conductor encapsulated within plastic tubing and insulated for the length of the tubing. By proper selection of a foam agent with properties of being a fast-setting electrical insulator, as well as adhering to the surface of the electrical conductor, the electrical conductor may be inserted on a reel on the surface and, upon setting of the liquid foam, installed in the wellbore. Concomitantly, the duct may already be in place, and the specialized liquid foam and cable inserted in the duct. Other benefits may include the selection of a foam agent such that the liquid foam provides protection for the cable against corrosive elements, or to provide structural support for the cable, thereby enabling the cable to bear a load without external support, etc.
The foaming agent of this exemplary embodiment was a 20% solution of a polymer commonly known as 7139Plus, manufactured by Malchem, however, any polymer based foaming agent having similar properties may equivalently be used. Such polymers are commonly available through numerous distributors well known as suppliers of chemical products. Concomitantly, it is possible to use polymers that have properties that additionally enhance the performance of cable insertion. For example, the cable may be coated with a polymer having the property of being anionical. By using a foaming agent having the property of being cationical, then the cable insertion is faster, and more efficient. The insertion may be controlled by proper selection of the charge characteristics of the polymers. The polymer for coating the cable may be selected with a charge of one polarity. A foaming agent may then be selected with a charge characteristic opposite to that of the coating polymer, which maximizes the efficiency of the cable insertion. She insertion of the cable may additionally be controlled by selecting polymers with differing molecular weight characteristics. | The present invention describes a method and apparatus for inserting a cable, in a duct, tube, or other hollow, elongated structure which can be sealed at the point of insertion of the cable to create a pressure housing. The invention comprises positioning a tube in the well, positioning a source of cable adjacent the well, and inserting the cable through a pressure housing into the tubing by means of polymer foam mixture under pressure. A mechanical force may be employed on the fiber optic to overcome any resistance created by the lubrication fitting at the pressure housing. The foam is in the form of a concentrate, which, when mixed with a liquid source and air, expands significantly when injected into the capillary. Due to such expansion, the foam adheres to the surface of the cable, creating a viscous drag against the cable in the direction of pressure flow. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to improved methods for completing wells formed in both consolidated and unconsolidated formations, and for completing deviated wells formed in consolidated formations which require stimulation by hydraulic fracturing. More particularly, the present invention relates to more efficient and less expensive methods for well completion in underground reservoir rock formations comprising novel techniques for the utilization of permeably consolidatable, resin coated packing materials.
2. Description of the Prior Art
Increased emphasis is being placed on proper initial well completion as the value of nonrenewable natural resources increases and the costs associated with their production escalate. While such emphasis is especially felt in the areas of hydrocarbon extraction, production of other valuable liquids, such as groundwater, also emphasizes the need for low cost, efficient production techniques. Maximum reliability and productivity of any production program is essential, particularly offshore and in remote locations.
The aforestated general objectives are difficult to obtain where the reservoir rock is unconsolidated or otherwise subject to failure, or where the reservoir requires stimulation to make production or injection economically attractive. Extraction from such formations usually require the utilization of techniques cumulatively referred to as "sand control". Alternatively, such extraction may require hydraulic fracturing, or the combination of the two. The sand control mechanism, however, is exceedingly complex and is influenced by every well operation from first bit penetration throughout the lifetime of production or injection of the well.
Sand problems are most common in younger Tertiary sediments, particularly of the Miocene epoch. Notable examples are extensive, troublesome sand production areas in such sediments in the U.S. Gulf Coast, the Los Angeles basin of California, Canadian tar sands, Indonesia, Nigeria, Trinidad and Venezuela. However, sand inflow also occurs in other formations (i.e., older tertiary) if existing in situ stresses are altered by drilling, completion and production operations such that the rock matrix is weakened, thus allowing movement of sand into the wellbore, casing and tubing.
Factors contributing to the onset and continuance of uncontrolled sand production are numerous. One common basis is alteration of the stresses on the reservoir rock. If the balance of forces on the reservoir rock are sufficiently unbalanced, destruction of the rock matrix generally will follow.
Sand flow from unconsolidated or failure prone consolidated formations is often controlled through chemical or mechanical means to prevent or correct various problems including premature failure of artificial lift equipment; production loss caused by sand bridging in casing, tubing, and/or flow lines; failure of casing or lines and formations damage near the wellbore due to removal of surrounding formation, compaction, and erosion; abrasion of downhole and surface equipment; and handling and disposal of production formation materials.
A variety of techniques have been developed in the art to address the above noted problems of sand flow. One such method involves the process of injecting chemicals into the naturally unconsolidated formation to provide in situ grain-to-grain cementation Techniques for accomplishing this successfully are perhaps some of the most sophisticated undertaken in completion work. In closely related methods, sand or other appropriate matrix particulates are treated chemically and then injected into the wellbore (or through the perforations if casing is set), and into the formation where the resulting "pack" consolidates. Production is then commenced through a slotted or perforated liner or casing which is run along the length of the production zone. This technique is commonly referred to as resin coated sand gravel packing, or alternatively, resin coated sand consolidation.
In the consolidated gravel packing art, a particulate, usually a round silica sand of appropriate size and density, is coated with a suitable oil or water based epoxy or plastic resin and placed in a suitable carrier to form a viscous slurry. Such a resinous particulate slurry is described, for example, in Copeland, et al., U.S. Pat. No. 4,074,760. This slurry is then injected into the formation through the work string and perforations in the casing to form an area of high mechanical strength and high flow conductivity immediately adjacent the production inlets in the casing. Alternatively, a resin coated particulat may be placed between a wire wrapped screen or slotted liner and the casing.
Standard techniques for the application of such viscous particulate slurries may be described as follows. Once a well is established in the reservoir zone, the wellbore may generally be completed by one of two methods, either cased hole completion or open hole completion.
The general sequence of performing a cased hole completion includes drilling the hole, setting and cementing casing in place, perforating the casing for production; cleaning the perforation of damage and debris by flowing back, washing the perforations using a perforation wash tool, surging or perforating underbalanced; and stimulating the formation to decrease the skin factor as needed to make the well economically attractive. If the formation requires sand control, this is an additional step which must be performed in addition to the above.
The typical cased hole completion sequence further contains some or all of the following elements. The borehole is drilled with mud as the well fluid leaves a region of impaired or damaged permeability adjacent to the borehole. Casing is next run and cemented in place using a Portland cement slurry. Use of such a cement slurry may cause further damage to the formation's native permeability adjacent to the wellbore. However, The Portland cement functions to mechanically support the casing and also to isolate individual permeable formation from each other. At this point, the drilling mud is exchanged with a clear, solids free, completion fluid to reduce the probability of severe damage to the formation permeability during the critical completion phases where the formation is not protected from incompatible fluid invasion by the protective filter cake of mud solids. The casing is next perforated, and a method of cleaning the crushed formation and perforating debris is used to clean and open the perforations. The perforation cleaning steps may consist of washing the perforations using a perforation wash tool, backsurging the perforations, or by underbalanced perforating. The latter method is now considered by most operators to be the most effective. Finally, the appropriate hardware can be positioned in the wellbore for either a RCS consolidation, a gravel pack, or a conventional completion without any sand control.
The general sequence of performing an open hole completion includes drilling a pilot hole through all formation down to the top of the deepest target formation; setting and cementing casing in place; drilling a pilot hole through the deepest target formation; opening the hole size of the formations to be completed using an underreamer to remove damage from prior operations; and stimulating the formation to decrease the skin factor, if needed, to make the well economical. Again, sand control measures are performed in addition to these steps.
The typical open hole completion further comprises the following elements. The final borehole through the interval to be completed is preferably drilled with a nondamaging drilling mud. Casing is then set above the productive interval. If the interval to be completed has not already been drilled though, a pilot hole is drilled through the interval or intervals to be completed. If the pilot hole is drilled with a damaging drill mud, then the hole must be underreamed through the completion internal to remove as much as possible of the damaged formation adjacent to the wellbore. This operation is normally performed with a underreamer rotated on a workstring of pipe, and using a non-damaging circulating fluid to carry cuttings to surface. Once the desired sections of formation are exposed, they may be isolated from each other using inflatable cement packers, or, alternatively, the isolated sections of hole may be cemented using formation packers and port collars. If sand control is required, normally a gravel slurry is placed between a slotted liner or wire wrapped screen and the exposed formation, again using ported collars and a combination tool. The combination tool functions to open and close the port collar and also isolates the port collar to direct the slurry placement. Once each exposed formation section is treated in this way, sand control is accomplished and the well is ready to produce.
The production rate possible from the above described completions techniques may be enhanced by stimulating the well. Well stimulation may consist of a chemical stimulation using some kind of acid or solvent solution to dissolve or remove material from the formation. Alternatively, the well may be stimulated by hydraulic fracturing. In hydraulic fracturing, a fracture is created in the reservoir rock by hydraulic forces and then propped open by a particulate material. This propped fracture provides a low resistance flow channel from deep within the formation to the wellbore.
The above described methods of well completion have a number of disadvantages. Present methods of completing unconsolidated or failure prone consolidated formations using the combination of a hydraulic fracturing method and some type of sand control have not yet addressed the problem of having both fracture entry control and the high perforation density needed for a high efficiency completion. If the fracture stimulation is performed with a limited number of perforations to achieve fracture propagation throughout the entire interval, then the well must be produced at low efficiency through the limited number of perforations. If the interval is re-perforated after the fracture stimulation, several problems arise. First, there is no guarantee that most or all of the second set of perforations will connect to the propped fracture. Therefore, the increased flow capacity of the fracture will be choked back at the wellbore since the fracture will connect to only some of the perforations.
Second, operations employed to clean the second set of perforations by flowthrough or surging may cause loss of proppant from the fracture, resulting in closure of the propped fracture at the critical wellbore juncture. Third, the high flow density at the interface between the fracture and the wellbore represents a potential problem area for both fines movement and plugging, as well as problems arising from deposition of organic deposits. The high flow velocity at the interface causes the fines to migrate and the large pressure drop at this point tends to precipitate out any paraffin or asphaltene deposits where they give the most restriction to production. A further problem with such high velocity fluid movement through the sands involve the possible erosion of the plastic bonds between the particulates. This problem of erosion is particularly acute for zones close to the wellbore and subject to multiphase flow.
Yet another disadvantage of conventional methods of completion utilizing contemporary techniques for sand control involve the time necessitated in securing the casing along the production zone and in isolating separate reservoirs, and further, in the numerous subsequent completion steps required to complete a number of narrow production intervals in such zone. In such cases, cement seals or formation packers must be introduced between each production interval. Then formation damage or debris must be removed from the interface between the virgin, undamaged formation and the wellbore to effect an efficient completion. Ordinarily, this removal must be accomplished prior to placement of sand control measures for each formation interval to be completed. This debris removal is generally accomplished via chemical means, mechanical means, or a combination of the two.
Underreaming is generally the preferred mechanical method for damage removal prior to placement of sand control measures in open hole completions Underreaming, however, is highly time consumptive since it entails the introduction of the underreaming tool via a work string, hence necessitating at least one "round trip" for each production interval. Furthermore, additional trips may be required if hole stability problems are encountered. Even when the production intervals are grouped in a single zone, such damage removal processes can involve extensive time expenditures. Such time expenditures are especially noteworthy in deeper wells or in deviated wells having a large net length. Additionally, underreaming procedures conducted in some unconsolidated formations might result in a complete collapse of the borehole, and hence abandonment of the well.
Further disadvantages of contemporary completion art involve the inconsistency in the character of the high conductivity region created by the resin coated particulate slurry. Contemporary completion techniques incorporating provisions for sand control describe the introduction of the resin particulate slurry into the wellbore in such a fashion as to cause laminar flow of the slurry in the annulus between the wellbore and the production casing. If the casing is situated off center in the wellbore, the laminar flow of the resin slurry often leaves unfilled voids immediately adjacent the casing which may often decrease production efficiency. Such problems are again particularly acute in deviated wells where undesirable "duning" occurs. Laminar flow of such sands into the annulus also allows time for the formation to dehydrate the resin slurry, also resulting in premature and often unsatisfactory set up of the consolidated formation adjacent the production casing.
SUMMARY OF THE INVENTION
The present invention addresses the aforementioned and other disadvantages by providing improved methods for completing wells in unconsolidated sand and limestone formations. The present invention also provides for the completion of deviated wells in consolidated formations which require stimulation by hydraulic fracturing.
In a preferred embodiment of the present invention, an open hole resin coated particulate pack is placed around the uncemented production casing across the projected production interval(s). The well is next hydraulically fractured with a resin coated sand proppant utilizing the limited entry perforating technique through the open hole resin coated sand consolidation. At this point a conductive channel or series of channels into the reservoir is realized with minimized restriction close to the wellbore region. In the next phase of the method, the casing is then perforated using a large hole diameter, shallow penetration depth, high shot density perforating gun. Finally, a gravel pack is performed inside the casing using a wire wrapped screen and a gravel packer.
Before production casing may be set in the wellbore, the wellbore must first be mechanically underreamed in order to remove the mudcake and also to enhance the diameter of the void around the casing. In such a fashion, the resin coated sand or particulate slurry is able to contact uncontaminated areas of the formation while establishing a larger cross sectional area of permeable consolidation. In another preferred embodiment of the invention, the wellbore is underreamed or scoured via an abrasive sand slurry which is injected down the casing or inner string and into turbulent contact with the formation. The turbulent action of the abrasive slurry simultaneously removes the mudcake from the walls of the wellbore while contouring the wellbore to a desired production diameter. This abrasive slurry may then be displaced in the wellbore by the introduction of a resin coated particulate slurry as above described which is introduced at a pressure so as to result in optimal flow characteristics, e.g. either transition flow or turbulent flow rates which do not impart sufficient stress on the walls of the borehole to cause formation sloughing or undesirable mixing of formation material with the RCP slurry. This second slurry then is allowed to set around the production casing or cement packer to form a consolidated zone of high conductivity.
The present invention has a number of advantages over the prior art. The proposed method of completion results in a high conductivity region surrounding the wellbore which acts like a channel between the fracture flow and the high density perforations while giving fracture propagation control during the hydraulic fracturing operation. As such, production efficiency is dramatically increased.
A second advantage of the present method is the ability to secure production casing along a potential pay zone without cementing, therefore avoiding undue contamination and formation damage along the production zone so as to necessitate time consuming opening, underreaming operations, or other rigorous methods of debris removal which risk formation damage.
Another advantage of the present invention is the ability to form an annulus of desired diameter without the need to resort to mechanical underreamers or openers. Such ability greatly reduces or eliminates the need to trip mechanical underreamers or the like in the hole. This advantage is particularly significant in deep wells, wells formed in highly unconsolidated formation, or in deviated wells which involve an abnormally long net production lengths.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A generally illustrates a side cutaway view of a well formed in an unconsolidated sand formation, in accordance with prior art methods of sand control.
FIG. 1B illustrates a side cutaway view of a mechanical underreaming tool as it may be used to enlarge the diameter of the wellbore through the production zone.
FIGS. 2A-J illustrate side cutaway views illustrating the process comprising the general embodiment of the present invention.
FIGS. 3A-C illustrate a side cutaway view illustrating the method by which the wellbore may be contoured by use of turbulent particulate injection.
FIG. 4 illustrates a top cross sectional view of the high productivity region surrounding the wellbore produced as a result of the claimed method.
FIGS. 5A-D illustrate a top cross sectional view of casing unsymetrically situated in the wellbore.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 generally illustrates a side, cross sectional view of a well completed in an unconsolidated formation in accordance with prior art techniques of well completion utilizing either a consolidatable resin coated packing material or a gravel pack. As seen in FIG. 1C of 1F, an open hole has been formed in a production zone 10, such as a younger tertiary sand lens, extending between two nonproducing intervals 14. Prepatory to setting casing through this zone 10, the wellbore has been "opened" or "underreamed" with a tool 20 similar to that illustrated in FIG. 1B.
Hole opening devices 20 such as that illustrated in FIG. 1B, feature cutting arms which may be expanded by hydraulic pressure after the tool 20 is first run through casing in order to enlarge the open hole beneath the shoe 19. Hole openers or underreamers 20 are used to enlarge the hole to allow for increased gravel thickness around slotted or screen type liners. Such underreaming operations are also necessary to remove the mudcake from the wall of the wellbore and form the adjacent damaged region.
Referring to FIG[S.] 1B[-C], . . . when the wellbore has thus been contoured or underreamed to a desired diameter as above described, a gravel pack, normally consisting of a particulate slurry (RCP) or a resin coated particulate slurry, is injected in the widened annular space 15 formed by the underreamer 20 between the walls of the wellbore 17 and the casing 2. Generally, this viscous slurry is injected into the annular space by pumping from the workstring through a crossover tool into the annular space between the slotted or screen liner, until the annulus is filled with the particulate, whereupon the well is essentially complete except for installation of tubing and wellhead.
Another open hole type completion utilizing a resin coated particulate slurry is the patented process known as the Puddle Pack This type of completion is performed on a well having an open hole interval such as that created by shooting the well with nitroglycerine. The Puddle Pack process entails filling the open hole space with a RCP slurry. When the resin has set a borehole is drilled through the consolidated pack, casing is run and cemented in place across the zone 4. A perforating tool (not shown) is then introduced in the well, forming perforations 16 through the casing 2 and cement 4 into the high conductivity region 12 formed by the resin coated Puddle Pack, whereupon the well may then be produced.
The method of the present invention generally facilitates the above-mentioned prior art technique while enhancing the productivity of a given formation. The method of the present invention further results in the realization of substantial economic benefits in deeper wells, as well as in deviated wells.
The general method of the present invention can generally be seen by reference to FIGS. 2 and 3 consisting of FIGS. 2A-J and 3A-3, respectively. FIG. 2 illustrates a bore 46 formed in a producing formation 40 situated vertically adjacent a nonproducing horizon 44 such as a shale or nonpermeable sand. In FIG. 2A, intermediate casing 42 has been set above the zone of interest 40 to the extent of this nonproducing zone 44. In accordance with prior art techniques, the bore 46 is then recontoured or underreamed (FIG. 2B) to remove the mudcake formed along the walls of the wellbore and to establish an annulus 48 of sufficient size to sustain the gravel pack. This recontouring or opening may be accomplished via an underreaming tool as illustrated in FIG. 1B. Alternatively, this underreaming may be accomplished via the introduction of an abrasive sand slurry as will be further discussed herein.
Referring to FIGS. 2C-2D, once the wellbore has been contoured to a desired dimension and the mudcake removed, production casing 50 is then set in the enlarged bore 46. Once the casing is in place, an inner workstring 56 is preferably set in place. (See FIG. 2C & 2D). The well is now prepared to receive the resin coated particulate slurry (RCP). In wells where undesired migration of formation sands is expected, a slotted liner or wire wrapper screen (not shown) may be used and a gravel pack performed between the screen and the casing later in the completion sequence.
Referring to FIGS. 2E-F, the placement of the resin coated packing material is accomplished by pumping the resin coated slurry 60 down through the workstring 56. The workstring 56 is preferably sealed into a casing shoe 54 or a float shoe if the zone to receive the packing material exists at the point of the casing seat. Otherwise, the workstring 56 is sealed to or isolated with a port or multistage cementing tool (not shown) placed at an appropriate depth in the casing string. The resin coated slurry is then pumped down the workstring 56 through the casing shoe 54 or port in the casing string (not shown) and up across the zone of interest 10. Preferably, the resultant high conductivity region 60 is equally consolidated around the production casing 50 so as to ensure even production flow.
Once the resin coated slurry injected in the annulus has consolidated around the production casing to form a high conducting region 60, the casing is then perforated (FIG. 2G). Such perforation may be accomplished via a deep penetrating bullet perforation or jet charge type technique. Once perforated at the desired interval spacing, the formation is then fractured. In a preferred embodiment, formation fracturing is induced by injecting a suitable proppant, such as additional amounts of the resin coated slurry, into the perforations 62 (See 2H).
Once fractured, the formation is then re-perforated (FIG. 2I). In preferred embodiments, a large bore, high shot density, shallow penetration, tubing conveyed perforation device is utilized to achieve this reperforation. Since a highly permeable sheath of resin coated particulates surrounds the casing, the optimal charge design is a maximum bore charge which will penetrate only the casing. Where extensive migration of formation sands through the gravel pack is expected, a slotted or perforated screen 80 may then be introduced inside the production casing.
The consolidatable, resin coated packing material, e.g. Hydrocon-E, is important to provide a high permeability interface region or "gravel pack" to connect the wellbore to the fracture. Utilized in accordance with the present invention, such "gravel pack" generally provides the following advantages:
1. Structural support for the casing;
2. Consolidated media to support the deep penetrating limited entry charges used for fracturing;
3. Creates a high permeability channel between the proposed fracture and the high density, large hole, shallow penetration (OHDLHSP) perforations in the casing which are necessary to minimize drawdown and restriction to flow through a gravel pack. The resin coated packing material provides the connection to allow flow from the fracture to access all the casing perforations;
4. Expands the effective wellbore radius to enhance and reduce the velocity of fluid flow through the formation pores near the wellbore. The reduced flow velocity will reduce the tendency of fine particles of formation material to migrate in the formation pores and cause plugging of the pores. This facilitates the completion to maintain high productivity with less chance of premature flow impairment due to fines migration;
5. Eliminates needs for cement across the production zone, thus eliminating cement filtrate damage.
In one preferred embodiment of the invention, a ported section of casing covered by a wire wrapped screen is introduced above the zone of interest so as to facilitate circulation of slurry across a given production interval, and to give more complete coverage and packing of the resin coated sand. An upper ported section or multistage cementing tool may be added in combination with formation packers so as to allow the completion of multiple zones utilizing the proposed method. In such an embodiment, the use of multistage cementing tools and formation packers, such as a Lynes ECP open hole gravel pack system, allows isolation of multiple high consolidation zones by placement of cemented sections between the production zones.
The resin coated sand or particulate slurry (RCP) is preferably introduced through the workstring or casing at a rate and pressure so as to result in sub-erosive flow of the slurry into the annulus around the casing. Sub-erosive flow, or a flow rate greater than laminar flow but less than the flow rate sufficient to cause shear and erosion of the borehole well to precipitate formation sloughing or mixing of formation material with the consolidatible slurry, enhances the consolidation of the resin coated packing material by filling in voids created during premature "setting"of the sand pack, or as created by off center placement of the casing in the wellbore.
Such off centered conditions are particularly severe in deviated holes. FIGS. 5A-D generally exemplify how a casing symmetrically aligned and seated in the wellbore 210 may begin to experience lateral displacement along its length to a point where it contacts or is near contact with the wall 212 of the wellbore. Referring to FIGS. 5A-B, a casing 200 is initially centered in the wellbore at the shoe (not shown), but at only 48" above the shoe the casing already demonstrates substantial off-center deflection from the wellbore axis. This deflection increases at 72" (5C) and at 120" (5D) above the shoe. Hence, at only ten feet above the casing shoe the centered casing 200 already contacts or nearly contacts the wellbore wall 212. When such deflection exists, resin coated sand slurry introduced into the annulus 208 under laminar flow leaves voids 204 at these areas where the casing 200 is off-center with respect to the wellbore. When the casing is perforated and production commences through the high permeability region 208, these voids 204 dramatically inhibit favorable production by allowing low conductivity formation sand 212 to fill casing perforations.
These problems may be addressed by injecting the slurry at a transition or sub-erosive fluid flow, i.e., greater than laminar flow, since the agitated slurry will be forced into voids 204 created in the annulus 208. In comparison, injection of the slurry as to result in greater than transition flow or turbulent flow is not desired since such turbulent flow might cause undesired sloughing or deterioration of the wellbore wall. Such deterioration in turn would introduce low permeability formation sands into the resulting matrix adjacent the production casing, hence detrimentally affecting production.
Prior to setting production casing through the production zone, the wellbore must often be "underreamed" or "opened" to remove mudcake from the walls of the wellbore. When sand control is implemented, the wellbore will also often have to be underreamed to an additional diameter so as to support the packing material. Such underreaming or opening procedures, while vital to efficient production from the zone, involves the use of mechanical tools which must be run or "tripped" into the hole. Such tripping necessitates the utilization of a derrick rig and involves a time consumptive and hence expensive process. Such is particularly true if a plurality of individual producing horizons must be addressed, each involving an individual underreaming operation. One embodiment of the present invention substantially eliminates the need for this time-consuming procedure. In accordance with the method of the present invention, casing is run across the target zone in the original borehole and hole opening, and damage removal is accomplished immediately prior to setting the casing via placement of the RCP.
FIGS. 3A-C illustrate yet another preferred embodiment of the invention which addresses the above noted disadvantages of well completion. FIGS. 3A-C generally illustrate a bore 82 formed through a nonproducing zone 44 into an adjacent producing horizon 40. In these figures, intermediate casing 42 has been set in the nonproductive zone 44 and cemented in place. From this intermediate casing 42 has been hung production casing or liner 80. This casing 80 is run into the bore 82 which has not been underreamed or opened. Once the casing 80 is fully run on the bore 82, an abrasive slurry 90 is pumped down into the casing at a pressure so as to induce turbulent flow of the abrasive slurry 90 down the bottom of the casing 80 and up between said casing 80 and the wellbore 82. This abrasive slurry 90 strips the mudcake from the wellbore wall while simultaneously recontouring the wellbore 82 to a diameter sufficient to accept the resin coated packing material as will be later described.
Once a sufficient area has been formed in the production zone 40 adjacent the casing 80 such that damage from drilling is substantially eliminated and the bore diameter is sufficiently large to allow laminate flow at the projected producing rate, a resin coated packing (RCP) material 100 is then injected down into the casing 80 into the resulting annulus 94. This packing material 100 displaces the abrasive slurry 90 which is then retrieved along with formation debris at the surface. Preferably, the resin coated packing material is injected at a pressure so as to induce sub-erosive flow in the slurry 100. As such, a maximum flow rate is achieved in this material so as to give sufficient displacement of debris by the RCP slurry 100 while not inducing additional abrasion of the wellbore wall 83.
While it is envisioned that a separate abrasive slurry e.g. walnut hulls or blasting sand, and a packing material may be used in accordance with the above-described embodiment, some occasions may suggest the use of a single slurry compound, e.g., a resin coated sand, which accomplishes the above described result by use of varying injection pressures. Hence, it is envisioned that it may be possible to first inject the resin coated packing compound at a pressure so as to induce turbulent flow. Once the wellbore is appropriately contoured, the pump pressure would then be reduced to allow for the injection of the resin coated packing material under non-turbulent conditions, preferably sub-erosive flow.
The foregoing descriptions of selected embodiments of the invention shall be construed as illustrative only, and not as a limitation upon the scope of the invention as defined in the claims. | An improved method for completing wells formed in both consolidated and unconsolidated formations is disclosed. Further, methods are disclosed for completing deviated wells formed in consolidated formations which require stimulation by hydraulic fracturing. The present invention specifically relates to more efficient, less expensive techniques for well completion comprising novel techniques for the utilization of permeably consolidatably, resin coated particulates. |
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CROSSED-REFERENCED TO RELATED APPLICATIONS
[0001] None
FEDERALLY SPONSORED RESEARCH
[0002] None
SEQUENCE LISTING
[0003] None
BACKGROUND
[0004] The section of occupational safety and health administrations and mining safety and health administrations rules/guidelines governing the ascending and descending of ladders is often times overlooked or disregarded in many industries such as mining and construction. I believe this could be changed if a solution were to be discovered to make this everyday task safer. Unnecessary risk can be eliminated by securing workers to a rope that goes up the center of the ladder.
[0005] While in a safety meeting our attention was drawn to an incident where a worker took a fatal fall from a ladder. The worker was climbing up the ladder to secure it when it slipped and he fell over 40 feet to his death. As my primary job as an electrician the tasks at hand requires frequent portable extension ladder use. This tragedy inspired me to create a solution to help prevent such incidents. I grabbed a rope and a ladder and started to experiment. First, I had to determine a way to secure the rope up the ladder while maintaining the ability to adjust the ladder. My first idea was to secure roller to the bottom of the top rung in which the rope would go up through then back to the base of the ladder. That design was going to put almost all the weight of the user onto the center of the top rung, which could break during a fall, sending the climber to the ground. Therefore, I thought to modify by evenly distributing the weight across the top rung of the ladder, mimicking human feet in which the ladder was designed to withstand. I drew up, traced out, modified and constructed a wooden prototype of this top rung bracket FIG. 4 .
[0006] My first prototype of the top bracket was constructed out of three wooden 2×6's and had a hole drilled through the center of the boards in a curved direction so that the rope could guide through the wood and across the top rung easily. This wooden device was secured by screws through the side of the ladder to hold it securely on the top ladder rung. During testing I realized that while my original design worked well, it was not practical because it increased weight of the ladder, and therefore difficult to stand up. Extending the ladder was easy with the rope remaining through the top rope guide.
[0007] Based on the first prototype, the rope guide needed lightened. 1 decided aluminum best satisfy the weight and strength requirements to meet this goal. Also to create a long lasting guide for the rope, I thought up hardened plastic. After drawing up an aluminum bracket on paper I measured actual ladder rungs and traced the drawing onto cardboard. I used cardboard to make wooden templates. After having a wooden base I cut out a block out of sheets of plastic and cut a half moon shape out of the center plastic sheet for the center of the rope guide and screwed all the sheets together. I installed the plastic top guide block onto the wooden base template and had a built unit to test. I immediately installed it on the ladder and removed the 2×6 test piece. I very quickly noticed that it was much lighter than the other design as I set it up to test the newly built model. After performing the same test's I did on the first test 2×6's design I knew the new design was a success. Next I had to come up with a safe way to secure myself to the rope.
[0008] Starting with a device that “Petzl” manufacturer's called a Gri Gri a device designed for rope climbing. This device was capable of ascending the ladders rope safety easily by placing the device on the rope at the bottom of the ladder then the user could climb safety to the top of the ladder. The device would catch every time I would slip. After tying off the top of the ladder I then tested the device by jumping off, slipping down, sitting down, reaching out, and slipping off the side of the ladder and the device caught me every time. Then to work off of the unit I could rely on the rope to hold me and I could safely reach out resting on the rope to hold me and I could work comfortably. However, when I wanted to go down I had to remove that device and climb down unsafely. To eliminate this unsafe act I found a device that would go up and down. The Fuji Denko was the device that said it could do just that, up and down the rope without removing it from the rope. Finding a device that worked well with my set up was a relief and using it or any device like it would be the way to go.
SUMMARY
[0009] The use of the portable ladder safety guide (A, B&C), rope anchor point (F), ⅝″ rope (D), full body harness (J) and a rope grab (K) would enable an individual to safely climb a portable ladder without ever having to remove their fall protection. This solution system is a tremendous and necessary advantage in an industry where portable ladders are part of everyday jobs.
Objective of the Invention
[0010] The Portable Ladder Solution System is a system designed to be used as a 100% tied off solution for portable ladders. This system is the solution to eliminate falls from ladders from everything between the ascents to tie the ladder off through the descent to the ground. This system will be capable of being fitted to all extension ladders and step ladders that are tall enough to utilize a safety. The system will work with a device that is capable of ascending and descending a portable ladder on a guide rope, without ever having to undo or redo the user's fall protection device. In addition, this solution system is also capable of being used as a working safety once the ladder is secured with side to side fall risks eliminated by tying the ladder off with whatever means necessary to prevent it from falling. This system is designed to fit portable ladders and does not affect the integrity of the ladder.
[0011] The Portable Ladder Solution System will consist of one or more devices that attach to the ladder, and will be capable of removal and replacement as necessary. The system will utilize a full body harness with waist and chest attachment capabilities. There will be a rope guide at the top of the ladder ( FIGS. 1 & 2 ) and an anchor point at the bottom of the ladder ( FIG. 6 ). ⅝″ static rope (D) or ⅝″ dynamic rope (D) then runs from the bottom anchor point (F) through the top rope guide (C) and reconnected to the bottom anchor point (F) by means of a rope ascender/anchor (E) that is fixed to the rope anchor point ( FIG. 3 ). The use of a rope grab (K) device like the Fuji Denko or similar device will be used with the system attached to a full body harness on all users.
[0012] Advantages of the Rope Ladder Solution:
[0013] 1. Will save lives.
[0014] 2. Easy to use.
[0015] 3. Compatible with ladders that are already being used every day.
[0016] 4. Lightweight to eliminate burden on users.
[0017] 5. User Friendly to maintain efficiency.
[0018] 6. Will not impact integrity of ladders or compromise efficiency of ladder use.
REFERENCES
[0000]
1. U.S. Pat. No. 5,323,873; Incorporates the rope grab device similar to what would be used in the portable ladder solution system. This patent is not used as a ladder climbing solution, but mainly as a secondary safety device while using rope ascending gear to climb another rope. Also, this device was said to be used as rooftop safety line where it could slide back and forth allowing the user of this device to move around the edge of a roof freely and safely secured to a lifeline. I am not trying to patent this device but merely use a similar device covered here with my invention to achieve the fall protection requirements.
2. U.S. Pat. No. 8,353,387 Vollenweider patent date Jan. 15, 2013: Uses a metal track like device to slow the descent rate in the event of a fall. The invention does not mention the use on a portable ladder but does mention usage on a ladder and scaffoldings. However, I am not planning on using a similar track like system due to the fact that this system is heavy and not feasible for a light weight portable ladder that is continuously being lifted and adjusted.
3. U.S. Pat. No. 7,014,594 Stoltz, Mar. 21, 2006: In this invention the claims are for use of rope and a one direction ascender unlike my proposed ascending and descending device called a rope grab. Stoltz's invention was designed for a trapeze set-up with use of a singled ascending rope that was secured to a trapeze tower. This patent does not mention a portable ladder or descending the same device or ladder.
4. U.S. Pat. No. 8,251,179 Anderson, et al. Aug. 28, 2012. This invention is called a portable safety ladder assembly but is not a close resemblance to the invention I am proposing due to the absence of ropes or safety harnesses. Anderson's portable safety ladder assembly is used on a railing on a portable ladder which allows the user better grips on a ladder especially in times of transferring to scaffolding or other platform.
[0023] Similar climbing techniques out there exist for fixed/permanently mounted ladders. One technique involves the steel cable being secured at both the top and bottom of the permanently fixed ladder. Once cable is secured the user can hook to the cable with a metal cable specific grab device and ascend and descend the ladder. In the event of a fall the device will catch the user. This is the same concept I am suggesting with several modifications and manufactured parts to effectively use it on a portable ladder.
[0024] Another technique is a rope grab setup that is used to ascend ropes without the use of a portable ladder. In this set up, the user is hanging from the rope and using rope ascender's to go up the rope and rappelling devices to go down the rope. Rope ascending can be very technical and requires very advanced climbing techniques that would not be favorable or cost effective to the industry. I am not suggesting the same practice be used in my portable ladder solution system.
DESCRIPTIONS OF THE DRAWINGS
[0025] FIG. 1 is a drawing which includes a view of the top portion of the portable extension ladder with the rope safety guide (A, B, &C) shown on the ladders top rung (M) giving the front view.
[0026] FIG. 2 is an exploded isometric view of the rope safety guide (A, B, &C) block drawn in detail.
[0027] FIG. 3 is the proposed system, drawn with both the top portion of the ladder and the bottom portion of the system (F, G, I, &E) on the ladder rungs with the rope (D) shown as well.
[0028] FIG. 4 is a close up side view of the ladder rung clamp (A&B).
[0029] FIG. 5 is a close up side view of the rope guide block (C) showing the rope guide channel.
[0030] FIG. 6 is an isometric view of the rope anchor point (F).
[0031] FIG. 7 is a drawing of a portable ladder rung protector (H).
[0032] FIG. 8 is an assembled isometric drawing of the rope safety guide (A, B, &C)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The main embodiment in FIG. 1 is the portable ladder rope safety guide (A, B, &C) shown on the top rung of the ladder (L). In this illustration the ladder rope safety guide block is drawn as I have tested it to the length of 8 inches. This length has worked well in the testing process and proves to be substantial in strength. In the center of the top guide block (C) there is a hole to show the rope tunnel where the rope goes through the top guide block (C). More details on the tunnel in the top guide block (C) are shown in FIG. 2 . Also included in the figure in the top left hand corner is a brief side view for a quick and easy reference to what is being shown in the middle of the page, but as a side view and disassembled from the top guide block (C). This view includes the top clamp (A) and the bottom clamp (B) in which the shaded spot between the top (A) and bottom clamp (B) represents the ladder rung (L) side view.
[0034] In the top right hand corner is a brief side view of the top guide block (C) shown as a quick reference. The dotted lines shown on this device demonstrate that there is a drilled tunnel in an arch form in the center of the block. This tunnel is where the rope will run through and is basically a hole bored through the proposed hardened plastic top guide block (C).
[0035] FIG. 2 is an exploded isometric drawing of the proposed rope safety guide block (A, B, &C). The rope safety guide block that I am proposing is constructed of both aluminum and plastic, but is not limited to those materials. The device could possibly be made lighter and smoother with other materials, but in order to remain cost efficient I am implementing aluminum top (A) and bottom clamps (B). The aluminum clamps (A&B) are strong enough to handle a person's weight and are constructed from the same material as the ladder rungs (M), which will help prevent rust or corrosion after long term use on aluminum ladder rungs. In the bottom clamps there are circles where I'm implementing drilled holes (O) approximately ¼″ in diameter for the use of a bolt through the bottom clamps (B). In both the right side and the left side of the bottom clamps there could be a total of 2 to 4 holes (O) in each clamp up to two holes (O) on the front side of each bottom clamps and up to two drilled holes (O) on the back side of each bottom clamps (B). There are a total of two bottom clamps (B), a right side and a left side. The bottom clamps (B) are fitted to the ladder rung (M) to prevent it from rolling, which can better be seen in the side view in the top left corner of FIG. 1 .
[0036] Both the top clamp (A) and the bottom clamp (B) I am implementing in the drawing are made of aluminum. There is one solid piece of aluminum for the top clamp (A) which could be 8 inches in length as is the length I tested. The top clamp (A) is form fitted to the ladder rung (M) to prevent it from rolling and can better be seen in the side view of FIG. 1 . Inside to the top clamp (A) there will be threaded holes (N) which are drawn by holes (N) with parallel lines drawn inside them. I am implementing up to four threaded holes (N) in the left and an additional four holes in the right side of the top clamp (A) accessible from the bottom. The intent of the bottom accessible threaded holes (N) is to be able to secure the bottom clamp (B) to the top clamp (A) with the use of bolts (P). A series of bolts (P) would come up through the drilled holes (N) in the bottom clamps (B) and into the threaded holes in the top clamps (A). Once the top clamp (A) is bolted to the bottom clamp (B) around the top ladder rung (M) the clamps will then be secured to the ladder rung (M). The threaded holes (N) that are accessible from the top of the top clamp (A) are for the use of securing the top guide block (C) onto the top clamp (A). Once the top clamp (A) is bolted to the bottom clamps (B) around the top ladder rung (M) and the top guide Block (C) is bolted to the top clamp (A), the portable ladder safety guide (A, B, &C) is assembled on the ladder rung (M) and ready to be fitted with a rope (D).
[0037] The top guide block (C) needs to be smooth, so I am implementing a hardened plastic to do this task. The job of the top guide block is to provide a smooth surface for the rope to travel over while clearing the aluminum ladder rung (M) that the portable ladder safety guide is secured to. The strength of the top guide blocks (C) needs to be substantial enough to hold a person's weight from crushing the block upon a fall. To successfully achieve this I am implementing the top guide block (C) be made of solid hardened plastic. The top guide block (C) is a solid piece of hardened plastic with flanges designed into the mold on both the left and the right side to allow the top rope guide to be bolted easier with shorter bolts to the top clamp (A). In the flanges there could be anywhere from two to four bolts (P) in each flange to secure it to the top clamp (A). There is a half-moon hole drilled through the top rope guide block (C) that enters through the front and out the back of the of the top rope guide (C). The hole drilled through can be anywhere from ⅝ inches in diameter to 2 inches in diameter. The half-moon design's sole purpose is to make it easier for the rope (D) to slide through the top rope guide (C) while the user adjusts the ladder height from the ground. The width of the top rope guide (C) is designed to clear the aluminum rungs (M) while allowing the easiest and safest way to adjust the rope (D) tension from the ground.
[0038] FIG. 3 is the process in which the unit will be used as is whole on the ladder (L). Figure three has all the components of the portable ladder solution system without the user or the rope grab/Fuji Denko (K). The ladder is shown with the portable ladder safety guide (A, B, C) positioned on the top ladder rung (M). Illustrated with paralleled dotted lines is the ⅝ inch rope (D) that runs down from the portable ladder safety guide (A, B, C) past the portable ladder rung protector (H) through the anchor/ascender (E) past the mallion (G) and finally past the rope anchor point (F) into the proposed rope bag (I). This is the process that it takes to set up the portable ladder solution system without the rope grab/Fuji Denko (K). The ropes (D) short end is routed through the front of the portable ladder safety guide and comes out the back and down the ladder past the portable ladder rung protector (H) and anchors on the rope anchor points (F) back anchoring eye. For more detail on the anchoring eye, see FIG. 6 . Once the rope (D) is routed and anchored it needs to be tensioned from the front of the ladder by pulling down on the rope (D) tight and securing it into the anchor/ascender (E). Once the rope (D) is tight the rope (D) is then ready to be used as a safety to ascend up using a rope grab or Fuji Denko (K) and tie the ladder off securely. The rope bag (I) is only a suggested idea to keep the rope cleaner than if it were laid in the dirt during every use. The mallion (G) is a connecting device that can be used to connect an anchor/ascender to the rope anchor point (F). The mallion is only the suggested connecting device but any climbing rated connecting device will do the same job.
[0039] FIG. 4 is a detailed side view drawing of the top (A) and bottom clamps (B) discussed in FIG. 2 in great detail. The top (A) and bottom clamps (B) are shown not to scale but to a much more accurate drawing of the actual tested and proposed prototype.
[0040] FIG. 5 is a detailed side view drawing of the top guide block (C) that is discussed in great detail in FIG. 2 . In FIG. 5 a more detailed description is shown of the discussed half-moon design for the rope to glide easier. The hole drilled through can be anywhere from ⅝ inches in diameter to 2 inches in diameter. The half-moon design's sole purpose is to make it easier for the rope (D) to slide through the top rope guide (C) while the user adjusts the ladder height from the ground then tensioning the rope (D) using the anchor/ascender (E). The material is proposed to be solid hardened plastic to maximize strength.
[0041] FIG. 6 is a detailed drawing of the rope anchor point (F). The right drawing is and exploded view and the left drawing is an assembled view. The rope anchor point is fitted to the ladder rung (M) to prevent it from rolling as seen in the top (A) and bottom (B) clamp. There are two parts comprising the rope anchor point (F). Part one (P 1 ) is the top which has the anchoring eye's (Q) and threaded holes (N). Part two (P 2 ) is the bottom which has drilled holes (O), to allow a series of bolts (P) to pass through, clamping the bottom to the top and forming the rope anchor point (F). Both the top and bottom portion will be made from aluminum and anywhere from 3 inches to 5 inches in length, measured horizontal with the rung (M) for each piece, part one and part two. Part one (P 1 ) is the actual rope anchoring point (F) in which the rope ( 0 ) ends (short and long) will be secured to. Part one (P 1 ) is to have two anchoring eyes (Q) fabricated into the aluminum body. There will be a anchoring eye (Q) in the front of Part 1 (P 1 ) and another anchoring eye (Q) in the back of part one (P 1 ). Part 2 (P 2 ) of the rope anchor point (F) is the bottom of the clamp in which the bolts will run through the piece and secure it to the top piece know as part one (P 1 ). Part 2 (P 2 ) is the same length and width as part 1 (P 1 ) with the bottom of part 2 (P 2 ) being flat as its sole purpose is to hold part 1 (P 1 ) to the ladder rung and distribute the weight evenly across the ladder rung (M) when weight is applied.
[0042] FIG. 7 is a simple drawing of a piece of material, most likely plastic, being secured to the middle of the ladder (L). This piece of plastic is known as the portable ladder rung protector (H). This portable ladder rung protector (H) will be placed on the top rung of the bottom section of a portable extension ladder. This device is necessary to prevent the rope (D) on the back where the two portions of the ladder meet from rubbing the top rung (M) of the lower portion. In order to keep the rope from wearing the aluminum top rung (M) the portable ladder rung protector (H) will be installed. To protect the ladder rung effectively, the portable ladder rung protector (H) will be placed in the center of the rung and be approximately 2 to 3 inches in length, measured from left to right across the ladder rung (M). The protector (H) could have ridges on the outside edges to prevent the rope from siding off onto the rungs. Two drawings on the right of FIG. 7 the top of the two drawing labeled side view with protector, show the protector (H) installed. Below that drawing is the side view without protector (H) to show the difference without the portable ladder rung protector (H) on the ladder rung (M).
[0043] FIG. 8 is an assembled unit of the ladder rope safety guide block in an isometric view. The ladder rope safety guide block has all three units shown assembled. Units assembled are the top guide block (C), top clamp (A), and bottom clamp (B). The combination of those three units secured together make up the ladder rope safety guide block which is designed to bolt to a ladder rung (M).
REFERENCE NUMERALS
[0000]
Portable ladder safety guide (A, B, & C)
Top Rung Clamp (A)
Bottom Rung Clamp (B)
Top guide block (C)
Ladder rung clamp (A &B)
Rope ⅝″ in diameter (D)
Anchor/Ascender (E)
Rope anchor point (F)
Rope Anchor Point Part One (P 1 )
Rope Anchor Point Part Two (P 2 )
Mallion (G)
Portable ladder rung protector (H)
Rope bag (I)
Full Body Harness (J)
Rope Grab/Fuji Denko (K)
Ladder (L)
Ladder Rung (M)
Threaded holes (N)
Drilled Holes (O)
Bolt (P)
Anchoring Eyes (Q) | The Portable Ladder Solution System is designed as a safety system used with portable extension ladders and any other ladders tall enough to require use of fall protection (J). The system uses any existing ladder (L), rope (D), rope guide (A, B, & C), anchor point (F), and rope grab (K) to safety act as a 100% safety tie off solution to anyone using the system. This system is vital to eliminating fatalities in the working industry. |
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to geotextile/polyurethane/polyurea and/or geotextile/polyurea composite liners prepared by soaking geotextiles with one-component heterogeneous liquid polyurethane compositions and subsequently curing by heat or solvent addition to form a geotextile/polyurethane/polyurea composite. Geotextile/polyurethane/polyurea and/or geotextile/polyurea composites of the present invention can be used as liners for canals and ditches for irrigation and wastewater, roof membranes, secondary containment, etc.
BACKGROUND OF THE INVENTION
[0002] In recent years, the management of natural resources has become important in many countries throughout the world. Efforts have been directed both toward the conservation of our resources and toward the elimination of pollution from our environment. Particular emphasis has been placed on waste leakage and water loss.
[0003] Losses in the distribution of water using unlined irrigation ditches are estimated at a minimum to be 25% and in some situations to be more than 50% depending upon the porosity of the ditch surface and the distance the water is being moved. In most rural areas, ditches are typically formed by excavating the soil to the desired depth and width. The water moves through the ditch in contact with the exposed natural surface. This can be sand, clay, rocks, etc. and, more commonly, mixtures thereof. The porosity will depend upon the proportions of the different components.
[0004] The loss of water in unlined irrigation ditches at one time was considered acceptable only because the supply of water exceeded demand. However, as civilization developed and world population increased, more water was required for both greater food production and for the marked increase in non-agriculture uses. In addition to greater domestic uses in sanitation, industry now employs large quantities of water in manufacturing and processing procedures.
[0005] This high level of consumption plus the very high cost of developing new water supplies has shifted attention to water conservation. Domestic appliances that use less water have been developed. Also, industry has installed recycling purification systems to reduce water consumption.
[0006] Although conservation efforts have reduced water consumption to a degree, water still is in relatively short supply, particularly in recent years with the severe droughts in the United States and other countries. Because the most cost effective conservation opportunities and readily accessible water supplies already have been developed, greater attention must be directed to improving the efficiency of water distribution systems.
[0007] Improvements in water distribution have been made. A limited number of ditches and canals have been lined with concrete and/or preformed concrete pipes. Concrete is durable and has a long life when properly used. However, concrete is expensive to place and finish and is damaged by unfavorable temperatures during curing. Also, concrete is subject to frost damage, cracking and heaving which results in leaks.
[0008] Processes for forming polyurethane composite liners for canals and ditches and apparatuses to perform such a processes are disclosed, for example, in U.S. Pat. Nos. 4,872,784; 4,955,759; 4,955,760; 5,049,006; 5,062,740; 5,421,677 and 5,607,998.
[0009] U.S. Pat. No. 5,421,677 (“the '677 patent”) is directed to an improved process of forming a ditch liner. The mixture of the '677 patent is a two component polyurethane resin and one or more fillers in an amount of up to 60% by weight based upon the total weight of the mixture. The mixture is dispensed on a geotextile, thereby forming a liquid filler containing polyurethane soaked geotextile composite. The liquid polyurethane soaked geotextile composite is then placed over the surface of an area to be lined.
[0010] One drawback of the resins used in the patents listed above is the use of reactive resins having at least two components which have to be metered and mixed at the job site using special equipment. Another problem encountered in using reactive resins like polyesters, epoxy resins or polyurethanes is that after mixing the resins have only a limited potlife before they solidify. This allows for only a short time between application on a geotextile and installation. In some resins, i.e., polyurethanes, water has to be carefully excluded to avoid foaming upon reaction with the isocyanate component
[0011] For the foregoing reasons, it would be desirable to produce geofabric/polymer composites using a binder composition that does not have these shortcomings.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention provides such a geotextile/polyurethane/polyurea and/or geotextile/polyurea composite prepared from one or more geotextiles and a one-component heterogeneous liquid polyurethane composition and also to a process for preparing such composites. The inventive composites can be used as liners for canals and ditches for irrigation and wastewater, roof membranes, secondary containment, etc.
[0013] These and other advantages and benefits of the present invention will be apparent from the Detailed Description of the Invention herein below.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention will now be described for purposes of illustration and not limitation. Except in the operating examples, or where otherwise indicated, all numbers expressing quantities, percentages and so forth in the specification are to be understood as being modified in all instances by the term “about.”
[0015] The present invention provides a geotextile/polyurethane composite with one or more geotextiles substantially impregnated with a one-component heterogeneous liquid polyurethane composition made of an isocyanate groups containing solid dispersed in a liquid isocyanate reactive compound, or a solid isocyanate reactive compound dispersed in a liquid isocyanate, isocyanate adduct, or isocyanate terminated prepolymer, optionally catalysts, viscosity adjusting additives, solvents, surfactants, crosslinking agents, pigments, fillers, and other additives.
[0016] The present invention further provides a process of forming a geotextile/polyurethane composite involving the steps of impregnating one or more geotextiles substantially with a one component heterogeneous liquid polyurethane composition made of an isocyanate groups containing solid dispersed in a liquid isocyanate reactive compound, or a solid isocyanate reactive compound dispersed in a liquid isocyanate, isocyanate adduct, or isocyanate terminated prepolymer, optionally catalysts, viscosity adjusting additives, solvents, surfactants, crosslinking agents, pigments, fillers, and other additives, conforming the one or more heterogeneous liquid polyurethane impregnated geotextiles to a surface, and applying heat or a solvent to the heterogeneous liquid polyurethane impregnated geotextile to form a geotextile reinforced polyurethane composite.
[0017] The term “geotextile/polyurethane” composite as used herein is meant to include geotextile/polyurethane/polyurea composites and geotextile/polyurea composites. The term “heterogeneous” as used herein means solid particles dispersed in a continuous liquid phase. In a one component heterogeneous liquid polyurethane composition, the dispersed solid will contain functional groups that have the capability to react with functional groups present in the continuous liquid phase.
[0018] The ratio of the functional groups in the dispersed solid and the continuous liquid phase may be chosen such that whenever reaction between these two phases occurs, a solid polymer is formed that contains urethane or urea or urethane and urea groups. No, or very little, reaction will occur as long as the two phases (solid and liquid) remain separated, but reaction to form a solid polymer will occur whenever the solid becomes dissolved in the liquid phase. Heat or addition of a suitable solvent may induce this dissolution.
[0019] One-component heterogeneous liquid polyurethane compositions are known in the art and are solid isocyanates dispersed in liquid polyols or liquid amino-terminated polyols or solid polyols or amines dispersed in liquid isocyanates, isocyanate adducts, or isocyanate terminated prepolymers. References to both types of heterogeneous liquid polyurethane compositions can be found, e.g., in U.S. Pat. Nos. 5,142,014; 5,138,011; 5,124,447; 3,488,302; 4,390,678; 4,483,974; 4,442280; 4,619,985; 4,667,008; 4,757,105; 5,091,497; 5,091,497 and 5,574,123.
[0020] References concerning the technology of using solid polyisocyanates stabilized with amines are given in the proceedings of the FSK/SPI “Polyurethane World Congress 1987”, Sep. 29-Oct. 2, 1987, Aachen, Federal Republic of Germany, p.316-322 and the “Third Annual International Conference on Crosslinked Polymers”, Luzern, Switzerland May 29-31, 1989, p.139-151.
[0021] Examples of suitable solid isocyanates may be found in U.S. Pat. No. 4,483,974, including, but not limited to 1,5-naphtalene diisocyanate, 3,3′-diisocyanato-4,4′-dimethyl-N,N′diphenylurea, dimeric 1 -methyl-2,4-diisocyanatobenzene, dimeric 4,4′-diisocyanatodiphenylmethane and 3,3′-dimethyl-4,4′-diisocyanatodiphenyl. Also disclosed are “amine stabilizers” and hydroxyl and/or amino groups containing compounds representing the continuous liquid phase. U.S. Pat. Nos. 4,442,280; 4,619,985; 4,667,008; 4,757,105; 5,091,497; 5,091,497 and 5,574,123 disclose solid isocyanates dispersed in liquid hydroxyl and/or amine terminated compounds.
[0022] Suitable one-component heterogeneous liquid polyurethane compositions containing a solid isocyanate reactive compound (amine and/or hydroxyl terminated) dispersed in a liquid isocyanate or phenolic blocked isocyanate phase are disclosed in, e.g., U.S. Pat. Nos. 3,488,302; 4,390,678; 5,142,014; 5,138,011 and 5,124,447.
[0023] U.S. Pat. No. 3,488,302 discloses suitable liquid isocyanate terminated prepolymers and solid polyhydroxyl compounds with pentaerithritol and mannitol being the more preferred. The '302 patent requires a molecular ratio of reactive hydrogen to terminal isocyanate groups in the range of 2/1 to 100/1, or higher, a range of 5/1 to 30/1 being preferred. These ambient temperature stable heterogeneous compositions are useful as caulks and sealants and can be applied as ribbons or coatings and by heat curing are firmly bonded to the surfaces. The excess polyol acts as a filler.
[0024] U.S. Pat. No. 4,390,678 claims a very similar composition, however, the amount of OH groups in the solid hydroxy compound phase to NCO in the isocyanate terminated prepolymer liquid phase is limited to less than 2:1. These compositions are also stable at ambient temperature and heat cured to form a solid polyurethane polymer.
[0025] U.S. Pat. Nos. 5,142,014; 5,138,011 and 5,124,447 use phenolic blocked isocyanates or isocyanate prepolymers as the liquid phase and solid polyamines or polyamine salts as the solid dispersed phase. These compositions are also stable at ambient temperature and can be cured to form solid polyurethane/urea polymers either by heat or the addition of solvents.
[0026] Viscosity adjusting additives, surfactants, pigments, fillers and other additives as known in the art may also be added as needed to the one-component heterogeneous liquid polyurethane compositions prior to use to form a geotextile/polyurethane composite.
[0027] As used herein, the term “geotextile” refers to any woven or non-woven porous blanket or mat produced from natural or synthetic fibers. Geotextiles may be made from a variety of synthetic materials such as polypropylene, polyester, nylon, polyvinylchloride and polyethylene or from natural fibers such as jute or cotton. They may be woven using monofilament yarns or slit film, or non-woven needled, heat set, or resin bonded fabrics. Geotextiles are available commercially from numerous manufacturers in the United States. As those skilled in the art are aware, geotextiles are used primarily to line earthen surfaces. Such liners may have secondary uses in lining roofs, ponds, reservoirs, landfills, and underground storage tanks, canals or ditches. As used herein, the terms “ditch” and “canal” are interchangeable and can refer to any liquid-carrying surface.
[0028] It is preferred in the present invention that at least one of the geotextiles used in the present invention be thicker, with a “fluffier” texture that can absorb the one-component heterogeneous liquid polyurethane composition like a sponge. One or more geotextiles may be used in combination with the one component heterogeneous liquid polyurethane composition. The ultimate thickness of the geotextile/polymer composite liner may be determined by the choice of geotextiles (number of layers and thickness of the individual layers) as well as the amount of the one-component heterogeneous liquid polyurethane composition applied.
[0029] It is preferred to adjust the viscosity of the one-component heterogeneous liquid polyurethane composition to the extent that it will not run off, even on vertical surfaces after being applied to the geotextile substrate.
[0030] In the simplest embodiment of the present invention, precut geotextile sheets may preferably be dipped into a bath of the one-component heterogeneous liquid polyurethane composition and the soaked geotextile subsequently applied on the surface to be lined.
[0031] One or more geotextiles may also be pulled continuously through a bath of the one-component heterogeneous liquid polyurethane composition, cut to size and placed over the surface to be lined. If a consistent thickness of the composite is desired, the soaked geotextile may preferably be passed through a die or rollers prior to being cut.
[0032] In one embodiment of the present invention, the geotextile/polymer composite liner may be prepared using a machine such as that described in U.S. Pat. No. 5,639,331 (“the '331 patent”). The '331 patent discloses a mobile ditch lining apparatus having reservoirs for supplying raw materials such as resin, catalysts, colors or other additives.
[0033] In the simplest version of this embodiment, only one reservoir is necessary to accommodate the one-component heterogeneous liquid polyurethane composition. No mixing chamber is required and the one-component heterogeneous liquid polyurethane composition is directly metered into the vat. If, however, a solvent to cure the composition or any other of the before mentioned additives is metered and mixed continuously with the one-component heterogeneous liquid polyurethane composition, more than one reservoir is desirable.
[0034] The geotextiles may be pulled from a vat containing the one-component heterogeneous liquid polyurethane composition through an adjustable die. The opening of the die provides even distribution of the one-component heterogeneous liquid polyurethane composition on the geotextiles, determines how much of the one-component heterogeneous liquid polyurethane composition is dispensed on the geotextile and also controls the thickness of the polymer soaked geotextile composite. The polyurethane soaked geotextile may be cut to the desired length and placed on the area to be lined where it conforms to the surface and preferably cures by heat or the addition of solvents to form a geotextile/polymer composite liner. Installing the one-component heterogeneous liquid polyurethane composition soaked geotextile liners in such a way that they overlap to a certain extent assures that after curing, a seamless permanent flexible composite liner is obtained.
[0035] In yet another embodiment of the present invention, the one-component heterogeneous liquid polyurethane composition is spray applied to the geotextile with, for example, commercially available spray equipment.
[0036] The one-component heterogeneous liquid polyurethane composition soaked geotextile may be placed on the area to be lined where it conforms to the surface and cures to form a geotextile/polymer composite. The geotextile may also first be cut to size and then placed on the area to be lined and, the one-component heterogeneous liquid polyurethane composition may be sprayed onto it. Preferably, the geotextile with the still liquid one-component heterogeneous liquid polyurethane composition on it is rolled with a roller, such as a paint roller, to allow the one-component heterogeneous liquid polyurethane composition to penetrate through the geotextile to the surface of the area to be lined.
[0037] In still another embodiment of the invention, the one-component heterogeneous liquid polyurethane composition may first be sprayed on a broken concrete surface of a concrete lined ditch and a geotextile placed over it so that the geotextile absorbs the still liquid heterogeneous polyurethane composition to form a soaked composite, which is cured to form a solid, yet flexible polyurethane/geotextile composite.
[0038] The above-described composition cures in a reasonable amount of time with either externally applied heat or by addition of a suitable solvent.
[0039] The thickness of the geotextile/polymer composite may be varied over a wide range, but preferably measures from 40 microns to 500 microns.
[0040] The amount of polymer applied to the geotextile(s) may be varied, but preferably the polymer applied per square meter ranges from 0.2 kg to 20 kg, more preferably from 0.5 kg to 5 kg. The amount of polymer applied may be in an amount ranging between any combination of these values, inclusive of the recited values.
[0041] If desired, several layers of the one-component heterogeneous liquid polyurethane composition soaked geotextile(s) may be applied over each other to obtain a composite of higher strength and dimensional stability. This is the preferred mode for lining an earthen canal or ditch.
EXAMPLES
[0042] The present invention is further illustrated, but is not to be limited, by the following examples. The following components were used in the working examples:
[heading-0043] PU Composition A:
[0044] A one-component heterogeneous liquid polyurethane composition was prepared according to U.S. Pat. No. 4,483,974 (Example 2) using the following composition:
250 g of linear polypropylene glycol ether, MW=2000 0.15 g of ethylene diamine “amine stabilizer” 43.8 g of dimeric finely particulate tolylene diisocyanate 22.25 g of 2,4-/2,6-diamino-3,5-diethyl toluene isomer mixture (65/35) “DETA” 0.5 g of dimethyltin dilaurate, commercially available as FOMREZ UL-28 from Witco, New York, N.Y. (catalyst replacement for the lead octoate solution used in U.S. Pat. No. 4,483,974 (Example 2)).
PU Composition B:
[0051] A one-component heterogeneous liquid polyurethane composition was prepared according to U.S. Pat. No. 3,488,302 (Example 1). A prepolymer was prepared from:
183.7 g of MONDUR TD-80, toluene diisocyanate containing about 80 percent by weight of the 2,4-isomer and 20 percent of the 2,6-isomer (commercially available from Bayer Polymers LLC) and 1000 g of PPG 2000, a linear polypropylene glycol ether, MW=2000.
[0054] This prepolymer was prepared by adding the toluene diisocyanate to the polyol under agitation in a flask under dry nitrogen at 80° C. The reaction time was two (2) hours. The NCO-content was determined to be 3.6%. After that the material was cooled down to room temperature. The following were added to this prepolymer and agitated until a fine stable suspension was formed.
340 g pentaerythritol (finely ground), and 59.2 g colloidal silica.
The product was stored in a tight container under dry nitrogen.
Geotextile A:
[0059] TYPAR-3301, spunbonded polypropylene, 3 oz/yd 2 , 12 mils thickness (Reemay).
[heading-0060] Geotextile B:
[0061] TREVIRA Spunbound Type 1620, polyester, nonwoven, heatbonded, 5.7 oz/yd 2 , 37 mils thickness, (Fluid Systems).
Example 1
[0062] A piece of Geotextile B (one square foot, 24.2 g), burnished side down was placed on a polyethylene sheet. PU Composition A (250 g) was poured on Geotextile B and evenly distributed using a small plastic paint roller. Subsequently, a piece of Geotextile A (one square foot 9.9 g) was placed on top of the coated Geotextile B and rolled with the paint roller until the liquid composition had soaked through the upper sheet. The sample was then postcured at 150° C. for two (2) hours. The resulting geotextile/polyurethane composite had the physical properties summarized below in Table I.
TABLE I Property (Test) Tensile Strength (ASTM D 412) 1034 psi Elongation (ASTM D 412) 112% Tear Strength (ASTM D 3489) 152 pli Die “C” Tear Resistance (ASTM D 624) 518 pli Water Absorption (ASTM D 570-98) 168 hours 5.06%
Example 2
[0063] A piece of Geotextile B (one square foot 24.2 g,) burnished side down was placed on a polyethylene sheet. PU Composition B (250 g) was poured on Geotextile B and evenly distributed using a small plastic paint roller. Subsequently, a one (1) square foot piece of Geotextile A (9.9 g) was placed on top of the coated Geotextile B and rolled, with the paint roller, until the liquid composition had soaked through the upper sheet. The sample was then postcured at 150° C. for two (2) hours. The resulting geotextile/polyurethane composite had the physical properties summarized below in Table II.
TABLE II Property (Test) Tensile Strength (ASTM D 412) 930 psi Elongation (ASTM D 412) 112% Tear Strength (ASTM D 3489) 209 pli Die “C” Tear Resistance (ASTM D 624) 344 pli Water Absorption (ASTM D 570-98) 168 hours 6.21%
[0064] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention. The scope of the invention is to be measured by the appended claims. | The present invention relates to geotextile/polyurethane/polyurea and/or geotextile/polyurea composites prepared by soaking geotextiles with one-component heterogeneous liquid polyurethane compositions and subsequently curing by heat or solvent addition to form a geotextile/polyurethane composite. The inventive composites may find use as liners for canals and ditches for irrigation and wastewater, roof membranes, secondary containment, etc. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. patent application Ser. No. 13/382,207, filed on Jan. 4, 2012, which is a national phase application of International Application No. PCT/DE2010/000685, filed on Jun. 18, 2010, which claims priority to German Patent Application No. 10 2009 033 572.2, filed on Jul. 16, 2009, and the present application also claims priority to German Patent Application No. 10 2012 003 087.8, filed on Feb. 18, 2012, each of which is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a hydraulic circuit for longwall support by means of a support device (support shield) for use in underground mining.
2. Description of Related Art
Such circuits are well known from PCT/DE2010/000685 (the publication of which is W02011006461A2). The proposed pressure monitoring system prevents unforeseen operating conditions where pressure conditions may occur that are sufficient to manipulate the hydraulic pilot control, i.e. the opening of essential valves even in case of failures to the pumping system, or if in case of an emergency the overall electric and hydraulic control systems are switched off, or in case of extremely high pressures from the rock which the load maintaining valves are not capable of handling.
The arrangement of W02011006461A2 according to one embodiment also monitors the annular piston line for each cylinder/piston assembly by means of a pressure sensor. When a pre-determined maximum pressure is achieved, the entire longwall is depressurized so that particularly the unlocking process for the check valves that retain the rock pressure is disabled. This can, however, cause operating conditions that may require the system to be controlled either manually or automatically.
The purpose of the invention is to design the circuit in such a manner that a comprehensive monitoring of the system as well as any necessary manipulation of the control system is possible.
SUMMARY OF VARIOUS EMBODIMENTS
This is achieved by means of the various embodiments described herein.
An alternate embodiment includes a supplementary improvement that allows for a so-called negative emergency operation, and therefore enables the control if, due to a pressure signal activated by the pressure monitor, an emergency signal would cause a system failure.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention is hereafter described by means of a preferred embodiment. Explicit reference is made to the drawing descriptions relating to FIGS. 1A, 1B and 2 of W02011006461A2 and particularly to FIG. 1B and its description.
The terms used and their reference signs are also taken up in this application. Any divergences will be expressly noted in the following detailed description of the invention.
FIG. 1 is an electrical/hydraulic circuit of a support shield in a longwall mine in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The electric/hydraulic circuit of a support unit in a longwall according to W02011006461A2 comprises the following elements, which are also illustrated or indicated in the drawing:
1. the longwall supply line 1 (pumps—manifold, flow pipe), which extends through a portion of the longwall or the entire length of the longwall and which is connected to the pump station—without reference mark. 2. the return flow manifold 2 (return flow—manifold, return flow), which extends through a portion of the longwall or the entire length of the longwall and which is connected to the tank—without reference mark—of the pump station. 3. the hydraulic control device of the shield control device for a support shield. Shown is one of the power transmitters 4 . The hydraulic control device 3 is connected through the feed line stub 12 with the feed line and through the return line stub 13 with the return line. 4. A power transmitter, which is here illustrated as cylinder-piston unit. 5. The electrical control device 5 of the shield control unit for controlling the hydraulic control device 3 . The hydraulic control device 3 and the electrical control device 5 together comprise the excavation control device, which is designed for inputting switching and control commands, however, may also receive its switching and control commands from the central longwall control device 15 .
Other existing secondary valves, particularly check valves, have not been illustrated or further described.
The hydraulic control device comprises multiple valves. The connection for each power transmitter 4 with the pump manifold of the longwall between the power transmitter outlet, which is acted upon by the rock pressure, and the hydraulic control device 5 is generally blocked by a pressure holding valve 14 which is designed as an unlockable check valve so that in case the pump pressure fails or is turned off the load pressure of the power transmitter acts upon the tightly locking check valve 14 . This check valve 14 can be unblocked by means of hydraulic pilot operation through the system pressure when the pressure variation between load pressure and pilot pressure fall below a value that is predetermined by the valve construction. The check valve 14 is hydraulically designed in such a manner that when it is hydraulically unblocked the working space of the power transmitter is through outlet 6 and the return line stub connected with the return line manifold. Such unlockable check valve is, for example, well known through DE 38 04 848 A1.
The pressure monitoring device 19 prevent the pressure between the unlockable check valve 14 and the cylinder annular space and/or the hydraulic control device 3 from reaching a level that could cause the check valve 14 , which acts as a load maintaining valve, from being unintentionally unlocked (turned on). See also W02011006461A2.
The detailed drawing of FIG. 1 illustrates the individual valves of the hydraulic control device 3 .
The pilot control valve 16 . 1 for setting the power transmitter and the pilot control valve 16 . 2 for removing the power transmitter are both activated through bus line 20 by means of the electric control device 5 of the support shield and/or by means of the central longwall control unit 15 through the signal line 21 and hydraulically activate the main valve 17 . 1 for setting the power transmitter and main valve 17 . 2 for removing the power transmitter between two settings.
The encoding of the switching signals causes the magnet of the pilot control valves to be interlocked in the following manner:
when hydraulically actuated in the course of setting (lifting):
Main valve 17 . 1 opens the connection (feed line stub 12 , setting line 22 ) between longwall supply line (pump line, pressure line) 1 and power transmitter input 6 ; Main valve 17 . 2 releases the connection (annular piston line 10 , return line stub 13 ) of the annular space 24 to the return line manifold 2 . The piston of power transmitter 4 and the load acting upon it are elevated.
at standstill:
Main valve 17 . 1 blocks the connection between connection 6 of the power transmitter and longwall supply line (pump line, pressure line) 1 and opens the connection to the return line manifold 2 . Main valve 17 . 2 releases the connection of the annular space 23 to the return line manifold 2 . The load acting upon the piston of the power transmitter is held by the blocked check valve 14 /load maintaining valve.
when hydraulically actuated in the course of removing the timbering (lowering the piston):
Main valve 17 . 1 blocks the connection between longwall supply line (pump line, pressure line) 1 and opens the connection to the return line manifold 2 . Main valve 17 . 2 releases the connection of the annular space 23 to the longwall supply line (pump line, pressure line) 1 . The load acting upon the piston of the power transmitter is held by the blocked check valve 14 /load maintaining valve until the check valve 14 is unblocked by the rising pressure in the annular piston line 10 through line stub 24 . The load acting upon the piston of the power transmitter is thus lowered.
Standstill is a critical condition since persons staying inside the longwall are subject to injury or death from the unintentional movement of the expansion equipment. This hazard is prevented by the pressure sensor 19 which is installed into annular piston line 10 of each cylinder/piston assembly 4 . Each of these pressure sensors 19 is switched through another bus line 20 to the longwall shutoff valve 11 through the central longwall control device 15 in such a manner that upon reaching a predetermined maximum pressure in the annular piston line 10 the entire longwall is pressureless switchable. This also ensures that internal pressure, which could cause the unblocking of the check valves that are holding the rock pressure, is no longer present. Therefore the maximum allowable pressure at which all support units of the longwall are depressurized is set significantly lower, in fact at least 20% lower, for example, at 50 bar, than the inherent pressure of, for example, 80 bar that is sufficient to unlock the check valve.
It is, however, possible for operating conditions to occur for which it may become desirable or even necessary to manually adjust the control system. For this reason it is intended that the longwall shutoff valve 11 can only be activated when a triggering signal for the main valves 16 . 1 , 16 . 2 is no longer present. For this reason the central longwall control device 15 is activated through a UND—member 25 , which only sends a positive output signal if the pressure signal of the pressure sensor 19 is positive and at the same time the signal for triggering the pilot control valves 16 . 1 , 16 . 2 is negative. This is here illustrated by means of a negative (NANO) member 26 , which is connected with the signal line 21 and only sends a positive output signal to the UND member 25 of the longwall control device 15 when a negative input signal is present. This prevents the possibility that the pressure sensor 19 interferes with any intentional manually or automatically controlled operating condition or process of the power transmitter. Such a situation could cause serious hazards.
It is furthermore intended that the function of the pressure sensor 19 can be completely disabled. For this purpose a push button switch 28 is installed in the line between longwall control device 15 and longwall shutoff valve 11 . If necessary, this push button switch can be opened when it is disadvantageous that the entire longwall is shut off accidentally. It is also possible to bypass the pressure sensor by means of a circuit which is not illustrated here. | A hydraulic circuit for longwall support for use in underground mining for supporting a longwall by means of a plurality of support shields includes in the annular piston line of each cylinder/piston unit a pressure sensor. The pressure sensor, upon reaching a predetermined maximum pressure activates a pressure deviation signal, causes the entire longwall to be depressurized by means of a longwall shut-off valve. The pressure deviation signal is blocked for one of the hydraulic valves against each triggering signal. |
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BACKGROUND OF THE INVENTION
This application is a continuation of application Ser. No. 07/496,229 filed on Mar. 20, 1990 and now abandoned.
1. Field of the Invention
Sweeper hopper and filter assemblies are typically utilized in riding type sweepers. Such sweepers include a hopper having a dirt and debris receiving chamber provided with an inlet opening for receiving dirt and debris directed therethrough by a rotating sweeper broom. The hopper is further provided with an exhaust chamber communicating with an exhaust blower for effectively establishing an air flow through the inlet opening, the dirt and debris receiving chamber, and the exhaust chamber. A filter assembly is employed to separate the two chambers and is effective to trap the transient particulate contaminants and allow clean air to flow therethrough to the exhaust chamber.
2. Description of Related Art
U.S. Pat. No. 4,328,014 to J. L. Burgoon et al discloses such a system and more specifically illustrates and describes a filter cleaning mechanism for periodically physically shaking the filter to cause contaminants collected thereon to be dislodged and fall into an associated dust contaminant receiving chamber. Manifestly, the contaminant dislodgement is most effectively achieved during a period when the sweeper is stopped and exhaust blower is deenergized. Obviously, the amount of down-time of the sweeper is a function of the type and volume of contaminant to which the sweeper is exposed.
U.S. Pat. No. 4,345,353 to G. L. Sommerfield discloses a sweeping machine and a striking mechanism for removing collected dust from an associated pleated filter disposed in the air stream between the inlet and the clean air outlet. The apparatus would function must efficiently during a period when the sweeper and associated exhaust blower mechanism is deenergized.
SUMMARY OF THE INVENTION
An object of the invention is to produce a sweeper hopper and filter assembly capable of handling a wide variety of dirt and debris and to minimize the down-time required to maintain optimum air filtering efficiency.
The objectives of the invention are typically achieved by a sweeper hopper and filter assembly comprising a main housing defining a hopper, the housing including a particulate contaminant inlet, a clean air outlet, conduit means providing communication between the inlet and the outlet, and means for maintaining a decreased pressure at the outlet compared to the pressure at the inlet; and a filter assembly disposed within the conduit means providing communication between the inlet and outlet of the housing, the filter assembly including filter media for militating against the flow of particulate contaminants therethrough and means to selectively block one portion of the filter media to prevent communication between the inlet and outlet of the housing through the blocked portion of the filter media, and means to dislodge particulate contaminants from the blocked portion of the filter media.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become manifest to one skilled in the art by reading the following detailed description of an embodiment of the invention when considered in the light of the accompanying drawings, in which:
FIG. 1 is a schematic side elevational view of a riding sweeper embodying the present invention;
FIG. 2 is an enlarged fragmentary sectional view of the hopper and associated filter assembly of the sweeper illustrated in FIG. 1;
FIG. 3 is a fragmentary top plan view of the filter assembly illustrated in FIG. 2 with portions cut-away to more clearly illustrate the structure;
FIG. 4 is an enlarged sectional view taken along line 4--4 of FIG. 3 illustrating one filter element and an associated filter element shaker assembly;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4 with the shaker motor broken-away to illustrate the pivotal mounting of the plate for supporting the motor and associated plate pads for impacting the filter element;
FIG. 6 is an enlarged fragmentary sectional view taken along line 6--6 of FIG. 2 illustrating the selectably operable air control doors for directing air flow through one or the other or both of the filter elements illustrated in FIG. 3; and
FIG. 7 is a fragmentary sectional view taken along line 7--7 of FIG. 6 illustrating an air control door and associated control mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the accompanying drawings wherein like reference numerals are employed to designate similar parts throughout, there is illustrated in FIG. 1 a riding power driver sweeper, generally indicated by reference numeral 10, embodying the features of the invention.
The sweeper 10 includes a main body portion 12 supported by ground engaging front wheels 14, and a rearwardly disposed and centrally located wheel 16 which may be moved about a suitable pivot axis by an associated steering wheel 18 to effectively steer the sweeper 10. An operator's seat 20 is typically positioned immediately to the rear of the steering wheel 18.
A main rotary drum-type broom 22 is disposed rearwardly of the front wheels 14 and is typically power driven by suitable power take-off means from the motive force imparting engine of the sweeper as is well known in the art. Typically, the broom 22 is of sufficient length to be coextensive with the inlet opening of the associated hopper as will be explained hereinafter.
A hopper 24 is disposed at the forward portion of the sweeper 10 and may be pivotally mounted to the main body portion 12 by suitable pivot means (not shown). Such pivotal mounting enables the hopper 24 to be pivoted about the pivot axis by any suitable means, such as for example, pressure fluid actuating means 26 to effect dumping of debris and contaminants therefrom. The hopper 24 includes a bottom wall 28, upstanding front, side, and rear walls 30, 32 and 34, respectively. Typically, the rear wall 34 is provided with an inlet opening 36 through which debris picked up by the rotating broom 22 may enter into the interior of the hopper 24.
Further, the hopper 24 includes an intermediate wall 38 which is adapted to extend between the spaced apart side walls 32 and extends downwardly from the upper terminal edge of the side walls 32. A cooperating dividing wall 40 extends forwardly and upwardly of the inlet opening 36 and terminates in an upwardly extending wall. Both of the walls 38 and 40 span the entire distance between the facing interior surfaces of the side walls 32 and function to effectively define a debris chamber 42 and an exhaust chamber 44. The lower portion of the exhaust chamber 44 is divided into two separate dust chambers 46 and 48 by a vertically disposed dividing wall 50.
The hopper 24 is provided with top having a front section 52 which forms the top of the debris chamber 42 and a rear section 54 which forms the top of the exhaust chamber 44. The rear of the front section 52 and the front of the rear section 54 are respectively hingedly mounted by suitable hinge means, generally indicated by reference numeral 56, to the upper edge portion of the intermediate wall 38.
The rear wall 34 is provided with an outlet opening 58 which establishes communication with the exhaust chamber 44 and a vacuum blower 60. The blower 60 is effective to vacuumize the hopper 24 and cause a flow of air through the inlet 36, the chamber 42, and the exhaust chamber 44 and the associated dust chambers 46 and 48, the exhaust chamber 44, and the outlet opening 58, which vents to atmosphere.
A filter system is provided to filter the transient air and remove particular contaminants from the air stream. More specifically, the filter system includes two separate filtering units A and B and each unit is substantially identical with the other. Accordingly, only a single unit will be explained in detail and prime numerals will be used in respect of the second unit to simplify the explanation and resultant understanding of the structure.
The filtering unit A includes a filter element 62 having a pleated paper-type core 64, an expanded metal screen 66 and a metal frame 68, clearly illustrated in section in FIG. 4. The upstream surface of the filter element 62 faces the dust chamber 46, while the downstream surface faces the exhaust chamber 44. One side of the peripheral marginal edge of the filter frame 68 is supported on an inwardly extending flange 70 and associated gasket means 72. The opposite side of the peripheral marginal edge of the frame 68 is firmly held by a plurality of bracket members 74 which extend outwardly of a frame 76. The frame 76 is hingedly mounted to the inner surface of the rear wall 34 by suitable hinge means 78.
The frame 76 and the associated bracket member 74 are suitably locked in place by a latch mechanism 80 having a main portion 82 and an upper angular end portion 84. The lower end of the main portion 82 of the latch mechanism 80 has an aperture for receiving an L-shaped handle 86. The L-shaped handle 86 is provided with an externally threaded end 88 to be threadably received in a nut 90 affixed, as by welding for example, to a rocker mounting base 92. An associated upper nut 94 is threaded on an upper portion of the threaded end 88 of the handle 86 and is adapted to turn with the handle 86. When the handle 86 is turned in a counter-clockwise direction, as viewed in FIG. 3, the nut 94 firmly engages the portion 82 of the latch 80 and holds it in place with the upper end 84 disposed adjacent the lower surface of a flange member 96 secured to the upper edge portion of the intermediate wall 38. This provides ample force to hold the holding frame 76 against the filter element frame 68. When the handle 86 is turned in an opposite direction, the nut 94 moves with it and away from the latch portion 82, thereby permitting the latch 80 to be swung out to the side to simultaneously move the end portion 84 from the underside of the flange 96. It will be understood that the nut 94 may be replaced by a washer, for example, which could be formed integral with the handle 86.
Further, it will be readily apparent that the frame 76 is securely held against the filter element frame 68 during the operation of the overall system, and may be readily movable by swinging the latch 80 to the side and moving the frame 76 about the hinges 78 to provide access to the filter element 62 for service and replacement when necessary.
The rocker mounting base 92 is mounted on the filter holding frame 76 and typically spans the entire length of the frame 76. The opposing ends of the rocker mounting base 92 and integrally secured to respective portions of the frame 76 as welding, for example.
A rocker plate 98 is pivotally mounted on the rocker mounting base 92 by means of a pair of spaced apart pivot assemblies 100, each of which includes a hollow sleeve 102 mounted to depend from the underside of the rocker plate 98, a hollow sleeve 104 mounted to project upwardly from the upper surface of the rocker mounting base 92, a hollow collar 106, and a pivot pin or rod 108. As clearly illustrated in FIG. 5, the collar 106 is provided with a set screw 110 adapted to firmly secure the pivot pin 108 and thereby enable the rocker plate 98 to pivot about the axis of the pivot pins 108 and relative to rocker mounting base 92.
Laterally extending rocker plate pads 112 are affixed to opposing sides of the rocker plate 98 by suitable threaded fasteners 114. Vertical adjustment of the pads 112 with respect to the rocker plate 98 is achieved by forming elongate slots 116 in each of the pads 112. Relative positioning of the pads 112 is effected by loosening the respective threaded fasteners 114, adjusting the pad 112, and thence tightening the fasteners 114 after the desired adjustment has been made. It will be noted that the pads 112 may be adjusted vertically with respect to the rocker plate 98, but also may be rocked generally about the axis or axes of the fasteners 114 to effect the desired positioning of the pads 112 relative to the surface of the metal screen 66 of the filter element 62.
The mounting bracket 118 of generally semi-circular configuration is affixed to a central portion of the rocker plate 98 by suitable fasteners 120. The bracket 118 securely holds an electric motor 122 to the rocker plate 98. An eccentric weight 124 is affixed to a drive shaft 126 of the motor 122 and is effective to shake the motor 122 and the rocker plate 98 about the pivot pins 108 when the driveshaft 126 and the associated eccentric weight 124 are rotated.
Upon energization of the motor 122, the assemblage noted above is rocked about the pivot pin 108 causing the associated pads 112 to alternately strike or contact the expanded metal screen 66 of the filter element 62. This action causes particulate contaminants collected by the pleated paper core 64 to be dislodged therefrom and fall downwardly through the dust chamber 46 and onto the upper surface of the dividing wall 40.
The filter assembly also includes means for effectively selectively blocking air flow through one or the other of the filtering units A or B and its associated filter element 62 or 62', respectively. More specifically, elongate doors 128 and 130 formed of elastomeric sheet material, for example, are secured to the intermediate wall 38 by closure strips 132 and 134, respectively. The closure strips 132 and 134 are secured to the intermediate wall 38 by any suitable fastening means, such as threaded fasteners, for example. The lower depending portion of the doors 128 and 130 are provided with suitable backing plates 135 which may be substantially coterminous with the respective one of the doors 128 and 130. When the doors 128 and 130 are moved upwardly, the lower ends thereof are designed to contact the inner surface of the upwardly extending portion of the dividing wall 40, as is clearly illustrated in phantom lines in FIG. 7. The upper most edges of the backing plates 135 may be provided with a flange extending generally normal to the plane of the plates 135. The purpose of such a construction is to supplement the inherent structural rigidity of the material used in fabricating the plates 135.
The plates 135 are secured to the closure doors 128 and 130, by spaced pairs of substantially rigid strips 148, 148', and 150, 150', respectively. Threaded fasteners, as illustrated, may be employed to suitably secure the strips 148, 148', 150, 150' to the appropriate backing plate 135. In typical embodiments, the closure doors 128 and 130 are effectively sandwiched between the backing plates 135 and the rigidizing strips 148, 148', 150, and 150'.
Electrically actuated solenoid motors 136 and 138 are mounted on the intermediate wall 38 by suitable brackets 140 and 142, respectively. Reciprocatively moveable solenoid drive shafts 144 and 146 depend from the solenoid motors 136 and 138, respectively, and are adapted to have their distal end portions pivotally connected to the strips 148 and 150, respectively.
It will be noted that the portion of the sheet material of the closure doors 128 and 130 between the closure strips 132, 134 and the lifting strips 148 and 150, respectively, function as a living hinge as will be manifest from the description of the operation of the invention to follow.
It is considered that the ideal energization of the closure doors 128 and 130 would involve the opening and closing thereof in a sequence to assure a continuous flow of air to be treated through at least one of the filter elements 62 and 62' at all times.
It would be understood that when one of the closure doors 128 or 130 is caused to be closed and thereby cut-off the flow of air therethrough, the electrical circuitry would simultaneously energize the respective electric motor 122 or 122'. For example, simultaneously with the movement of the closure door 128 to a closed position, as illustrated clearly in FIG. 7, the air flow through the filter element 62 is interrupted. At the same time, the electric motor 122 is energized effecting rotation of the eccentric 124 causing the rocker plate 98 and the associated plate pads 112 to rock about the pivot pins 108. This action caused the pads 112 to impact or strike the expanded metal screen 66 which in turn impacts the pleated paper core 64 and dislodges particulate contaminant collected on the surface thereof. The dislodged particulate contaminants fall downwardly and are collected in the dust chamber 46.
The resultant system can be seen to be extremely efficient and one in which the amount of down-time is minimal compared with the known prior art.
Once the debris chamber 42 and the dust chamber 46 become full of debris and dust, the hopper 24 may be dumped by energizing the pressure fluid actuated means 26 to cause the hopper 24 to be pivoted forwardly. At this point in the operation, it will be appreciated that the closure doors 128 and 130 are maintained in their normally open position permitting the dust collected in the dust chamber 46 to pass between the intermediate wall 38 and the dividing wall 40 and thence out of the hopper 24 through the hinged top 52 as it swings to an open position due to the pivoting action of the hopper 24.
In accordance with the provisions of the patent statutes, the principle and mode of operation of the invention have been explained and what is considered to represent its preferred embodiment has been illustrated and described. It should, however, be understood that the invention may be practiced otherwise as specifically illustrated and described without departing from the scope of the appended claims. | A sweeper hopper and associated filter assembly as illustrated and described. The filter assembly effectively divides the hopper into a particulate contaminant receiving chamber and a clean air exhaust chamber. The filter assembly includes at least a pair of particulate blocking filter means and means for selectively directing the transient air stream through one or the other or both of the filter means. The filter assembly further includes cleaning means for selectively imparting the filter means, typically during periods of quiescence, to physically loosen and remove particulate contaminants therefrom and direct such contaminants into the contaminant receiving chamber. |
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FIELD OF THE INVENTION
[0001] The invention relates generally to agricultural and construction vehicles, and more particularly to skid steer loaders. The invention, in combination with existing locking pins, prevents loader arms from moving in two directions.
BACKGROUND OF THE INVENTION
[0002] Skid steer loaders and other work vehicles with traversing booms typically require maintenance both in the field and in a dedicated repair shop. The repairman needs access to all parts of the vehicle. Lifting the booms to an intermediate position is required, allowing manual access to the otherwise blocked area of, for example, a skid steer loader. Skid steer loader arms, or booms, are hydraulically controlled. If there are small leaks in the hydraulic system, the booms will slowly lower over time. To avoid this, there are various common mechanisms for preventing booms from lowering inadvertently. These include locking the boom control levers in the operator cab, placing a block such as a drum under the implement at the end of the booms, and locking the boom(s) itself.
[0003] In the area of boom locking devices the prior art teaches various methods of locking a boom for transport. Typically the boom is lowered against the chassis such that the chassis blocks movement in one direction and the boom lock blocks movement in the opposite direction. One example of a transport boom lock uses an operator in-cab control with a linkage to a pin or hook assembly that locks a backhoe boom against the chassis in the boom's fully upright position. While this locks the backhoe boom against all movement, it requires the boom to be in a non-working position, i.e. fully upright, as for transport. This blocks access to part of the backhoe for repair.
[0004] The prior art also teaches locks that are carried on the boom itself, either on the housing, rod or cylinder, locking the boom in an intermediate position. One example teaches a lock that is placed on the end of the hydraulic cylinder, and acts against the rod and cylinder, preventing retraction of the rod into the cylinder and thereby preventing the loader arm from lowering. This method only prevents the boom movement in one direction relative to the boom itself, that of the rod retracting into the cylinder, i.e. boom contraction.
[0005] The prior art also teaches locking pins that extend through the cab wall and extend into the plane of the skid steer loader arms, locking the booms in an intermediate position. This method prevents the loader arms from lowering with respect to the cab, but not from raising.
[0006] However, in the case of a skid steer loader with a removable combined cab and boom assembly, the situation is different. The cab and boom are tilted away from the base of the vehicle during the repair. As a result, the boom overhangs the end of the vehicle considerably. While the skid steer loader may be equipped with locking pins or sliding bars that prevent the loading arms from lowering (see U.S. Pat. No. 3,730,362 for a complete description of the layout and function of such locking pins), the weight of the cab and boom assembly will tend to pull the boom arm upwards from the cab and away from the locking pins. During repair, the implement at the end of the boom arms (bucket, rake, blade, dozer blade, etc) will typically be supported on a stand. By the force of gravity, the tilted cab boom assembly will descend toward the ground if there is a hydraulic leak, causing the boom arms to pivot upward with respect to the cab. In other words, the existing locking device only prevents the boom from pivoting downward with respect to the cab, and what is needed is a second complimentary device, or boom clamp, to prevent boom movement in the other direction. What is further needed is a simple, low cost-to-manufacture boom clamp. What is also needed is a clamp that a repairman or operator can install and remove quickly without tools when needed. What is further needed is a boom clamp that will not pinch hydraulic cables.
SUMMARY OF THE INVENTION
[0007] In accordance with a first aspect of the invention, a boom clamp for a work vehicle having a lock and a boom, said lock configured to prevent movement of the boom in a first direction is provided, the boom clamp comprising a restraint configured to engage the boom, and a sleeve fixed to the restraint, the sleeve configured to engage the lock, wherein the restraint prevents the boom from moving in a second direction.
[0008] The second direction may be opposite the first direction. The lock may be movable between a first position and a second position, wherein the lock does not prevent the boom from moving in the first direction when the lock is in the first position, wherein the lock prevents the boom from moving in the first direction when the lock is in the second position, and further wherein the restraint prevents the boom from moving in the second direction when the lock is in the second position. The clamp may be configured to be installed and removed by an operator without tools. The boom clamp may further comprise a handle configured to be grasped by an operator during installation and removal of the clamp. The sleeve may be configured to surround the lock. The lock may be a pin and the sleeve may be a cylinder. The restraint may comprise a first plate fixed to the sleeve and configured to face a lower surface of the boom, a second plate fixed to the first plate and configured to extend parallel to the boom, and a third plate fixed to the second plate configured to face an upper surface of the boom. The boom may further include hydraulic lines, and a shroud surrounding the hydraulic lines, wherein the restraint is configured to surround the shroud.
[0009] In accordance with a second aspect of the invention, a boom lock for a skid steer loader, said skid steer loader having a chassis, an operator cab removably attached to the chassis, and a boom pivotally coupled to the operator cab is provided, the boom lock comprising first means for preventing the boom from pivoting in a first direction with respect to the cab, and second means for holding the first means and the boom together.
[0010] The second means may prevent the boom from pivoting in a second direction with respect to the cab. The first means may comprise a locking pin movably attached to the cab. The second means may comprise a boom restraint and a pin sleeve. The second means may be removably attached to the first means and the boom.
[0011] In accordance with a third aspect of the invention, a method for locking a boom on a work vehicle is provided, comprising the steps of extending a locking pin to prevent motion of the boom in a first direction, and coupling a clamp to the locking pin after the step of extending, to prevent motion of the boom in a second direction.
[0012] The step of extending may include extending the locking pin from an operator cab. The step of extending may include moving the boom to a position adjacent the locking pin. The step of coupling may include sliding the locking pin into a hole in the clamp after the step of extending. The clamp may be c-shaped and the step of coupling may include sliding the clamp around the boom. The step of coupling may include sliding the clamp around a protective shroud.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side view of a skid steer loader with the invention attached.
[0014] FIG. 2 is a partial perspective view of the skid steer loader from FIG. 1 showing a loader arm with locking pin extended and without the invention attached.
[0015] FIG. 3 is identical to FIG. 2 except the invention is attached.
[0016] FIG. 4 is a cross section view of the skid steer loader taken at line 4 - 4 of FIG. 3 showing the cab wall, boom and extended locking pin, with the invention attached.
[0017] FIG. 5 is a perspective view of the invention from the handle (back) side.
[0018] FIG. 6 is a perspective view of the invention from the front side.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIG. 1 shows a skid steer loader 100 for material handling viewed from the left side, with the booms locked in an intermediate position according to the present invention. The “front” of the vehicle is defined as the direction of normal forward movement and the direction the operator will face when operator will face when operating the vehicle to handle materials, and is shown in FIG. 1 by the directional arrow F. The directions of boom movement of “up” and “down” are relative to the operator cab.
[0020] The loader includes wheels 102 , a main body frame 104 , and a cab boom assembly 106 . The wheels 102 (left front and rear wheels shown, right front and rear wheels not visible in this drawing) are rotatably coupled to and support the main body frame 104 . The main body frame 104 encloses the engine, drive mechanism, and hydraulics (not shown), and supports the cab boom assembly 106 .
[0021] The cab boom assembly 106 is removably attached to the main body frame and rests on top of the frame. The assembly 106 includes the operator cab 108 , the boom structure 110 , and the boom clamp 111 . The operator sits in the operator cab while operating the skid steer loader. Operator controls and seat (not shown) are enclosed by the cab. The cab is composed of left and right sidewalls 112 , a roof, and a (left, right) pair of boom locking pins 113 . The right sidewall and roof are not visible in FIG. 1 . The boom structure 110 is pivotally attached to the left and right side of the cab 108 .
[0022] The boom structure 110 uses hydraulics and a four-bar linkage to move materials with an implement according to operator commands issued via control levers in the cab 108 . The FIGS. 1-4 show only the left side portion of the boom structure 110 . An identical mirror-image right side boom structure (not shown) is coupled to the right side of the cab. The left side portion and the right side portion together comprise the boom structure 110 . In all ways other than as stated below, the function and interconnection of the right boom elements is identical to that of the left boom elements. The boom structure comprises left side and right side upper boom arms 114 , left and right side lower boom arms 116 , left and right side supporting links 118 , left and right side hydraulic cylinders 120 , left and right side linkage plates 122 and an implement mounting plate 124 . Further description relates to the left side interconnections of the boom structure, however the right side of the boom structure is interconnected identically.
[0023] The upper boom arm 114 , the supporting link 118 , the hydraulic cylinder 120 and the lower boom arm 116 are all coupled to the linkage plate 122 and, together with the cab, create a four-bar linkage. One end of the lower boom arm 116 is pivotally attached to a rearward section of the sidewall 112 of the cab 108 and extends generally rearwardly and upwardly. The other end of the lower boom arm is pivotally attached to a lower portion of the linkage plate 122 . The cylinder end of the hydraulic cylinder 120 is pivotally attached to a central section of the sidewall 112 and extends generally rearwardly and upwardly. The rod end of the hydraulic cylinder is pivotally attached to a central section of the linkage plate 122 . One end of the supporting link 118 is pivotally attached to an upper section of the sidewall 112 and extends generally rearwardly. The other end of the supporting link is pivotally attached to an upper section of the linkage plate 122 . One end of the upper boom arm 114 is pivotally attached to the implement holder 124 and extends generally rearwardly and upwardly, curving down. The other end of the upper boom arm is fixed to an upper section of the linkage plate 122 .
[0024] The boom structure 110 operates in a left vertical plane parallel to the left sidewall 112 and a right vertical plane parallel to the right sidewall 112 (not shown). By extending the hydraulic cylinder 120 , the four-bar linkage moves such that the implement holder 124 located at the front end of the upper boom arms 114 moves upward. Conversely, retracting the hydraulic cylinder moves the implement holder downward. Further details of the boom structure can be found in U.S. Pat. No. 3,215,292.
[0025] Locking pins 113 (only the left side shown, an identical pin exists on the right side) are slidably supported by the cab of the vehicle. They are configured so the operator can slide them laterally and horizontally from a first position in which they do not interfere with the movement of the boom to a second outward position where they interfere with the movement of the boom, preventing it from pivoting downward. (See FIGS. 2 & 3 and additional details in U.S. Pat. No. 3,730,362 which is incorporated herein by reference for all that it teaches.)
[0026] In FIG. 1 , the operator has extended the hydraulic cylinder 120 far enough such that the lower boom arm 116 is above locking pin 113 . The operator has then engaged the locking pin 113 by moving it from the first non-interfering position laterally outward from loader 100 to the second interfering position. The locking pin 113 extends through the sidewall 112 of the operator cab 108 and crosses the left vertical operation plane of the boom structure 110 . The operator has then retracted the hydraulic cylinder and lowered the lower boom arm 116 until it is close to or resting on the locking pin 113 . The operator has then installed the boom clamp 111 , by getting out of the vehicle, picking up the boom clamp, orienting it with the locking pin 113 , orienting it with the lower boom arm 116 , and simultaneously sliding it over the lower boom arm 116 and the locking pin 113 . The combination of the locking pin and the boom clamp prevent the lower boom arm, and thus the entire boom structure 110 , from pivoting either upward or downward with respect to the cab 108 . The hydraulic cylinder 120 is under compression from the weight of the boom structure 110 .
[0027] FIG. 1 also shows, in phantom, a tilted position 126 of the cab boom assembly 106 . This is a common position during repairs, allowing the repairman access to the components contained within the main body frame 104 . It can be seen that tilting the cab boom assembly 106 toward the front moves more of the boom structure 110 and cab 108 closer to or forward of a vertical centerline of the vehicle. This causes the weight of the cab, implement holders 124 and upper boom arms 114 to act upon the hydraulic cylinder 120 such that the cylinder is under extension rather than compression. When the cab 108 is tilted thusly, if there is a hydraulic leak the weight of the cab will tend to cause the cylinder to extend and the lower boom arm 116 to pivot upward with respect to the cab unless the lower boom arm is locked from upward movement (with respect to the cab) with the boom clamp 111 . Thus the boom clamp provides additional useful boom locking functionality as compared to the locking pin 113 which only prevents the lower boom arm 116 from moving downward (with respect to the cab).
[0028] FIGS. 2 & 3 show the left lower boom arm 116 in intermediate locked position and the locking pin 113 in its second interfering position. The FIGURES are identical except FIG. 3 shows the boom clamp 111 installed and does not show the hydraulic cables 206 . The locking pin 113 extends outward through the sidewall 112 and beneath the lower boom arm 116 . The lower boom arm includes a lower surface 200 , a wear plate 201 , an outer surface 202 , an upper surface 400 ( FIG. 4 ), an inner surface 402 ( FIG. 4 ), a protective shroud 204 and hydraulic cables 206 (shown in phantom). The lower surface, inner surface, outer surface and upper surface are fixed to each other such that they form a beam of rectangular cross section. The wear plate 201 is parallel to and fixed to the bottom of the lower surface 200 , and strengthens the area where the boom rests on the locking pin 113 . The wear plate only extends 4-6″, providing a stop for the locking pin to rest against. The shroud 204 is also generally rectangular in cross section, and is attached to the upper surface 400 of the lower boom arm 116 . In the present embodiment, the shroud does not extend the entire length of the lower boom arm, but only extends 6-8″, and is open at both ends. This is sufficient to restrain the hydraulic cables 206 inside the shroud. The cables run parallel to the lower boom arm 116 , entering the shroud 204 at one open shroud end and leaving at the other open shroud end.
[0029] The lower boom arm 116 pivots about a point 208 where it is connected to the sidewall 112 . The lower boom arm pivots in a first direction downward, shown by arrow A. The lower boom arm also pivots in a second direction upward, shown by arrow B. The locking pin 113 contacts the wear plate 201 of the lower boom arm 116 , preventing the lower boom arm from pivoting in the first direction A beyond it's current intermediate locked position. In FIG. 2 there is nothing preventing the lower boom arm from pivoting in the second direction B.
[0030] FIG. 3 shows the lower boom arm 116 in its intermediate locked position, the locking pin 113 extended to its second interfering position, and the boom clamp 111 installed onto the lower boom arm 116 and locking pin 113 . The lower boom arm is locked from pivoting upward or downward. The boom clamp comprises a pin sleeve 300 , a boom restraint 302 and a handle 304 . The pin sleeve 300 is configured to slide around the locking pin 113 . The sleeve is cylindrical with an inside diameter slightly larger than the outside diameter of the locking pin. The restraint 302 is c-shaped and fixed to the sleeve, and is configured to slide around the lower boom arm 116 . The handle 304 is a rod bent into a generally semicircular shape, fixed at one end to the restraint 302 and fixed at the other end to the sleeve 300 . The restraint is further made up of a first plate 306 , a second plate 308 and a third plate 310 . The first plate 306 is fixed to the top of the sleeve 300 and is disposed generally parallel to the lower surface 200 of the lower boom arm 116 . The second plate 308 is fixed to the first plate and is disposed generally vertically and parallel to the outside surface 202 . The third plate 310 is fixed to the second plate and is disposed generally parallel to the upper surface 400 . The second plate is long enough such that the first plate 306 and third plate 310 define an opening therebetween wide enough to surround the lower boom arm 116 .
[0031] In FIG. 3 the lower boom arm is prevented from pivoting in the second direction B by the third plate 310 of the restraint 302 . Thus the addition of the boom clamp locks the lower boom arm 116 (and thus the entire boom structure 110 via the four-bar linkage) in the intermediate position.
[0032] FIG. 4 shows a partial cross section of the lower boom arm and locking mechanism taken at line 4 - 4 of FIG. 3 . The rectangular cross section of the lower boom arm 116 beam is clearly evident, as a box formed by surfaces 400 , 402 , 200 & 202 . The protective shroud 204 is a similar cross section extending upward from the beam. The wear plate 201 is fixed to the bottom of the lower surface 200 of the lower boom arm 116 and touches the top of the locking pin 113 . The handle 304 is fixed to the third plate 310 and the bottom of the sleeve 300 . By grasping the handle and pulling, the boom clamp 111 may be quickly removed from the vehicle without the use of any tools.
[0033] FIGS. 5 and 6 show two perspective views of the boom clamp 111 removed from the vehicle. Typically, the boom clamp is installed after the lower boom arm 116 has been lowered all the way to the locking pin 113 . This means that there is no space between the locking pin 113 and the wear plate 201 of the boom. Thus the sleeve 300 has a gap 500 in the outside of the cylinder along the top edge of the cylinder, and the first plate 306 has a corresponding gap 502 in the central section. The sleeve 300 and restraint 302 are joined by a weldment along each side of the gaps 500 , 502 . If a different intermediate position of the lower boom arms is desired, the boom clamp could be configured with a continuous cylinder sleeve 300 and a spacer between the sleeve and the restraint 302 . This would lock the arms in a position higher than that of the locking pins alone, equal to the original height plus the width of the spacer. In this case, the locking pins would not directly contact the lower boom arm.
[0034] It will be understood that changes in the details, materials, steps, and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. For example, the boom clamp may be attached upside down, after the boom has been lowered below the locking pin, such that the pin prevents upward movement and the boom clamp prevents downward movement—allowing the pin/clamp combination to work with the boom at two different levels with only one pin predetermined height. There may be multiple locking pins at predetermined heights on each side of the skid steer loader, and the clamps may be attached at any pair of pins, thereby locking the arms at a plurality of predetermined heights. The coupling between the sleeve and the restraint need not be fixed, as in a weldment, but may be variable. The coupling may be fixed with a spacer such that there is a considerable separation between the locking pin and the boom. The locking pin may be a rectangular bar or other shape, and may project in a non-orthogonal manner across the plane of boom movement. The sleeve may be rectangular or some other shape, as long as it captures the locking pin. The restraint may be made of one continuous plate, and may be semicircular in shape. The protective shroud surrounding the cables may be inside the boom arm housing rather than outside. The handle may be a different shape, may be attached at only one end, and may be attached to either the restraint or the sleeve or both.
[0035] Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | A boom clamp for a work vehicle having a lock and a boom is provided, the lock being configured to prevent movement of the boom in a first direction, the clamp comprising a restraint configured to engage the boom; and a sleeve fixed to the restraint, the sleeve configured to engage the lock; wherein the restraint prevents the boom from moving in a second direction. |
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PRIORITY INFORMATION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/441,521, filed on May 20, 2003.
FIELD OF THE INVENTION
[0002] The field of this invention is expanding tubulars and more particularly a gripping system for hangers or patches that is energized by longitudinal dimension change of the tubular induced by the expansion process.
BACKGROUND OF THE INVENTION
[0003] When downhole tubulars crack or otherwise need repair, patches or cladding are inserted to the proper depth and expanded into contact over the damaged area. As a result of expansion, the cladding assumes a sealed relation with the surrounding tubular. In other applications a hanger attached to a tubular string is inserted into a larger tubular. Expansion is used to anchor and seal the newly inserted string to the existing string.
[0004] Expansion is accomplished by driving a swage through the hanger or cladding. Applied hydraulic pressure from the surface is used to stroke a piston, which, in turn, drives the swage. An anchor assembly initially is energized to hold the hanger in response to applied pressure. Initially, the running tool that delivered the hanger is released when the anchor grabs the hanger to provide support for the hanger as the piston strokes the swage to obtain initial support. Once initial support is accomplished the anchor is released and the stroker for the swage is re-cocked for a repetition of the process until the swage passes through the hanger.
[0005] The specification for the tubular being repaired or the tubular in which the hanger is to be attached can vary widely. The condition of that tubular can also affect its internal diameter.
[0006] When using a swage that has a fixed dimension care must be taken to properly size it for the anticipated inside diameter where the patch or hanger is to be attached. The problem is that there is uncertainty as to the actual inside diameter after years of service. Additionally, a given swage size may be used for a variety of casing weights of a given size. If the actual diameter is smaller than anticipated, there may not be enough available force in the stroking mechanism for the swage to drive it through. In this case the swage will stall and the expansion cannot be properly completed without time-consuming trips out of the hole and replacement swages. Even worse, the swage could hang up in the hanger if it can't be driven all the way through.
[0007] One expensive way around this is to use a variable diameter swage that has the ability to change dimension in response to unexpected inside diameter dimension in the tubular in which the patch or hanger is to be attached. Fixed diameter swages are more economical and, in the past, some efforts have been made when using a fixed swage to compensate for unexpected variation from the planned inside diameter. FIGS. 1 and 2 show a prior technique for compensating for dimensional variations in the casing
[0008] Referring to FIG. 1 , a fixed diameter swage 10 is disposed inside the hanger or cladding 12 and the entire assembly is in position for expansion inside casing 14 . When hanger is mentioned it will be considered to also encompass other downhole structures such as patches or cladding. Hanger 12 has an exterior serrated surface 16 built into it for eventual engagement with the casing 14 , as shown in FIG. 2 . An inner sleeve 18 made of soft material underlays the serrations 16 . The intent is for the swage 10 to go inside sleeve 18 . If the inside diameter turns out to be smaller than anticipated, then the swage 10 will deform sleeve 18 by design. This can happen because sleeve 18 is made deliberately soft. The objective is to prevent the swage from stalling when the inside diameter of the casing turns out to be smaller than expected. Using sleeve 18 also helps to give the swage 10 an opportunity to provide sufficient contact force against casing 14 by the serrations 16 when the actual inside diameter turns out to be somewhat larger than expected. Yet the ability to provide flexibility and latitude for the actual inside diameter being smaller or larger than anticipated is limited in this design. The apparatus of the present invention seeks to provide greater latitude for diameter variations in both directions that may be incurred in the field. Additionally, the present invention seeks to improve the grip and provide resistance against release from net forces in opposed directions. One way this is accomplished is to take advantage of the phenomenon of longitudinal dimension change of the hanger under compressive or tensile stress that occurs as force is applied to drive the swage. The slip is articulated for radial extension from longitudinal shrinkage to allow a greater variation of inside diameters in which a proper grip can be maintained and the swage driven through without stalling. These and other advantages of the present invention will be more readily appreciated by those skilled in the art from a review of the description of the preferred embodiment and the claims, which appear below.
SUMMARY OF THE INVENTION
[0009] A slip for an expanding hanger or patch is disclosed. The slip is mounted over the hanger body and has an internal profile that nests within a mating profile on the exterior of the hanger. When the swage is forced through the hanger, the hanger shrinks longitudinally and as a result the slip is cammed radially to the extent the inside diameter of the surrounding tubing permits. As the swage is further advanced, the diameter of the hanger increases in the region where longitudinal dimension change has already taken place forcing the slip into preferably penetrating contact with the inside wall of the surrounding tubular.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a run in view of a prior art hanger;
[0011] FIG. 2 is the view of FIG. 1 in the set position;
[0012] FIG. 3 is a run in view of a part of a hanger showing the distinct slip and the camming mechanism;
[0013] FIG. 4 is the view of FIG. 3 with the slip set in the surrounding tubular without an opportunity to be cammed away from the hanger;
[0014] FIG. 5 is the view of FIG. 3 after the slip has had room inside the tubular inside diameter to be cammed out before being forced against the wall of the surrounding tubular;
[0015] FIGS. 6 a - 6 b shows the upper end of a hanger in the set position with slips disposed in mirror image orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The overall layout can best be understood from FIG. 6 . The casing 20 has a split or an area of perforation 22 that needs to be covered with the hanger 24 . Alternatively, hanger 24 may be mounted at the uphole end of a tubing string (not shown) such that when it is expanded by the swage 26 the final result is support for the string from the casing 20 . Swage 26 has a fixed diameter and is mounted for sliding movement with respect to running tool 28 . Hanger 24 has a groove 30 into which a latch 32 on the running tool 28 is initially held. In this manner, a running string (not shown) can support the hanger 24 for proper placement in the casing 20 . Generally, the swage 26 is driven by a hydraulic stroker device (not shown). Initially, application of hydraulic pressure through the running string actuates the schematically illustrated anchor 34 for an initial grip of the hanger 24 . After some advancement of the swage 26 a grip is established between the hanger 24 and the casing 20 , as will be described below. Such expansion of the hanger 24 also results in a release of latch 32 from groove 30 . Thereafter, by cycles of applying and removing the hydraulic pressure, the swage 26 is advanced until it clears the opposite end of the hanger 24 . Those skilled in the art will appreciate that the anchor 34 can be mounted downhole of the swage 26 (as shown) or uphole of the swage 26 and still obtain sequential grips to allow repeated stroking to advance the swage 26 to its desired end of travel. The above-described technique for stepwise advancement of a fixed diameter swage 26 is a known procedure and sets the stage for the detailed description of the operation of the invention.
[0017] It should be noted that in FIG. 6 , the swage 26 is bearing down and initiating expansion by fixating the uphole end of hanger 24 . The lower end of hanger 24 is not restrained but merely held by the anchor 34 . The swage actually puts the hanger 24 in tension. For a diameter expansion of about 20% the length will decrease by about 5%. Alternatively, the swage can be forced in an uphole direction with the upper end of the hanger 24 being retained. In this situation, the hanger 24 will be in compression and the wall thickness will try to remain constant. Since the volume will remain constant after expansion, the length will shrink even more than expansion under tension. It is this change in length, as the expansion is underway that is employed in the present invention to push out the slips such as 36 and 38 to the wall of the casing across clearance 66 , if present. This use of longitudinal dimension change to drive the slip allows for greater flexibility to have the hanger 24 get a bite in a wider range of casing inside diameters than was possible in the prior designs.
[0018] Broadly stated, one aspect of the invention is the ability to take advantage of the longitudinal shrinkage of the hanger 24 , when placed under compressive or tensile stress from swaging.
[0019] FIG. 6 a illustrates slips 36 and 38 . Slip 36 has serrations or other surface treatment 40 so that upon expansion it can preferably penetrate into the wall of the casing 20 . The surface treatment 40 can also incorporate hard materials such as carbide inserts or it can be a regular pattern of protrusions or a series of rings or a thread or any other grip enhancing treatment or coating of the exterior of the slip 36 . Slip 36 is preferably a split ring with a single split longitudinally. Alternatively, the slip 36 can be a plurality of segments held to hanger 24 with a band spring or other retainer that can allow the segments to be cammed outwardly as will be described below. In another form, slip 36 can be a solid thin walled ring that can be cammed out if space permits by simply yielding or by fracturing. In the preferred embodiment slip 38 is identical to slip 36 and is installed in a mirror image manner. As seen in FIG. 6 a , slip 36 has a shoulder 42 adjacent to a mating shoulder 44 near the uphole end 46 of hanger 24 . Slip 38 is identical but is oppositely oriented so that it has a shoulder 48 near shoulder 50 on hanger 24 . Shoulder 48 is oriented closer to the downhole end of hanger 24 . While two mirror image slips 36 and 38 have been shown near one end of hanger 24 , those skilled in the art will appreciate that slips 36 and 38 can be in the same as opposed to mirror image orientation. Only one slip such as 36 or 38 can be used or even more than the two slips shown can be placed near a given end of the hanger 24 . The design of each slip can vary and some variations are suggested above. These variations can be mixed or matched.
[0020] FIG. 3 illustrates a portion of slip 36 with the casing 20 represented by a dashed line. Shoulder 42 is disposed close to shoulder 44 on hanger 24 . Hanger 24 has a recessed surface 52 that begins at shoulder 42 and a plurality of projections 54 . Typically, a projection 54 is trapezoidal in section and has opposed surfaces 56 and 58 that have intersecting slopes. In between is a preferably flat surface 60 . Slip 36 has an interior surface 62 with voids 64 that preferably conform in shape to projections 54 . Shape conformity is merely the preferred mode and is not essential. The indicated shape using inclined surfaces separated by a flat surface for the projections 54 or for conforming voids 64 is simply the preferred embodiment. Those skilled in the art will appreciate that the invention encompasses shapes that can nest during run in, as shown in FIG. 3 to allow a clearance 66 to exist. Then, when swage 26 begins moving into hanger 24 its length will decrease and to the extent a clearance 66 still exists, the nesting relation turns into a camming relationship as the slip 36 , or for that matter any other similarly mounted slip, is moved outwardly due to longitudinal shrinkage of the hanger 24 under stress loading. For example, if the planned expansion is about 20% the longitudinal shrinkage is approximately 5%. As shown in FIG. 5 , the further a given projection is from a point on the hanger 24 that is restrained the greater the offset between previously nested pairs of projection and corresponding depression. For example, projection 68 is fully misaligned from depression 70 so as to fully cam out the lower end 72 of slip 36 . Further uphole, projection 74 is somewhat less misaligned from depression 76 while still further uphole projection 78 is separated from but virtually still in alignment with depression 80 . FIG. 5 illustrates that where the inside diameter of the casing 20 permits, driving the swage 26 through hanger 24 will shorten it drawing the various projections about 5% of their original distance from the restrained point of the hanger 24 . Initially, until shoulder 42 on slip 36 engages shoulder 44 on hanger 24 any slack between the projections and depressions will be taken out. Thereafter, as the projections keep moving, shortening their original distance from the restrained point by about 5% or more depending on the amount of diametric expansion, due to longitudinal shrinkage the camming action commences to the extent a clearance to the inside casing wall is present. The maximum radial displacement due to shrinkage of the hanger 24 is shown in FIG. 5 . It happens when flat surface 60 is on interior surface 62 of the slip 36 . While the preferred embodiment has been shown with projections on the hanger 24 and nesting depressions on the slip 36 , those skilled in the art will appreciate that the desired camming action can occur by presenting the projections on the slip 36 and the nested depressions on the hanger 24 . It is only after the camming action described above, which occurs due to shrinkage of the hanger 24 from the swage 26 moving through it, that the swage 26 can force the slip 36 into a preferably biting relation with the casing 20 through expansion of the diameter in the area of the slip 36 . The camming of slip 36 begins before the diameter under it is actually expanded.
[0021] One extreme is illustrated in FIG. 4 where the inside wall of the casing 20 is so close to slip 36 that camming action cannot occur. In this case, the applied stress that would otherwise result in longitudinal shrinking of the hanger 24 instead merely reduces the wall thickness of the hanger 24 since the slip 36 acts to fixate its end as the expansion begins.
[0022] While the preferred method described above is to longitudinally shrink the hanger 24 those skilled in the art will appreciate that it is the camming action caused by relative movement that results in the ability of the hanger 24 to compensate for inside diameters of the casing 20 . Thus any technique that results in a camming action to move a slip such as 36 outwardly, up to the point of closing an available clearance, where the camming takes place before the diameter under the slip is actually expanded, is within the scope of the invention, whether the camming is caused by shrinkage or growth of one member with respect to another or induced by other techniques.
[0023] Those skilled in the art will appreciate that the lower end (not shown) of the hanger 24 can be similar to what has been illustrated for a slip layout in FIG. 6 . Alternatively, the slip arrangements can be different at opposing ends or slips can be used on only one end and still be within the scope of the invention.
[0024] After expansion, a net uphole directed dislodging force pushes shoulder 42 of slip 36 against shoulder 44 of hanger 24 to help the slip 36 dig in better to resist such force. In the opposite direction, the engagement between shoulders 48 and 50 also helps slip 38 retain its grip. In general, during the camming action, shoulder engagement between a slip and the hanger 24 converts what may have previously been longitudinal displacement into radially cammed movement.
[0025] Those skilled in the art will now appreciate that the present invention with slips that can be cammed out, or not, depending on the inside diameter of the casing 20 , allows the apparatus a greater flexibility to obtain the proper grip in a broader range of casing inside diameters than the prior designs such as shown in FIGS. 1 and 2 . The radial range of camming is flexible from none to a maximum value where the slip is fully cammed out as a result of complete misalignment between a previously nested projection and depression or whatever the outer limit of the camming mechanism that is used due to the available relative movement. Optionally, resilient seals can be employed with the slips to enhance the sealing against the casing 20 .
[0026] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: | A slip for an expanding hanger or patch is disclosed. The slip is mounted over the hanger body and has an internal profile that nests within a mating profile on the exterior of the hanger. When a compressive force is applied to the hanger, it shrinks longitudinally and as a result the slip is cammed radially to the extent the inside diameter of the surrounding tubing permits. When the swage is advanced, the diameter of the hanger increases forcing the slip into preferably penetrating contact with the inside wall of the surrounding tubular. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a self-propelled construction machine, in particular a road milling machine, which has a machine frame and a milling drum housing, inside which a milling drum is arranged. In addition, the invention relates to a method for operating a self-propelled construction machine.
[0003] 2. Description of the Prior Art
[0004] Known road milling machines have a milling drum, with which the material is milled off. The milling drum is arranged inside a milling drum housing, inside which the milled material collects.
[0005] The road milling machines have a conveying device, which takes the milled material away from the drum housing in order to load the material onto a transportation vehicle. In addition, the road milling machines have a scraping device, which is provided behind the milling drum in the direction of work. The scraping device has a height-adjustable scraper blade. If the milled material is to be loaded during the work, the lower edge of the scraper blade skims over the milled surface such that the surface is removed cleanly. In the process the scraper blade shuts the milling drum housing behind the milling drum in the direction of work.
[0006] If, on the other hand, it is not intended for the milled material to be loaded, it is necessary to raise the scraper blade in relation to the milling drum so that the milled material can remain behind the milling drum housing in the direction of work. Because of the loosening factor, which is approximately 1.2-1.5, the volume of the milled material increases such that the milled channel can only accommodate part of the milled material. The rest of the milled material is thrown out into a heap, which takes on an angle of friction of approximately 30 to 40° at least on the outer flanks. The height of the heap depends inter alia on the depth of milling and the actual loosening factor that occurs.
[0007] If the scraper blade has too low a height in this operating mode, the milled material is retained in the milling drum housing such that the milling drum housing fills increasingly with material, which generates additional friction as a result of which the performance is reduced, the wear is increased, and not least it results in higher fuel consumption. On the other hand, the scraper blade cannot be raised arbitrarily either, since otherwise the milling drum housing would be open behind the milling drum in the direction of work as a result of which the milled material does not remain in the milled track in the desired form of a swathe, but rather is spread widely, leading to time-consuming work afterwards.
[0008] In practice, the machine operator is forced to move the scraper blade to a relatively wide open position, since he does not have the chance to examine the relevant region in order to adjust the height of the scraper blade precisely due to the arrangement of the individual components of the machine.
[0009] Stabilisers and recyclers do not have a conveying device. Therefore, the drum flap of stabilisers and recyclers, which shuts the drum housing, has to be adjusted such that the material can come out of the drum housing.
[0010] The object of the invention is to create a self-propelled construction machine, in particular a road milling machine, which can also be operated if the milled material is not loaded but rather is to remain in the milled track. Another object of the invention is to disclose a method for operating a self-propelled construction machine, if the milled material is not loaded but rather remains in the milled track.
[0011] These objects are achieved according to the invention with the features of the independent claims. The dependent claims relate to preferred embodiments of the invention.
[0012] The construction machine according to the invention, in particular a road milling machine, has a drive unit with which the scraper blade of the scraper device is height-adjustable in relation to the milling drum. In addition, the construction machine according to the invention has a control and/or regulator unit for the drive unit to adjust the height of the scraper blade and a measurement device to measure the distance between at least one reference point, which relates to the lower edge of the scraper blade, and the milled material.
[0013] The control and/or regulator unit of the construction machine according to the invention is designed such that the height of the scraper blade is adjusted depending on the height of the milled material remaining in the milled track. The control and/or regulator unit ensures that, on the one hand, the milled material can come out of the milling drum housing behind the milling drum in the direction of work largely unhindered and, on the other hand, the milling drum housing is largely shut above the material coming out of it. Thus, on the one hand, trouble-free operation of the milling machine is ensured and, on the other hand, a clean result of the work is achieved.
[0014] In particular, the self-propelled construction machine is a road milling machine, which has a conveying device in particular to convey the milled material from the milling drum housing to a transportation vehicle. The road milling machine can be a front-loader road milling machine, in which case the milled material is loaded via the front of the machine onto an HGV driving in front of it, or a rear-loader road milling machine, in which case the milled material is loaded via the rear onto a heavy goods vehicle (HGV) driving behind it.
[0015] A preferred embodiment of the road milling machine provides for an input unit with which two operating modes can be specified. In the process the design of the input unit is irrelevant. For example, the input unit can comprise one or more switches or buttons. It can, however, also be part of a menu navigation system. In the first operating mode, the conveying device is activated and the control and/or regulator unit is deactivated. This is the case if the milled material is to be loaded. If the milled material is not to be loaded, however, but rather is to remain in the milled track, the second operating mode is specified, in which the conveying device is deactivated and the control and/or regulator unit is activated.
[0016] A preferred embodiment provides for the control and/or regulator unit to control or regulate the drive unit in such a way that the measured distance between at least one reference point, which relates to the lower edge of the scraper blade, and the milled material corresponds to a specified value or lies within a specified value range. In practice, it is sufficient if a height correction is only performed when the measured distance leaves a specified tolerance range such that corrections to the height setting of the scraper blade are not being performed constantly.
[0017] In order to measure the distance between at least one reference point, which relates to the lower edge of the scraper blade, and the milled material, one or more distance measurements can be performed. The distance measurement can relate to one small measurement point (spot measurement) or a larger measurement region (regional measurement) on the surface of the milled material.
[0018] The measurement device is preferably designed such that one or more distance measurements are performed outside the milling drum housing behind the scraper blade in the direction of work. In principle, it is also possible, however, to measure the distance inside the milling drum housing.
[0019] The measurement device preferably has one or more distance sensors, which are preferably arranged on the rear side of the scraper blade in the direction of work above its lower edge. The distance sensors can be designed in different ways. They can measure the distance in a contactless or tactile manner. For example, the contactless distance sensors can be known ultrasonic distance measurement sensors, inductive, capacitive, optical distance measurement sensors or radar distance measurement sensors. Tactile distance sensors have at least one tactile element, which rests on the milled material.
[0020] In the case of a preferred embodiment, the measurement device is designed in such a way that the distance between the surface of the milled material and a reference point, which is not at the height of the lower edge of the scraper blade, is measured with the distance sensor so that the distance sensor does not have to be located directly on or near the lower edge of the scraper blade. A large scope for the arrangement of the distance sensor is thereby created.
[0021] In a sectional plane running transverse to the direction of work, the material thrown out behind the milling drum in the direction of work has a characteristic cross section that depends inter alia on the type of milling drum. Milling drums are known, which are characterised in that the material is thrown out in the center of the milling drum housing such that the maximum height of the material that has been thrown out is at its greatest in a region that is roughly central between the left and right-hand edges of the scraper blade and the height of the material falls away towards the sides. It is, however, also possible, for example, for the material to be conveyed inside the milling drum housing to one of the two sides, a cone of rubble again forming, which then lies on the left or right side, however.
[0022] In the simplest case, the control and/or regulator provides for the scraper blade to be located above the highest point of the material that is thrown out, it being possible for said point to be at the center or on the right or left side of the milling drum housing depending on the cross section of the material that is thrown out. The remaining gap between the lower edge of the blade and the upper side of the material should then be as small as possible. It is, however, also possible for the control and/or regulator to intentionally provide for the scraper blade to dip into the material at the highest point if the distance between the lower edge of the blade and upper side of the material is not measured at the highest point.
[0023] In a preferred embodiment, the measurement device to measure the distance between the lower edge of the scraper blade and the milled material is designed such that the distance measurements are performed at a plurality of reference points, which are located between the left and right-hand edges of the scraper blade in the direction of work. One embodiment provides for the height of the scraper blade to be adjusted depending on the mean value of the measured distances between the respective reference points, which relate to the lower edge of the scraper blade, and the milled material.
[0024] A particularly preferred embodiment provides for the height of the scraper blade to be adjusted depending on the smallest or largest measured distance between a reference point, which relates to the lower edge of the scraper blade, and the milled material. If the height of the scraper blade is adjusted depending on the greatest distance, the scraper blade dips deeper into the material at the highest point whereas in the case of the adjustment of the height of the scraper blade depending on the smallest distance, a gap may even remain between the scraper blade and the material.
[0025] The type of distance sensor with which the measurement is to be performed can be selected by the vehicle operator. For example, the vehicle operator may select a central distance sensor that measures the smallest distance for the type of milling drum that throws the material out in the center. The selection of the distance sensor can, however, be undertaken by the control and/or regulator unit itself in that during the measurement of the distance, the sensor with which the currently smallest or largest distance is being measured is always used for control/regulation.
[0026] If the material that is thrown out has a symmetrical cross section, for example, a particularly preferred embodiment provides for a central measurement in a region that is preferably 50%, in particular 30% of the width of the scraper blade such that a gap remains between the scraper blade and the material.
[0027] In the case of a symmetrical cross section, an alternative embodiment provides for the control and/or regulation to be performed in such a way that the scraper blade dips into the material that is thrown out such that the milling drum housing is completely shut behind the milling drum in the direction of work. The scraper blade must not be allowed to dip too deep into the material in the process, however, since otherwise the material would remain inside the milling drum housing. An ideal adjustment is therefore only given when the scraper blade only dips slightly into the center of the material that is thrown out.
[0028] The measurement device in this alternative embodiment is designed such that when the cross section is symmetrical, at least one distance measurement is performed at a specified distance to the left-hand edge of the scraper blade in the direction of work and/or at least one distance measurement is performed at a specified distance to the right-hand edge of the scraper blade in the direction of work. The height of the lateral flanks of the material that is thrown out can be determined using these distance measurements. This height is always lower than the height at the center of the material that is thrown out between the left and right-hand edges of the scraper element. For example, the lower edge of the scraper blade can be adjusted to the height of a point on the left and/or right flanks of the material that is thrown out. In this case, the lower edge of the scraper blade dips at the center slightly into the material that has been thrown out.
[0029] The specified distance from the left-hand edge and the specified distance from the right-hand edge of the scraper blade can for example be between 0 and 30%, preferably 10 to 20% of the width of the scraper blade, i.e. of the distance between its left and right-hand edges, since the characteristic extension of the flanks occurs here.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] A plurality of embodiments of the invention are described in more detail hereinafter with reference to the drawings, in which
[0031] FIG. 1 shows a road milling machine in a side view,
[0032] FIG. 2A shows a scraper device of a road milling machine in a perspective view, where the scraper blade is lowered,
[0033] FIG. 2B shows the scraper device from FIG. 2A , where the scraper blade is raised,
[0034] FIG. 3 shows a greatly simplified schematic view of the scraper blade from FIG. 2A and 2B in a view from the rear, the material that has been thrown out having a symmetrical cross section,
[0035] FIG. 4 shows a section through the scraper blade from FIG. 3 along the line IV-IV,
[0036] FIG. 5 shows an embodiment where the material that has been thrown out has an asymmetrical cross section, and
[0037] FIG. 6 shows an alternative embodiment with just one distance sensor that is movable transverse to the direction of work.
DETAILED DESCRIPTION
[0038] FIG. 1 shows a road milling machine as an example of a self-propelled construction machine. The road milling machine has a machine frame 1 and a chassis 2 , which can comprise front and rear ground engaging units 3 which may be crawler tracks or wheels.
[0039] The road milling machine has a milling drum 4 , which is arranged in a milling drum housing 5 on the machine frame 1 . In the present embodiment, the milling drum housing 5 is located at the rear of the machine. The height of the machine frame 1 can be adjusted by means of piston/cylinder arrangements 6 in relation to the surface 7 B of the ground 7 . By raising or lowering the machine frame 1 in relation to the ground 7 , the depth of milling is adjusted.
[0040] The milled material can be loaded onto a transport vehicle. For this purpose, the road milling machine has a conveying device 8 with a conveyor belt 9 , which conveys the milled material from the milling drum housing 5 to an HGV.
[0041] The milling drum housing 5 is shut by lateral plates 5 A, 5 B on the left and right sides in the direction of work 10 , only the right lateral plate 5 B in the direction of work being visible in FIG. 1 . Behind the milling drum 4 in the direction of work 10 there is a scraper device 11 , which has a height-adjustable scraper blade 12 , with which the milling drum housing can be shut at the rear.
[0042] FIGS. 2A and 2B show the milling drum housing 5 with the scraper device 11 in a perspective view. The scraper blade 12 is conveyed in lateral guides 14 in a portal 13 on the machine frame 1 . The scraper blade can be adjusted so as to be slightly inclined to the ground in the process.
[0043] The drive unit to raise and lower the scraper blade has a piston/cylinder arrangement 15 , the cylinder 15 A of which is fastened in an articulated manner to the portal 13 and the piston 15 B of which is fastened in an articulated manner to the scraper blade 12 . FIG. 2A shows the scraper blade 12 in the lowered position and FIG. 2B shows it in the raised position.
[0044] The drive unit 16 of the scraper device 11 is controlled or regulated by a control and/or regulator unit 17 , which may be a component of the central control and/or regulator unit of the road milling machine ( FIG. 3 ).
[0045] The construction and function of the scraper unit 11 are described in detail below with reference to FIGS. 3 to 4 .
[0046] The road milling machine provides for two operating modes, which can be selected on an input unit 18 . In the first operating mode, the conveyor belt 9 of the conveying device 8 of the road milling machine is switched on and the control and/or regulator unit 17 for the drive unit 16 of the scraper unit 11 is switched off, i.e. its particular function is deactivated, the scraper blade 12 being moved downwards such that the lower edge 12 A of the scraper blade rests on the surface of the milled ground 7 ( FIG. 2A ). Consequently the milled surface is scraped off and the milled material is loaded. This is the preferred operating mode of the milling machine. A special control or regulator can be provided for this purpose, which is not subject-matter of the invention, however.
[0047] It is also possible, however, to operate the road milling machine in a second operating mode, if it is not intended for the milled material to be totally loaded, but for it to remain at least partially on the surface 7 B of the milled ground 7 . In the second operating mode, the control and/or regulator unit 17 for the drive unit 16 of the scraper device 11 is activated and the conveying device 8 is deactivated.
[0048] FIGS. 3 and 4 show a greatly simplified schematic view of the construction and function of the scraper device 11 in the second operating mode. FIG. 3 shows the raised scraper blade in a view from the rear with the side plates 5 A, 5 B, which shut the milling drum housing 5 on the left and right sides in the direction of work 10 . When the milling drum housing 5 is open at the rear, the milled material remains lying on the ground. The material that is thrown out has a characteristic contour in a sectional plane extending transverse to the direction of work 10 that depends on the type of milling drum.
[0049] Firstly, an embodiment is described where the milling drum 4 throws the material out in the center of the milling drum housing such that the material that is thrown out has a symmetrical cross section. The material 19 that has been thrown out therefore has its greatest height, which depends on the depth of milling and the loosening factor, at the center between the side plates 5 A, 5 B. On the two sides, the contour has sloping flanks 19 B that fall away, the friction angle α of which also depends on the properties of the material. The control and/or regulator unit 17 controls or regulates the drive unit 16 such that the height of the scraper blade 12 can be adjusted optimally in relation to the material that is thrown out. In order to determine the distance between the lower edge 12 A of the scraper blade 12 and the surface 19 A of the material 19 that is thrown out, a measurement device 20 is provided, which comprises one or more distance sensors 21 , 22 , 23 . The distance sensors can be designed in different ways.
[0050] In a first embodiment, the measurement device 20 has a distance sensor 21 , which is arranged on the rear of the scraper blade 12 above its lower edge 12 A. The height of the distance sensor 21 in relation to the lower edge of the scraper blade is identified by a. The distance sensor 21 measures the distance between a point P 1 in the plane of the distance sensor and a point P 2 , in which the axis A intersects the surface of the material that is thrown out ( FIG. 4 ), in the direction of a preferably vertical axis A.
[0051] From the distance b between the points P 1 and P 2 and the height a of the distance sensor 21 in relation to the lower edge 12 A of the scraper blade 12 , the measurement device 20 calculates the distance Δ between the lower edge 12 A of the scraper blade 12 and the surface of material 19 A. Since the distance sensor 21 is arranged centrally between the two side plates 5 A, 5 B and between the left and right-hand edges of the scraper blade 12 , the measurement is made at the maximum height of the heap in the case of a symmetrical profile.
[0052] The control and/or regulator unit 17 controls or regulates the drive unit 16 in such a way that the distance Δ between the lower edge 12 A of the scraper blade 12 and the surface 19 A of the milled material 19 corresponds to a specified value or lies within a specified value range. Preferably a height correction is performed if the gap between the lower edge of the scraper blade and the material that is thrown out falls below a specified minimum value in the center between the side plates or exceeds a specified maximum value. If the minimum value is fallen short of the scraper blade is raised and if the maximum value is exceeded the scraper blade is lowered. A spot measurement or regional measurement can be performed with the central distance sensor. The distance Δ can also be measured with a plurality of distance sensors in the central region, the mean value being established and drawn upon for control and/or regulation.
[0053] Because of the characteristic contour of the heap, the distance measurement is preferably performed in a region in the center between the left and right-hand edges of the scraper blade 12 , the width of which is 50%, preferably 30% of the width d of the scraper blade.
[0054] The control or regulation described above is conditional upon the initially raised scraper blade 12 being lowered or the lowered scraper blade being raised until the distance between the scraper blade and the material corresponds to the specified value or value range, i.e. the scraper blade does not penetrate the material.
[0055] An alternative embodiment provides for a slight penetration of the scraper blade 12 into the material such that no gap remains at least in the center between the side plates 5 A, 5 B. In this embodiment, the measurement device 20 has a right and left distance sensor 22 , 23 in the direction of work 10 , the left sensor 22 being arranged at a distance e from the left-hand edge and the right sensor 23 at a distance e from the right-hand edge of the scraper blade. The distance e from the left and right-hand edges can, for example, be up to 20% of the width of the scraper blade. Because of the symmetry of the contour of the material that is thrown out, just one left or right distance sensor is sufficient in principle. Establishing the mean value of two distance sensors increases the accuracy of the measurement, however.
[0056] In the case of the alternative embodiment, the distance to the points PL and PR indicated in FIG. 3 , which points are located on the flanks 19 B of the material that is thrown out 19 , is measured with the two distance sensors 22 , 23 . In the process the height of the scraper blade 12 is controlled or regulated in such a way that the distance AL and AR respectively corresponds to a specified value or value range, which is measured in such a way that the lower edge 12 A of the scraper blade 12 dips into the material 19 that is thrown out slightly at the center without, however, touching the flanks 19 B of the surface of the material 19 A in the region of the measuring points P L and P R .
[0057] The measurement device can have one or more central distance sensors as well as one or more lateral distance sensors, i.e. in the present embodiment all of the distance sensors 21 , 22 , 23 . In an embodiment with a plurality of distance sensors 21 , 22 , 23 , the machine operator can select the distance sensors with which the distance measurement should be performed on the input unit 18 . For example, the machine operator can select the central distance sensor 21 , which measures the smallest distance, for the control and/or regulation such that a small gap remains between the scraper blade and the material. The machine operator can, however, also select at least one of the two lateral distance sensors 22 , 23 , which measure a greater distance, for the control and/or regulation such that the scraper blade dips slightly into the material at the center of the heap. The distances measured with the sensors 21 , 22 , 23 can be displayed on a display unit 18 A so that the machine operator can select the respective sensor with no knowledge of the milling drum type.
[0058] In another embodiment, the control and/or regulator unit 17 is designed in such a way that the selection of the distance sensors 21 , 22 , 23 is performed by the control and/or regulator unit itself. The control and/or regulator unit is designed in such a way that the distances measured with all of the sensors are compared to each other, the control and/or regulator unit determining the distance sensor where the smallest or greatest distance is being measured. The control and/or regulator unit then provides for control and/or regulation on the basis of the smallest or greatest distance.
[0059] If the milling drum type is entered on the input unit 18 , the control and/or regulator unit 17 can extrapolate the cross section of the material that is thrown out such that a selection of the sensor to be used can also be made without comparing the measured distances.
[0060] It is also possible to combine the distance measurements in the center and at the flanks of the material that is thrown out with one another. For example, it is possible on the basis of control or regulation to move the scraper blade towards the material surface as far as a specified minimum distance with one distance measurement in the center of the material that is thrown out in order to then transfer to a distance measurement on the flanks of the material that is thrown out in order to adjust the scraper blade to the height of the material surface in the center or to allow it to dip slightly into the material.
[0061] FIG. 5 shows an embodiment where the material that is thrown out has an asymmetrical cross section, the maximum height of the material being located on the right-hand side. Consequently, the distance measurement is performed with the right-hand distance sensor 23 , which measures the smallest distance Δ R . Again, this can be selected by the machine operator or by the control and regulator unit 17 depending on the milling drum type. The equivalent parts are provided with the same reference numerals. A measurement can, however, also be performed by a plurality of sensors 21 , 22 , 23 , it also being possible to establish the mean value.
[0062] FIG. 6 shows an embodiment with a measurement device 20 , which instead of a plurality of distance sensors only has one sensor 21 , which is movable on an axis extending transverse to the direction of work 10 between the side plates 5 A and 5 B. The equivalent parts are again provided with the same reference numerals. The sensor 21 is mounted in the center for a central distance measurement and it is mounted on one of the two sides for a lateral measurement. The distance sensor can, however, also be moved between the individual positions on a guide. | A self-propelled construction road milling machine, includes a machine frame and a milling drum housing, in which a milling drum is arranged. The machine includes a drive unit with which the height of the scraper blade of a scraper device can be adjusted in relation to the milling drum. A control unit for the drive unit adjusts the height of the scraper blade and a measurement device measures the distance between the lower edge of the scraper blade and the milled material. The control unit is designed in such a way that the scraper blade is height-adjustable depending on the height of the milled material remaining in the milled track. The control unit ensures that, on the one hand, the milled material can come out of the milling drum housing unimpeded behind the milling drum in the direction of work and, on the other hand, that the milling drum housing is shut above the material that is coming out. On the one hand, an unimpeded operation of the milling machine is thus ensured and, on the other hand, a clean result of the work is achieved. |
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FIELD OF THE INVENTION
[0001] The field of this invention related to running tools that can deliver an object to a selected location downhole and more particularly to running tools that can be used with standardized landing nipples and release from the object after securing it in the selected nipple.
BACKGROUND OF THE INVENTION
[0002] Landing nipples have special profiles that allow tools or plugs to be located at desired locations in a well. The landing nipples are part of a tubing string and their placement is determined when the tubing is run into the borehole. In the past, seal bore size has decreased as the well depth increased. Accordingly, the landing nipples had to have different sizes, depending on their location. More recently, with the increased use of expansion technology, wells are being completed as a monobore, where the tubing size is the same for the depth of the well. In monobore applications the landing nipples at various depths had to be unique as did the lock assembly that became supported at a selected landing nipple. An example of such a design is U.S. Pat. No. 4,043,392. The problem with such a system is that an array of landing nipples had to be available to be run in at specific depths and the matching configuration for the lock had to be used to get the lock to land at the proper depth. In systems with decreasing tubing size upon greater depth, selectivity was obtained by keeping on hand an assortment of lock sizes and running in the lock that would catch at the desired depth.
[0003] In the past a tool from Baker Hughes known as the Sur-Set® model AM-40 was available to attach to a lock for delivery to a predetermined depth. Thus in a monobore application, this system could be positioned adjacent a desired landing nipple among many that were identical to each other and then locked in place. The problem with this assembly was that the selective feature was integrated with the lock and had to stay in the hole as long as the lock remained in place. Leaving the selective feature in the hole was a large item of expense for the well operators that essentially had to purchase the selective feature as an item left in the hole.
[0004] Accordingly, the present invention is designed to allow separation of the selective feature after setting the lock, leaving only the essential components of the lock in the hole and removing the running tool and the selective feature. Since the running tool and the selective feature are removed from the hole, the cost to the well owner is decreased in that purchase of the running tool is avoided and instead the operator pays for a service using the running tool, which is a considerably lower charge. This advantage of the present invention, and others, will become more readily apparent to those skilled in the art from a review of the description of the preferred embodiment and the claims, which appear below.
SUMMARY OF THE INVENTION
[0005] A running tool that delivers an object selectively to one of a plurality of landing nipples and then releases from the object is disclosed. The tool is actuated by raising it after it has passed the desired landing nipple to release a locating dog. The locating dog places locking dogs on the object even with a groove on the landing nipple. Movement of the tool downhole secures the locking relationship and releases the running tool from the object. A shear pin allows testing at the surface that the object is locked in place, prior to removal of the running tool. The object comprises a fishing neck to allow it to be subsequently retrieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIGS. 1 a - 1 d are a section view of the running tool and the lock at the start of the sequence to actuate the lock at a pre-selected landing nipple;
[0007] [0007]FIGS. 2 a - 2 d are the view of FIGS. 1 a - 1 d shown with the lock engaged and the running tool released from the lock except for a shear pin connection to allow testing of the locked connection from the surface;
[0008] [0008]FIG. 3 is a detailed view of the select dog used to allow escape of the jarring dog for locating the running tool in the selected nipple profile for actuating the locking sequence; and
[0009] [0009]FIG. 4 is a detailed view of the jarring dogs engaged in the landing nipple groove for actuation of the locking and release sequence.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring to FIGS. 1 a - 1 d , a mandrel 32 is made of multiple components. From the uphole end is a fishing neck 1 that is connected to inter-linkage sleeve 23 at thread 34 . Sleeve 23 has a longitudinal groove 36 through which inter-linkage dog 22 extends. Lower dog prong 29 is connected to inter-linkage sleeve 23 at thread 38 . For run in, lower dog prong 29 supports lower dog 30 in a locking relation to groove 40 , see FIG. 1 d . A groove 42 on lower dog prong 29 is initially offset from lower dog 30 . Fishing neck dog retainer 25 is connected to sleeve 23 at thread 44 . Fishing neck dog 27 extends through an opening 119 in fishing neck dog retainer 25 . Dog 27 extends into groove 48 at the upper end of lock assembly 50 . Inter linkage probe 28 extends between inter-linkage sleeve 23 and lower dog prong 29 . It has a groove 52 that is initially offset from dog 27 . At its lower end, inter-linkage probe 28 has an opening 54 in which resides dog 30 . Dog 30 supports lock assembly 50 in a locked relation to probe 28 for run in. The lock assembly 50 has an outer sleeve 56 with an opening 58 in which anchoring dog 60 resides in a recessed relationship for run in. The lock assembly has an inner sleeve 62 that has groove 48 near its upper end. A recessed surface 64 on inner sleeve 62 is juxtaposed against dog 60 for run in to allow dog 60 to locate within opening 58 . Inner sleeve 62 has a ramp 64 that will ultimately push dog 60 into anchoring groove 66 in nipple profile 68 . A snap ring 70 is mounted to sleeve 62 and will ultimately snap into groove 72 on outer sleeve 56 . A seal assembly 74 is mounted to a housing 76 that is secured to outer sleeve 56 at thread 78 . Seal assembly 74 will ultimately seal inside the nipple profile 68 . A lower sub 80 is connected to housing 76 at thread 82 to seal off the passage inside the nipple profile 68 when the lock assembly is secured. Finally a shear pin 84 extends through outer sleeve 56 and into probe 28 to allow surface personnel to confirm that the lock assembly 50 is secured to groove 66 . Breaking this shear pin 84 will allow the lock assembly 50 to remain in place while everything else is removed from the wellbore.
[0011] Referring again to FIG. 1 a , a retaining sleeve sub 5 is secured with shear screw 6 to fishing neck 1 . A retaining ring cap 2 holds a retrieving ring 4 . Ultimately, ring 4 will snap into groove 86 on fishing neck 1 . Sub 5 is connected to locator sub 16 at thread 88 . Jarring dog retainer 19 is connected to locator sub 16 at thread 90 . Retainer 19 defines a recess 92 in which is disposed jarring dog 17 and leaf spring 18 to bias it out. Initially dog 17 is misaligned with opening 94 in lower cover sleeve 12 . Cover sleeve 12 is biased uphole by power spring 14 acting on stop ring 13 and supported off of locator sub 16 . Upper cover sleeve 8 is attached to cover sleeve 12 at thread 96 . Upper cover sleeve 8 has a longitudinal opening 98 through which select dog 11 extends. Spring 9 biases sleeve 8 against snap ring 7 in an uphole direction and pushes down on retainer ring 10 and select dog 11 in a downhole direction. Retaining sleeve sub 5 has upper groove 100 and lower groove 102 . Groove 102 has a reverse shoulder 104 that eventually traps mating shoulder 106 , as shown in FIG. 2 a . When running in the hole select dog 11 is pushed against the bias of spring 9 into groove 100 to allow the tool to advance unhindered. Once the select dog 11 enters groove 102 , the bias of spring 14 and the interaction of shoulders 104 and 106 retains the select dog 11 in groove 102 . Finally, cross-link dog retainer 20 is secured to jarring dog retainer 19 at thread 108 . Dog retainer 20 has a recess 110 in which sits inter-linkage dog 22 . Dog 22 supports inter-linkage probe 28 from dog retainer 20 . While dog retainer 20 abuts fishing neck dog retainer 25 , they are not connected and they come apart from each other, as shown in FIG. 2 b.
[0012] The significant components of the apparatus now having been described, the operation will be reviewed in more detail. FIGS. 1 a - 1 d illustrate the run in position. Dogs 18 are offset from window 94 and are held inwardly retracted. Shear screw 6 holds retaining sleeve sub 5 to fishing neck 1 . Dog 60 in lock assembly 50 is in a retracted position. The inner sleeve 62 is supported from dog 27 . The outer sleeve 56 is supported from dog 30 and shear pin 84 . When the tool is lowered through a given nipple profile 68 the select dog 11 encounters obstructions and is pushed back against the bias of spring 9 into groove 100 where it is sufficiently retracted to allow the assembly to continue to travel lower. Once a selected nipple profile 68 is reached and passed, the assembly is raised to the position shown in FIGS. 1 a - 1 d . Select dog 11 hangs on surface 112 in nipple profile 68 . When the tool is moved up more, the select dog 11 is forced into groove 102 and is trapped there. Select dog 11 pushed on the bottom of opening 98 to force down lower cover sleeve 12 . This allows spring 18 to push out jarring dog 17 into the now aligned opening 94 . Indexing dog 17 is raised above indexing grooves 114 and 116 and then the entire assembly is lowered until dog 17 can be pushed into grooves 114 and 116 as shown in FIGS. 2b and 4. With dog 17 in grooves 114 and 116 , dog 60 is aligned with groove 66 . Pushing down on fishing neck 1 breaks shear screw 6 . The connected pieces from cross-link dog retainer 20 at the lower end and up to retaining ring cap 2 remain stationary as the fishing neck 1 advances. Dog 22 and inter-linkage probe 28 do not move as they are supported by retainer 20 which now can't move. Since dog 22 is in opening 36 lower dog prong 29 and inter-linkage sleeve 23 can move down with respect to dog 22 that is held stationary. Dog 22 winds up at the uphole end of opening 36 as a result of such movement of prong 29 and sleeve 23 . Dog 27 engages inner sleeve 62 in groove 48 and pushed it down so that ramp 64 pushes out dog 60 into groove 66 and locks it in there with surface 118 . Snap ring 70 jumps into groove 72 to hold the locked position of dog 60 . As this happens, dog 27 falls into groove 52 to release the lock assembly 50 from fishing neck dog retainer 25 . At the same time, downward movement of lower dog prong 29 puts groove 42 opposite dog 30 to release housing 56 from inter-linkage probe 28 leaving just the shear pin 84 holding them together. Also at the same time retrieving ring 4 registers in groove 86 . At this time, the dog 60 is locked in groove 66 of the landing nipple 68 with snap ring 70 holding the locked position by expansion into groove 72 . There is no longer any connection by the lock assembly 50 to any other part of the tool except for shear pin 84 . Surface personnel can now apply a pulling force to break shear pin 84 as their signal that the lock assembly is properly secured to groove 66 . When a subsequent upward force is applied, dog 17 simply is cammed out of grooves 114 and 116 and the fishing neck 1 and all parts supported by it can come out of the hole leaving only the lock assembly 50 . At a later time groove 48 can be engaged by a fishing tool and inner sleeve 62 can be picked up, taking snap ring 70 out of groove 72 and moving surface 118 out from behind anchoring dog 60 so that the lock assembly 50 and whatever tool is attached to it can be removed from the well.
[0013] Those skilled in the art will appreciate that although the lock assembly is illustrated to be a plug in the preferred embodiment, other types of tools may be selectively positioned in one of a plurality of landing nipples. Where items are referred to in the singular, multiple quantities are also contemplated, such as, for instance, the various dogs in the apparatus. While a specific preferred structure to release a running tool that has capability to be actuated at a selected location from any tool that it carries has been disclosed, those skilled in the art will appreciate that the present invention contemplates any type of system of release of the downhole tool from the running tool when the running tool is configured for selective actuation at a predetermined location. While the present invention is particularly useful in a monobore application, other applications can also be within the scope of the invention. The present invention allows the running tool to be removed after it is used to place the downhole tool selectively at one of a plurality of anchoring points. In a monobore application identical landing nipples 68 can be used with one selective running tool that can come out of the hole after the downhole tool is anchored. The shear pin 84 allows a surface signal to be sensed that the anchoring dog 60 is secured to its anchoring groove 66 .
[0014] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A running tool that delivers an object selectively to one of a plurality of landing nipples and then releases from the object is disclosed. The tool is actuated by raising it after it has passed the desired landing nipple to release a locating dog. The locating dog places locking dogs on the object even with a groove on the landing nipple. Movement of the tool downhole secures the locking relationship and releases the running tool from the object. A sheer pin allows testing at the surface that the object is locked in place, prior to removal of the running tool. The object comprises a fishing neck to allow it to be subsequently retrieved. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the construction industry and, in particular, concerns a method of interconnecting building members with paired connectors and tie rods.
2. Description of the Related Art
In typical residential and light industrial and commercial building frame wall construction, load bearing frame walls comprise a series of studs and posts that are anchored to the foundation and covered with sheathing material installed over both sides of the frame. Typically, the frame is constructed from a number of vertically extending studs that are positioned between and connected to horizontally extending top and bottom plates. The bottom plate and the vertical studs are typically anchored to the foundation by some means. The sheathing material, which can be plywood, gypsum wallboard, siding, plaster, or the like, is then attached over the studs.
Natural forces commonly impose vertical and horizontal forces on the structural elements of the buildings. These forces can be the result of earth movements in an earthquake and from high-velocity winds, as in a hurricane or tornado. If these forces exceed the structural capacity of the building, they can cause structural failures leading to anything from minor damage to catastrophic destruction of the building, attendant economic loss, and injuries or fatalities.
The typical method of interconnecting the stories of a building is to use lengths of coil strap to tie the studs of an upper to story to the studs of the story below. The disadvantages of coil strap are manifold. Coil strap cannot be installed within a wall because of the intervening sill plates. Coil strap cannot accommodate any offset in the upper and lower studs. Wood shrinkage after strap installation across horizontal wood members can cause the strap to buckle outward. Coil strap is a general-purpose utility strap that is not tailored to the specific connection. Vertically-paired holdowns can eliminate some of the disadvantages of the coil strap, but holdowns are typically engineered for higher load values that are necessary in a floor-to-floor connection and therefore waste material and increase costs.
SUMMARY OF THE INVENTION
The present invention provides a single-piece connector that uses less material, and is therefore more economical to produce, than connectors in the prior art. In particular the diagonally-slanted support leg, preferably reinforced with shallow walls on either side, eliminates the need for an additional member to support or reinforce the seat member.
The present invention provides a connector that can be used, and a connection that can be made, inside the walls of the structure, thereby eliminating the exposure of coil strap, as in the prior art, which must be attached to the outer faces of the wall studs.
The present invention provides a connector with obround openings that permit limited adjustability and ease installation in narrow wall cavities.
The present invention provides a connection that is easy to install because it uses standard all thread rod, which is easily procured and can be easily run through a hole or holes drilled in the sill plates of the floor structure between the connected wall studs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the connector of the present invention.
FIG. 2 is a perspective view of the connection of the present invention.
FIG. 3 is a front elevation view of the connector of the present invention.
FIG. 4 is a side elevation view of the connector of the present invention.
FIG. 5 is a top plan view of the connector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The connector 1 of the present invention is preferably formed out of galvanized sheet steel using automated machinery. The connector 1 is preferably formed by cutting, punching and bending the sheet steel. However, the connector 1 can be formed by any appropriate method and material, for instance by casting metals such as aluminum and molding plastics.
At its most basic, the connector 1 of the present invention comprises a first substantially planar attachment tab 2 , a first substantially planar seat member 3 , a first substantially planar support leg 6 , and a second substantially planar attachment tab 9 .
Preferably, the first attachment tab 2 has an attachment face 20 and an opposite outer face 21 . Preferably, the first attachment tab 2 is elongated, with two relatively long and parallel side edges 44 and a relatively short end edge 45 that connects the two side edges 44 . The end edge 45 preferably has two diagonal end portions 46 that cut off what would otherwise be sharp corners on the first attachment tab 2 .
The first seat member 3 preferably has an inner face 22 and an opposite outer face 23 . The first seat member 3 has a first tie member opening 4 , which is preferably obround to allow a degree of adjustability. The first seat member is integrally connected to the first attachment tab 2 at a first bend line 5 , which is preferably straight.
Preferably, the first support leg 6 has an inner face 24 and an opposite outer face 25 . The first support leg 6 has a second tie member opening 7 . The first support leg 6 is integrally attached to the first seat member 3 at a second bend line 8 , which is preferably straight. The first bend line 5 and the second bend line 8 are substantially parallel to each other and are separated from each other by the first seat member 3 .
The second substantially planar attachment tab 9 preferably has an attachment face 26 and an opposite outer face 27 . The second attachment tab 9 is integrally attached to the first support leg 6 at a third bend line 10 , which is preferably straight. The second bend line 8 and said third bend line 10 are substantially parallel to each other and separated from each other by said first support leg 6 .
Preferably, the first attachment tab 2 and the first seat member 3 are substantially orthogonal. The inner face 22 of the first seat member 3 and said inner face 24 of the first support leg 6 preferably define a first angle 28 that is acute. Preferably, the outer face 25 of the first support leg 6 and the outer face 27 of said second attachment tab 9 define a second angle 29 that is obtuse.
The first seat member 3 preferably has a first edge 30 and a second edge 31 . Preferably, the first edge 30 of the first seat member 3 is bent toward the outer face 23 of the first seat member 3 to form a first reinforcing side wall 32 . The second edge 31 of the first seat member 3 is preferably bent toward the outer face 23 of the first seat member 3 to form a second reinforcing side wall 33 .
Preferably, the first seat member 3 has a central portion 43 between the first reinforcing side wall 32 and the second reinforcing side wall 33 of the first seat member ( 3 ). The first reinforcing side wall 32 and the second reinforcing side wall 33 of the first seat member 3 preferably converge between the first bend line 5 and the second bend line 8 so that the central portion 43 of the first seat member 3 narrows between the first bend line 5 and the second bend line 8 . Preferably, the first reinforcing side wall 32 is bent up along a first bend 47 and the second reinforcing side wall 33 is bent up along a second bend 48 . The first bend 47 and the second bend 48 preferably form two shallow inward-facing arcs in the first seat member 3 .
The first support leg 6 preferably has a first edge 34 and a second edge 35 . Preferably, the first edge 34 of the first support leg 6 is bent toward the outer face 25 of said first support leg 6 to form a first reinforcing side wall 36 . The second edge 35 of the first support leg 6 is preferably bent toward the outer face 25 of the first support leg 6 to form a second reinforcing side wall 37 .
Preferably, the first support leg 6 has a central portion 41 between the first reinforcing side wall 36 and the second reinforcing side wall 37 of said first support leg 6 . The first reinforcing side wall 36 and the second reinforcing side wall 37 of the first support leg 6 preferably converge between the second bend line 8 and the third bend line 10 so that the central portion 41 of the first support leg 6 narrows between the second bend line 8 and the third bend line 10 . Preferably, the first reinforcing side wall 36 is bent up along a first bend 49 and the second reinforcing side wall 37 is bent up along a second bend 50 . The first bend 49 and the second bend 50 preferably form two shallow inward-facing arcs in the first support leg 6 .
Preferably, the first bend line 5 has a first reinforcing gusset 38 that bridges the first bend line 5 from the outer face 21 of the first attachment tab 2 to the outer face 23 of the first seat member 3 .
The first tie member opening 4 preferably has a reinforcing rim 39 that is bent toward the outer face 23 of the first seat member 3 . Preferably, the first tie member opening 4 is preferably obround to provide a degree of lateral adjustability.
The second tie member opening 7 is preferably obround. Because of the angle of the first support leg 6 , the second tie member opening must be elongated.
Preferably, the first attachment tab 2 has a plurality of fastener openings 40 , and the second attachment tab 9 also has a plurality of fastener openings 40 . Most preferably, the first attachment tab 2 has twelve fastener openings and the second attachment tab 9 has three fastener openings 40 . The fastener openings 40 in the first attachment tab 2 and said second attachment tab 9 preferably are obround, providing a degree of lateral adjustability.
The connector 1 of the present invention is preferably formed first by cutting the connector 1 from sheet metal, preferably 12 gauge galvanized sheet steel. Preferably, the first seat member 3 is bent up from the first attachment tab 2 at the first bend line 5 . The first support leg 6 is preferably bent down from the first seat member 3 at the second bend line 8 . Preferably, the second attachment tab 9 is bent up from the first support leg 6 at the third bend line 10 .
At its most basic, the connection 11 of the present invention comprises a first structural member 12 , a second structural member 15 , a third structural member 18 between the first structural member 12 and the second structural member 15 , a first connector 1 attached to the first structural member 12 , a second connector 1 attached to the second structural member 15 , and a first tie member 19 interconnecting the first connector 1 and the second connector 1 .
Preferably, the first structural member 12 has a first side face 13 and a first end 14 . The second structural member 15 preferably has a first side face 16 and a first end 17 . Preferably, the third structural member 18 is sandwiched between the first end 14 of the first structural member 12 and the first end 17 of the second structural member 15 .
The first connector 1 is preferably attached to the first side face 13 of the first structural member 12 . Preferably, the second connector 1 is attached to the first side face 16 of the second structural member 15 .
Preferably, the first tie member 19 is restrained against the first seat member 3 of the first connector 1 and restrained against the first seat member 3 of the second connector 1 . Preferably, the first tie member 19 is all thread rod (ATR), preferably ⅜″ (0.9525 centimeter) in diameter. The first tie member 19 is preferably 4 to 5 feet (1.2192 to 1.524 meters) long and grade A307 or better. Preferably, the first tie member 19 is restrained with matching nuts 51 , preferably augmented with cut washers. The first tie member 19 preferably passes through the first tie member opening 4 and the second tie member opening 7 in the first connector ( 1 ), and the first tie member 19 passes through the first tie member opening 4 and the second tie member opening 7 in the second connector 1 .
Preferably, the first structural member 12 and the second structural member 15 are vertically oriented, the third structural member 18 is horizontally oriented, and the first tie member 19 is vertically oriented. In the preferred embodiment, the connection 11 of the present invention is a vertical floor-to-floor connection 11 . However, the connector 1 of the present invention could be used in a horizontal purlin-to-purlin connection 11 or the like. The connector 1 of the present invention could also be used singly, rather than paired, for example as a holdown.
The first structural member 12 is preferably an upper-storey wall stud 12 . The second structural member 15 is preferably a lower-storey wall stud 15 . The third structural member 18 is preferably an intervening floor 18 .
Preferably, the floor 18 comprises a horizontal bottom plate 20 , a floor diaphragm 21 and a floor beam 22 . The bottom plate 20 supports the first structural member 12 , the first end 14 of the first structural member 12 resting on the bottom plate 20 . The floor diaphragm 21 supports the bottom plate 20 . The floor beam 22 supports the floor diaphragm and preferably rests on a top plate 23 . The top plate 23 rests on the first end 17 of said second structural member 15 and the top plate 23 is supported by the second structural member 15 . In this embodiment, the first end 14 of the first structural member 12 is the lower end 14 of the first structural member 12 and the first end 17 of the second structural member 14 is the upper end 17 of the second structural member 14 .
The top plate 23 is preferably a double top plate 23 . Preferably, the first structural member 12 , the second structural member 15 , the bottom plate 20 , and the top plate 23 are all formed from nominal 2×4″ lumber. The connector 1 of the present invention is preferably used on at least a single 2× stud. The lumber is preferably Douglas Fir, Larch or Southern Pine. Alternatively, Spuce, Pine, Fir or Hem Fir may be used. The allowable tension load (the maximum load that the connection 11 is designed to provide) for the connection 11 of the present invention 1830 pounds (830.074 kilograms) with Douglas Fir, Larch or Southern Pine and 1570 pounds (712.140 kilograms) with Spuce, Pine, Fir or Hem Fir. Load values are based on a minimum lumber thickness of 1½″ (3.81 centimeters).
Preferably, a first plurality of fasteners 24 attaches the first attachment tab 2 of the first connector 1 to the first side face 13 of the first structural member 12 . A second plurality of fasteners 24 preferably attaches the second attachment tab 9 of the first connector 1 to the first side face 13 of the first structural member 12 . Preferably, a third plurality of fasteners 24 attaches the first attachment tab 2 of the second connector 1 to the first side face 16 of the second structural member 15 . A fourth plurality of fasteners 24 preferably attaches the second attachment tab 9 of the second connector 1 to the first side face 16 of the second structural member 15 . Although separate mechanical fasteners 24 are preferred, integral mechanical fasteners 24 such as nail prongs could be employed, for instance if the connectors 1 were factory preinstalled on the structural members. Similarly, fasteners 24 could be eliminated if the connectors 1 were attached with a sufficiently strong adhesive or if they were welded or otherwise bonded to structural members made of materials other than wood, such as metals or plastics, particularly if the connectors 2 were likewise. Most preferably, the fasteners 24 are nails 24 , specifically fifteen 10 d×1½″ (0.148 inch [0.375 92 centimeter] diameter by 1.5 inches [3.81 centimeters] long) nails. Preferably, the nails 24 are driven straight into the first structural member 12 and the second structural member 15 , but the connection 11 of the present invention preferably allows for the nails 24 to be driven in at up to a 30 degree angle with no reduction in load capacity.
The first connector 1 is preferably attached to the first side face 13 of the first structural member 12 proximate the first end 14 of the first structural member 12 , preferably no more than 18″ (45.72 centimeters) from the third structural member 18 . Preferably, the second connector 1 is attached to the first side face 16 of the second structural member 15 proximate the first end 17 of the second structural member 15 , preferably no more than 18″ (45.72 centimeters) from the third structural member 18 .
The preferred method of making the connection 11 of the present invention consists first of selecting the first structural member 12 , the second structural member ( 15 ), and the third structural member ( 18 ). The preferred method then consists of placing the third structural member 18 between the first end 14 of the first structural member 12 and the first end 17 of the second structural member ( 15 ). As most preferably practiced, this is done as part of erecting a multistory structure, with a plurality of wall studs in each story wall and a floor between each pair of stories. The preferred method then consists of attaching the first connector 1 to the first side face 13 of the first structural member 12 , and attaching the second connector 1 to the first side face 16 of the second structural member 15 .
Then a hole 42 is preferably drilled in, and though, the third structural member 18 . Preferably, the hole 42 is ½″ to ¾″ (1.27 to 1.905 centimeters) in diameter and approximately 1½″ (3.81 centimeters) away from the first side face 13 of the first structural member 12 and the first side face 16 of the second structural member 15 . The preferred method then consists of passing the first tie member 19 through the hole 42 in the third structural member 18 , passing the first tie member 19 through the first tie member opening 4 ) and the second tie member opening 7 in the first connector 1 , and passing the first tie member 19 through the first tie member opening 4 and the second tie member opening 7 in the second connector 1 .
Finally, the method of making the connection 11 of the present invention consists of restraining the first tie member 19 against the first seat member 3 of the first connector 1 and against the first seat member 3 of the second connector 1 . The first tie member 19 , which is preferably ⅜″ (0.9525 centimeter) all thread rod (ATR), is preferably restrained with matching nuts 51 and standard cut washers. Preferably, the connectors 1 are offset no more than 3″ (7.62 centimeters) from each other. | A connector for connecting wall studs of two adjacent floors in a light frame building structure, the connector having a first attachment tab, a seat member, a diagonally slanted support leg, and a second attachment tab, all substantially planar. The connector is intended to be paired and the paired connectors joined by an elongated tie member that pierces the sill plates of the intervening floor structure. |
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 722,411, filed Apr. 10, 1985 which is now U.S. Pat. No. 5,007,585, issued Apr. 16, 1991, which is a continuation of application Ser. No. 636,066, filed Jul. 30, 1984, now abandoned, which is a continuation of application Ser. No. 348,509, filed Feb. 12, 1982, now abandoned, which is a continuation-in-part application Ser. No. 067,552, filed Aug. 7, 1970, which is now U.S. Pat. No. 4,315,602, issued Feb. 16, 1982.
BACKGROUND OF THE INVENTION
This invention relates to spray apparatus and more particularly to automated apparatus for roadside spraying of herbicides which is mounted on a front of a vehicle and controlled by a operator of the vehicle.
Many state highway departments, counties and cities, have for several years been actively mowing and brush cutting undesirable weeds, grass and brush in their right-of-ways. This has been primarily accomplished by hand labor or mechanical means. Many of these publicly funded organizations have attempted to spray their right-of-ways with selective herbicides that would control the undesirable plant growth and leave predominantly low growing grasses. Two programs that have been used for several years are MSMA to control johnson grass and 2-4-D to control broad leaves and brush.
The equipment which has been used in the past has been of generally three types. A common type of equipment is the long boom extending out to the side of the truck and across the right-of-way. An example fo a long boom is shown in U.S. Pat. No. 2,995,307 issued to J. J. McMahon. The use of the handgun is still common today for lack of anything with more versatility. Another has been the use of an off-center nozzle mounted to the side of the truck. The use of the off-center nozzle is discussed further below.
The long-extending boom has been used widely because of its ability to reach 25 to 30 feet into the right-of-way. Some designs have provided the boom in sections to give the operator more flexibility as to where he could spray the herbicide. This has also allowed the operator to save chemical. A problem with this type of unit is that it does not lend itself to many right-of-way applications because of hills, back slopes and obstructions in the areas to be sprayed. Obstructions are believed to be a major problem. The extended boom is vulnerable to contact with obstructions causing extensive down time and delays with loss of production. It is also believed to be very expensive to replace such booms. The use of hydraulic cylinders mounted along the boom may make the application even more cumbersome since the driver may have to slow the speed of the spray truck upon the encountering of several obstructions, such as trees, signs, bluffs, and the like. Under such circumstances, the operator might get too little, or no herbicide at all in certain areas because the boom was raised to go over the sign and wind blew many of the small particles away or the sprayed area received excessive rates of the herbicide due to the slower speeds of the truck. In some situations it is necessary to use two operators. This increases the costs due to the extra labor required and often the spray may not get to the target area while passing over obstructions. Also long booms require the vehicle to have greater gross vehicle weight because a long spray boom attached to the front of the vehicle may require heavier axles and generally heavier duty vehicles to support the long beams.
It is believed that the off-center nozzle in many cases had advantages over the long booms because the operator could spray all day without worrying about obstructions in the right-of-way. This nozzle could be mounted anywhere to the side of the vehicle and the spray pattern covered an area beginning immediately beside the truck and extending from 10 to 30 feet out into the right-of-way. Wind velocity tended to dramatically effect the distance and in such circumstances the spray might not extend past 10 to 15 feet from the vehicle. This type of nozzle also did not give the operator much versatility to place a herbicide only in areas where undesired vegetation existed across the right-of-way. In practice, the weeds are often in spotted areas lying 20 to 40 feet away from the spray truck and the operator has no way to get the herbicide to the target, especially if the wind velocity over powers the spray. The operator also, in certain situations, needs to spray the herbicide next to the vehicle, where only undesirable taller growing vegetation exists. In certain situations this may cause more herbicide to be used than necessary such as with off-center nozzles, which unnecessarily may increase the costs of the spraying program.
The same problems also exist with controlling undesirable brush. A long extending boom as far as known, is not often used for this purpose. Generally the use of a handgun and the off-center spraying means are used in such situations. Spotted applications to the soil under the undesirable brush with the use of a handgun, spraying specially selected herbicides, provide easy control of brush. In such situations, herbicides were often used, whereby rain would carry the chemical into the root zone to be picked up by the brush. This type of chemical interfers in the natural processes in the plant causing its ultimate death. A problem with spotted application of such herbicides by handguns on such undesirable brush, is that it is slow, which increases application cost and in most cases the herbicide is overapplied resulting in excessively killing of low growing desirable ground cover.
With the development of new herbicides, especially new selective herbicides, it has become more important to eliminate the problem encountered with extended booms, off-center nozzles and handguns. In the case of certain chemicals, it is necessary to apply them from 1 to 11/2 quarts per acre or 43,560 square feet. In the case of other currently used chemicals, it is necessary to apply them at 4 to 8 ounces to control more susceptable tall growing vegetation. Greater amounts of these herbicides may kill the low growing, more tolerant species of vegetation and leave partial to total bare ground. Such problems often prevent many highway departments, counties and cities from going into vegetation management programs with the new herbicides to eliminate the more costly program of hand labor and mechanical mowing.
Applicant's invention helps overcome the above discussed problems. An object of the invention is to provide a spraying apparatus capable of spraying smaller particles in spray swaths adjacent to the vehicle and larger particles in areas farther away from the vehicle. An object of the invention is to allow an operator to spray the larger particles up to 40 feet away from the vehicle. Another object of the invention is to provide a spray pattern which is less affected by wind. Another object of the invention is to allow an operator to spray spotted weed problems at any location up to 40 feet away from the vehicle without wasting herbicide where only desirable low growing vegetation exists. Another object of the invention is to allow an operator the option of applying herbicides at exacting rates at selected locations across the right-of-way to prevent overuse of herbicide and potential damage to low growing grass, where no undesirable weeds exist. Another object of the invention is to provide a spraying apparatus which provides foliar applications of herbicides on brush at any selected location in the right-of-way. Other objects of the invention will be apparent from the following detailed disclosure.
SUMMARY OF THE INVENTION
The invention comprises a spraying apparatus having a plurality of separately operable spraying nozzles for selectively spraying a herbicide or other material on a desired location at the side of a motor vehicle. The nozzles are mounted upon a spraying head which may be remotely operated by an operator to change the inclination of the nozzles to spray any desired location. Separate spraying nozzles on the head are oriented to spray at selected locations and some of the nozzles spray smaller particles for short distances and other nozzles spray large particles for longer distances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing the spraying apparatus of the invention.
FIG. 2 is a plan view showing the spraying apparatus of the invention.
FIG. 3 shows the spraying apparatus of the invention mounted on a motor vehicle and the spray pattern of the device.
FIG. 4 is another view of the spray apparatus mounted on a vehicle showing another spray pattern.
FIG. 5 is a broken cross sectional view showing the nozzle arrangement.
FIG. 6 is taken along 6--6 in FIG. 5.
FIG. 7 is taken along line 7--7 in FIG. 5.
FIG. 8 is taken along line 8--8 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The spraying apparatus of FIG. 1 is adapted to be used upon a motor vehicle in connection with tank and pump means. U.S. Pat. No. 4,315,602 discloses tank and pump means which may be used in connection with this invention and this patent is incorported herein into to by this specific reference thereto for any and all purposes.
Referring to FIG. 1, there is shown a spraying apparatus 10 which is mounted on a motor vehicle V as shown in FIGS. 4 and 5. Spraying apparatus 10 includes a main support beam 11 which is mounted to the front of the vehicle V in a manner such as disclosed in U.S. Pat. No. 4,315,602. A journal 12 is connected with the beam 11. A pivot mechanism including a bifurcated member 13 is pivoted to the journal and maintained in position by spring means 14 as also disclosed in U.S. Pat. No. 4,315,602.
A first vertical beam 15 is connected to the bifurcated member 13. The vertical beam 15 is in the form of a square channel member for receiving post 16. A plurality of apertures 17 receive the removable pin 18 which provides vertical adjustment of the post 16.
Secured to the vertical beam 15 is a support arm 19. An electric air or hydraulic cylinder means 20 or other remotely controlled power means is connected at one end to the support arm 19 and at its upper end to a support arm 21. The support arm 21 is connected to a spraying means or head 22. The spraying means 22 includes a generally U-shaped shield 23 which is connected to U-shaped member 24. The post 16 includes a pivot bracket 25 which is secured to the post 16. The U-shaped member 24 is pivotally connected to the pivot bracket 25 by pivot pin 26. The support arm 21 is connected to the connecting portion 27 of the U-shaped member 24. As will be apparent, extension and retraction of the hydraulic cylinder means 20 will cause the spraying means 22 to pivot as shown in broken lines in FIG. 1 and also as shown in FIGS. 4 and 5.
The spraying means 22 includes a plurality of independently operated nozzle means to provide a predetermined droplet size and to provide a spraying band at a predetermined location. The spraying band covers a preselected swath to deposit spray at the desired location.
The spraying apparatus includes a first nozzle means 30, as best shown in FIG. 2, for spraying an area adjacent or directly below the spraying means 22. The spraying means further includes a plurality of nozzle means 31, 32, 33, 34 and 35 as best shown in FIG. 6. These nozzle means may provide a large droplet size in a straight stream flow for spraying areas such as undesirable brush or weeds and objects closely or remotely adjacent to vehicle V. As will be apparent, the nozzles 31 through 35 are oriented to spray a narrow straight stream swath or area at short or long distances from the vehicle. The nozzle means 31 through 35 are controlled by an operator. They may be either controlled to spray at the same time or to selectively spray.
The spraying means 22 further includes nozzle means 36, 37, 38 and 39 as best shown in FIG. 7. The nozzle means 36 through 39 may be designed to spray relatively large droplets at a relatively large distance. The nozzles 36 through 39 are connected to a single supply pipe 40 which may be controlled by the operator to supply spray to the nozzles 36 through 39.
The spraying means 22 further includes nozzle means 41, 42 and 43 as also shown in FIG. 7. The nozzle means 41 through 43 are connected to supply pipe 44 which is selectively supplied with spray by an operator. The supply pipes 40 and 44 are connected by a bracket means 45 to the U-shaped shield 23. The nozzle means 41 through 43 may be oriented to spray a swath at a closer distance than are the nozzle means 36 through 39.
Referring to FIG. 8 of the drawing, there is shown nozzle means 46, 47, 48 and 49. The nozzle means 46 through 49 are connected to supply pipe 50. The supply pipe 50 is supplied with spray from the pumping unit (not shown) which is controlled by suitable valve means by the operator. The nozzle means 46 through 49 may be oriented to spray at a distance slightly less than the nozzle means 36, 37, 38 and 39.
Again referring to FIG. 8 there is shown nozzle means 51, 52 and 53. The nozzle means 51, 52 and 53 are connected to supply pipe 54 which is supplied with spray by the operator. The nozzle means 51, 52 and 53 may be oriented to spray at a relatively close distance. The supply pipes 50 and 54 are connected by bracket means 45a to the U-shaped shield 23.
These nozzles spray smaller droplets because they are located next to the truck. The particles must be smaller nearer the truck because the spray is moving at a line of travel parallel to the upright growing undesirable weeds and results in better herbicide coverage. As the weeds become a farther distance away from the vehicle, the spray, such as that delivered from nozzles 36 through 49, in FIG. 5, penetrate through the vegetation at a direction perpendicular to the upright plant.
The nozzle means 36, 37, 38 and 39 may be oriented to spray a swath at the farthest distance. It is preferably to use larger spray droplets to minimize draft at larger distances. The nozzle means 46, 47, 48 and 49 may be oriented to spray a swath adjacent the swath sprayed by the nozzles 36 through 39 but closer to the vehicle. The nozzle means 41, 42 and 43 may be oriented to spray a swath closer the vehicle but adjacent the swath sprayed by the nozzles 46, 47, 48 and 49. The nozzle means 51, 52 and 53 may be oriented to spray a swath closer to the vehicle than the nozzle means 41, 42 and 43 and adjacent to the swath sprayed by the nozzle means 41, 42 and 43.
The nozzles are mounted in a manner well known in the art.
In operation, an operator, through electrically operated solenoid switches controls the operation of the nozzle means to provide the desired spray. When it is desired to spray down hillsides, such as shown in FIG. 3, the spraying means 22 can be tilted downwardly by the hydraulic cylinder means 20. When it is desired to spray large objects such as trees, the spraying means 22 may be tilted upwardly as shown in FIG. 4 by the hydraulic cylinder means 20. By selectively controlling the solenoid operated switch means, which controls the various nozzle means, an operator can predetermine where the spray will be directed.
Although the invention has been described in conjunction with the foregoing specific embodiment, many alternatives, variations and modifications are intended to fall within the spirit and scope of the appended claims. | A roadside spray apparatus having a spraying head with a plurality of nozzles mounted on the spraying head. The inclination of the spraying head is selectively adjustable to direct spray to a desired location. The spray head includes a plurality of independently operated nozzles oriented to spray side-by-side swaths at the side of a vehicle. |
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BACKGROUND
Annular seals are a common part of virtually all hydrocarbon recovery systems. Such seals come in many different configurations and ratings. Such seals are a necessary and important part of hydrocarbon recovery efforts and generally function well for their intended purposes. In situation where there is a high differential pressure across the seal however extrusion of the seal becomes a concern. Extrusion occurs axially when the seal is extruded through a small gap between the tubular at an inside surface of the seal and the tubular at the outside surface of the seal. The gap is there because in order to run a tubular into a casing, clearance is necessary. This is also the reason that a seal is needed in the first place. While many configurations have been created to limit the gap and improve extrusion resistance, the art is always receptive to alternative methods and particularly to configurations capable of accommodating higher pressure differentials.
SUMMARY
A resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, and a gauge ring attached to the ramp.
A method for sealing a tubular including compressing a resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, a gauge ring attached to the ramp, urging the backup ring along the ramp to gain a greater radial dimension than the gauge ring, deforming an element at the system into contact with the tubular adjacent the backup ring.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a cross section view of a resettable antiextrusion backup system in an unsealed condition;
FIG. 2 is a cross section view of a resettable antiextrusion backup system in a sealed condition;
FIG. 2 a is a view similar to FIG. 2 but with the backup ring in contact with a tubular;
FIG. 3 is a perspective view of a backup ring as disclosed herein;
FIG. 4 is a perspective view of a ramp as disclosed herein;
FIG. 5 is a perspective view of a gauge ring as disclosed herein;
FIG. 6 is a perspective view of an assembly of FIGS. 3 and 4 ;
FIG. 7 is a perspective view of an assembly of FIGS. 3 , 4 and 5 ;
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 a cross section of a resettable antiextrusion backup system 10 is illustrated in an unset ( FIG. 1 ) and set ( FIG. 2 ) condition respectively. Focusing upon FIG. 1 , the system 10 is illustrated in cross section within another tubular structure 12 such as a casing segment. It will be apparent that there is a clearance 14 between a gauge ring 16 and an inside surface 18 of the casing 12 . This clearance is taken up by an element 20 when the system 10 is compressed. This is similar to prior art devices in that those devices cause an element to expand into contact with an inside surface of a tubular in which they are set but due to the size of the clearance, extrusion of such elements is possible. In the system disclosed herein, extrusion is prevented by a backup ring 22 that is displaceable to occupy the clearance space entirely (see FIG. 2 a ). With the backup ring 22 in place, it is impossible for the element 20 to extrude in the direction of the backup ring 22 . Advantageously, in the system disclosed, it is also possible to retract the backup ring 22 to an outside dimension less than that of the gauge ring 16 . Moreover, setting and unsetting of the system 10 is possible for a great number of cycles.
In order to actuate the backup ring 22 , a number of other components of the system 10 are utilized. A ramp 24 exhibits a frustoconical surface 26 that interacts with the backup ring 22 during axial compression of system 10 to cause the backup ring 22 to gain in radial dimension resulting in the backup ring spanning the entirety, in one embodiment ( FIG. 2 a ), or at least a substantial portion of, in other embodiments, the clearance 14 . In one embodiment the frustoconical surface 26 has an angle of about 40 to about 60 degrees and in a specific embodiment has an angle of about 50 degrees. In this position, the backup ring 22 effectively prevents extrusion of the element 20 due to differential pressure thereacross.
The ramp 24 is fixedly connected at one or more connections 28 to the gauge ring 16 such that the ramp 24 and the gauge ring 16 always move together in an assembled system 10 . In order to provide a greater understanding of the backup ring 22 , ramp 24 and gauge ring 16 , reference is made to FIGS. 3-7 in which is illustrated each one of these components in perspective view in FIGS. 3 , 4 , and 5 and then combinations of these components in FIGS. 6 and 7 . The backup ring 22 includes one or more openings 30 that allow for the fixed connections 28 between the ramp 24 and the gauge ring 16 . The fixed connections 28 , in one embodiment hereof comprise a thread 32 at an inside surface 34 of the gauge ring 16 and a thread 36 at an outside surface 38 of the ramp 24 . The two threads are complementary and engage one another through the openings 30 when the backup ring 22 , ramp 24 and gauge ring 16 are assembled. It will be noted by the astute reader that the openings 30 are larger in the axial direction that the thread 36 is in the axial direction. This is to allow for axial movement of the backup ring 22 relative to the fixedly connected ramp 24 and gauge ring 16 . Axial movement is provided to allow for the backup ring 22 movement up the frustoconical surface 26 of the ramp 24 which in turn causes the backup ring 22 to gain in radial dimension and fill the clearance 14 . A review of FIGS. 6 and 7 will make the assembly clear to one of ordinary skill in the art.
Referring back to FIG. 1 , the ramp is slidably in contact with a booster sleeve 40 that in turn is supported by more downhole components not germane to this disclosure but represented schematically by the structure identified with numeral 42 . At an opposite end of the system 10 is another schematically represented structure 44 representing components more uphole of the system 10 which again are not germane to the disclosure. These two illustrated structures are only illustrated to show a structure to which certain components of the system 10 are attached. Booster Sleeve 40 is one such component of the system 10 and is attached to structure 42 via a thread 46 . A spacer 48 is supported by the structure 42 in some embodiments to limit overall stroke of the system 10 to prevent damaging the element 20 . Spacer 48 is sized to be contacted by a connector sleeve 50 that is itself fixedly connected to structure 44 . This connection is via a thread 52 in one embodiment though any fixed connection could be substituted. Structure 44 is also fixedly connected to backup ring 22 at thread 54 . Finally a retraction dog 56 is disposed in a slot 58 in ramp 24 to ensure that with a tensile load placed on system 10 , the load is transferred to the Booster Sleeve 40 and subsequently reduces the radial dimension of the Back Up Ring 22 to an outside dimension less than the outside dimension of the Gage Ring 16 .
In operation, the system 10 provides, as above noted, up to a full clearance 14 obstruction and upon unsetting, the backup ring 22 can be brought back to a sub gauge dimension. This is exceedingly beneficial to the art because it means that extrusion of seals can be reliably and effectively prevented while the system 10 can be repositioned in the wellbore without concern for becoming stuck or doing damage to other wellbore tools due to an antiextrusion configuration having an outside dimension greater that gauge size.
While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, and a gauge ring attached to the ramp. A method for sealing a tubular. |
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to modular construction systems and more particularly to a system of modular blocks which can be connected in various ways.
[0002] Various construction systems exist in which identical or similar modular elements are built up into larger structures. Known examples of modular building elements include bricks and concrete blocks. While these provide a modular configuration, they lack a self-connecting feature and must be assembled with separate fasteners, adhesives, or mortar.
[0003] Systems of interlocking construction blocks are also known. These are typically used for toys or small-scale models, and typically rely on friction or snap-type connectors. While these systems provide a self-connecting feature, the user is limited to preformed blocks which have fixed connector elements.
[0004] Accordingly, there is a need for a modular construction element having a connector that can be configured in different ways.
BRIEF SUMMARY OF THE INVENTION
[0005] Therefore, it is an object of the invention to provide a block that can be used to build up modular structures.
[0006] It is another object of the invention to provide a modular block with a connector that can be oriented in different directions.
[0007] These and other objects are achieved by the present invention, which in one embodiment provides a modular block apparatus, including: first and second blocks, each block having a generally upwardly protruding locking member and an internal recess sized to receive the locking member of the other block such that the blocks can be assembled with one block above the other. The blocks are secured together in a vertical direction by relative lateral movement of the locking member and the internal recess. Means are provided for preventing relative lateral movement of the locking member and the internal recess so as to retain the blocks in a connected condition.
[0008] According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, a front sidewall, and an interior cavity formed therein, the interior cavity defining a locking recess communicating with the bottom surface, and a lug receptacle communication with the top surface; and a locking lug received in the lug receptacle, the locking lug having a laterally-extending hook protruding above the top surface.
[0009] According to another embodiment of the invention, the lug receptacle includes at least one protruding side boss disposed therein; and the locking lug includes at least one lug boss disposed thereon. The lug bosses and the side bosses are arranged such that the hook faces in a selected one of a plurality of directions relative to the front sidewall, and the lug is retained, by engagement of the bosses, against withdrawal from the lug receptacle in a vertical direction.
[0010] According to another embodiment of the invention, the interior cavity includes a generally vertical portion extending between the lug receptacle and the locking recess.
[0011] According to another embodiment of the invention, the modular block apparatus further includes a key disposed in the vertical portion which prevents lateral motion of the locking lug.
[0012] According to another embodiment of the invention, the key prevents lateral motion of a hook received in the locking recess.
[0013] According to another embodiment of the invention, the block has at least one generally vertical edge, and includes: at least one open corner slot formed in the vertical edge; and a generally vertically-extending corner hole disposed near the vertical edges and intersecting the corner slot.
[0014] According to another embodiment of the invention, B 7 the modular block further includes: a connector plate having a thickness sized to fit in the corner slot, and a connector pin hole formed therethrough; and a connector pin sized to fit into the corner hole and the connector pin hole to retain the connector plate in the corner slot.
[0015] According to another embodiment of the invention, the connector plate further includes additional connector pin holes formed therethrough and is sized for engaging corner slots of at least two adjacent blocks.
[0016] According to another embodiment of the invention, the modular block apparatus of claim B 6 further includes a finish element having: a exterior surface having a desired shape; and a laterally-extending connector plate having a thickness sized to fit in the corner slot, and a connector pin hole formed therethrough.
[0017] According to another embodiment of the invention, the hook is substantially smaller than the locking recess.
[0018] According to another embodiment of the invention, the block includes a plurality of laterally-extending hooks protruding above the top surface, and each of the hooks is substantially smaller than the locking recess.
[0019] According to another embodiment of the invention, the hook is substantially larger than the locking recess.
[0020] According to another embodiment of the invention, the block includes a plurality of laterally-extending hooks protruding above the top surface, and each of the hooks is substantially smaller than the locking recess.
[0021] According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, and at least one generally cylindrical core passage extending between the top and bottom surfaces; and a locking assembly received in the core passage, the locking assembly including: a core sized to be received in the core passage and having a through-bore extending therethrough, the through-bore defining alternating core grooves and lands; a locking rod having a array of alternating rod grooves and lands complementary to the core grooves and lands; and means for retaining the locking rod in engagement with the core with the locking rod protruding from the top surface.
[0022] According to another embodiment of the invention, the retaining means comprise a rod key received in the through-bore and urges the locking rod laterally against the core grooves and lands.
[0023] According to another embodiment of the invention, the core passage includes at least one key slot extending laterally therefrom, the key slot being in communication with the bottom surface; and the core carries at least one core key which is moveable between a retracted position and a laterally-extended position. Engagement of the locking means causes the core key to move to the laterally-extended position, where the core key engages the core key slot to prevent withdrawal of the core assembly from the core passage.
[0024] According to another embodiment of the invention, the modular block apparatus of claim C 4 further includes: a connector plate having a thickness sized to fit in the connector slot, and a connector pin hole formed therethrough; and a connector pin sized to fit into the core passage and the connector pin hole to retain the connector plate in the connector slot.
[0025] According to another embodiment of the invention, the connector plate has a generally cylindrical stud protruding therefrom, the stud including a land sized and shaped to engage the core grooves and lands.
[0026] According to another embodiment of the invention, the block includes a plurality of core passages of different diameters formed therein.
[0027] According to another embodiment of the invention, the block is a generally rectangular solid.
[0028] According to another embodiment of the invention, the block is curved.
[0029] According to another embodiment of the invention, the block is trapezoidal.
[0030] According to another embodiment of the invention, the block includes a pair of lobes connected by a relatively narrow waist.
[0031] According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, a front sidewall, and an interior space formed therein. The block includes; first and second spaced-apart side members each having an inner surface and an outer surface; and at least one locking lug disposed between the side members, the locking lug having upper and lower notches formed near each its upper and lower ends, respectively, so as to define upper and lower laterally-extending hooks, wherein the upper hook protrudes from the top surface, and is sized and shaped to engage a lower notch of a second block.
[0032] According to another embodiment of the invention, the hook extends towards the front sidewall.
[0033] According to another embodiment of the invention, the hook extends generally perpendicular to the front sidewall.
[0034] According to another embodiment of the invention, the side members and the locking lug are a single integral component.
[0035] According to another embodiment of the invention, the modular block apparatus further includes at least one generally vertical key groove formed in the side members.
[0036] According to another embodiment of the invention, the modular block apparatus further includes a key received in the interior space and having an alignment rail which engages the key groove, the key extending between upper and lower positioned blocks to prevent relative lateral movement thereof.
[0037] According to another embodiment of the invention, the key includes at least two spaced-apart alignment rails which are adapted to engage respectively key grooves of two laterally-adjacent blocks to prevent separation thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
[0039] FIG. 1 is a perspective view of a modular block constructed in accordance with the present invention;
[0040] FIG. 2 is a another perspective view of the modular block of FIG. 1 ;
[0041] FIG. 3A is a perspective view of a pair of modular blocks constructed in accordance with the present invention in position to be connected;
[0042] FIG. 3B is a perspective view of the modular blocks of FIG. 3A in a partially contacting position;
[0043] FIG. 3C is a perspective view of the modular blocks of FIG. 3B in a fully contacting position;
[0044] FIG. 3D is a perspective view of the modular blocks of FIG. 3C in a fully engaged position;
[0045] FIG. 3E is a perspective view of the modular blocks of FIG. 3D , along with a locking key about to be inserted therein;
[0046] FIG. 3F is a perspective view of the modular blocks of FIG. 3E , with a locking key partially inserted therein;
[0047] FIG. 3G is a perspective view of the modular blocks of FIG. 3F , with a locking key fully inserted therein;
[0048] FIG. 4A is a perspective view of a modular block along with a connector plate and connector pin;
[0049] FIG. 4B is a perspective of a plurality of modular blocks connected with connector plates and pins;
[0050] FIG. 5A is a perspective view of a modular block along with a connector plate, connector pin, and a finish element;
[0051] FIG. 5B is a perspective view of a plurality of modular blocks connected with connector plates and pins, and having finish elements attached thereto;
[0052] FIG. 6 is a perspective view of a plurality of modular blocks having locking elements oriented in varied directions;
[0053] FIG. 7 is a perspective view of a structure built-up from a plurality of modular blocks having locking elements oriented in varied directions;
[0054] FIG. 8 is a perspective view of a structure built-up from a plurality of modular blocks having locking elements oriented in the same direction;
[0055] FIG. 9 is a perspective view of a truss structure built-up from a plurality of modular blocks;
[0056] FIG. 10 is a perspective view of a wall structure built-up from a plurality of modular blocks;
[0057] FIG. 11 is a perspective view of a group of modular blocks of different sizes;
[0058] FIG. 12 is a perspective view of a modular block adapted to be connected to a plurality of smaller modular blocks;
[0059] FIG. 13 is a perspective view of the modular block of FIG. 12 connected to a plurality of smaller modular blocks;
[0060] FIG. 14 is a perspective view of another modular block adapted to be connected to a plurality of smaller modular blocks;
[0061] FIG. 15 is a perspective view of the modular block of FIG. 14 connected to a plurality of smaller modular blocks;
[0062] FIG. 16 is a top perspective view of a modular block constructed according to an alternative embodiment of the present invention;
[0063] FIG. 17 is a bottom perspective view of the modular block of FIG. 16 ;
[0064] FIG. 18 is an enlarged view of a portion of the top of the modular block of FIG. 16 ;
[0065] FIG. 19 is an enlarged view of a portion of the bottom of the modular block of FIG. 16 ;
[0066] FIG. 20 is a perspective view of a locking assembly for use with the modular block of FIG. 16 ;
[0067] FIG. 21 is a top perspective view of a modular block having a locking assembly installed therein;
[0068] FIG. 22 is an enlarged view of a portion of the top of the modular block of FIG. 21 ;
[0069] FIG. 23 is an enlarged view of a portion of the bottom of the modular block of FIG. 21 ;
[0070] FIG. 24A is a perspective view of a core forming a portion of a locking assembly;
[0071] FIG. 24B is a perspective view of the core of FIG. 24A with a locking rod about to be inserted therein;
[0072] FIG. 24C is a perspective view of the core and locking rod of FIG. 24B connected together;
[0073] FIG. 24D is a perspective view of the core and locking rod of FIG. 24C with a rod key about to be inserted therein;
[0074] FIG. 24E is a perspective view of the core and locking rod of FIG. 24C with a rod key fully inserted therein;
[0075] FIG. 25 is a perspective view of a lower end of a rod key;
[0076] FIG. 26 is a perspective view of a core along with a rod key and a pair of core keys;
[0077] FIG. 27 is a perspective view of a plurality of modular blocks connected together;
[0078] FIG. 28 is a perspective view of a connector plate;
[0079] FIG. 29 is perspective view of a connector plate disposed in a groove of a modular block;
[0080] FIG. 30 is a perspective view of the modular block and connector plate of FIG. 29 with a connector pin inserted therein;
[0081] FIG. 31 is a perspective view of a pair of modular blocks connected end-to-end with a connector plate and connector pins;
[0082] FIG. 32 is a perspective view of another type of connector plate;
[0083] FIG. 33 is a perspective view of a plurality of modular blocks of varying sizes connected together;
[0084] FIG. 34 is a perspective view of another finish element;
[0085] FIG. 35 is a perspective view of a modular block with a plurality of finish elements connected thereto;
[0086] FIG. 36 is a perspective view of a rotational connector plate;
[0087] FIG. 37 is a perspective view of a modular block with the connector plate of FIG. 36 attached thereto;
[0088] FIG. 38 is a perspective view of a plurality of modular blocks connected together;
[0089] FIG. 39 is a perspective view of a plurality of modular blocks of varying sizes connected together;
[0090] FIG. 40 is a perspective view of the components of a locking assembly of a first size;
[0091] FIG. 41 is a perspective view of the components of a locking assembly of a second size;
[0092] FIG. 42 is a perspective view of the components of a locking assembly of a third size;
[0093] FIG. 43 is a schematic top view of a representative hole pattern in a modular block;
[0094] FIG. 44 is a perspective view of a wheeled vehicle constructed from modular blocks;
[0095] FIG. 45 is partially exploded view of the vehicle of FIG. 44 ;
[0096] FIG. 46 is a perspective view of a curved modular block;
[0097] FIG. 47 is a perspective view of a cylindrical structure assembled from the modular blocks shown in FIG. 46 ;
[0098] FIG. 48 is a perspective view of a structure assembled from a combination of curved and straight modular blocks;
[0099] FIG. 49 is a perspective view of trapezoidal modular block;
[0100] FIG. 50 is a perspective view of a structure assembled from the trapezoidal modular blocks shown in FIG. 49 ;
[0101] FIG. 51 is perspective view of a lobed modular block;
[0102] FIG. 52 is a perspective view of a wall structure assembled from the lobed modular blocks shown in FIG. 51 ;
[0103] FIG. 53 is a perspective view of the wall structure of FIG. 52 in a pivoted position;
[0104] FIG. 54 is a perspective view of a structure assembled from different shapes of modular blocks;
[0105] FIG. 55 is a perspective view of a modular block constructed in accordance with another alternative embodiment of the present invention;
[0106] FIG. 56 is an exploded perspective view of the block shown in FIG. 55 ;
[0107] FIG. 57 is a perspective view of a variation of the block shown in FIG. 55 ;
[0108] FIG. 58 is a perspective view of a key for use with the block of FIG. 55 ;
[0109] FIG. 59 is another perspective view of the key shown in FIG. 58 ;
[0110] FIG. 60 is a perspective view of an alternative key for use with the block shown in FIG. 55 ;
[0111] FIG. 61 is another perspective view of the key shown in FIG. 60 ;
[0112] FIG. 62 is a partially exploded perspective view of a structure built up from the blocks shown in FIGS. 55 and 57 ; and
[0113] FIG. 63 is a perspective view of the structure shown in FIG. 62 showing keys being inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
[0114] Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 illustrates an exemplary modular block 10 constructed according to the present invention. The modular block 10 includes a top surface 12 , a bottom surface 14 , and front, rear, left and right sidewalls 16 , 18 , 20 , and 22 , respectively. An interior cavity 24 is formed in approximately the center of the modular block 10 . The interior cavity 24 includes a generally vertical portion 26 which extends between a locking recess 28 adjacent the bottom surface 14 of the modular block 10 , and a lug receptacle 30 adjacent the top surface 12 of the modular block 10 . A ledge 32 extends laterally partway into to the locking recess 28 . The lug receptacle 30 is a parallel-sided opening having an end boss 34 extending across an end wall thereof at a selected distance from the top surface 12 , and a pair of spaced-apart side bosses 36 and 38 disposed on opposite side walls thereof.
[0115] A four-faced locking lug 40 includes an inverted “L”-shaped hook 42 which is sized and shaped to engage the locking recess 28 disposed at its upper end. A lug boss 44 is disposed at each of the lower corners of the locking lug 40 . The lug bosses 44 are disposed in a pattern so that they define a lateral slot 46 around the periphery of the locking lug 40 , which communicates with a vertical slot 48 on each of the faces of the locking lug 40 .
[0116] As can be seen in FIG. 1 , the locking lug 40 is assembled to the modular block 10 by first inserting it into the lug receptacle 30 in a downwards direction. The side bosses 36 and 38 pass into opposed ones of the vertical slots 48 . Once the lug bosses 44 have cleared the side bosses 36 and 38 and the end boss 34 in a vertical direction, the locking lug 40 is then shifted laterally so that two of the lug bosses 44 are aligned with the end boss 34 , and two of the lug bosses 44 are aligned with the side bosses 36 and 38 . In this position, the locking lug 40 is prevented from being withdrawn vertically from the lug receptacle 30 .
[0117] The dimensions, material, and surface finish of the locking lug 40 may be selected to provide the desired interface with the lug receptacle 30 . For example, if an easily-disassembled joint is desired, a small clearance may be provided between the exterior of the locking lug 40 and the lug receptacle 30 . If a more permanent joint is desired, the locking lug 40 may be provided with a tighter fit in the lug receptacle 30 , for example by providing a slight interference fit, or by providing a relatively rough surface finish.
[0118] FIG. 2 illustrates the modular block 10 with the locking lug 40 assembled thereto. In the illustrated example the hook 42 of the locking lug 40 extends towards the left sidewall 20 of the modular block 10 . However, it will be appreciated that the locking lug 40 may be assembled to the modular block 10 so that it points in any one of four directions.
[0119] The modular block 10 and the locking lug 40 may be constructed of any material which is suited to the application for which the modular block 10 is to be used and which can be formed into the necessary dimensional features. For example, the modular block 10 may be used as a toy, a modeling element, or a light structural element, in which case it may be molded from a material such as plastic resin. The modular block 10 may also be used for heavier structural applications, in which case it may be formed from materials such as concrete, wood or engineered wood materials, pressed fiber, metals, or fiber composite materials. Specific applications of the modular blocks 10 are discussed in more detail below.
[0120] FIGS. 3A-3G illustrates the two identical modular blocks 10 and 10 ′ to form a larger structure. Modular block 10 is provided with a locking lug 40 having a hook 42 as described above. As shown in FIGS. 3B , 3 C and 3 D, the hook 42 is inserted into the locking recess 28 ′ of the block 10 ′ and then shifted laterally so that the hook 42 is disposed behind the ledge 32 ′ of the locking recess 28 ′. This prevents the modular blocks 10 and 10 ′ from being disconnected in a vertical direction.
[0121] To secure the blocks together, a key 50 is inserted into the vertical portion 26 ′ (see FIGS. 3E and 3F ). The key 50 is an elongated member sized to fit into the vertical portion 26 ′ of the cavity 24 ′ (identical to cavity 24 ). As shown in FIG. 3G , the presence of the key 50 prevents lateral motion of the hook 42 relative to the locking recess 28 ′. The key 50 may be provided with a cut-back edge 52 that engages a shelf 54 of the lug receptacle (best seen in the identical block 10 of FIG. 2 ), to prevent the key 50 from falling out of the bottom of the modular blocks 10 and 10 ′. As noted above with respect to the locking lug 40 , the dimensions, materials, and surface finish of the key 50 may be selected to prevent unintended withdrawal.
[0122] As shown in FIG. 2 , the modular block 10 includes an array of laterally-extending corner slots 56 formed in each of its vertical edges. A corner hole 58 passes through the modular block 10 near each of its vertical edges and thus intersects the corner slots 56 formed along each vertical edge. FIG. 4A illustrates components used to connect two or more modular blocks 10 together laterally, including a connector pin 60 , and various connector plates 62 , 64 , 66 , and 68 . The connector pin 60 is an elongated pin sized to fit the corner hole 58 . It may include an enlarged head 70 to prevent it from falling through the modular block 10 . Each connector plate is a flat member having a thickness sized to fit in one of the corner slots 56 of a modular block 10 , and one or more connector pin holes 72 . In the illustrated example, the connector plate 62 has a single hole and is sized to fill in a corner slot 56 but not to perform any joining function. The connector plate 64 is rectangular and has two connector pin holes 72 therein. The connector plate 66 is “L”-shaped and has three connector pin holes 72 . Finally, the connector plate 68 is square and has four connector pin holes 72 therein.
[0123] FIG. 4B illustrates several modular blocks 10 , 10 ′ and 10 ″ connected together. The modular blocks 10 , 10 ′ and 10 ″ meet at a common vertical edge 74 , and connector plates 68 are inserted into corner slots 56 of each of the modular blocks 10 , 10 ′, and 10 ″. A connector pin 60 is then inserted into the corner holes 58 of each of the modular blocks 10 , 10 ′, and 10 ″. This secures each of the modular blocks 10 , 10 ′, and 10 ″ to the connector plates 68 and thus secures the modular blocks 10 , 10 ′, and 10 ″ to each other, in both lateral and vertical directions.
[0124] FIG. 5A illustrates a modular block 10 along with a connector pin 60 , connector plates 62 - 68 , and a finish element 76 . The finish element 76 has a planar inner side 78 which is sized and shaped to mate with a side wall of the modular block 10 . The inner side 78 includes one or more connector tabs 80 with connector pin holes 72 therein. The connector tabs 80 are positioned and sized to fit into corner slots 56 of the modular block 10 . The finish element 76 has an exterior surface 82 with one or more sides or facets which are formed into a desired shape. In the illustrated example, the exterior surface of the finish element 76 is shaped to form a portion of a cylinder.
[0125] FIG. 5B illustrates several modular blocks 10 , 10 ′, 10 ″, and 10 ′″ connected together with several finish elements 76 , using the connector plates 68 , connector tabs 80 , and connector pins 60 as described above to form a solid structure with a cylindrical outer surface. As can be observed from FIG. 5B , the use of finish elements 76 allows the creation of structures that are essentially modular, but which have arbitrary external shapes.
[0126] FIG. 6 illustrates a plurality of building elements 84 . Each of these building elements 84 has multiple “L”-shaped hooks 42 extending from an upper surface thereof, and multiple locking recesses 26 on a lower surface thereof. The building elements 84 can be made as a single element, or built up from individual modular blocks 10 . The direction that each hook 42 faces can be arbitrarily selected to suit a particular application. In FIG. 6 , each hook labeled 42 A is facing towards the left of the page, each hook labeled 42 B is facing towards the bottom of the page, each hook labeled 42 C is facing towards the right of the page, and each hook labeled 42 D is facing towards the top of the page. If the eight hooks 42 on each building element 84 are divided into groups of four, there are then 16 possible combinations of hook directions. FIG. 7 illustrates a structure which is built up from building elements 84 having hooks 42 facing in different directions, while FIG. 8 illustrates a structure which is built up from building elements having hooks 42 all facing in a single direction.
[0127] FIG. 9 illustrates an example of a truss structure 86 which may built up from the modular blocks 10 described above. The modular blocks 10 are connected side-by side and vertically to form longitudinal members 88 , lateral members 90 , and vertical members 92 . Tapered blocks 94 are disposed at the upper ends of the vertical members 92 so that the uppermost longitudinal members 88 will be at the proper angle.
[0128] FIG. 10 illustrates a ladder truss-type structure 96 having longitudinal members 98 and lateral members 100 which may be built up from modular blocks 10 described above.
[0129] FIG. 11 illustrates a modular block 10 alongside additional modular blocks 110 and 112 . The modular blocks 110 and 112 are substantially identical in construction to the modular block 10 , and include hooks 114 and 116 , and locking recesses 118 and 120 , respectively. The modular blocks 110 and 112 differ from the modular block 10 in their size. This may vary from a size small enough to construct items such as electronic circuit boards, to as many as several feet on a side for elements for constructing buildings.
[0130] FIG. 12 illustrates a modular block 122 which is designed to serve as an “adapter” for connection to different-sized modular blocks. The modular block 122 includes a single locking recess 124 on its lower side. Four “L”-shaped hooks 126 protrude from the upper surface of the modular block 122 . As shown in FIG. 13 , this allows the modular block 122 to be connected to additional modular blocks 128 and 130 which are each one-quarter of the size of the modular block 122 .
[0131] FIG. 14 illustrates another modular block 132 which is designed to serve as an “adapter” for connection to different-sized modular blocks. The modular block 132 includes a single “L”-shaped hook 134 protruding from its upper surface. Four locking recesses 136 are disposed on its lower side. As shown in FIG. 15 , this allows the modular block 132 to be connected to additional modular blocks 138 which are each one-quarter of the size of the modular block 132 .
[0132] FIGS. 16 and 17 illustrate an exemplary modular block 200 constructed according to the present invention. The modular block 200 is generally rectangular and includes a top surface 212 , a bottom surface 214 , and front, rear, left and right sidewalls 216 , 218 , 220 , and 222 , respectively. A plurality of generally cylindrical core passages 224 of various sizes pass through the modular block 200 from top to bottom. As shown in more detail in FIG. 18 , each core passage 224 has an enlarged-diameter counterbore 226 formed at its upper end. As shown in more detail in FIG. 19 , each core passage 224 has a plurality of semi-cylindrical key slots 228 formed around the periphery of its lower end.
[0133] FIG. 20 illustrates an exemplary locking assembly 230 , which includes a core 232 , a locking rod 234 , one or more core keys 236 , and a rod key 238 , all of which are described in more detail below. The locking assembly 230 is received in one of the core passages 224 of a modular block 200 to enable the modular block 200 to be connected to other blocks, as shown in FIG. 21 . The locking assembly 230 fits in the core passage 224 so that the upper end of the core 232 fits flush with the top surface 212 of the modular block 200 , as shown in FIG. 22 , and the lower end of the core is flush with the bottom surface 214 of the modular block 200 , as shown in FIG. 23 .
[0134] FIGS. 24A through 24E illustrate the assembly sequence of the locking assembly 230 . Referring to FIG. 24A , the generally cylindrical core 232 has an enlarged boss 240 formed at its upper end which is sized and shaped to fit into the counterbore 226 of the core passage 224 . The core 232 has a through-bore 242 passing along its length. Approximately one-half of the through-bore 242 defines a series of alternating semi-cylindrical core grooves 244 and core lands 246 . The core grooves 244 have a first inner diameter, and the core lands 246 have a second inner diameter which is smaller than the first inner diameter. The remaining portion of the through-bore 242 is formed into a semi-cylindrical passage 247 having an inner diameter somewhat larger than the first inner diameter.
[0135] FIG. 24B illustrates a locking rod 234 . The locking rod 234 is generally cylindrical. Its outer surface defines a series of alternating cylindrical rod grooves 248 and rod lands 250 . The rod lands 250 have a first outer diameter which is approximately equal to the first inner diameter of the core grooves 244 , and the rod grooves 248 have a second outer diameter which is approximately equal to the second inner diameter of the core lands 246 .
[0136] FIG. 24C shows the locking rod 234 inserted into the core 232 and shifted laterally so that the rod lands 250 engage the core grooves 244 , and the rod grooves 250 engage the core lands 246 . Thus engaged, the locking rod 234 is prevented from moving axially relative to the core 232 . The locking rod 234 is inserted approximately halfway into the core 232 , so that a space will be left in the core for receiving another locking rod 234 in a manner described below.
[0137] FIG. 24D shows a rod key 238 about to be inserted into the core 232 . The rod key is an elongated, arcuate cross-section member with a laterally-extending lip 252 at its upper end. The outer wall 254 of the rod key 238 mates with the semi-cylindrical passage 247 of the core 232 , and the inner wall 256 of the rod key 238 mates with the rod lands 250 . When the rod key 238 is fully inserted into the core 232 , it prevents the locking rod 234 from shifting laterally and thus retains it in the core.
[0138] A pair of oblong core keys 236 , best seen in FIG. 26 , are disposed in core key openings 258 near the bottom end of the core 232 so that they can slide transversely to the long axis of the core 232 . The rod key 238 has opposed chamfers 260 at its bottom end (see FIG. 25 ) which engage the core keys 236 and force them outwards as the rod key 238 is fully inserted into the core 232 .
[0139] The locking assembly 230 is attached to a modular block 200 as follows. First, the core 232 with retracted core keys 236 is inserted into one of the core passages 224 of the modular block 200 . The locking rod 234 is then inserted into the through-bore 242 and shifted laterally as described above. The rod key 238 is then inserted into the core 232 , securing the locking rod 234 in place and also forcing the core keys 236 outward. As seen in FIG. 23 , the core keys 236 engage the key slots 228 of the core passage 224 . The entire locking assembly 230 is thus securely attached to the modular block 200 and cannot be removed until the rod key 238 is removed. If desired, the materials, dimensions, and finish of the rod key 238 may be chosen to prevent its unintended removal from the core passage 224 . Furthermore, the rod key 238 may be provided with a means for assisting its removal, such as a fingernail slot or tool ledge (not shown).
[0140] FIG. 27 shows a group of modular blocks 200 , 200 ′, and 200 ″ connected together with a plurality of locking assemblies 230 . To assemble the modular blocks 200 and 200 ′ together, a locking assembly 230 is first installed into a core passage 224 so that approximately half of the locking rod 234 extends upward from the top surface 212 of the modular block 200 (see FIG. 21 ). Then, a second core 232 ′ is inserted into the upper modular block 200 ′ without a locking rod 234 or rod key 238 . The locking rod (obscured in FIG. 27 ) is inserted into the second core 232 ′ and shifted laterally so that its grooves and lands engage the grooves and lands of the second core 232 ′, similar to the manner described above with respect to FIGS. 24A-24E . At this point, the modular blocks 200 and 200 ′ are assembled in an upper-and-lower touching relationship. If desired, a second locking rod 234 ′ may be inserted into the second core 232 and engaged with the grooves and lands thereof. A second rod key 238 ′ is then inserted into the second core 232 to lock both of the locking rods 234 and 234 ′ into place in the second core 232 ′ and prevent disassembly of the modular blocks 200 and 200 ′.
[0141] FIG. 28 illustrates a connector plate 262 for being used to join two or more modular blocks 200 together side-by-side. The illustrated connector plate 262 is a flat member having a thickness sized to fit in a connector slot 264 formed in the periphery of a modular block 200 (see FIG. 29 ). One or more connector pin holes 266 are formed through the connector plate 262 . In the illustrated example, the connector plate 262 is rectangular and has a two-dimensional array of connector pin holes 266 therein.
[0142] As shown in FIGS. 29 and 30 , some of the core passages 224 in the modular block 200 intersect the connector slots 264 thereof. A connector pin 268 , is sized to fit the core passage 224 . It may include an enlarged head 270 to prevent it from falling through the modular block 200 .
[0143] FIG. 31 illustrates two modular blocks 200 and 200 ′ connected end-to-end. A connector plate 262 is inserted into connector slots 264 of each of the modular blocks 200 and 200 ′. A connector pin 268 is then inserted into core passages 224 of each of the modular blocks 200 and 200 ′, passing through the connector pin holes (obscured in FIG. 31 ). This secures each of the modular blocks 200 and 200 ′ to the connector plate 262 and thus secures the modular blocks 200 and 200 ′ to each other, in both lateral and vertical directions.
[0144] FIG. 32 illustrates another connector plate 272 for being used to join two or more modular blocks 200 together. The illustrated connector plate 272 is substantially similar to the connector plate 262 described above, differing only in the fact that it includes an array of relatively small-diameter connector pin holes 274 A, and another array of relatively larger connector pin holes 274 B are formed through the connector plate 272 . The connector plate 272 can be used to join modular blocks 200 having different-sized core passages 224 . As shown in FIG. 33 , this allows the joining of relatively large modular blocks 200 and 200 ′ with a smaller modular block 200 ″.
[0145] FIG. 34 illustrates a finish element 276 . The finish element 276 has a planar inner side 278 which is dimensioned and shaped to mate with a side wall of the modular block 200 . The inner side 278 includes one or more connector tabs 280 with connector pin holes 282 therein. The connector tabs 280 are positioned and sized to fit into the connector slots 264 of the modular block 200 . The finish element 276 has an exterior surface 284 with one or more sides or facets which are formed into a desired shape. In the illustrated example, the exterior surface 284 of the finish element 276 is shaped to form a portion of a cylinder.
[0146] FIG. 35 illustrates a modular block 200 with several finish elements 276 attached thereto. They may be secured with connector pins (not shown) as described above, to form a solid structure with a cylindrical outer surface. The use of finish elements 276 allows the creation of structures that are modular, but which have arbitrary external shapes.
[0147] FIG. 36 illustrates another type of connector plate 286 . The connector plate 286 is a flat member having a thickness sized to fit in a connector slot 264 formed in the periphery of a modular block 200 . An array of connector pin holes 288 are formed through the connector plate 286 . One or more cylindrical studs 290 , each having at least one cylindrical land 292 and one cylindrical groove 294 , are attached to the connector plate 286 and are extend parallel to the plane thereof. The installation of the connector plate 286 into a connector slot 264 , as shown in FIG. 37 , gives the side of a modular block 200 the same connectivity as the top of the modular block 200 . More particularly, the studs 290 perform the same function as the locking rods 236 so that a modular block 200 ′ can be connected to the side of a modular block 200 (see FIG. 38 ).
[0148] FIG. 39 illustrates how various sizes of modular blocks 200 , 200 ′, 200 ″, 200 ′″, and 200 ″″ may be connected to each other by using appropriately-sized locking assemblies 230 in the core passages 224 . Exemplary locking assemblies 230 , 296 , and 298 , varying only in the size of their constituent components, are shown in FIGS. 40 , 41 , and 42 , respectively. The use of these different-sized locking assemblies 230 , 296 , and 298 is enabled by the provision of different-sized core passages 224 in the modular blocks 200 . As shown in FIG. 43 , these core passages 224 are laid out in a regular grid pattern within the modular block 200 .
[0149] FIGS. 44 and 45 illustrate an example of how a complex structure, in this case a wheeled vehicle, can be built up from the components described above, including modular blocks 200 , locking assemblies 230 , finish elements 276 , connector plates 286 , and connector pins 268
[0150] The modular blocks need not be square or rectangular. For example, FIG. 46 illustrates a curved modular block 300 . The curved modular block 300 includes a top surface 312 , a bottom surface 314 , and front, rear, left and right sidewalls 316 , 318 , 320 , and 322 , respectively. The front and rear sidewalls 316 and 318 are curved into parallel arcs. A plurality of generally cylindrical core passages 224 pass through the curved modular block 300 from top to bottom. As shown in FIGS. 47 and 48 , these curved modular blocks 300 can be used solely with other curved modular blocks 300 , or with rectangular modular blocks 200 to form structures with a desired shape.
[0151] FIG. 49 illustrates a trapezoidal modular block 400 . The trapezoidal modular block 400 includes a top surface 412 , a bottom surface 414 , and front, rear, left and right sidewalls 416 , 418 , 420 , and 422 , respectively. The left and right sidewalls 420 and 422 are angled in opposite directions. A plurality of generally cylindrical core passages 224 pass through the curved modular block 300 from top to bottom. As shown in FIG. 50 , these trapezoidal modular blocks 400 can be used with other trapezoidal modular blocks 400 to produce polygonal structures.
[0152] FIG. 51 illustrates a lobed modular block 500 which includes a top surface 512 , a bottom surface 514 , and a continuous sidewall 516 . The sidewall 516 is curved into a shaped having a pinched-in “waist” 518 disposed between two cylindrical lobes 520 . A generally cylindrical core passage 224 passes through the lobed modular block 500 from top to bottom at the center of each lobe 520 . As shown in FIGS. 52 and 53 , these lobed modular blocks 500 can be used to build up wall-like structures which can pivot about the locking rods 500 which hold them together.
[0153] Any of the various shapes of modular blocks described above may be attached to any other shape as long as a core passage is available. An example of a structure built up from various block shapes is shown in FIG. 54 .
[0154] FIG. 55 illustrates another alternative modular block 600 constructed according to the present invention. The modular block 600 includes a top surface 610 , a bottom surface 612 , and front, rear, left and right sidewalls 614 , 616 , 618 , and 620 , respectively. An interior space 621 is defined along the central portion of the modular block 600 . As shown more clearly in FIG. 56 , the modular block 600 is built up from two side members 622 A and 622 B, and one or more locking lugs 624 . Each of the side members 622 has an inner surface 626 and an outer surface 628 . The inner surface 626 of each side member 622 is generally planar and has a plurality of key grooves 623 formed therein. Because the inner surfaces 626 are identical, the side members 622 may be produced in large quantities by providing a workpiece with a flat surface, machining long, continuous grooves in the flat surface, and then cutting the workpiece into individual side members 622 .
[0155] Each of the locking lugs 624 includes upper and lower notches 630 A and 630 B formed near its upper and lower ends. These notches 630 are positioned and sized so as to define “L” shaped upper and lower hooks 632 A and 632 B, respectively. The hooks 632 are sized to engage the notches 630 .
[0156] Referring again to FIG. 55 , the locking lugs 624 are assembled to the modular block 600 by clamping them between the side members 622 A and 622 B. It will be appreciated that the locking lug 624 may be assembled to the modular block 600 so that it points in any one of four directions. In FIG. 55 the upper hooks 632 A of the locking lugs 624 extend towards the front endwall 614 of the modular block 600 , whereas in FIG. 57 , the upper hooks 632 A′ of the locking lugs 624 ′ extend towards the right sidewall 620 ′ of the modular block 600 ′. The components may be secured together by adhesives, welding, thermal or sonic bonding, fasteners, or any other method that will create a unitary whole. The entire modular block 600 may also be formed as an integral component, for example by casting it from a mold.
[0157] The modular block 600 and the locking lug 624 may be constructed of any material which is suited to the application for which the modular block 600 is to be used and which can be formed into the necessary dimensional features. For example, the modular block 600 may be used as a toy, a modeling element, or a light structural element, in which case it may be molded from a material such as plastic resin. The modular block 600 may also be used for heavier structural applications, in which case it may be formed from materials such as concrete, wood or engineered wood materials, pressed fiber, metals, or fiber composite materials. In the illustrated example, the modular block 600 includes an exterior fascia 601 intended to present a finished appearance. The fascia 601 may be formed as an integral part of the modular block 600 , or it may be added to the exterior of the modular block 600 , for example by building up a layer of mortar, joint compound, or the like, and applying an appropriate finish thereto.
[0158] FIGS. 58 and 59 illustrate a key 634 to be used with the modular blocks 600 . The key 634 is an elongated member sized to fit into the interior space 621 . The key 634 has an upper end 636 with an alignment pin 638 protruding therefrom, and a lower end 640 with a complementary alignment hole 642 formed therein. The key 634 also includes at least one alignment rail 644 adapted to engage the key grooves 623 . In the illustrated example, the body of the key 634 is an “H” shaped cross-section, and the alignment rail 644 is formed by positioning a dowel between the uprights of the “H” section. This simplifies manufacture of the key 634 .
[0159] FIGS. 60 and 61 illustrate an alternative key 646 . The key 646 is substantially similar to the key 634 and has an upper end 648 with an alignment pin 650 protruding therefrom, and a lower end 652 with a complementary alignment hole 654 formed therein. The key 646 also includes at least one alignment rail 656 adapted to engage the key grooves 623 . In the illustrated example, the body of the key 656 is generally rectangular, and the alignment rails 656 are formed by positioning dowels within slots 658 in the surface of the key 656 .
[0160] FIGS. 62 and 63 illustrate how a plurality of modular blocks 600 may be assembled to form a larger structure. A first modular block identified as 600 A is positioned down over the locking lugs 624 of one or more other modular blocks 600 B, 600 C, and then shifted laterally so that the hooks 632 of the modular blocks 600 B and 600 C engage the notches (not visible in FIG. 62 ) in the locking lugs 624 of the first modular block 600 A. This prevents the modular blocks 600 A, 600 B, and 600 C from being disconnected in a vertical direction. In creating the assembled structure, the orientation of the locking lugs 624 are preferable chosen so that the hooks 632 will all be facing in the same direction regardless of the orientation of the modular blocks 600 . For example, in FIG. 62 , the modular block identified as 600 D has its hooks 632 facing perpendicular to its long axis.
[0161] To secure the modular blocks 600 together, one or more keys are inserted into the central spaces 621 , with the alignment rails 644 engaging the key grooves 623 of both an upper modular block 600 A, and the modular block 600 C below it (see FIG. 63 ). The engagement of the key 634 prevents lateral motion of the hook 632 relative to the notches 630 . A larger key 646 has multiple alignment rails 656 and therefore holds together two adjacent modular blocks 600 A and 600 E by engaging key grooves 623 in each of the blocks 600 A and 600 D. The dimensions, materials, and surface finish of the keys 634 and 646 may be selected to prevent unintended withdrawal.
[0162] The modular blocks (for example items 10 , 200 , 300 , 400 , 500 , and 600 ) described above may be used for any type of construction which requires or would benefit from a modular characteristic. Several non-limiting examples of possible applications for theses blocks will now be set forth, without regard to a particular embodiment of the blocks themselves. Of course, the modular blocks can be used as toys or as small-scale modeling elements when produced in a proper size, say a few centimeters on a side.
[0163] When produced in larger sizes, they may be used for residential or commercial building elements such as walls, roofs, floor, retaining walls, and windows (if made from transparent or translucent material). They may also be used to construct industrial structures such as factory floors, machine tool bases and machine bodies.
[0164] The modular blocks can also be used to build marine structures such as piers, barges, underwater structures, and boat hulls.
[0165] On a smaller scale, the modular blocks may be used to build up three-dimensional circuit cards, or if made of bio-compatible materials, they may be used to form three-dimensional frames for bone or organ tissue construction. If reduced to a sufficiently small scale, they can be used for nanostructures.
[0166] The modular blocks may be formed out of armor material or projectile-resistant material, such as KEVLAR aramid fibers. These armored blocks can be used to form containers to ship military supplies. After the supplies are received at the destination, the containers can then be disassembled into modular blocks. These blocks can then be used to construct custom made protective shields for personnel or equipment. Shipping containers may also be made from more conventional construction materials and then used to ship food, water, or other supplies to disaster areas. After the supplies are received, the shipping containers may be disassembled into modular blocks and then used for low-cost buildings that can be quickly erected.
[0167] The foregoing has described a modular block and a method of construction using such modular blocks. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation. | A modular block apparatus includes first and second blocks, each block having a generally upwardly protruding locking member and an internal recess sized to receive the locking member of the other block, such that the blocks can be assembled with one block above the other. The blocks are secured together in a vertical direction by relative lateral movement of the locking member and the internal recess. A locking device is provided to prevent relative lateral movement of the locking member and the internal recess so as to retain the blocks in a connected condition. The locking member may be an integral hook, a separate hook, or a cylindrical locking rod. If a hook is used, its orientation relative to the block may be varied. A variety of structures may be built up from the modular blocks. |
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This is a continuation-in-part application of U.S. Ser. No. 417,896 filed Apr. 6, 1995, now U.S. Pat. No. 5,498,451 which in turn is a continuation-in-part application of U.S. Ser. No. 07/964,051 filed Oct. 21, 1992 now U.S. Pat. No. 5,443,871.
FIELD OF THE INVENTION
The present invention relates to spacer elements for insulated glass assemblies having a single as well as a divided atmosphere therebetween.
BACKGROUND OF THE INVENTION
The prior art provides a complete plethora of insulated glass assemblies, sealant strips and spacer elements and improvements thereto used in insulated glass assemblies.
The modifications and improvements to the strips etc. have all had a common goal, namely, to improve the insulation capacity for such assemblies without sacrificing structural integrity or moisture degradation of the assembly.
Although the art is replete with such assemblies, it fails to provide an insulating sealant strip which provides:
i) warm edge technology;
ii) non-ultraviolet degradable material; or
iii) elastic deformation between the glass lites.
Typical of the art in the field of the present invention includes U.S. Pat. No. 4,576,841. This patent discloses the use of an aluminum foil into which is positioned desiccant material. Such an arrangement has two inherent limitations, namely:
i) aluminum is a thermal conductor which results in thermal transmission and thus obvious energy expenditures; and
ii) since the tube is solid, elastic recovery from the compression of glass lites engaged with the same is negligible.
Further, U.S. Pat. No. 4,113,905 discloses a composite foam spacer comprising an extruded tubular profile having an outer coating of foam material thereon. The spacer further includes projecting edges which project laterally relative to the longitudinal axis of the spacer. Although a useful arrangement, the spacer does not facilitate compression dampening and, if the spacer were compressed, this would result in unnatural force dispersion due to the projecting edges which may lead to breakage of the substrates. Further, if compressed, the spacer element may disrupt sealant material associated therewith thus leading to an ineffective seal.
Mucaria, in U.S. Pat. No. 4,368,226 provides a glass assembly in which there is included aluminum spacers. As such, the arrangement is limited similar to U.S. Pat. No. 4,576,841 as discussed herein previously.
Further prior art in the field of the present invention includes U.S. Pat. Nos. 4,536,424; 4,822,649; 4,952,430; 4,476,169; 4,500,572; and Canadian Patent Nos. 884,186; 861,839; and 1,008,307.
SUMMARY OF THE INVENTION
Thus, having regard to the prior art arrangements, there exists a need for a sealant strip which provides a partitioned atmosphere, high insulation value and hygroscopic capabilities without creating an unnecessarily complicated arrangement; the present invention fulfils this need.
According to one object of the present invention, there is provided an insulated glass spacer element comprising a pair of spaced apart substrate engaging members each having a top and bottom surface; a base extending between and connected to each bottom surface of each of the substrate engaging members, and a support member extending between the substrate engaging member and connected to the top surface of one of the substrate engaging members.
The spacer element is preferably a fabricated from a resiliently deformable material to allow flexure of the same.
In a preferred form, the support member extends diagonally between the substrate engaging surfaces to partition the area therebetween. Applicant has found that such an arrangement is well suited to dampening compression between substrates engaged therewith in an insulated glass assembly and accordingly, it is a further object of the present invention, to provide an insulated glass assembly comprising a pair of glass lites; an elastically deformable body having a first substrate engaging member associated therewith; a second substrate engaging member spaced from the first substrate engaging surface, the second substrate engaging surface being operatively associated with the body and extending therefrom, whereby when a glass lite is engaged with the first substrate engaging member and the second substrate engaging member, the second substrate engaging member facilitates limited resilient compression of the assembly.
The spacer element according to a further embodiment of the present invention may be used in combination with a similar spacer element to provide a multiple atmosphere insulated assembly. Such an arrangement is extremely useful for dual insulated window assemblies commonly used in highrises. Previously, aluminum extruded bodies not capable of providing warm edge technology had to be used for such an application. Thus, a further object of the present invention is to provide an insulated glass assembly having opposed substrates with an atmosphere therebetween and sheet material extending between the opposed substrates comprising a pair of glass lites; a sheet of flexible material, a pair of insulating spacer members, each of the spacer members having a sheet engaging member for engaging the sheet material, a substrate engaging member, each of the substrate engaging member and the sheet engaging member having an upper and lower edge, a base extending between and connected to each the upper edge of each the substrate engaging member and the sheet engaging member, a support member extending between the engaging surfaces and connected to the lower edge of the substrate engaging surface whereby when the substrates are engaged with the substrate engaging surfaces of each of the spacer members and the engaging surface of each of the spacer members is in facing relation, the sheet material extends within the atmosphere spaced from the opposed substrates, whereby when the substrates are engaged with the substrate engaging surfaces the sheet material extends within the atmosphere spaced from each of the substrates engaged with the insulating bodies.
In applications where compressive forces are not so extreme, a further embodiment of the present invention is provided which comprises a support member for supporting and spacing opposed substrates in a window construction comprising a self-supporting elastically deformable body having a pair of opposed and spaced apart arms each adapted to engage one of the substrates, the arms extending outwardly from the body at either end thereof, the body having a width sufficient to space the opposed substrates apart from one another, and desiccant receiving means associated with the main body and adapted to receive desiccant material therein.
In one variation of the present invention, the generally vertically oriented support member may function solely as a supporting member; alternately, this supporting element may be of a corrugated nature which functions to permit some flexing of the support member to relieve stress on double glass lites formed into an assembly where stress may be encountered due to wind or atmospheric conditions which will cause flexing of the glass panes or lites with consequent flexing of the spacer element or strip. In this way, where large surface areas of glass panes are used in conjunction with the spacer element, a degree of flexibility can be provided without disrupting the integrity of the spacer element.
In a still further embodiment, the vertically oriented as well as the angularly disposed supporting members of the spacer element may include additional reinforcing means such as by including an embossed structure thereon. Such an embossed structure could be in the form of a plurality of spaced apart ribs, etc.
A coating may be applied over the outer chamber or insulative body to protect the material therein, such a coating may be in the form of a silicon coating. Alternatively, a suitable end cap may be provided to protect the material within the outer chamber.
Preferably, the spacer strip of the present invention includes a integral polymeric support frame which includes a first generally horizontal arm, the angularly disposed support arm forming a second arm extending from one end of the first horizontal arm; a third generally horizontal arm extending from one end of the angularly disposed support arm; the vertically oriented support arm forming a fourth arm extending downwardly from the third horizontal arm. The first and third horizontal arms being generally parallel. In this arrangement, the first and third horizontal arms form the strip portions which engage the glass lites.
In a particularly preferred arrangement, the polymeric support frame is also provided with a fifth horizontal arm which extends from the fourth arm and is adjacent and parallel to the first horizontal arm. In this arrangement, the third horizontal arm and the fifth horizontal arm from the strip portions which engage the glass lites.
Having thus generally described the invention, reference will now be made to the accompanying drawings, illustrating preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a perspective view of one alternate embodiment of the spacer strip according to the present invention;
FIG. 2 is a perspective view of the strip as positioned between two substrates;
FIG. 3 is an end view of a further alternate embodiment of the spacer strip of the present invention;
FIGS. 4 through 7 are end views of the spacer strip according to further embodiments;
FIG. 8 is a perspective view of a part of an insulated window assembly utilizing one embodiment of the insulative spacer strip of the present invention;
FIG. 9 is an end view of the spacer strip illustrated in FIG. 8;
FIG. 10 is a laid-open view of the rigid polymeric support frame of the spacer strip illustrated in FIG. 9;
FIG. 11 is an end view of an alternate embodiment of the spacer strip of the present invention;
FIG. 12 is an end view of another alternate embodiment of the spacer strip of the present invention; and
FIG. 13 is an end view of a further alternate embodiment of the spacer strip of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, shown is a first embodiment of the present invention.
FIG. 1 illustrates a perspective view of a spacer member, generally indicated by numeral 40, comprising a body resiliently compressible material such as those discussed herein previously.
The spacer 40, as illustrated in FIG. 1, includes a base 42 extending between and connected to substrate engaging members 44 and 46. The members 44 and 46 project from the base 42. Extending diagonally between the members 44 and 46 is a support member which is flexibly connected at one end to one of the engaging members 44 and 46, shown in the illustrated example as member 48. The other end of the support member 48 is free.
The spacer 40, according to this embodiment, may be fixed between a pair of opposed substrates 14 and 16 as illustrated in FIG. 2, by providing a butyl material such as polyisobutylene between each substrate and a respective engaging member 44 or 46 or may be adhered thereto using other suitable materials or methods.
The structure of the spacer 40 of this embodiment is particularly efficient for compression damping to thus prevent seal disruption and/or substrate fracture. The support member 48, being diagonally disposed between the substrate engaging members 44 and 46, is useful for this purpose. Upon compression of the substrates 14 and 16, the engaging members 44 and 46 flex somewhat towards one another which, in turn, results in the support member absorbing at least some of the force.
The spacer 40 may be extruded in the form illustrated in the drawings, or may be formed from an elongated length or sheet. Applicant has found that the use of the polyethylene terephthalate class of polymers as well as the polyvinyl halide polymers provide these properties and are extremely useful for highly efficient insulated glass assemblies. These materials are generally elastically deformable and are capable of resilient compression, while additionally providing a warm edge unit.
Further, the support member 48, as disposed between the members 44 and 46 provides a longitudinal generally tubular opening into which may be charged desiccant, butyl material, silicone material and other such materials. Suitable desiccant material may be selected from, for example, zeolites, silica gel, calcium chloride, alumina etc. The material selected may be loose or dispersed in a permeable matrix of, for example, silicone. This material has been removed to more clearly illustrate the structure of spacer 40.
FIG. 3 illustrates yet a further embodiment of the invention in which the spacer 40 is in opposition with a similar spacer for a dual atmosphere assembly. In this arrangement, substrate engaging members 46 of each of the spacer 40 each function as sheet engaging menders for maintaining the sheet material 32 taut between the substrates 14 and 16.
The film divides the atmosphere between the substrates 14 and 16 into separate air spaces such as is known dual seal insulated glass units. The film may comprise any of the known materials employed by those skilled in the art e.g. vinylidene polymers, PVC, PET, etc. Where ultraviolet exposure is a concern, the sheet may comprise a suitable UV screening material, e.g. Tedlar™.
Suitable adhesives or butyl material may be positioned between the facing engaging members 46 for securing the same and sheet material together. Similar to the embodiment of FIG. 2, suitable adhesive materials will be provided for engaging menders 44 for sealing engagement with substrates 14 and 16.
A bead 50 of butyl material can be positioned adjacent the free end of the support member 48 of each spacer 40 to maintain the same and adjacent with the corner formed by the base 42 and substrate engaging member 44.
Due to the disposition of the support member 48 in the spacer 40, a tubular form 52 is created which may receive desiccant material therein.
In an alternate form, the base 42 may include desiccant receiving means such as pockets embossed in base 42 to receive desiccant material.
Further, although the embodiment illustrated in FIG. 3 comprises two separate spacers 40, it will be appreciated by those skilled in the art that the two may be coextruded as a single piece in which provision would be made to allow reception of the sheet material 32 therebetween.
FIGS. 4 through 7 illustrate further forms of the spacer in which similar elements from previous embodiments are denoted with similar numerals.
Referring to FIG. 4 in greater detail, a support member 60 extends between engaging members 44 and 46 to divide the same, similar to the support member 48 from previous embodiments. The primary differences in the structure of support member 60 reside in a transversely extending partitioning member 62 positioned adjacent base 42.
FIG. 5 shows a further embodiment in which the support member, represented by numeral 64 in this embodiment, includes two generally diagonal portions 66 and 68 joined by a transversely extending portion 70.
FIG. 6 represents a composite of the support members 60 and 64 of FIGS. 4 and 5, respectively. Support member 72 in this embodiment corresponds in structure to portion 66 illustrated in Figures and the lower portion of the support member illustrated in FIG. 4.
FIG. 7 illustrates yet another embodiment for the spacer in which the support member includes partitioning members 74 and 76. In this manner, the desiccated material area 78 is divided as is the hollow air containing area 80.
In the embodiments illustrated in FIGS. 4 through 7, as well as herein previously, each spacer 40 may include a cap 58 comprising a polysilicone and desiccant material therein. This material would, in use, be directed to the interior volume of the window assembly.
The use of the partitioned structure for the spacer improves the thermal performance of the spacer by breaking the conductivity path in the silicone and separating the air filled area into a plurality of areas.
Reference will be initially made to FIGS. 8 and 9, which illustrate yet another embodiment of the spacer of the present invention.
The spacer strip of this embodiment, generally designated by reference numeral 90, includes a first insulative body 92 and a second insulative body 94. The first insulative body 92 is a generally hollow body which includes air therein, air being known as a good insulative material. Alternatively, the first insulative body 92 may include any suitable insulative material therein (not shown). The second insulative body includes a desiccant material 96 therein which may be selected from those materials discussed herein previously.
The insulative bodies 92 and 94 are formed by a rigid polymeric support frame structure, generally designated by reference numeral 97.
The rigid polymeric support frame member 97 is preferably of a one-piece unitary construction, although other constructions may be utilized such as two or more different coextruded or laminated strips.
The rigid polymeric support frame 97, as best illustrated in FIG. 9, includes a first arm 98 which is generally horizontally oriented, a second arm 100 which is generally angularly oriented, a third arm 102 which is generally horizontally oriented and is generally parallel to the first arm 98, a fourth arm 104 which is generally vertically oriented and a fifth arm 106 which is generally horizontally oriented.
The support frame 97 preferably has a thickness of approximately 0.005" to 0.030 inch and is of any suitable material which is self-supporting and suitably rigid such as polyolefins, polyesters, silicones and polyamides; polyesters being particularly preferred. If desired, the support frame 97 may also have a metallized surface or surfaces.
As best seen from FIG. 9, the fifth arm 106 is preferably parallel, adjacent and coextensive with the first arm 98; although the first arm 98 may be shorter or larger than the fifth arm 106. In a particularly preferred form, the fifth arm 106 and the first arm 98 are fixedly secured together by way of any suitable adhesive means (not shown) and the first arm 98, the second arm 100 and the third arm 102 form a generally "Z" shaped configuration.
Both the second arm 100 and the fourth arm 104 preferably have embossments 108 thereon. Such embossments 108, which may be in the form of spaced apart ribs, add strength to the support frame structure 97. It is contemplated that the embossed structures 108 may also include a desiccant material therein as previously discussed for earlier embodiments.
As will be noted, from FIG. 9 in particular, the second arm 100 forms a common border for each of the insulative bodies 92 and 94.
An end member 110 may be provided which covers and protects the desiccant material 96 in the second insulative body 94 and extends from the fifth arm 106 to the third arm 102. Such an end member may be in the form of any suitable polymeric coating or may be in the form of an end cap of any suitable material. Preferably, such an end member is in the form of a silicone coating having a UV resistant additive and further having the property of preventing rapid moisture absorption and saturation of the desiccant material 96 when exposed to atmospheric conditions, and providing sufficient necessary moisture absorption when between two panes of glass.
As best illustrated in FIG. 8, when the spacer strip 90 of the present invention is assembled between two panes of glass 116, the third arm 102 and the fifth arm 106 are fixedly secured to the panes of glass 116 by way of any suitable adhesive.
FIG. 10 illustrates the rigid polymeric support frame 97, as described above with reference to FIGS. 8 and 9, in a laid out condition. The embossments 108 on the second arm 100 and the fourth arm 104 are readily apparent from this Figure. Although in FIG. 10, the embossments 108 on the second arm 100 are shown on the top surface, and the embossments 108 on the fourth arm 104 are shown on the bottom surface, it will be understood that the embossments 108 could be on either or both of the surfaces of arms 100 and 104.
To form the spacer strip, the rigid polymeric support frame 97 is bent along the margins 109 to form the first horizontal arm 98, the second angularly disposed arm 100, the third horizontal arm 102, the fourth generally vertical arm 104 and the fifth horizontal arm 106 (see polymeric support frame 97 in the spacer strip illustrated in FIGS. 8 and 9).
FIG. 11 illustrates an alternative embodiment of the present invention. The embodiment of FIG. 11 is very similar to the embodiment illustrated in FIG. 9, with like reference numerals designating like parts.
In the embodiment of FIG. 11, however, the fourth arm 104 is of a corrugated construction, which permits some flexing of this support member to release stresses. All other elements of this embodiment are as shown and described with reference to FIGS. 8 to 10.
FIG. 12 illustrates another embodiment of the spacer strip 90 of the present invention, which again is very similar to the embodiment of FIG. 2, with like reference numerals designating like parts. In the FIG. 12 embodiment, the support frame 97 does not include a fifth arm. The end cap 110 covering the desiccant material 96 extends from the first arm 98 to the third arm 102. In this embodiment, the first arm 98 and the third arm 102 form the strips which engage the glass panels, and are affixed thereto by any suitable adhesive.
A further embodiment of the present invention is illustrated in FIG. 13. In this embodiment, a first arm 120 is provided which is generally horizontal. A second arm 122, which is generally vertical, extends upwardly from one end of the first arm 120. A third arm 124 which is parallel to the first arm 120 extends from the second arm 122 and a fourth arm 126 is angularly disposed and extends downwardly from the third arm 124, the fourth arm 126 has a free end which is adjacent the point where the first arm 120 and the second arm 122 are joined. The fourth arm 126 forming a common border between the first and second insulative bodies 92 and 94. In this arrangement, the first arm 120 and the third arm 124 form the glass lite engaging strips and the end cap 110 covering the desiccant material 96 extends from the first arm 120 and the third arm 124.
As those skilled in the art will realize, these preferred illustrated details can be subjected to substantial variation, without affecting the function of the illustrated embodiments. Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention. | There are disclosed spacer elements for use in insulated glass assemblies of the single and multiple atmosphere type which incorporate non-thermally conductive materials as the main structural support member in the assembly. The result is a lightweight, warm edge assembly. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Canadian Patent Application No.: 2,691,891 filed Feb. 4, 2010.
FIELD
This invention relates to smart fluid compositions and methods for well service operations.
BACKGROUND
Many wells are drilled in reservoirs that have multiple pay zones. To stimulate each zone effectively it is crucial that the stimulation fluid, for example, fracturing fluid, be diverted to the targeted zone. It is common to use mechanical isolation to help ensure effective stimulation of each zone or groups of closely spaced zones. Normally it involves the following steps:
1. Perforate the lowest zone, then perform the hydraulic fracture treatment; 2. Flowback the stimulated zone; 3. Mechanically isolate the stimulated zone and then repeat the processes of fracturing and flowback; (and possibly a third or more zones when needed); and 4. Finally, remove the mechanical isolation devices, and put the well on production.
Mechanical isolation methods are generally reliable for diverting multi-staged fracture treatments. However, extra work-over equipment is needed to set and remove the mechanical isolation devices in the well, thus, making such methods time consuming and expensive.
Another type of isolation method involves the use of sand plugs to isolate the treated zones. Such a method involves fracture treating the lowest zone, and then setting a sand plug across the lower zone to isolate the treated zone. The upper zone is then perforated and fracture treated. The process is repeated. Setting the sand plug is achieved by pumping sand slurry into the well and allowing sands to settle to the bottom. The permeability of the sand plug should be low enough to ensure that it would not allow the re-fracturing of the lower zone. The sand plug method is simple, less time consuming and economic. Unfortunately, this method is incapable of isolating zones in horizontal wells, as gravity pulls sands away from upper part of the well.
In recent years, drilling horizontal wells in combination with multi-staged fracturing has become a common practice, especially for tight formations including shale formations. In order to effectively fracture the targeted formation, zone isolation using mechanical means normally has to be applied in a horizontal well, despite the fact that it is time consuming and expensive.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to plugs comprising a viscosified smart fluid for zone isolation during well completion and hydraulic fracturing operations, as well as in other operations.
In another aspect, the present invention relates to smart fluid compositions and their use for diverting a fracturing fluid during multi-staged hydraulic fracturing operations.
In another aspect, the present invention relates to a smart fluid that is a magnetorheological (“MR”) fluid. The MR fluid is used for diverting a fracturing fluid to a targeted zone in a multi-staged well service operation, including without limitation, an hydraulic fracturing operation in a well which can be vertical, horizontal or diverted.
In another aspect, the present invention relates to a method of diverting fracturing fluid to a targeted zone in a wellbore comprising flowing a smart fluid composition, such as the MR fluid, into the wellbore; inducing an electromagnetic field in the fluid sufficient to increase the viscosity of the smart fluid; flowing a fracturing fluid in the wellbore whereby fracturing fluid contacting the viscosified smart fluid is diverted to a targeted zone.
In another aspect, the present invention relates to a method of isolating a zone in a wellbore comprising providing a smart fluid in a wellbore; and inducing a magnetic field in the fluid; whereby the fluid is changed from a liquid state to a solid state thus isolating the zone.
In another aspect, the present invention relates to a well treatment method comprising providing a work string comprising a well treatment tool at an end of the string, the tool comprising an electromagnet; inserting the tool into a wellbore in a subterranean formation; injecting a smart fluid into the wellbore via the string; inducing a magnetic field with the electromagnet in the smart fluid in the wellbore; injecting a well treatment fluid into the wellbore at a pressure sufficient to fracture the formation.
In another aspect, the present invention relates to a well treatment apparatus comprising a tubular body closed at one end; connection means at another end for connection to a work string; a pair of spaced electromagnetic coils on the body connectable to an electrical source; whereby when electricity is conveyed to the coils, a magnetic field is induced.
In another aspect, the present invention relates to a wellbore casing comprising an electromagnetic coil in the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-section of one or more embodiments of an apparatus and method according to this invention;
FIG. 2 is an enlarged diagram of tool 12 of FIG. 1 ;
FIG. 3 is a schematic cross-section of one or more embodiments of an apparatus and method according to this invention;
FIG. 4 is an enlarged diagram of tool 12 of FIG. 3 ;
FIG. 5 is a schematic cross-section of one or more embodiments of an apparatus and method according to this invention;
FIG. 6 is an enlarged diagram of tool 30 of FIG. 5 ;
FIG. 7 is a schematic cross-section of one or more embodiments of an apparatus and method according to this invention; and
FIG. 8 is an enlarged diagram of a section of FIG. 7 ;
DESCRIPTION OF THE INVENTION
In one aspect, the invention relates to use of a smart fluid to isolate a zone in a subterranean formation. The smart fluid in one or more embodiments is an MR fluid.
In another aspect, the invention relates to a method of isolating a zone in a wellbore comprising providing a smart fluid in a wellbore; and inducing a magnetic field in the fluid, whereby the fluid is changed from a liquid state to a semi-solid or solid state thus isolating the zone and/or forming a barrier for diverting a fracturing fluid to a targeted zone in a multi-staged well service operation, including without limitation, an hydraulic fracturing operation.
A smart fluid is a fluid whose properties, for example, the rheological property, changes dramatically in response to a magnetic field or an electric field. These fluids are able to change from free-flowing viscous liquids to semi-solids having controllable yield strength in milliseconds when exposed either a magnetic or an electric field. In the absence of a magnetic or electric field, smart fluids have low viscosity.
The most developed smart fluids today are magnetorheological (“MR”) fluids whose viscosity increases significantly when a magnetic field is applied. A basic MR fluid normally comprises ferromagnetic particles, including without limitation, iron particles, suspended in a carrier liquid. The size of the iron particles is generally in the range of 0.1-10 μm. The carrier fluid is most commonly hydrocarbon oil, although MR fluids are also made using silicone oil, water or other suitable fluids for different applications. The concentration of the iron particles is typically in the range of 20%-40% by volume. Without being bound by theory, the magnetorheological response of MR fluids originates from the particle polarization induced in the magnetic field. The polarization causes the particles to line up, increasing the viscosity of the fluid dramatically. The force of magnetism can change both the shape and the viscosity of MR fluids. The hardening process occurs very fast, taking around twenty thousandths of a second. The magneto-rheological response of MR fluids can vary dramatically depending on the composition of the fluid and the size and shape of the particles, and the strength of the magnetic field. The MR fluids in accordance with one or more embodiments of this invention can also contain non-ferromagnetic particles, for example, silica particles, which can be either hydrophilic or hydrophobic treated, for example, using organic silicone compounds.
Another interesting characteristic of MR fluids is that their mechanical properties under the magnetic field are anisotropic, i.e., the largest resistance to the flow is in the direction perpendicular to the direction of magnetic field. These fluids, especially MR fluids, have been commercially used in various applications including fluid dampers and clutches.
In one or more embodiments of this invention, smart fluids are used to isolate zones in a wellbore as plugs during multi-staged fracturing treatment in horizontal wells. In one or more embodiments of this invention, a work string, including, without limitation, jointed tubing or coiled tubing, is run into a wellbore to a depth where the first fracturing treatment is to be initiated. In a vertical well, this normally is at the wellbore nearest the bottom of the well. In a horizontal well, this normally is at the wellbore nearest the toe of the well. A smart fluid, such as a MR fluid, is pumped into the wellbore. At the same time or after a magnetic field is induced in the MR fluid in the direction perpendicular to the wellbore turning the MR fluid to a solid state whereby it acts as an effective barrier to fluid in the longitudinal direction along the wellbore, a fracturing fluid is pumped at a pressure sufficient to initiate the first fracturing treatment.
The locations of the magnetic field are adjusted according to the locations of the targeted zones. A magnetic field can be induced in a MR fluid using conventional methods and equipment. For example, electromagnetic coils can be wound on the work string. When an electric current runs through the electromagnetic coils, a magnetic field is generated in the desirable locations. After the first fracturing treatment, the magnetic field is turned off and the MR fluid returns to a liquid state and the coiled tubing is moved to the next fracturing location and the same fracturing process is repeated.
In one or more embodiments of this invention, the gel plugs and the methods of using them as disclosed in Canadian Patent Application 2,679,948 can be combined with the smart fluids. The gel can first fill up part of the wellbore followed by a smart fluid and then another gel plug. The sequence can be repeated few times. The same fracturing procedures as indicated above can be applied. Both aqueous-based and oil-based gels can be used.
In one or more embodiments of this invention, the surface of iron particles used in the smart fluid can be treated to change their wettability toward the carrier fluid. For example, compounds including polysiloxanes and fluorosilanes or fluorosiloxanes can be applied to the surfaces of the iron particles. The alteration of the wettability of the particles may affect the rheological properties of the MR fluid in either “on” (i.e. magnetized) or “off” (non-magnetized) states.
In one or more embodiments, a smart fluid according to this invention can be gelled to enhance its viscoelastic property. In the case where an oil-based smart fluid is used, for example, a phosphate ester with a metal cross-linker or a metal carboxylate can be used to gel the smart fluid. In case where an aqueous-based MR fluid is used, gellants including water-soluble polymers and viscoelastic surfactants can be used to gel the MR fluid. These gellants are known to people skilled in the art.
In one or more embodiments of this invention, an MR fluid according to this invention is contained in a soft shell container, for example, a ring made of soft or flexible materials including fibres, soft rubber or flexible plastic, which can be placed or wound around a work string which could be jointed pipe or coil tubing for example. In the absence of a magnetic field, the work string enters into the wellbore easily. Under a magnetic field during a fracturing operation, the MR fluid changes to a solid state sealing up the annular space between the coiled tubing and the casing or the space between the work string and the formation as in an open hole application, and isolate the targeted zone from the surround zones.
Referring initially to FIG. 1 , in one or more embodiments of this invention, a horizontal well 2 is drilled in a hydrocarbon bearing zone 4 in formation 6 . The initial section of the well 2 is cased with a conventional casing 8 . The rest of the well 2 is uncased. A coiled tubing string 10 is run into the well. It will be understood by those skilled in the art that other types of work strings may be used in place of coiled tubing, including but not limited to jointed pipe.
An electromagnetic fracturing tool indicated generally at 12 is connected on the end of coiled tubing 10 . Slots 14 are provided in the tool 12 for permitting fluid, such as but not limited to a fracturing fluid, to pass from inside the coiled tubing 10 into the wellbore 2 . The tool 12 is provided with a pair of first and second electromagnetic coils 16 which encircle the tool 12 . The coils 16 are operably connected to a downhole power generator 25 which provides electricity to energize the coils 16 . A convention downhole power generator such as disclosed in U.S. Pat. No. 6,191,561 can be used. Alternatively, other power sources can be used such as, but limited to, running power cables by wireline, to the tool 12 from a surface generator (not shown).
The coils 16 in turn are each encircled by a malleable ring 18 containing a magnetorheological fluid 20 comprising iron particles according to this invention.
In operation, the tool 12 is positioned such that the rings 18 straddle the zone that is to be treated. Referring to FIGS. 3 and 4 , the coils 16 are then energized and act as electromagnets and induce a magnetic field in the vicinity of the coils 16 , including in the fluid 20 . The magnetic field causes the fluid 20 to viscosify as the iron particles align in the direction of magnetic flux lines in the magnetic field. The shape of the rings 18 change with the alignment of the iron particles such that the rings 18 expand in a direction transverse to the longitudinal direction of the wellbore to form packer-like isolators 18 which close off the annulus 24 between the the ring/isolators 18 . A well treatment fluid 26 such as a fracturing fluid can then be pumped the ring/isolators 18 . A well treatment fluid 26 such as a fracturing fluid can then be pumped out of the coiled tubing 10 though the slots 14 into the isolated annulus 24 .
After completion of the well treatment, the electricity being supplied to the coils 16 is switched off and the fluid 20 loses high viscosity. As the fluid 20 losses high viscosity, the rings 18 become malleable once again such that the rings 18 can be pulled away from the side of the wellbore 2 and the tool 12 can be moved to another interval or zone for well treatment.
Referring to FIGS. 5 and 6 , in one or more embodiments of this invention, an electromagnetic fracturing tool 30 is provided which is similar to the tool 12 . Unlike tool 12 , however, the tool 30 does not have a malleable ring ( 18 ) containing a magnetorheological fluid which encircles the electromagnetic coils 16 . The coils 16 are operably connected to a downhole power generator 25 which provides electricity to energize the coils 16 .
In operation, the tool 30 is positioned such that the coils 16 straddle the zone that is to be treated. A magnetorheological fluid 36 comprising iron particles is introduced into the annulus 24 sufficient to at least fill the annular space between the tool 30 and the side of the formation 40 in the vicinity of the coils 16 . The coils 162 are then energized and act as electromagnets and induce a magnetic field in the fluid 36 . The magnetic field causes the fluid 36 to viscosify as the iron particles align in the direction of magnetic flux lines in the magnetic field. The fluid 36 becomes sufficiently viscous and even solid such that it forms plugs 38 which closes off the annulus on either side of the slots 14 in the tool 30 . A well treatment fluid 40 such as a fracturing fluid can then be pumped out of the coiled tubing 10 though the slots 14 into the isolated annulus 24 . After completion of the well treatment, the electricity being supplied to the coils 32 is switched off and the plugs 38 loses their high viscosity. As the plugs 38 lose their viscosity, the plugs 38 no longer close off the annulus 24 and the tool 30 can be moved to another interval or zone for well treatment.
Referring to FIGS. 7 and 8 , in one or more embodiments of this invention, a wellbore 42 is lined with a casing 44 which is cemented into place with cement 46 . Electromagnetic coils 48 are located at intervals in the casing 44 . The coils 48 are electrically connected by wireline or other suitable means to a generator (not shown) which would typically be at the surface. A magnetorheological fluid 50 comprising iron particles is pumped to fill the casing 44 in the zones where isolation is required. One or more of the coils 48 are then energized and act as electromagnets and induce a magnetic field in the vicinity of the coils 48 , including in the fluid 50 . The magnetic field causes the fluid 50 to viscosify as the iron particles align in the direction of magnetic flux lines in the magnetic field forming plugs 52 . The plugs 52 close off the wellbore. The plugs 52 can be formed and reformed at the same time or in any desired sequence by turning the power to one or more of the coils 48 off and on. A well treatment fluid such as a fracturing fluid can be introduced when desired and can be diverted by one or more of the plugs 52 .
The electromagnets according to this invention can be powered by a downhole dynamo that is energized by pumping the treatment fluid through its inner passage. The electromagnets can also be powered by downhole batteries and be switched by fluid flow and or pressure. The electromagnets can also be powered by downhole batteries and be switched by a signal from surface.
In one or more embodiments of the invention, an MR fluid is injected into casing or tubing. One or more coils are attached to the casing or tubing at desirable distance. The magnetic field at the designated locations is initiated simultaneously with pumping of the fracturing fluid. MR fluid in strong magnetic field, i.e., near the coils, is transformed into semi-solid while MR fluid in weak field, i.e., far from the coils, has lower viscosity. The vast viscosity contrast of the MR fluid in casing or tubing diverts the fracturing fluid to the desirable zones. In this application the MR fluid can be gelled, for example, by adding into the oil medium gellants known in the art. Gelled MR fluid can fill the tubing space more efficiently.
In one or more embodiments of the invention, an MR fluid is injected into casing or tubing or wellbore. Instead one or more coils are attached to the coil tubing, which is used to deliver the fracturing fluid to the formation. The magnetic field at the designated locations is initiated simultaneously with pumping of the fracturing fluid. MR fluid in strong magnetic field, i.e., near the coils, is transformed into semi-solid while MR fluid in weak filed, i.e., far from the coils, has lower viscosity. The vast viscosity contrast of the MR fluid in casing or tubing diverts the fracturing fluid to the desirable zones. In this application the MR fluid can be gelled, for example, by adding into the oil medium gellants known in the art. A gelled MR fluid can fill the tubing space more efficiently. | Compositions, apparatuses and methods for isolating target zones for hydraulic fracturing, in particular, the use of smart fluids (i.e., magnetorheological fluids) to isolate target zones for fracturing by inducing an electromagnetic field to increase the viscosity of the fluids to form packers or plugs in the annulus of the wellbore and to isolate the target zone are disclosed. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to systems and methods for producing or delivering heat at or near the down hole end of production tubing of a producing oil or gas well for improving production therefrom.
2. Background Information
Free-flowing oil is increasingly difficult to find, even in oil wells that once had very good flow. In some cases, good flowing wells simply “clog up” with paraffin. In other cases, the oil itself in a given formation is of a viscosity that it simply will not flow (or will flow very slowly) under naturally ambient temperatures.
Because the viscosity of oil and paraffin have an inverse relationship to their temperatures, the solution to non-flowing or slow flowing oil wells would seem fairly straight forward—somehow heat the oil and/or paraffin. However, effectively achieving this objective has proven elusive for many years.
In the context of gas wells, another phenomena—the buildup of iron oxides and other residues that can obstruct the free flow of gas through the perforations, through the tubing, or both—creates a need for effective down hole heating.
Down hole heating systems or components for oil and gas wells are known (hereafter, for the sake of brevity, most wells will simply be referred to as “oil wells” with the understanding that certain applications will apply equally well to gas wells). In addition, certain treatments (including “hot oil treatments”) for unclogging no-flow or slow-flow oil wells have long been in use. For a variety of reasons, the existing technologies are very much lacking in efficacy and/or long-term reliability.
The present invention addresses two primary shortcomings that the inventor has found in conventional approaches to heating oil and paraffin down hole: (1) the heat is not properly focused where it needs to be; and (2) existing down hole heaters fail for lack of design elements which would protect electrical components from chemical or physical attack while in position.
The present inventor has discovered that existing down hole heaters inevitably fail because their designers do not take into consideration the intense pressures to which the units will be exposed when installed. Such pressure will force liquids (including highly conductive salt water) past the casings of conventional heating units and cause electrical shorts and corrosion. Designers with whom the present inventor has discussed heater failures have uniformly failed to recognize the root cause of the problem—lack of adequate protection for the heating elements and their electrical connections. The down hole heating unit of the present invention addresses this shortcoming of conventional heating units.
Research into the present design also reveals that designers of existing heaters and installations have overlooked crucial features of any effective down hole heater system: (1) it must focus heat in such a way that the production zone of the formation itself is heated; and (2) heat (and with it, effectiveness) must not be lost for failure to insulate heating elements from up hole components which will “draw” heat away from the crucial zones by conduction.
However subtle the distinctions between the present design and those of the prior art might at first appear, actual field applications of the present down hole heating system have yielded oil well flow rate increases which are multiples of those realized through use of presently available down hole heating systems. The monetary motivations for solving slow-flow or no-flow oil well conditions are such that, if modifying existing heating units to achieve the present design were obvious, producers would not have spent millions of dollars on ineffective down hole treatments and heating systems (which they have done), nor lost millions of dollars in production for lack of the solutions to long-felt problems that the present invention provides (which they have also done).
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved down hole heating system for use in conditioning oil and gas wells for increased flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
It is another object of the present invention to provide an improved design for down hole heating systems which has the effect of more effectively focusing heat where it is most efficacious in improving oil or gas flow in circumstances when such flow is impeded because of oil viscosity and/or paraffin blockage conditions.
It is another object of the present invention to provide an improved design for down hole heating systems for oil and gas wells which design renders the heating unit useful for extended periods of time without interruption for costly repairs because of damage or electrical shorting caused by unit invasion by down hole fluids.
It is another object of the present invention to provide an improved method for down hole heating of oil and gas wells for increasing flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
In satisfaction of these and related objects, the present invention provides a down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The system of the present invention, and the method of use thereof, provides two primary benefits: (1) the involved heating unit is designed to overcome an unrecognized problem which leads to frequent failure of prior art heating units—unit invasion by down hole heating units with resulting physical damage and/or electrical shortages; and (2) the system is designed to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a producing oil well with the components of the present down hole heating system installed.
FIG. 2 is an elevational, sagittal cross section view of the heating unit of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the complete down hole heating system of the present invention is generally identified by the reference numeral 10 . System 10 includes production tubing 12 (the length of which depends, of course, on the depth of the well), a heat insulating packer 14 , perforated tubing 16 , a stainless steel tubing collar 18 , and a heating unit 20 .
Referring in combination to FIGS. 1 and 2, heating unit 20 includes electrical resistance type heater rods 26 , the electrical current for which is supplied by cables 22 which run down the exterior of production tubing 12 and connect to leads 24 at the upper end of heating unit 20 .
Heat insulating packer 14 and stainless steel collars 18 are includes in their stated form for “containing” the heat from heating unit 20 within the desired zone to the greatest practical degree. Were it not for these components, the heat from heating unit 20 would (like the heat from conventional down hole heater units) convect and conduct upward in the well bore and through the production tubing, thereby essentially directing much of the heat away from the area which it is most needed—the production zone.
Perhaps, it goes without saying that oil that never reaches the pump will never be produced. However, this truism seems to have escaped designers of previous down-hole heating schemes, the use of which essentially heats oil only as it enters the production tubing, without effectively heating it so that it will reach the production tubing in the first place. Largely containing the heat below the level of the junction between the production tubing 12 and the perforated tubing 16 , as is achieved through the current design, has the effect of focusing the heat on the production formation itself. This, in turn, heats oil and paraffin in situ and allows it to flow to the well bore for pumping, thus “producing” first the viscous materials which are impeding flow, and then the desired product of the well (oil or gas). Stainless steel is chosen as the material for the juncture collars at and below the joinder of production tubing 12 and perforate tubing 16 because of its limited heat conductive properties.
Physical and chemical attack of the electrical connections between the power leads and the heater rods of conventional heating systems, as well as shorting of electrical circuits because of invasion of heater units by conductive fluids is another problem of the present art to which the present invention is addressed. Referring to FIG. 2, the present inventor has discovered that, to prevent the aforementioned electrical problems, the internal connection for a down hole heating unit must be impenetrably shielded from the pressures and hostile chemical agents which surround the unit in the well bore.
As shown in FIG. 2, a terminal portion of the heater rods 26 which connect to leads 24 are encased in a cement block 28 of high temperature cement. The presently preferred “cement” is an epoxy material which is available as Sauereisen Cement #1, and which may be obtained from the Industrial Engineering and Equipment Company (“Indeeco”) of St. Louis, Mo., USA. Cement block 28 is, in turn, encased in a steel fitting assembly 30 (“encasement means”), each component of which is welded with continuous beads to each adjoining component. To safely admit leads 24 to the interior of heating unit 20 , a CONAX BUFFALO sealing fitting 32 (available from the Conax Buffalo company of Buffalo, N.Y., USA) is used to transition the leads 24 from outside the production tubing 12 to inside heating unit 20 where they connect with rods 26 .
Fitting assembly 30 and sealing fitting 32 are, as would be apparent to anyone skilled in the art, designed to threadingly engage heating unit 20 to the perforated tubing which is up hole from heating unit 20 .
The shielding of the electrical connections between leads 24 and rods 26 is crucial for long-term operation of a down hole heating system of the present invention. Equally important is that power is reliably delivered to that connection. Therefore, solid copper leads with KAPTON insulation are used, such leads being of a suitable gauge for carrying the intended 16.5 Kilowatt, 480 volt current for the present system with its 0.475 inch diameter INCOLOY heater rods 26 (also available from Indeeco).
The present invention includes the method for use of the above-described system for heat treating an oil or gas well for improving well flow. The method would be one which included use of a down hole heating unit with suitably shielded electrical connections substantially as described, along with installation of the heat-retaining elements also as describe to properly focus heat on the producing formation.
In addition to the foregoing, it should be understood that the present method may also be utilized by substituting cable (“wire line”) for the down hole pipe for supporting the heating unit 20 while pipe is pulled from the well bore. In other words, one can heat-treat a well using the presently disclosed apparatuses and their equivalents before reinserting pipe, such as during other well treatments or maintenance during which pipe is pulled. It is believed that this approach would be particularly beneficial in treating deep gas wells with an iron sulfide occlusion problem.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | A down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The heating unit the present invention includes shielding to prevent physical damage and shortages to electrical connections within the heating unit while down hole (a previously unrecognized source of system failures in prior art systems). The over-all heating system also includes heat retaining components to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing. |
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FIELD OF THE INVENTION
This invention relates to a modular unified floor assembly suitable for towed transport from a manufacturing facility to the site where it is to be used, and more particularly to such a unified floor assembly which incorporates a cost-efficient longitudinal wooden girder beam and provides an optional preformed reinforced stairway opening.
BACKGROUND OF THE RELEVANT ART
A variety of unified floor assemblies, incorporating varying amounts of wood and steel and suitable for specific purposes, are known. These include manufactured unified floor assemblies, of a type readily towed on public highways to a selected site for use, as taught in my patents U.S. Pat. Nos. 4,930,809, 5,028,072, and 5,201,546.
The goal is to provide an economically-manufactured, strong but light, conveniently transportable floor assembly which can be cooperatively mounted on site with one or more other similar floor assemblies as part of a building structure. There are numerous advantages in manufacturing floor assemblies in this manner, including uniform quality control, economies of scale in manufacture, optimum utilization of skilled and trained manpower, and the facility for precisely customizing product to suit the needs of individual customers. The use of lengthwise steel beams in such floor assemblies provide strength but may add to the weight and costs more than wood. It is therefore desirable to minimize the use of steel in such floor assemblies. This is best accomplished by judiciously combining wood and steel.
One increasingly common use for such manufactured floor assemblies is in forming the ground level floors of building structures that have basements. It is not uncommon nowadays to have each floor assembly of fairly large size, e.g., such as to provide a useful floor area of the order of 14 ft.×40 ft. or longer. The resulting floor structures typically are supported either on upright basement walls or on metal or masonry posts disposed where two immediately adjacent floor assemblies come together and are connected to provide a large continuous useful floor.
Such floor assemblies typically provide a floor at an upper surface and also a lower surface which can inherently serve as a ceiling for the basement portion of the finished structure. As in all floors, there is in such floor assemblies a vertical spacing between the uppermost horizontal surface which serves as the floor for the space above the floor assembly and the lowermost horizontal surface which usually serves as the ceiling for the basement portion of the finished structure. By suitable selection of the dimensions of this space it becomes possible during the process of manufacturing the floor assembly to include ventilation ducting, piping, electrical power telephone lines, wiring, and the like, for easy connection to sources of warm or cold air, hot or cold water, and the usual electrical power and telephone lines from outside, respectively.
Uniformity of the finished product and high quality control are readily realized where the manufacturing of the floor assembly and its innards takes place under a roof rather than in the open as is common in forming floor structures on site in the open and when exposed to inclement weather conditions.
As noted, for different needs it is desirable to have particularized structural features. One such need is for a floor assembly having a precisely-dimensioned preformed opening for the location of a stairway. As persons of ordinary skill in the art will appreciate, the formation of such a hole in a floor assembly of conventional type can generate a structural weakness which can become a serious problem when the manufactured floor assembly is towed at typical highway speeds over uneven road surfaces. Such an opening must therefore be properly reinforced when the floor assembly is manufactured, i.e., before it is towed away.
There is, therefore, a clear need for a lightweight, reasonably priced, modular floor assembly which allows an architectural designer to specify an opening for a stairway leading downwardly from the floor on site. The present invention is particularly suited to meet this need.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of this invention to provide in a preferred embodiment a unified floor assembly employing a relatively long, lightweight, strong, longitudinal wooden girder beam.
It is a related object of this invention to provide a modular unified floor assembly which is lightweight, strong and reasonably priced, and which incorporates a lengthwise wooden girder beam formed to facilitate cooperating disposition in use with another similar modular floor assembly to generate extensive floor structures with provision for ventilation ducting, piping and wiring included within.
It is another object of this invention to provide a lightweight, economically-manufactured, unified floor assembly which includes a preformed opening for a stairway.
These and other related objects of this invention are realized by providing a modular unified floor assembly having a longitudinal axis, which includes a longitudinal first interior beam means parallel to the longitudinal axis for providing interior support and a longitudinal second interior beam means also parallel to the longitudinal axis and on an opposite side thereof relative to the first beam means, for providing additional interior support. The floor assembly also includes an exterior longitudinal rail means which is disposed parallel to the longitudinal axis and provides longitudinal support and defines a first longitudinal perimeter portion of the floor assembly. A longitudinal girder beam having numerous openings to accommodate utility elements and to reduce weight is disposed parallel to the axis and on an opposite of the floor assembly to the rail means, for providing longitudinal support and defining a second longitudinal perimeter portion of the floor assembly. The structure also includes a plurality of transverse truss means each connected to the side rail means at a first end, to the girder beam at a second end, and to the first and second interior beam means respectively intermediate the first and second ends.
In another aspect of this invention, the floor assembly as described in the immediately preceding paragraph is modified by making the second interior beam means in two collinear portions separated by a first gap corresponding to a longitudinal side of a stairwell disposed therebetween, and in the plurality of transverse truss means including at least one shortened truss means which extends from a first end connected to the rail means, past the first interior beam means and connected thereto, to a second end which is intermediate the first and second beam means, the second end being separated from the girder beam by a second gap corresponding to a transverse side of the stairwell disposed therebetween.
To obtain extensive floor assembly structures, two of the above-described unified floor assemblies may be disposed in use so that their respective girder beams are immediately adjacent and connected to each other, the combined unified floor assemblies being supported underneath so that they are horizontal and at the same level.
In yet another aspect of this invention, each of the above-described unified floor assemblies has its girder beam formed so that it has a gap of selected width and length defined at a first end and an extension of corresponding width and length at an opposite end. Two such unified floor assemblies may be longitudinally connected to each other with the extension at the end of the girder beam of one unified floor assembly being fitted into the corresponding gap in the girder beam of the second unified floor assembly. Then, with the two unified floor assemblies each supported to be horizontal and at the same level, the combination of the two unified floor assemblies provides an extensive longitudinal combined floor assembly.
Persons of ordinary skill in the art can be expected to consider these and other equally obvious and advantageous ways of combining and supporting two or more such unified floor assemblies to suit particularized needs, e.g., for L-shaped floors, etc., upon understanding the detailed disclosure of the invention as provided below with reference to the accompanying drawing figures.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a fragmentary perspective view of a unified floor assembly partially supported along outer edges by vertical structural walls and supported elsewhere by an exemplary support post.
FIG. 2 is a partial perspective view of two side-by-side cooperating unified floor assemblies according to a preferred embodiment of this invention, one of the floor assemblies being manufactured with a rectangular, reinforced stairway opening.
FIG. 3 is a partially-exploded vertical cross-sectional view of the principal elements forming a transverse truss in the unified floor assembly according to the preferred embodiment of FIG. 2.
FIGS. 4, 5, and 6 are respective enlarged views illustrating structural details of how certain transverse elements are joined to lengthwise elements in the preferred embodiments.
FIG. 7 is a vertical side elevation view of a transverse chord incorporated at an upper portion of a truss the floor assembly according to the preferred embodiments.
FIG. 8 is a partially-exploded perspective view to illustrate details of an elongate girder beam and the manner of its disposition relative to transverse elements in the preferred embodiments.
FIGS. 9, 10, 11 and 12 are enlarged views of various junctions between cooperating elements in the elongate wooden girder beam per FIG. 8.
FIG. 13 is a perspective view of an exemplary footing for a support post of a type suitable for supporting the unified floor assembly of this invention at locations away from supporting walls.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The floor assembly is conveniently manufactured at a central facility where cost efficiencies are realized and uniform quality controls are exercised over the manufacturing process. The floor assembly is then mounted to a suitable wheeled carriage structure of known kind and towed behind a tractor vehicle over highways with the normal amount of shock-loading experienced in transit. A primary goal, therefore, is to form the floor assembly such that even when a stairwell opening is formed therein during manufacture the floor assembly will cope with all foreseeable shock loads which it will encounter before coming to rest at its final destination.
One way to obtain high strength in a floor assembly, is to selectively employ properly proportioned steel elements. This adds to the weight and cost, hence sophisticated structural analyses are performed and steel elements for support are employed only in places and in a manner deemed optimum in light of all the factors, e.g., ease of manufacture, weight, cost, and anticipated loading both during transportation and in its ultimate use. Thus, for example, a floor assembly which is expected to ultimately support rather heavy machinery, equipment, heavily-loaded shelves, etc., may need heavyduty steel elements. By contrast, a relatively small floor assembly for use in the living room of a dwelling may require less steel. In short, the amount, physical dimensions, and overall strength of any metal elements used in the floor assembly according to the preferred embodiments of this invention must be chosen in light of such factors. Persons of ordinary skill in the mechanical arts can be expected to make the necessary choices and decisions in the exercise of their normal professional skills, hence any dimensions discussed below are intended to be exemplary and not as limiting.
FIG. 1 is a fragmentary perspective view of a unified floor assembly according to a first preferred embodiment of this invention. This floor assembly 100 has a generally rectangular form with its length along a longitudinal axis X-X being greater than its width measured normal to this axis. This, however, is not intended to be definitive or limiting, and square floor assemblies may be manufactured in accordance with the present invention. However, when a rectangular form is selected, the finished floor assembly will likely be towed in a direction along the axis X-X. As can be expected, unevenness of the road surface will cause up-and-down movement of the towed floor assembly, generating external and inertial forces principally in a vertical plane. This will tend to cause bending or flexing of the floor assembly in a vertical plane, i.e., the front and back ends of the floor assembly will tend to move up and down relative to their unstressed positions. It is therefore necessary to provide strong longitudinal internal support to counter foreseeable shock-loading during transportation of the floor assembly from the point of manufacture to its ultimate site of use.
Even when the floor assembly 100 reaches its final destination, and is supported as indicated in FIG. 1 by upright vertical support walls such as 102 and 104 positioned along its outermost edge portions, the need for strong longitudinal internal support remains. For this reason, it is preferable, although not absolutely necessary, to employ elongate I-section steel beams 106 and 108 disposed parallel to and on opposite sides of axis X-X. These beams in the embodiment per FIG. 1 will extend without interruption for substantially the entire length of the floor assembly 100 if no stairwell opening is formed. As described below with reference to FIG. 2, the formation of a stairwell opening requires the inclusion of reinforcing elements to ensure against undue stressing and structural damage during transportation of the floor assembly and its subsequent use.
As generally indicated in FIG. 1, one elongate side of floor assembly 100 has the form of a side wall 110 comprising a plurality of elongate wood elements 112,114 and 116 stacked in a vertical relationship. Side wall 110 rests on an elongate, flat, horizontal sill plate 118 disposed over upright support wall 102. Similarly, immediately below a transverse end portion of floor assembly 100 there is provided another sill plate 120 at the top of upright support wall 104.
On an opposite side from side wall 110 and parallel thereto, the longitudinal edge portion of floor assembly 00 comprises a unique elongate girder beam 122 which, like side wall 110, extends the entire length of floor assembly 100.
Transversely of side wall 110 and girder beam 122 disposed parallel thereto, there is provided a plurality of transverse trusses 124, parallel to each other and each preferably perpendicular to longitudinal axis X-X. Each of these transverse trusses is formed of a plurality of cooperating components which is described more fully hereinbelow.
Side wall 110 has an uppermost longitudinal surface 26, longitudinal girder beam 122 has an uppermost longitudinal surface 128, and transverse trusses 124 each have an upper surface 130. When floor assembly 100 is properly supported, surfaces 126,128 and 130 are all in a common horizontal plane upon which is affixed flooring 132 which provides a smooth upper floor surface. Simultaneously, by its common connection to side wall 110, girder beam 122 and trusses 124, flooring 132 stiffens and unifies the overall structure and may comprise plywood, masonite, metal, or other suitable known material.
Although not clearly shown in FIG. 1, a layer of wood, e.g., plywood, may also be affixed to the respective lowermost surface of side wall 110, girder beam 122, and trusses 124, and could serve as a ceiling surface for the space underneath floor assembly 100. A conventional false ceiling could be suspended beneath floor assembly 100.
As indicated in FIG. 1, additional support may have to be provided to floor assembly 100 at suitable locations beneath girder beam 122 along the corresponding longitudinal side of the floor assembly. Such support may take the form of upright support posts such as 133 each resting on a post support plate 134 provided on a floor 136 beneath floor assembly 100. At the top of support post 133 there is preferably provided a load plate 138 to extend beneath the lowermost surface of floor assembly 100 directly under longitudinal girder beam 122. The number and separation of such posts must necessarily be related to the total weight to be imposed upon floor assembly 100 and the necessary choices may be readily made by persons of ordinary skill in the mechanical arts as needed.
As generally indicated earlier, steel I-section beams 106 and 108 could, under appropriate circumstances, be replaced by I-section beams made of wood. However, for relative large floor assemblies according to this invention, it is preferable to employ steel I-section beams such as 106 and 108 in FIG. 1.
Although it is not very clearly seen in FIG. 1, it will be readily understood that trusses such as 124 may be readily utilized to define the transverse ends of floor assembly 100, e.g., over transverse sill plate 120 above support wall 104, and in similar manner at an opposite transverse end (not shown in FIG. 1 for simplicity).
As best seen in FIG. 2, assorted utility elements such as heating and/or air conditioning ducting 150, water pipe 152, and electric power and/or telephone wires 154, 156 may be installed within floor assembly 100 (or 200), at the time of manufacture, with conventional end fittings (not shown).
The floor assembly 100 illustrated in FIG. 1 includes no stairwell openings formed therein during manufacture. However, with some modification of the structure illustrated in FIG. 1 it becomes possible to provide another preferred embodiment, i.e., floor assembly 200, best seen in FIG. 2, which has a stairwell 202 formed therein during manufacture. Such a floor assembly 200 can be readily combined with a floor assembly 100 to provide an extended floor structure with a suitably located and sized stairwell 202. Note that floor assembly 200 is generally very similar to floor assembly 100, i.e., each has a longitudinal side wall or rail 110, a longitudinal girder beam 122 parallel thereto, a plurality of full width transverse trusses 124, and longitudinal interior beams 108.
Floor assembly 200, however, has a break in its interior longitudinal support beam 106. The two portions 106a and 106b are maintained to be collinear with each other and are separated by a distance corresponding to a dimension of stairwell opening 202 in a direction parallel to support beams 106a and 106b.
Correspondingly, at least one of the plurality of the transverse trusses 124 must be made shorter by an extent corresponding to a transversely-oriented dimension of stairwell opening 202. Such a shortened transverse truss 124s, like the other full width trusses 124, is joined to rail 110 (in a manner to be described in greater detail below), lies over the interior longitudinal support beam 108 and ends at and is connected to a reinforced longitudinally-oriented support element 204 which is itself connected at its ends to two reinforced transverse trusses 206 and 208.
The net consequence is that stairwell opening 204 is defined, as best seen in FIG. 2, by reinforced support element 204, reinforced transverse trusses 206 and 208, and at least a total thickness of the respective girder beams 122, 122 of floor assemblies 100 and 200 in the structure of FIG. 2. The reinforced support member 204 may be constituted of a double thickness of wood as illustrated in FIG. 2, and would have an uppermost surface parallel to that of guide rail 110 and the full width trusses 124. Similarly, the shortened truss 124s must be positioned so that its uppermost surface is parallel, i.e., coplanar, with the uppermost surfaces of side rail 110, full width trusses 124 and reinforced support element 204. The goal is to ensure that the flooring continues to be uniformly horizontal over the entire floor assembly 200 except for the stairwell.
Reinforcement of full width trusses 206 and 208 may be most readily realized by providing two trusses 124 side by side and firmly connected to each other, e.g., by nails or other suitable fastening elements.
In the structure illustrated in FIG. 2, comprising a floor assembly 100 (without a stairwell) and a floor assembly 200 (formed with a stairwell 202), the total thickness of the two girder beams 122, 122 provides the necessary reinforcement at the corresponding side of stairwell 202. However, to ensure that floor assembly 200 may be safely transported without suffering permanent damage due to transportation shock forces, a laminated beam 210 may be attached to that portion of girder beam 122 (of floor assembly 200) which corresponds to the stairwell. This laminated beam 210 may be of a width comparable to the vertical height of girder beam 122 and preferably has a length sufficient to extend past both sides of the stairwell to a distance sufficient to be attached to three adjacently separated successive full width trusses 124. The purpose of such a laminated beam 210 is two-fold: first, to ensure that there is added stiffness at the side of stairwell 202 corresponding to girder beam 122; and, secondly, to provide reinforcement where the double thickness, reinforced, full width trusses 206 and 208 connect to girder beam 122. It should be remembered that floor assembly 200 must be transported by itself to the final location and, therefore, that unless laminated beam 210 were thus provided the portion of girder beam 122 corresponding to the stairwell would be a singularly weakened point in the structure being transported. Persons of ordinary skill in the art would appreciate that the provision of laminated beam 210 of at least the dimensions discussed immediately above will not only strengthen floor assembly 200 around the stairwell but will add to the ability of the floor assembly 200 to withstand twisting or torque-related stresses which could well be encountered during transportation over uneven road surfaces.
The above-discussed reinforcement aspects are intended to be only exemplary, and persons of ordinary skill in the art upon becoming aware of the need to provide sufficient reinforcement can be expected to consider other alternatives, e.g., providing C-section metal channel members or the like in place of the second thicknesses of wood in support member 204 or full width reinforced trusses 206, 208. Such obvious variations are intended to be comprehended within this description, the principal goal being to ensure that even a relatively large floor assembly 200 can be transported safely so that it arrives to be used without suffering any loss of structural integrity or strength since its manufacture.
Referring now to FIG. 3, it will be seen how in the preferred embodiment the exemplary full width transverse truss 300 (intended to be structurally similar to the trusses 124) comprises an elongate chord 302 of a length corresponding to the total width of the floor assembly 100 or 200. Such a chord 302 preferably is made of wood in a length in the range 10 ft.--20 ft., and a cross-section preferably about 2 in.×6 in. It may be desirable to form dadoed cuts preferably not more than 5/8 in. deep and preferably not closer than 3 in. from the nearest point of either of I-section steel beams 106, 108. Such dadoed cuts 304 may be used to accommodate support boards for providing additional support and stiffness to the floor covering to be applied thereover.
I-section steel beams 106, 108 are preferably separated by a distance approximately 8 ft. apart. Just above the bottom flanges of longitudinal support beams 106, 108, each of the full width transverse trusses includes a C-section steel structural channel element 306 which may be welded or bolted at its ends to the respective upper surfaces of the flanges of beams 106, 108. Inclined bracing members 308, 308 may be welded or bolted in place as illustrated in FIG. 3 to ensure stiffness and strength in the transverse interconnection thus provided between I-beams 106, 108. As best seen in FIG. 3, on the side of truss 300 adjacent to longitudinal side wall 110 there is preferably provided a sheetmetal cross member 400 shown in greater detail in FIG. 4. Cross member 400 has an upper flange 402 which is affixed to an under surface of chord 302, e.g., by driving nails, screws or the like through apertures 404 provided therein. Cross member 400 also has a lower flange 406 parallel to upper flange 402, and a vertical web 408 therebetween. The ends of lower flange 406 and vertical web 408 may be attached to the corresponding immediately adjacent surfaces of I-support beam 106 by welding, bolting, or in any other suitable manner. At the end immediately adjacent to rail 110, cross member 400 is provided with vertical, longitudinally-oriented flanges 410, 410 affixed to a laminated beam 412, the respective dimensions being selected such that an outer vertical surface of laminated beam 412 is in the same vertical plane as the end of top chord 302 and allows affixation of laminated board 412 directly to an inside surface of side wall 110.
At the other end of full width transverse truss 300 there is provided a generally similarly structured, mirror-image type cross member 500 having an upper flange 502 provided with apertures 504, by which it is connected to an under surface of top chord 302, a bottom flange 506 and a vertical flange 508 which may be connected to corresponding immediately adjacent surfaces of I-support beam 108 by welding, bolting, or the like. Truss member 500 is also provided with end flanges 510, 510 formed with apertures 512 through which conventional nails, screws or the like may be applied or connected to inside surfaces of longitudinal girder beam 122.
As will be appreciated, when reinforcement beam 210 is provided as part of the reinforcement of girder beam 122 and stairwell opening 202, flanges 510 would be affixed thereto for reinforced trusses 206, 208 and immediately adjacent full width trusses 124 as previously discussed.
As best seen in FIG. 6, where top chord 304 passes over the top flanges of I-beams 106, 108, it is preferable to affix shear blocks 602 to provide reinforcement and additional stiffness. Shear blocks 602 may be affixed to top chord 302 with the corresponding truss 124 by nails or the like. See also FIG. 7 which clearly indicates that shear blocks 602 have a height corresponding to that of top chord 302 so that any flooring placed thereabove may be affixed to both the chord 302 and shear blocks 602 to thereby further stiffen and make the entire unified structure more rigid.
Details of longitudinal girder beam 122 are best understood with reference to FIG. 8. Girder beam 122 comprises a top elongate chord 802. If the length of the corresponding floor assembly, i.e., 100 or 200, is in excess of about 20 ft., it may not be possible to provide a single element continuous top chord 802. Separate cooperating or linear elements 802, 802 may thus be butted to each other at interfaces 804 and affixed to each other thereat by conventional nail plates such as 806.
Girder beam 122 also has an elongate longitudinally-oriented bottom chord 808 spaced from top chord 802 by spacer blocks 810 and cross bracing elements 812, 814. Various conventional nail plates, e.g., 816,818 and 820 may be employed as needed to affix these elements to each other in a strong and permanent manner.
The above-described construction of longitudinal girder beam 122 ensures that there are numerous openings therethrough to accommodate assorted utility elements, e.g., ventilation ducting 250 connectable to a floor register 252, pipes, wires, etc. The provision of these openings also reduces the total weight while the spacer blocks and bracing elements combine to provide the desired stiffness, strength and overall flexibility needed to accommodate the shock loads which the floor assembly 100 or 200 is expected to encounter during transportation.
There is yet another aspect of girder beam 122 which provides singular advantages in longitudinally combining and connecting successive floor assemblies 100 or 200. This feature is best understood with reference to FIGS. 8, 9 and 10. As best seen in FIG. 9, at one end of girder beam 122 top chord 802 ends short relative to the corresponding adjacent end of bottom chord 808. Instead of a single spacer block 810, there are provided two cooperating spacer blocks 902 and 904, of which spacer block 904 is longer and projects beyond the aligned ends of spacer block 902 and lower chord 808. The various spacer blocks and top and bottom chords of the same thickness, as best seen in FIGS. 8, 9 and 10, and are interconnected to each other by the use or conventional nail plates 906, 908. By the just-described structure, there is provided at one end of girder beam 122 a male projecting portion of spacer block 904.
At the opposite end of the same girder beam 122 an opening is left between top chord 802 and an upper surface of spacer block 902 which ends in alignment with bottom chord 808. Furthermore, top chord 802 extends beyond the immediately adjacent end of bottom chord 808 by an amount which corresponds to the longitudinal spacing apart between the ends of top chord 802 and bottom chord 808 at the opposite end of girder beam 122. There is thus created a female end to girder beam 122 shaped, sized and aligned to closely receive therein a corresponding male end of a girder 122 of the same thickness and belonging to another floor assembly 100 or 200 longitudinally aligned therewith.
Then, as indicated at the left-hand end of FIG. 8, when two longitudinal girder beams 122, 122 each belonging to a respective longitudinally aligned floor assembly are moved into engagement with each other the male and female elements fit closely and being of the same thickness may be affixed to each other by additional conventional nail plates (not shown for simplicity). When two floor assemblies are thus cooperatively connected to each other by their respective longitudinal girder beams 122, the flooring applied thereof may be disposed to further consolidate and unify the two floor assemblies by additional connecting nail plates or the like.
As persons of ordinary skill in the art will appreciate, in FIG. 2 there is illustrated and made clear how two floor assemblies, one of which may optionally have a stairwell, may be disposed to be unified at their immediately adjacent longitudinal sides. In similar manner, FIGS. 8-10 illustrate and make clear how to interconnect the respective longitudinal girder beams 122 of two cooperating floor assemblies in a longitudinal cooperative relationship. Persons of ordinary skill in the art can be expected to explore and consider other variations, e.g., employing three floor assemblies in a cooperative manner so as to create a L-shaped unified floor therefrom. Such variations are intended to be comprehended within the present invention.
FIGS. 11 and 12 indicate somewhat enlarged views of the above-discussed aspects, i.e., the manner in which spacer block 810, top chord 802, bottom chord 808, and inclined bracing elements 812 and 814 are interconnected to each other by nail plates 816, 818 and 820.
FIG. 13 is a perspective view illustrating an exemplary masonry or concrete-block footing structure which may be formed to support the lowermost end of a support post such as 132 if no preexisting floor 136 is available as in the structure illustrated in FIG. 1. Other alternative structures to accomplish this purpose may be considered to suit particularized needs. The goal is to ensure that there is sufficient load-bearing surface available beneath support post 132 to adequately support the anticipated weight to be received thereon from the floor assembly supported thereover, with an adequate factor of safety taken into account.
In this disclosure, there are shown and described only the preferred embodiments of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein. | A lightweight, strong, economically-manufactured, and safely transportable modular unified floor assembly includes a lengthwise wooden girder beam formed with male and female ends to facilitate cooperative integration thereby to another similar floor assembly. In another aspect of the invention, the floor assembly is manufactured with a stairwell opening of selected size and at a selected location. The floor assembly even with a stairwell opening according to this invention is strong enough to be transported comfortably and safely from its point of manufacture to the site at which it is to be located for use. |
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[0001] This Patent Application claims priority from U.S. Provisional Patent Application No. 60/523,377, filed on Nov. 18, 2003, and entitled “Building Protection Structures and Methods for Making and Using the Protection Structures.” The contents of this provisional application are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to form molded structures, and more particularly, to the manufacturer, installation and use of molded building component structures.
[0004] 2. Description of the Related Art
[0005] In current construction practice, there are two known and common methods of building outdoor decks and balconies, to be used as part of building structure. The first is the classic redwood deck, which allows rain water to leak down between gaps in the planks. The second is the moisture resistant tile or liquid plastic coating deck.
[0006] Most people are familiar with redwood decks. Floor joists are attached to the house either cantilevered from the second floor, or built on beams and posts for a larger deck. The 2×6 (inch) dimensional redwood boards are nailed down flat perpendicular to the joists with a ¼ inch gap between the planks. This has been a very popular and attractive decking system.
[0007] One downside to this system is that redwood cracks and ages, and redwood is becoming more scarce and expensive. Recently, firms like Trex™ have addressed these problems by extruding synthetic decking planks, that are similar in shape and size to the redwood 2×6 planks. They can be sawed and drilled almost as easily as wood. By mixing plastic and sawdust these products are longer lasting than redwood, wear and look better than redwood over the years and claim to be termite and mold resistant.
[0008] The problem that both redwood and synthetic wood decks have is that they are not rain-proof. When it rains, the water drops down between the gaps of the boards, hitting the ground below and wetting the joists and beams. Over time this rots the structural wood, eventually requiring rebuilding of the deck, or worse, complete structural collapse, killing in many cases those on the deck at the time.
[0009] The other drawback is that no habitable space can be built below. A watertight decking system is required for this application. There has been a long history of watertight decks and balconies built over the years. The most common way is to build a slightly sloping hot mopped deck using modified bitumen and galvanized metal flashings, much the same way a flat roof is done by roofing contractors. The difference is that a walking deck must be built much stronger than a roof, and must have a hard, slip resistant surface over the asphalt coating. Typically this is done like a tile shower pan. Over the hot mop, ¾′ of grout is placed, properly sloped for drainage, then tile or stone or pavers are set, then grouted, and finally weather sealed. Finally flashing must be installed and checked to avoid leaks into the house during rain storms.
[0010] The hot mopped and tiled exterior rain resistant deck is a very expensive and complex endeavor, involving 4 or 5 building trades, spending weeks on each deck. And worse, the deck is the most vulnerable part of the house to the freeze thaw cycle, the expansion and contraction between hot and cold weather. During hot weather the deck may expand cracking the asphalt coating underneath which may have become brittle over time. In the cold weather the tiles may pull away from the house, allowing water infiltration. Then when it rains, water may seep below the tile and migrate to some other location where the asphalt is cracked, causing leaks down into the sheet rock ceiling below.
[0011] When the homeowner calls out the contractor it generally happens that the real point of leakage is hidden from view from the deck above. Many times the only fix is to tear up the expensive tile and hot mop and do it all again.
[0012] In part to address this problem of the invisible leak, as well as the high cost of the installation of rain-proof decks, many liquid epoxy and plastic walkable coatings have been developed over the past 20 years. Firms like Dex-O-Tex sell liquid coatings installed by factory-approved installers, in several coats and with special flashings and fiberglass reinforcing. A sand finish is tossed onto the final coat for skid resistance, and different colors are offered. Durability depends on the sloping and structural strength of the exterior grade plywood on which the liquid coats are spread. A 5-coat job may take a week to complete and is still a relatively expensive and risky endeavor. These have also been leaks and liability problems in housing projects. The deck must be inspected regularly and repaired promptly to protect the habitable areas below.
[0013] Therefore, what is need is a durable and reliable structure that can be used as a deck or building component, without introducing the aforementioned problems.
SUMMARY OF THE INVENTION
[0014] Broadly speaking, the present invention fills these needs by providing a structure that is form-molded, in one piece. The form-molded structure can take on any number of forms, as will be described below. One particular form is the form of a deck of a building. The resulting deck is defined from plastic, and when formed, defines a plastic deck shell with integral flashing. The deck shell can be installed over or up against structural framing of a building to provide moisture protection and enable human traffic, if the form is a deck. It should be appreciated that the present invention can be implemented in numerous ways, including as a method, a structure, a system, or an article of manufacturer. Several inventive embodiments of the present invention are described below.
[0015] In accordance with a first aspect of the present invention, a structure for use in building construction is provided. The structure is defined by a body having a top surface, a bottom surface, and side surfaces. A flashing liner is integrally formed with the body, and the flashing liner is defined at one or more of the side surfaces of the body. The body is capable of being attached to a building structure, and the flashing liner provides a weather interface with the building structure.
[0016] In accordance with a second aspect of the present invention, a deck structure to be attached to a building is provided. The deck structure has a grooved top surface, a bottom surface, and side surfaces, and the deck structure is defined from a plastic mold. A flashing liner is integrally formed from the plastic mold along with the deck structure, and the flashing liner and the deck structure define a unitary structure without connecting seams. The flashing liner is defined at one or more of the side surfaces of the deck structure. The body is capable of being attached to the building, and the flashing liner provides a weather interface with the building and the top surface providing a supporting interface for human support and traverse when the deck structure is attached to the building.
[0017] In accordance with a third aspect of the present invention, a deck structure to be attached to a building is provided. The deck structure has a rough top surface, a bottom surface, and side surfaces, and the deck structure is defined from a plastic mold. A flashing liner is integrally formed from the plastic mold along with the deck structure, and the flashing liner and the deck structure define a unitary structure without connecting seams. The flashing liner is defined at one or more of the side surfaces of the deck structure, and the flashing liner is configured as an interface with the building at one of a wall or a door way of the building. The flashing liner establishing a weather tight interface between the wall or the door way of the building, and the rough top surface having grooves defined by the plastic mold. The grooves extend substantially perpendicularly away from the building, such that the grooves drive water away from the building.
[0018] In accordance with a fourth aspect of the present invention, a method for making building structure is provided. The method includes defining a mold. The mold having surfaces for defining a body with a top surface, a bottom, and side surfaces, and the mold further including surfaces for defining flashing liners to be coupled to at least one of the side surfaces of the body. The method then includes filling the mold with a plastic to define a deck structure with integral flashing. The deck structure defined for supporting a human when the deck structure is attached to a building.
[0019] In one embodiment, the deck is formed in the factory to the size and shape desired by the customer, and includes integral flashing, water run-off channels and a non-skid walking surface. The deck of the present invention provides a cost effective, easy and fail-safe method of installing moisture resistant decking surfaces in residential or commercial construction projects. In one embodiment, the process of making the one piece deck utilizes vacuum-formed technology, which allows the deck to be made as a seamless unitary and integral structure. The integral structure, in the decking application, will include integral flashing. The deck therefore installs easily and quickly to provide rain tight protection to structural wood and habitable space below and around the deck.
[0020] By using tough and flexible polyethylene plastic, ribbed for strength and surfaced for a skid resistance, a strong and nearly indestructible walking surface is provided. By including integral flashing down over the sides of the deck and up under the building paper and stucco, leaks are eliminated. By design, potential weak spots are strengthened, and expansion and/or contraction is anticipated and allowed. The deck surface can move back and forth through temperature and humidity swings, or earthquakes.
[0021] As a benefit, due to the single piece design, installation can be done in as little as one half hour per deck. This is compared to over a week for all other rain proof systems. In some markets, total material and labor cost can be as low as 10% of what is currently paid for prior art, less desirable techniques. Further, once a carpenter builds the structural deck and covers the joists with plywood, he can immediately cover the deck with a white neoprene foam, staple building paper to the lower walls, nail on the 1×2 cleats and then screw on the Deck with stainless steel screws and washers, and then tap in the plastic screw cover plugs. Compare to hot mop decks, after the carpenter frames the deck, the following sub-contractors are required: a. roofing/hot mop sub; b. sheet metal flashing sub; c. tile setter; d. sealer/painter; and e. more flashing. Liquid plastic decking subs handle most flashing themselves but the sheet metal sub usually is involved. By design, stops and guides allow the carpenter to install the deck in only one way—the right way. Should the carpenter forget a piece of building paper, he can unscrew a section until he can slip the paper in, then re-screw.
[0022] Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, and like reference numerals designate like structural elements.
[0024] FIG. 1 is a perspective view of a cantilever deck, in accordance with one embodiment of the present invention.
[0025] FIG. 2 is an exploded view of the deck to be attached to a building, in accordance with one embodiment of the present invention.
[0026] FIGS. 3A-3I show the deck attached to a building and integral flashing installed up against the building and detailed magnifications, in accordance with one embodiment of the present invention.
[0027] FIG. 4 illustrates a recessed deck, in accordance with one embodiment of the present invention.
[0028] FIG. 5 illustrates a recessed deck attached to a building, in accordance with one embodiment of the present invention.
[0029] FIGS. 6 and 7 illustrate a multi-panel deck, in accordance with one embodiment of the present invention.
[0030] FIGS. 8 and 9 illustrate an awning with integral flashing, in accordance with one embodiment of the present invention.
[0031] FIG. 10 illustrates a fireplace roof and integral flashing, in accordance with one embodiment of the present invention.
[0032] FIG. 11 illustrates a bay window roof with integral flashing, in accordance with one embodiment of the present invention.
[0033] FIG. 12 illustrates a bow window roof with integral flashing, in accordance with one embodiment of the present invention.
[0034] FIGS. 13-19 illustrate additional applications of a plastic molded structure for use in building construction, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] An invention is described for plastic form molded structures, which can be used in the construction of buildings. The structures can take on any number of forms, and examples of such forms are provided below. Of particular interest, a deck can be defined from a single plastic piece with integral flashing. In one example, the deck is formed in a mold which is filed with liquid plastic, and the liquid plastic is cured or allowed to cool until a hard material results. The plastic can optionally include fibers to introduce strength, and colors can be added to provide different ready to use styles. It will be obvious, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
[0036] A deck system is a one piece molded plastic unit. In one embodiment, the decking surface curves up the wall and becomes flashing. The flashing is thus integral with the deck body. At a sliding door or French doors, the flashings bend down under the door sill, preventing driving rains from soaking the carpet or wood framing. The plastic used is similar to that used in pickup truck bed liners, many of which have suffered 20 years of abuse (like daily loading and unloading of bricks) in the desert sun without cracking or denting. In one specific example, the plastic material will include fibers to introduce additional strength. Examples of the plastics, without limitation, can be selected from the group consisting of one or a combination of (a) polyethylene, (b) olefin (c) olefin fibers (d) polypropylene and polyethylene, (e) polystyrene, (f) poly (vinyl chloride), and (g) polytetrafluoroethylene.
[0037] In another alternative and optional embodiment, supporting framing may also be embedded in a mold so that the resulting molded plastic can have additional strength.
[0038] Slotted screw holes and the inherent flexibility of the plastic make it impervious to expansion, contraction and structural movement. Ample flashing wings are designed for horizontal rains. Radiant heat can be resisted by a light gray color of the plastic, the white painted underside and the white neoprene under-layment. Direct sunlight has no deterioration effect, chemicals or animal urine will not damage surface, and moist or salt air will not damage the plastic or the stainless steel screws. In sum, the resulting form molded deck or other structure, is capable of withstanding harsh outdoor weather elements, while maintaining its serviceability to the structure.
[0039] FIG. 1 is a perspective view of a cantilever deck, in accordance with one embodiment of the present invention. Made from a single piece of plastic, it is heat formed to the shape shown. The heat is used to melt the plastic used to define the deck, and the plastic is applied to a mold. The molding process can include, for example, a vacuum molded process, a form molded process, a pressure form molded process, or an injection molded process. In essence, the molding process can vary, so long as the mold can receive liquefied plastic, allow the plastic to flow into the appropriate shape, and then allow the plastic to cool until reaching a solid state.
[0040] In the illustrated example, the deck 20 has a slightly sloping flat surface, sloping about 2% from back to front. Of course, the slope is optional depending on the application. The flat areas at the left and right are the guard railing attachment areas. The drainage grooves 24 also slope back to front and also act as structural ribs spaced inches apart, giving the roughen walking surface 26 strength and the ability to span imperfections in the plywood structural wood surface below. The ribs prevent buckling and tie the entire unit together.
[0041] Sloping up from the back of the walking surface 26 is the back flashing 32 and to the right and left sides are the side flashings 36 . The flashings 32 / 36 facing forward have embedded grooves to define screw guide grooves 28 . The screw guide grooves 28 let the carpenter or installer know where to place the attachment screws 40 , as well as to help the screw tap into the plastic by starting it in the groove without slipping off the plastic. The screw will not be placed too close to the edge where it might break the plastic. The vertical cut guide grooves 30 in the back flashing 32 are placed to assist the installer in making the vertical cuts needed to install the patio doors and fold back that portion of the back flashing 32 . The grooves are placed at the rough opening widths of common patio doors. The grooves aids the use of a utility knife by providing a scored vertical line. The other horizontal grooves are the bending grooves 48 used when that portion of the back flashing 32 is bent back into the patio door opening. Reference should be made to the description of FIG. 3 for more information.
[0042] In the front apron 39 and the side aprons 49 , are screw hole recesses 46 which have slotted expansion holes inside. After installing the stainless steel screws 40 and washers provided, screw cap plugs 42 are tapped into the recesses 46 . The caps keep water out and visually hide the screws. Drip ledges 44 are designed to keep rain water away from the structure below. Gutters, stucco or wood trim can be installed by the contractor in the space provided beneath the bottom flashing 38 .
[0043] FIG. 2 shows the one-piece cantilever deck 20 floating directly above where it will be installed onto a typical wood framed house. We are looking down onto the wood framed second floor of a house under construction from the front right. Directly below the deck is the wood framed cantilever deck. Smaller floor joists 56 cantilever towards us supported by the stud wall 70 , 68 , below. The first floor studs 70 support the double top plates 68 above. The rim joist 58 of the second floor sits on the plates 68 . Note that the deck plywood 52 is 2′-4′ lower 72 than the second floor main level plywood 50 .
[0044] Perpendicular to the rim 58 and sitting on the top plates 68 are the large second floor joists 60 . Plywood 62 is nailed down on the joists 60 and the second floor wall is built. The sole plate 64 and the studs 66 are shown, as well as the opening 50 for the patio door. A cantilever deck is framed by extending the deck joists 56 out past the wall below and finished of with the deck rim joist 54 . These joists 56 slope down about 2% away from the wall. Plywood 52 is nailed to the top of the joists 56 and the rim 54 . Plywood sheathing and building paper will be placed on the studs later.
[0045] FIG. 3 shows the deck 20 installed on the wood framing. Building paper installed under the plastic deck is not shown for clarity. The front apron 39 and side aprons 49 are screwed using screw hole recesses 46 to the deck rim joist 54 and the deck joists 56 . The back flashing 32 and side flashings 36 are screwed to second floor studs 66 , sole plate 64 and rim joist 58 . In the patio door opening 50 , vertical cuts 76 are made in the back flashing 32 and the flashing is bent back 90 degrees along one of the bending grooves 48 and screwed down to the plywood 62 .
[0046] The deck is ready for more building paper, the patio door, lathe and plaster and stucco. After the stucco is painted a guard rail can be installed directly to the top of the plastic deck, or to the deck wood framing below. Nothing else needs to be done to the plastic deck—no paint, no sealer, no surfacing. The decking can take on any number of colors, and the colors are added to the plastic as an additive, to produce the desired color shading.
[0047] In the case where the rain proof deck is recessed back into the second floor, the recessed deck 78 takes the form shown. Looking at the deck from the front right, we see the drainage grooves 24 , which are also strengthening ribs, and the roughened walking surface 26 . Along the front apron 39 are the screw hole recesses 46 where the screws 40 and screw plugs 42 are installed. The back flashing 32 and side flashings 36 bend up from the walking surface. The entire deck is formed from one sheet of plastic, so it installs as one unit, and thus prevents leaks (as there are not seams). No hot mop or asphalt felt is required below the deck since it itself is rain tight. On the vertical flashings are bending grooves 48 , screw guide grooves 28 and vertical cut grooves 30 . This design allows doors to be installed anywhere on the left, right or back of the deck. Bottom flashing and drip 38 allows for a gutter or wood trim to be installed.
[0048] Looking at the recessed deck 78 again from the front right, we see it installed in typical wood framing. Note that the level of the deck drops 2′-4′ from the main second floor level 72 . This helps keep blowing rain out of the house. Like we saw in FIG. 3 , the first floor studs 70 support top plates 68 which support rim joist 58 and floor joists 60 , which are taller than the deck joists (not shown). Plywood 62 covers the second floor and is under the deck. Sole plate 64 , studs 66 and the patio door opening 50 are shown. The back flashing 32 is cut 76 at each side of the patio door opening 50 and bent back 74 along the bending grooves 48 , and it is screwed 40 down to the plywood 62 . The flashing are screwed to studs 66 , plates 64 and rims 58 . The front apron 39 is screwed 40 to the rim 58 , finished with tapped in screw plug covers.
[0049] FIGS. 1 through 5 illustrated the deck in its one piece configuration. Some deck projects are so large that they cannot be produced in one piece due to the size of available sheet plastic, the size of delivery trucks or the ability of the crew to efficiently and safely handle the material.
[0050] FIG. 6 shows a three piece deck system that when assembled and snapped together creates the watertight deck shown in FIG. 7 . In FIG. 6 we see the roughened walking surface 26 , the structural rib drainage grooves 24 , and the side 36 and back flashing 32 . FIG. 6 shows the three different pieces of the system: the left deck section 80 , center deck section 82 and right deck section 84 . Bottom flashing 38 , drip 44 and screw hole recess 46 are shown. Special overlap snap grooves 86 are shown facing the center section 82 on the left 80 and right section 84 .
[0051] FIG. 7 shows the three pieces assembled. The patio door opening 50 is shown with the cut section of the back flashing bent back 74 along a bending groove 48 and screwed 40 down Screws 40 are placed in the guide grooves 28 in the side 36 and back flashing 32 . Together, the three pieces can create a large deck that is completely water tight and three times bigger that the one piece deck. Of course, the size will depend on the application and the number of decks that are combined to form a large deck. In some commercial applications, the number of joined decks can be many, while in smaller residential projects a single deck will be sufficient.
[0052] The one piece awning is very similar to the one piece deck. The main surface slopes steeper like a roof, it has ribs 88 for strength and drainage grooves 24 , but it needs no wood structural support under it. It gains its strength from the triangular shape, the ribs and the screws 40 holding the side 36 and back flashings 32 to the structural wall. The flashing has structural ribs 88 which transfers loads to the screws 40 . It is intended to be installed over doors or windows for sun or rain protection. Since the flashings go under the stucco or siding, it is intended for new construction. But, it can also be used in remodels if appropriate adjustments are made.
[0053] FIG. 9 shows the optional built-in gutter 92 , which includes a hole to which a down spout can be attached. FIG. 10 provides the detailed illustration of a direct vent gas fireplace roof. The use of a direct vent fireplace is becoming more popular as municipalities are required to reduce pollution, and thus restrict the use of traditional wood burning fireplaces. Direct vent gas-only fireplaces are increasing sold with the gas vent going sideways straight out the back of the firebox. The traditional boxes are projecting into the side setbacks, but the chimneys are eliminated. As something has to cover the 2′×5′ projection so architects have been specifying matching composition or tile roof, or galvanized metal flashing. FIG. 10 shows the DV Fireplace Roof 100 installed over the box 96 with the side vent 98 . The back and side flashing 32 36 are attached with screws 40 though the screw grooves 28 . The top of the roof has structural ribs 88 and a drip 44 around the front and side aprons.
[0054] There are many smaller projections in residential construction like bay and bow windows that can use rain proof preformed roof and flashing systems. Installing the plastic molded bay and bow window roofs save a lot of time and money. No rafters or plywood are needed, and the structural ribs 88 keep the roof 104 from sagging. Screw 40 the flashing 32 36 and apron on, then snap the strip screw cover 106 into the screw channel 34 , and you are done.
[0055] FIG. 13 shows a parapet or free-standing stucco wall 102 . Too often no cap at all is placed on a stucco wall, only to discover years later that water has leaked down the wall through small crack in the stucco on the top of the wall. A metal cap is a better solution, but is not attractive if in a visible location such as a 36′ high stucco wall around a deck. FIG. 13 shows one piece plastic decorative caps that interlock with adjacent caps, maintaining the water seal even at the joints 86 . Four caps are offered: the end cap 110 , straight run 112 , 90 degree corner 114 , and end cap terminating into a wall 116 integral with top 32 and side flashing 36 . In this embodiment, all pieces have drips 44 .
[0056] FIG. 14 is a one piece cap 118 for pilasters 102 such as pilasters that support entry gates. Screws 40 are installed into screw recesses 46 and covered with screw caps. Drip 44 accepts trim or stucco. FIG. 15 shows a railing cap 120 designed to work with the recessed deck of FIGS. 4 and 5 .
[0057] FIG. 16 shows a patio cover. Similar to the 3 piece deck, the 3 piece Patio Cover spans the full length from wall to beam without any rafters or plywood, just with the strength of the ribs.
[0058] FIGS. 17, 18 and 19 illustrate a retro-deck. The retro-deck is designed to go over any size or shape existing redwood deck. Although not 100% watertight, retro-deck is a big improvement in keeping rain out from under the deck, it prevents further rotting of the joists and looks new and clean. All sections 122 are the same and they snap together at the long edges 124 . The top edges at the house side of the deck are finished with head stop 130 , and the front edge is contained by base stop 132 which has an integral drip. Stops are screwed down 40 to the existing decking 126 and joists 127 .
[0059] Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims. In the claims, elements and/or steps do not imply any particular order of operation, unless explicitly stated in the claims. | A structure and method for making a structure for use in building construction is provided. The structure is defined by a body having a top surface, a bottom surface, and side surfaces. A flashing liner is integrally formed with the body, and the flashing liner is defined at one or more of the side surfaces of the body. The body is capable of being attached to a building structure, and the flashing liner provides a weather interface with the building structure. |
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[0001] This is a continuation of copending application Ser. No. 09/841,649 filed on Apr. 23, 2001 and claims the benefit of the filing date of that applicalton.
RELATED APPLICATIONS
[0002] The present invention is related to the application entitled COLLAPSIBLE STRUCTURAL FRAME STRUT WITH POP-IN-CONNECTOR, filed on the same date as the present invention with the same inventor and under Ser. No. ______ Attorney Docket Number 2058-301, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0003] The present invention relates to the field of collapsible support structures.
BACKGROUND OF THE INVENTION
[0004] It is well known in the art to provide collapsible support structures for a variety of applications; e.g., supporting other structures, e.g., expandable antennae, e.g., for transportation into and use in outer space, ease of construction of relatively rigid building frames, and supporting such things as tents and other structures having forms composed of panels of material, e.g., cloth, canvas, plastic or other pliable fabrics and fabric-like material, including synthetics, e.g., Orlon, Gore-Tex and the like.
[0005] U.S. Pat. Nos. 3,968,808 and 4,026,313, each entitled COLLAPSIBLE SELF-SUPPORTING STRUCTURE, issued to Ziegler, respectively on Jul. 13, 1976 and May 31, 1977 each disclose collapsible structural support frames having a geodesic form. The '808 patent discloses: “ . . . a collapsible, self-supporting structure is disclosed wherein the structure is made up of a network of rod elements pivotally joined at their ends and forming scissors-like pairs in which rod element crossing points are pivotally joined. The network consists of a plurality of pairs of inner and outer apical points where groups of radiating rods are pivotally joined. The outer apical points lie on a surface of revolution such as a spherical section and each group of rods radiating from an inner apical point lie essentially in a common plane whereby to effect the self-supporting action. For any pair of apical points the group of rods defining the inner apical point radiate in their common plane and join rods of other groups at the surrounding outer apical points.” Abstract. The '808 patent states that “ . . . a preferred universal pivotal connection at the apical points is illustrated in FIGS. 12-14. As shown, each element has a double-ended fan flot 130 through which a wire ring 132 passes so as to allow universal movement of the rod elements. In the embodiment of FIG. 1, there may be as few as three elements intersecting at an apical point and as many as six elements, as shown.” Col 5, line 66-Col. 6, line 4. The '808 patent also notes that: “ . . . rferring more particularly at this time to FIG. 25, certain principles of the construction according to FIG. 1 will be apparent therefrom. The FIG. 1 construction may be further explained in terms of conventional geodesic nomenclature. Specifically, the FIG. 1 embodiment is constructed as a four frequency icosahedron in which one of the triangular regions is illustrated in FIG. 25 and, in FIG. 26, all of the triangular regions are shown but laid out in flat form so as to give a better understanding of the elements involved.” Col. 7, lines 53-61. Similarly, the '313 patent discloses a “ . . . self-supporting structures and panels of diverse shapes are disclosed in which basic assemblies of crossed rod elements are employed to achieve the desired shape. Further, the crossing points of crossed rod elements in the structure involved may include limited sliding connections which effect transfer of collapsing force to other crossing points which are pivotally joined. An improved hub structure for pivotally joining ends of the rod elements at the outer and inner apical points is also disclosed.” Abstract.
[0006] U.S. Pat. No. 6,089,247“ . . . a collapsible frame for use in erecting tents, insect screen rooms, shade awnings, canopies and the like at camp sights, back yard patios and other outdoor venues. The collapsible frame includes a plurality of telescopic legs for providing vertical structural support and a plurality of corner pin joints with one of the pin joints fixedly mounted upon a corresponding one of each of the telescopic legs. A plurality of horizontal support arms is included with one of the arms positioned between every adjacent pair of telescopic legs and attached to the corresponding corner pin joints. A mid-span hinge which includes a sliding sleeve is centrally positioned along each of the horizontal support arms. The mid-span hinge is flexibly collapsible when the sleeve is disengaged and is rigidly inflexible when the sleeve is engaged. A bottom slider is adjustably mounted upon each of the telescopic legs and is attached to the horizontal support arms which are connected to the corresponding corner pin joint. Finally, a plurality of top support members is included where each is anchored in a corresponding corner pin joint for stabilizing the frame. In the present invention, the telescopic legs, mid-span hinges and bottom sliders each cooperate to collapse the frame.” Abstract. The '247 patent also disclosed that “ . . . centrally positioned along each of the four horizontal support arms 162 is a mid-span hinge 188 clearly shown in FIGS. 1, 3 and 4. Each of the four horizontal support arms 162 is circular and comprised of a lightweight material such as, for example, aluminum. The length of each of the four horizontal support arms 162 is interrupted approximately at the center of the span thereof forming two opposing, open-ended mid-span terminal ends 190 and 192 as shown in FIG. 3. Extending outward from each of the open-ended terminal ends 190 and 192 is a pair of connectors 194 and 196 having penetrations formed therethrough. Connectors 194 and 196 may be comprised of plastic having an outer surface which exhibits a low coefficient of friction such as Teflon. Positioned between the pair of connectors 194 and 196 is a pair of parallel positioned plates 198 and 200 swivelly attached to the corresponding connectors 194 and 196, respectively, of each of the horizontal support arms 162. The parallel positioned plates 198 and 200 are attached to each of the corresponding connectors 194 and 196 as by, for example, use of a pair of rivets 202 through the penetrations formed in the connectors 194 and 196 as is shown in FIG. 3. Mounted over each of the horizontal support arms 162 and the mid-span hinge 188 is a sliding sleeve 204 shown in FIGS. 1, 3 and 4. The sliding sleeve 204 is cylindrical in shape and can be comprised of aluminum or a high strength plastic material such as polyvinylchloride (PVC). Further, the sliding sleeve 204 can have an inner surface (not shown) coated with a low friction material such as Teflon to minimize resistance to sliding. In the view of FIG. 3, the sliding sleeve 204 is disengaged and the mid-span hinge 188 is exposed and capable of swivelling. Under these conditions, the mid-span hinge 188 is flexibly collapsible and cooperates with the telescopic legs 108 and the bottom slider 130 to enable the collapsible frame 100 to collapse into the reduced size posture as clearly shown in FIG. 9. Located on the surface of the horizontal support arm 162 is a first mechanical stop 206 as shown in FIG. 3. The first mechanical stop 206 serves to limit the travel of the sliding sleeve 204 away from the mid-span hinge 188.” Col 7, line 47-Col. 8, line 11.
[0007] The '247 patent goes on to explain that “ . . . each of the top support members 174 comprise two portions best shown in FIG. 6. An outer portion 220 is shown fitting over the end of an inner portion 222 at a lip 224. With this arrangement, the inner portion 222 can be separated from the outer portion 220 under pressure. Running the length through the interior of each of the top support members 174 is an elastic cord 226 as shown in FIG. 6. The elastic cord 226 can be connected on each of its ends to the interior of each of the top support members 174 in any suitable manner such as, for example, by tying. The function of the elastic cord 226 is to urge the mating of the outer portion 220 with the inner portion 222 of the top support member 174 while simultaneously enabling them to be separated. This design facilitates the collapsing of the superstructure 106 but also prevents the outer portion 220 from being separated from the inner portion 222.” Col. 9, lines 7-22.
[0008] U.S. Pat. Nos. 5,797,412 and 5,632,293, each entitled COLLAPSIBLE SHELTER WITH FLEXIBLE, COLLAPSIBLE CANOPY, Aug. 25, 1998 and May 27, 1997 to Carter, disclose that “ . . . the collapsible shelter includes a truss and canopy framework that permits a flexible, collapsible canopy to be moved between a raised position and a lowered position. The collapsible shelter includes at least three legs supporting flexible poles removably mounted to the tops of the legs and forming the framework of the canopy. X-shaped truss pairs of link members are connected to each of the legs on each side of the shelter between adjacent legs.” Abstract. The '412 and '293 patents also disclose that “the present invention provides for a collapsible shelter with a flexible, collapsible canopy framework that can be raised to provide increased headroom, strength and stability, and can be lowered to provide a reduced profile to the wind. The invention provides for a collapsible shelter having at least three legs supporting a collapsible canopy supported by flexible poles removably mounted to the tops of the legs. At least two perimeter truss pairs of link members are connected to each of the legs on each side of the shelter between two adjacent legs. Each of the X-shaped perimeter truss pairs of link members are essentially identical, and include two link members connected together by a central pivot, with the first link member having an outer end connected to the upper end of one leg, and the second link member having an outer end slidably connected to the leg. The first and second link members are pivotally connected together in a scissors configuration so as to be extendable from a first collapsed position extending horizontally between two of the legs to a second extended position extending between the legs. The two perimeter truss pairs of link members on each side are connected together at their inner ends. The collapsible shelter preferably has four legs, but can also have three, five, or more legs. At least two flexible pole members are also provided that are removably mountable to the upper ends of the legs of the shelter to extend across the shelter to form a structure for a flexible, collapsible canopy. The canopy also preferably includes a cover secured to the upper ends of the legs. In a currently preferred embodiment of the invention, the flexible pole members comprise a plurality of segmented poles formed from a plurality of pole sections that are removably connectable together, and that are removably mounted in indexing holes in hinge means affixed to the upper ends of the legs, and the pole members are similarly removably connected together by a central hub that is preferably permanently connected to an inner end of one of the pole members. When the pole members are connected together and inserted in the hinge means of the legs, the pole members forming the canopy can flex and move between a normal raised position and a lowered position by exertion of a downward force on the top of the canopy, such as by a strong wind, to reduce the profile of the shelter that would be exposed to the wind and still provide rain run off. To facilitate this aspect of the invention the flexible poles in a currently preferred embodiment are made of a composite material such as fiberglass, but a variety of materials such as metal tubing and other composites can be used for such purposes. Col. 1, line 53-Col. 2, line 34.
[0009] The '412 and '293 patents go on to disclose that “ . . . an the currently preferred embodiment, four flexible pole members 82 are provided, corresponding to the number of legs, as is illustrated in FIGS. 6, 7 and 12. While a variety of materials such as metal tubing, composite tubing (tubing made of resin impregnated fibers) or solid composite poles may be used, the flexible pole members currently preferably each comprise segmented flexible poles formed from two fiberglass pole sections 84 that are removably connectable together, with an inner end 86 of one of the pole sections bearing a metal jacket 88, made of aluminum or steel for example, into which the adjacent inner end 90 of the other pole section is insertable, to join the pole sections together. The pole sections are preferably hollow, and an elastic cord 92 runs through the longitudinal centers of the pole sections. An outer end 94 of the cord of each pole member extends through an indexing aperture 96 in the hinge means, and is secured to the hinge means such as by a knot. The inner end 98 of the cord is secured to the inner end 100 of the pole member, such as by a knot, so that the pole sections of the pole member are biased together. The pole members are removably receivable for mounting in the indexing apertures 96 in the hinge means affixed to the upper ends of the legs. In a currently preferred embodiment, a central hub member 102, having four symmetrically located indexing holes 104 for removably receiving the inner ends of three pole members, and for permanently receiving the inner end of a fourth pole member, mounted in a hub indexing hole, such as by an adhesive such as epoxy, for example, for joining the pole members together.” Col 5, lines 14-38.
[0010] U.S. Pat. No. 4,074,682, entitled COLLAPOSIBLE TENT FRAME, issued to Yoon on Feb. 21, 1978 discloses “ . . . a collapsible tent frame has all of its parts permanently connected to one another to provide a complete single unit and is easily changeable between a fully deployed condition, a partially deployed condition and a compact collapsed condition by simple manual manipulations. In either its fully deployed condition or its partially deployed condition, the frame is adapted to receive and support a tent fabric or other covering to provide a shelter lending itself to a variety of uses.” Abstract. The '682 patent also discloses that “ . . . the frame is unitized insofar as all of its parts are permanently connected with one another and it is shiftable between a compact collapsed condition and at least one deployed condition.” Col 1, line 67-Col. 2, line 2. In addition the disclosure of the '682 patent notes that “ . . . a more specific aspect of the invention resides in each leg of the frame including an inboard section, an intermediate section and an outboard section with the outboard section being pivotally connected with the intermediate section for movement relative to the intermediate section between a folded condition and a spread condition. The intermediate section is also pivotally connected to the inboard section for pivotal movement between folded and spread conditions relative to the inboard section; and likewise, as previously mentioned, the inboard section is movable relative to the hub between deployed and collapsed positions. When all of the inboard sections are deployed relative to the hub and all of the intermediate sections are spread relative to the inboard sections, the outboard sections may be either spread relative to the intermediate sections to provide a fully deployed frame providing one form of structure, or the outboard sections may be folded relative to the intermediate sections to provide a partially deployed frame providing another form of structure. In either the fully deployed condition or the partially deployed condition of the frame, struts extending between adjacent pairs of legs aid in controlling the angular spacing of the legs and in thus rigidifying the frame, the struts each being made of two arms pivotally connected to one another and to their associated legs to permit collapsing of the frame.” Col 2, lines 26-51. The specification of the '682 patent goes on to say that “ . . . In the deployed condition of the frame, the arms 74, 74 of each strut are locked in their relatively aligned positions shown in FIGS. 2 and 16 by a suitable releasable locking means such as the sleeve 80 shown in FIGS. 13, 14 and 15. That is, in the aligned and locked arm situation of FIG. 13, the sleeve 80 fits over the joint between the two arms to prevent relative pivotal movement between such arms; but, the sleeve is slidable to the position of FIG. 15 at which the joint is freed to allow relative rotation between the arms. A spring 82 in the sleeve frictionally holds the sleeve to whatever position it is moved.” Col 5, lines 32-41.
[0011] U.S. Pat. No. 5,930,971, entitled BUILDING CONTRRUCTION WITH TENSION SUPPORT SYSTEM, issued to Ethridge on Aug. 3, 1999 discloses “ . . . a structural system for a building wherein multiple elongate rigid structural members, in the nature of posts and beams, include internal tensioning cables which, upon an end joining of the structural members, are interlocked and tensioned to each other and relative to a fixed foundation.” Abstract. The specification of the '971 patent goes on to say that “ . . . basically, the construction system utilizes a plurality of rigid, compression-accommodating structural members, preferably tubular, defining upright support posts, roof beams, cross beams, and the like. The rigid structural members are stabilized by elongate tension members, generically herein referred to as cables, received through each of the structural members and end joined, upon a proper tensioning thereof, at or immediately adjacent the adjoining ends of the structural members. The joined cables ultimately extend through uprights and are in turn anchored to an underlying foundation either in the nature of a solid cast concrete slab with anchoring loops extending therefrom, or individually cast footings associated with each upright.” Col. 1, lines 40-53.
[0012] U.S. Pat. Nos. 6,028,570, entitled FOLDING PERIMETER TRUSS REFLECTOR, ISSUED TO Gilger et al. on Feb. 22, 2000 discloses a “collapsible support structures, fold-up perimeter trusses, principally for deployable high frequency parabolic antennas used in spacecraft.” Col. 1, lines 5-7. U.S. Pat. No. 5,871,026, issued to Lin on Feb. 16, 1999, entitled UMBRELLA SHAPE TWO LAYERS FOLDABLE TENT, disclosed a “two layers half automatic foldable tent is comprised of a framework, an umbrella surface, and a tent cloth. The framework is enclosed on the outside of the tent, while the umbrella surface is expanded on the framework above the tent cloth, wherein the framework is presented as an expanding structure. The opening and closing of the umbrella frame is completed by a controlling rope. Any user may easily install the tent, the lower primary frame of the umbrella frame may be folded upwards as the framework is closed, thus it may be stored conveniently and may be carried. Another, since in the present invention, the umbrella surface and tent cloth are designed as the two layers type thus the sunlight, rain water and snow will not contact the tent directly, and the people within the tent will be safe and comfortable and the lifetime of a tent is prolonged.” Abstract.
[0013] U.S. Pat. No. 4,998,552, entitled GEODETIC TENT STRUCTURE, issued to Niksic et al on Mar. 12, 1991, discloses a “self supporting collapsible tent structure having a tension bearing polygonal shaped floor member defining a first tent level, a plurality of hub members each carrying a plurality of sockets which are pivotal about axes which are co-planer and are interrelated one to the other as the sides of polygon, a series of said hub members disposed in a plane at a second tent level which is spaced apart from said first tent level and whose sockets are pivotal in a first direction, and additional series of said hub members disposed in a plane at a third tent level which is spaced apart from said second tent level and whose sockets are pivotal in a second direction, opposite to the said first direction, a single, apex forming hub member disposed at a fourth tent level and whose sockets are pivotal in said first direction, a first plurality of compression rods, the ends of which are seated in the said sockets of the hub members in slightly curved polygonal planes defined and bounded by the rod members and a second plurality of compression rods, one end of which are seated in sockets of the hub members at the second tent level and the other end of which are connected to the perimeter of the floor member.” abstract.
[0014] U.S. Pat. No. 4,583,956, issued to Nelson on Apr. 22, 1986, entitled RIGID AND TELESCOPING STRUT MEMBERS CONNECTED BY FLEXIBLE TENDONS, discloses a “construction kit consisting of rigid or telescoping elongate strut members which may be attached together by flexible tendons to form a variety of designs and model structures. The invention places no limits on the number of struts which can be attached at one vertex or their relative angles, and the length of each strut may be varied within broad limits. Furthermore, the end of one strut may be attached not only to the end of another, but to any point along its length. Accordingly, an almost unlimited variety of constructions is possible.” Abstract.
[0015] U.S. Pat. No. 4,438,876 discloses a “back pack frame is comprised of tubular frame members which upon separation permit extraction of pairs of tent frame components stowed therein. The frame members and tent frame components are thereafter rejoinable to provide a geodesic tent frame. The tent frame components, upon extraction from a stowed position within the back pack frame members, are positioned in a divergent manner as permitted by a wire hinge component interconnecting the paired tent frame components. The back pack frame members are slotted at their ends to permit such divergent positioning of the associated tent frame components and include limit stops to prevent complete separation of the tent frame components from their frame member. The back pack frame members themselves are coupled to one another by flexible wire inserts and, in a modified form, by molded socket members. A back pack bag may be supported either externally on the back pack frame or, alternatively, over frame members.” Abstract. The disclosures of the above referenced prior art are hereby incorporated by reference.
[0016] None of the foregoing discloses or suggests solutions to the problems with the foregoing which do not fully satisfy the needs for s compact, light weight, fully portable and exceptionally strong, once assembled, collapsible support structure. The present invention satisfies those needs more effectively than the above described prior art.
SUMMARY OF THE INVENTION
[0017] A method and apparatus is described for providing a collapsible support structure, which may comprise a plurality of interconnected frame sections each of which may comprise a first elongated rigid member having a first end and a second end; a second elongated rigid member having a first end and a second end; wherein the first end of the first elongated rigid member and the second elongated rigid member are hingedly joined; a collapsible elongated member which may comprise an elongated flexible tensioning member connected between the second end of the of the first elongated rigid member and the second end of the second elongated rigid member; a first hollow tubular rigidizing member extending along a portion of the length of the elongated flexible tensioning member; a second hollow tubular rigidizing member extending along essentially the remainder of the length of the elongated flexible tensioning member; and a rigidizing sleeve member slideably mounted on the first or the second hollow tubular member and sized to slideably engage the other of the first and second hollow tubular when the first and second hollow tubular rigidizing members are essentially axially aligned and the rigidizing sleeve member is positioned to slideably engage each of the hollow tubular rigidizing members to form a collapsible elongated tubular member extending essentially between the second ends of each of the first and second elongated rigid members and having the elongated flexible tensioning member axially disposed therein. The apparatus and method may employ the interconnected frame sections on the form of a triangle or a parallelogram, and may form a portion of a geodesic structure, such as a truncated icosahedron, which in turn may have first and second lesser circle polygonal shapes, with the hingedly joined first ends of the first and second elongated rigid members being joined at a corner of the first lesser circle polygonal shape and the collapsible elongated tubular member forming a side of the second lesser circle polygonal shape. The method and apparatus may use one-piece elongated rigid members. The sections may form parallelograms using first, second and third elongated rigid members and first and second rigidizing means, with each of the rigidizing means in each section forming a side of a separate one of the lesser circle polygonal shapes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 shows a basic structure for a collapsible support structure frame according to an embodiment of the present invention;
[0019] [0019]FIG. 2 shows schematically the geodesic structural relationship of opposing vertical members in a level of a geodesic structure according to an embodiment of the present invention;
[0020] [0020]FIG. 3 shows a geodesic structural relationship of portions of the structure according to the embodiment of the present invention shown in FIGS. 1 and 2 in relation to lesser circles circumscribing the structure in horizontal planes at certain levels of the structure,
[0021] FIGS. 4 ( a ) and 4 ( b ) show in more detail a rigidizing means according to an embodiment of the present invention.
[0022] [0022]FIG. 5 is a more detailed view of an embodiment of an upper terrminal junction according to the present invention.
[0023] [0023]FIG. 6 is a perspective view of a portion of the present invention showing an entire vertical section from the ground to the apex of an embodiment of a collaplible support structure according to the present invention.
[0024] [0024]FIG. 7 is a plan view of an embodiment of a collapsible support structure according to the present invention in its erected state.
[0025] [0025]FIG. 8 shows a partially cut away side view of an embodiment of a collapsible support structure according to the present invention in an intermediate stage of being collapsed and stored.
[0026] [0026]FIG. 9 shows a side view of the embodiment of FIG. 8 in the next succeeding stage of being collapsed and stored.
[0027] [0027]FIG. 10( a ) shows the embodiment of FIGS. 8 and 9 in a final stage of being collapsed for storage and FIG. 10( b ) shows the stage of being placed into a storage bag.
[0028] [0028]FIGS. 11, 12 and 13 show alternative possible improved embodiments for the eyelet joiners shown in earlier illustrated embodiments according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Turning now to FIG. 1 there is shown a basic structure for a collapsible support structure frame 10 according to an embodiment of the present invention. The structure 10 may be a truncated icosahedron geodesic structure. Geodesic domes are sliced from a complex polyhedra which has a large number of triangular faces, all approximately, but not quite, equilateral. See. Kenner, Geodesic Math and How to Use It, University of California Press Berkeley, 1976, Chapter 7, the disclosure of the entire volume of which is hereby incorporated by reference. In the structure of the present inventions, however, the triangular faces on the side walls of the structure may be equilateral. The struts bounding the triangular faces in a geodesic dome may follow the paths of great circles that are concentric with the center of the domed structure, some whole, but more often interrupted. The cohesion of the whole, like that of a Tensegrity, is both compressive and tensile, with the tension system running along the outer surfaces of the struts, which are at the same time in compression. The structure 10 as shown may include a plurality of generally vertical sections 12 . Each of the sections 12 a, b, c, d and e may include a first elongated rigid member 14 a , a second elongated rigid member 14 b and a third elongated rigid member 14 c where the third elongated rigid member 14 c may also comprise the first elongated rigid member in an adjoining section 12 b , which may also contain a second elongated rigid member 14 b ′ and a third elongated rigid member 14 c ′. Each of the sections 12 a, b, c, d and e may have an upper collapsible member 30 a, b, c, d and e and a lower collapsible member 32 a, b, c, d and e , more fully described below. Each of the sections 12 a, b, c, d and e may have a roof section 20 a, b, c, d and e , which may be comprised of a first roof rigid member 22 a and a second roof rigid member 22 b , where the second roof rigid member 22 b may be the first roof rigid member in the adjoining roof section 20 b which can also include a second roof rigid member 22 c . It can bee seen that each of the sections 12 a, b, c, d and e form the essentially vertical side walls of the structure with the collapsible members 30 a, b, c, d and e and the collapsible members 32 a, b, c, d and e forming the sides of a pentagon polygon. The collapsible sections 32 a, b, c, d and e can form the base of the collapsible support structure 10 and the collapsible members 30 a, b, c, d and e may form the top of the essentially vertical side walls of the support structure 10 formed by the adjoining sections 12 a, b, c, d and e.
[0030] As shown in FIG. 2, a characteristic of a geodesic structural form such as the icosahedron of FIGS. 1-3 is that the respective upper and lower ends of the opposing vertical sides rigid members, e.g., 14 c and 14 b ′″ form equivalent opposing arcs of a greater circle concentric with the geometric center of the structure 10 if it were not truncated to form the base with the collapsible members 32 a, b, c, d and e , i.e., if it had a structure equivalent to the roof structure attached to the base members 32 a, b, c, d and e in the nature of a complete icosahedron.
[0031] Turning now to FIG. 3 there is shown another characteristic of a truncated icosahedron 10 according to such structures as employed in accordance with the present invention. Each of the upper and lower collapsible members, respectively 30 a, b, c, d and e and 32 a, b, c, d and e for the sides of a pentagon which is circumscribed by a lesser circle in the plane of the pentagon and intersected by the corners of the pentagon. it will also be appreciated by those skilled in the art that the respective pentagons formed by the collapsible members 30 a, b, c, d and e and 32 a, b, c, d and e may be of the same size or of a different size, and in the latter event, the vertical walls of the structure as shown in FIGS. 1-3 could slant slightly inwardly or slightly outwardly toward the top portion of the wall formed by the collapsible members 30 a, b, c, d and e , accordingly. In the truncated icosahedron 10 at six points along the top of the vertical walls formed by the sections 12 a, b, c, d and e five triangles meet at each vertex, e.g., 80 a or 80 b shown in FIGS. 1-3. At the vertexes along the base formed by the collapsible members 32 a, b, c, d and e , only three triangles meet at each vertex. Each of the five vertices of five intersecting triangles in a geodesic structure is called a pent after the pentagons that surround them. From each of the pents radiate portions of five great circles each of which has its center at the geometric center of the structure, were it a full icosahedron as opposed to a truncated one as shown. Each of the great circles sets of about 63.5° before intersecting the opposite end of the rigid structural member, e.g., 14 c or 14 b ′″ as shown in FIG. 2, radiating from the pent, generally in the plane of the great circle. Following the lead of either of the pentagon edges forming the base or the top of the vertical walls formed by sections 12 a, b, c, d and e one may trace a circuit around the geodesic sphere forming a lesser circle with its center at the center of the pentagram, girdling the sphere in generally parallel planes, e.g., like the trop latitudes on the globe of the earth. In the pure geodesic dome, the struts forming the arcs of the lesser circles are almost, but not quite coplanar. Of course, the vertically extending struts can be adjusted as necessary and desired to correct this lack of co-planarity. Truncated dome design of the present invention is completed by placing the base formed by the collapsible members 32 a, b, c, d and e on the ground with the collapsible members 32 a, b, c, d and e and 30 a, b, c, d and e in the rigidized configuration.
[0032] Turning now to FIG. 4( a ) the apex 82 b of the section 12 a of the vertical walls of the structure 10 is shown in more detail to explain the interrelationship between the rigid members 14 a, b and c , and the collapsible members 30 a and by example 30 b forming the section 12 a . Each of the elongated rigid members 14 a, b , and c may consist of an elongated wooden dowel 16 . Each of the elongated rigid dowels 16 may have attached to either end thereof an eyelet, e.g., a screw-in eyelet 18 . An upper flexible circumferential tensional support member, e.g., a length of rope (not shown) may extend through the eyelets 18 on the upper ends of the dowels 16 (not shown)-forming the elongated rigid structural members 14 a and 14 b , which may be positioned adjacent to each other forming an upright triangular portion 50 a (FIG. 2) of the section 12 a along with the lower collapsible member 32 a . A lower flexible tensional circumferential support member, e.g., a length of rope 42 or cable, may extend through the lower collapsible support member 32 a (shown in phantom by dotted/dashed lines) and through the pair of eyelets 18 on the lower ends of the dowels 16 forming the elongated rigid members 14 b and 14 c . Similarly the upper length of rope (not shown) extends through the upper collapsible member 30 a between the joined ends of the elongated rigid structural members 14 a and 14 b and the upper end of the elongated rigid structural member 14 c , and the lower length of rope 42 extends between the eyelets 18 on the lower ends of the elongated rigid structural members 14 b and 14 c that are joined together thereby, such that the elongated rigid structural members 14 b and 14 c along with the upper collapsible member 30 a form an inverted triangular portion 52 a (FIG. 2) of the section 12 a . Thus it can be seen that the section 12 a can be in the form of a parallelogram, with the corners of the parallelogram formed by upper junctions 80 a and b and the lower junctions 82 a and b , with the upper collapsible member between 80 a and b forming the base of the inverted triangular portion 52 a and the lower collapsible member 32 a forming the base of the upright triangular portion 50 a of the section 12 a.
[0033] In the embodiment shown in FIG. 4( a ) it can be seen that the collapsible member 30 a and 32 a (not shown in FIG. 4) may be formed by a pair of hollow cylindrical tubes 62 and 64 and an outer tubular sleeve 70 . In the embodiment shown in FIG. 4 the pair of tubes 62 , 64 extend substantially the length of the base of the respective upright and inverted triangular portions 50 a and 52 a and the outer sleeve 70 slideably engages both the tube 60 and the tube 62 when the respective upper or lower collapsible member, e.g., lower collapsible member 32 a is in the rigidized configuration. The abutment of the tubes 60 and 62 at junction 72 is illustrated in FIG. 4( a ). This abutment serves to hold the rigidized collapsible member 32 a in compression when the tensile forces exerted, e.g., by tightening the rope 42 around the lesser circle traveled by the rope 42 (along with the similar action of the upper rope (not shown) gives the structure 10 its structural rigidity.
[0034] Turning now to FIG. 4( b ) it can be seen that the outer sleeve 70 is of a length that it can be slideably moved to enclose only the one or the other of the two tubes 60 , 62 , such that the rigidity provided by the sleeve 70 engaging both the tubes 60 and 62 is eliminated. This enables the respective ends of the elongated rigid structural members, e.g., 14 a, b and c , the former two of which were maintained in separation by the collapsible member 32 a being rigidized, to move toward each other, enabling collapsing and folding of the structure 10 , when done in conjunction with similarly removing the rigidity of each of the collapsible members 30 a, b, c, d and e and 32 a, b, c, d and e.
[0035] Turning now to FIG. 5 there is shown a more detailed view of an embodiment of an upper terrminal junction or apex 80 ( a ) according to the present invention. The eyelets 18 for each of the dowels 16 forming verticle poles 14 a and 14 b and roof pole 22 a are joind by having the rope of cable 40 forming the upper flexible circumferential support member threaded through them and passing through the adjacent hollow tubes 64 of the upper collapsible member 30 e and 62 of the upper collapsible member 30 a , with the verticle poles 14 a and 14 b forming a triangular portion of section 12 a and roof pole 22 a extending to the top of the structure 10 . This is shown in further detail in FIG. 6. Turning to FIG. 6 there is shown a perspective view of a portion of the collapsible stgructure 10 according to the present invention showing an entire vertical section from the ground to the apex of the embodiment 10 . FIG. 6 shows that the roof poles 22 a, b, c, d and e are joined at the top apex of the structure, e.g., by an apex ring 120 . The apex ring may be, e.g., s ring that has a hinged opening allowing the ring to be inserted through the eyelets 18 and the upper ends of each of the roof poles 22 a, b, c, d and e . Alternatively the apex ring 120 may simply be a piece of rope or cable threaded through the eyelet 18 openings.
[0036] Turning now to FIG. 7 there is shown a plan view of an embodiment of a collapsible support structure 10 according to the present invention in its erected state.
[0037] Turning now to FIG. 8 there is shown a partially cut away side view of an embodiment of a collapsible support structure according to the present invention in an intermediate stage of being collapsed and stored. In this view one section containing portions bottom collapsible support members 32 b and 32 c and upper horizontal collapsible support members 30 b and 30 c are omitted. In the view of FIG. 8, there are shown a pair of anchor rings 130 . The anchor rings 130 may be in the form of a circular ring containing crossed members. The anchor rings 130 are constructed so as to easily connect one end of an upper horizontal flexible circumferential support 40 or lower horizontal flexible circumferential support 42 , e.g., a cable or rope, to the anchor ring, as by tying, welding, crimp locking or the like, and such that the anchor ring will not pass into the adjacent hollow tube 62 or 64 , as the case may be. It will also be understood that the anchor ring 130 , on the lower circumferential support 42 , except for necessary tightening due to loosening or shifting over time in use, may be essentially permanently affixed to the other end of the lower circumferential support 42 , whereas, unless the roof struts 22 a - e are constructed to enable, e.g., telescoping, the anchor ring 130 on the upper circumferential support may need to be undone each time to enable the roof struts 22 a - e to extend toward an apex position from the storage collapsed position due to their rigid length and the circumference of the upper circumferential support 40 in its tightened position.
[0038] As shown in FIG. 8 the sections 12 a, b, c, d and e are laid out with the anchor rings tight against the apexes 82 a a\nd 80 a respectively and with the upper and lower horixontal flexible circumferential support cable or ropes 40 and 42 extending out of one half of the apex 82 e and out of the apex 80 e , and through upper collapsible structural support member 30 e.
[0039] Turning now to FIG. 9 there is shown the initial stage of folding the collapsible horizontal support members between the respective adjacent vertical poles. The roof posts 22 a, b, c, d and e are then folded downwardly to the inside of the collapsed structure as shown in FIG. 10( a ), with the lower horizontal flexible support member 42 pulled to tighten the bundle, and with the portion of the upper horizontal flexible support structure wrapped around the upper portion of the collapsed bundle to further tighten the collapsed bundle prior to insertion of the bundle into the storage bag as Shown in FIG. 10( b ). It will be understood that the folding operation discussed in this paragraph can occur both with the apex ring in place (not shown) or not in place as shown.
[0040] [0040]FIGS. 11, 12 and 13 show alternative possible improved embodiments for the eyelet joiners shown in earlier illustrated embodiments according to the present invention. In FIG. 11 and FIG. 12 there is shown one version of a pop-in connector 160 , which consists of a loop 162 and a pair of straight leg portions 164 , along with a protrusion 166 at the terminal end of the straight leg portion 164 . In the embodiment shown in FIG. 11 the loop 162 can used in conjunction with a locking insert 165 . The locking insert 165 is constructed to have a diameter along at least one axis that allows the structure, which may be constructed of a rigid though partially flexible material such as nylon, so as to fit snuggly within the end of a hollow tube. In the case of FIG. 11 the hollow tube is shown to have replaced the wooden dowels 16 as, e.g., the vertical structural members. In operation the pop-in connector of FIG. 11 is constructed to have a spring-like mode of operation with the protrusions biased to press against the inner surface of the hollow tube 16 . Insertion into the grooves 167 of the locking insert 165 , the protrusions are forced even more toward engagement with the inner surface of the hollow tube 16 . In addition, depending upon the direction of the spring action of the leg portions, they may be biased against the surface of the respective groove 167 to further frictionally hold the pop-in connector 160 . In the embodiment of FIG. 12, the hollow tube has a pair of opposing holes 168 and in this case the legs 164 of the loop 162 of the pop-in connector 160 are springedly biased outwardly so as to engage the protrusions 166 in the holes 168 to hold the pop-in connector in place.
[0041] As shown it can be seen that the pop-in connectors 160 can be of great use, e.g., if a pole/strut, e.g., 14 or 16 were to break while the structure is erect. Without having to essentially disassemble the structure frame 10 by unthreading the entire, e.g., upper flexible circumferential support 40 or lower flexible circumferential support 42 to rethread it through an eyelet such as the eyelets 18 discussed above, the pop-in connector can be used to selectively engage one of the supports 40 , 42 at the respective end of a pole/strut at only the specific location of the pole/strut being replaced.
[0042] One possible disadvantage of the pop-in connector 160 described above is that over time the flexible support 40 , 42 , if it is made of fiber as opposed to being a metal cable, could fray on the ends of the tubular pole/strut. alternatively, the metal capable used as a flexible support 40 or 42 may wear down the tubular ends of the pole/strut. To prevent either of these, at the loss of flexibility in replacing poles/struts while the structure is erected, a pop-in connector such as the pop-in connector 170 shown in FIG. 13 may be employed. The pop-in connector of FIG. 13 has two loops, keeping the flexible circumferential support 40 , 42 away from the tubular end of the respective pole/strut.
[0043] It will be understood that the tensioning means at, e.g., the base and the top of the vertical side walls of the structure 10 may be formed by rope or cable or the like and may be brought into tension simply by pulling on the rope or cable at a vertex, e.g. 80 b and similarly, e.g., 82 b , with the rope or cable attached, e.g., to an eyelet 18 on one of the dowels 18 forming part of the vertex, and looped through the other eyelet at the vertex, such that the tensionizing rope or cable exerts tension between each of the vertices, while the collapsible members 30 a, b, c, d and e , or 32 a, b, c, d and e , as applicable, are placed in compression. It will also be understood that the compactibility of the structure 10 of the present invention may be increased, and the height of the vertical walls formed by the sections 12 a, b, c, d and e maintained by making the rigid members, e.g., 14 a, b and c , themselves collapsible, e.g., by forming them of a two piece hinged construction as is known in the art for such supporting struts for collapsible structures and frames. In addition, the height of the vertical walls may be increased by adding a third or a fourth or more set of sections defined by another pair of adjacent lesser circle pentagons connected by rigid struts, e.g., in the triangular pattern as shown in FIGS. 1-3. It will also be understood that the roof struts 22 a, b, c, d and e must be joined at the apex 88 of the structure 10 shown in FIGS. 1-3, which may be accomplished by simply as looping a rope through eyelets 18 at the terminal ends of the roof struts 22 a, b, c, d and e meeting at the apex 88 , or by any of the well known mechanical structures for forming such a roof apex in collapsible structure frames known in the art. It will be understood, however, that the making of this vertex at the apex 88 of the structure will ordinarily need to be formed before vertical side walls of the structure 10 are rigidized and will ordinarily need to be broken down before the structure 10 is collapsed, since the length of the roof struts 22 a, b, c, d and e will prevent the apex 88 from collapsing through the plane of the lesser circle formed by the top of the vertical wall, i.e., by collapsible sections 30 a, b, c, d and e , as shown in FIGS. 1-3 while remaining joined in abutted ends at the apex 88 .
[0044] The collapsible support structure of the present invention provides a number of advantages beyond simply being collapsible and storable in a relatively compact form in a storage bag and being relatively easy to assemble and rigidize and collapse and store. No ropes or tie downs are needed to hold the erected structure having placed over it one of a number of forms of plastic, fabric or hybrid covers to form, e.g., a tent or other generally water tight enclosure. The ropes inside the collapsible frame structure of the present invention provide the hold down function simply by the weight of the cover over the structure, or alternatively, if, e.g., because of high winds, etc. weighted bags filled with, e.g., sand or water can be place over the bottom horizontal collapsible members. this can be especially beneficial on surfaces that are exceptionally hard, e.g., pure rock, or exceptionally soft, e.g., sand, where tie downs are difficult if not impossible to anchor. The structure is also adaptable to a large variety of terrains, including relatively steep slopes, and the ability to suspend hammocks from the upper vertices of the structure are not impacted by the structure being on such a slope. Furthermore if the structure, once assembled needs to be moved, e.g., having been initially erected over an ant hill, it can be lifted and moved fully assembled relatively easily due to its rigidity and light weight.
[0045] In use the collapsible support structure of the present invention can be a form of rapidly deployable emergency shelter. The ability to hang hammocks from the vertices of the frame enable use in wet conditions even if the frame does not support a covering forming a tent with an integral floor.
[0046] In operation the collapsible support structure of the present invention can be erected by the following process. The structure is first removed from the storage bag. The user can simply open the carrying bag and stand the collapsed structure in the veticle collapsed position. The five lower horizontal collapsible members will naturally fall away from the vertical poles, with the upper horizontal collapsible members remaining suspended from the upper ends of the vertical poles. the user can then spread tot lower horizontal collapsible support members to form the lower pent by moving the vertical poles outwardly from the stored compacted assembly. Leaving the upper collapsible horizontal support members in the broken down condition, the user can rigidize the lower horizontal collapsible members to form a rigidized pent at the bottom of the structure. With the apex of the roof poles connected by an apex ring as described above and the upper horizontal collapsible members remaining un-rigidized, and or un-tightened, the roof poles can be moved to above the horizontal plane of the upper horizontal collapsible members. The upper horizontal collapsible members can then be rigidized. Both the lower horizontal collapsible members and upper horizontal collapsible members can be rigidized by, e.g., threading the respective upper or lower flexible circumferential support member, e.g., rope or cable through an anchor ring at the opposite end of the cable or rope and held in place at one of the apexes/vertexes 80 a, b, c, d and e or 82 a, b, c, d and e and tightening the rope or cable by hand or with a mechanical tightener so that the respective horizontal lesser circle is in compression. This can be done, e.g., with the user standing inside of the frame under assembly and holding the roof poles upward to form a roof apex, while tightening the upper collapsible horizontal support members. The upper apexes will be generally centered over the centers of the lower collapsible support members and the upper collapsible structural members will be centered generally over the junctions between the bottom collapsible support structural members.
[0047] A further application of the present invention to form a collapsible structure support can include other geodesic structures that are able to be formed and broken down according to the present invention, e.g., icosa, octa, tricon, etc., especially in multi-frequency large structures, e.g., using cables with somewhat heavier hardware.
[0048] The present invention has been described with respect to preferred embodiments. It will be understood by those skilled in the art that many variations and modification of the disclosed preferred embodiments may be made without changing or departing from the scope and spirit of the present invention, e.g., other forms of sleeves and tubes apart from those illustrated which maintain compression by the abutment of the inner tubes within the outer sleeve may be employed as known in the art, e.g., a sleeve with flouted ends and a more narrow central section such that the tubes coact with the narrowed center portion of the sleeve to create the compressive force. IN addition, the sleeve itself could be the internal tubular structure, e.g., having a protrusion that slides along a slot in one or the other of the two tubes running the length of a collapsible member, e.g., 32 a , so as to be able to be moved from a position in which the sleeve (now an internally disposed sleeve) slideably internally engages both of the other tubes to one in which it so engages only one of the other tubes, similarly to the configuration as shown in FIG. 5. Other such modifications may be made to the mechanical structural elements of the present invention, e.g., the dowels could be replaced with solid or hollow metal rods, or even generally flat struts, particularly if a hinged construction of the struts is desired, all of which may be made, e.g., of metal, e.g., made of aluminum, and/or the eyelets could be replaced with holes bored through the rigid structural members, whether such are wooden of metal, hollow or tubular or flat in construction. the present invention, therefore, should not be limited to any preferred embodiments disclosed in this application and should be considered described and claimed only through the following claims: | An apparatus and method is disclosed for providing a collapsible support structure strut, which may include a strut member; a hollow tubular terminal end portion of the strut member having an inner surface; and a detachable looped eyelet having at least one loop and a pair of extending legs, the legs being springedly biased to engage the tubular terminal end of the strut, thereby frictionally holding the looped eyelet in place at the terminal end of the strut. The apparatus and method may also employ a holding plug, with first and second holding groove opposingly placed in the periphery of the holding plug, having at least a portion thereof that is shaped and sized to frictionally engage the inner surface of the tubular terminal end of the strut, to frictionally hold the holding plug in engagement with the strut. The detachable looped eyelet may also have at least two loops. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drainage track of the type primarily intended for use in combination with exterior insulation and finish systems (generally referred to in the construction industry as EIFS), the construction of which provides for positive drainage of moisture which may collect between a structure's exterior surface or coating and its weather resistant barrier.
2. Description of the Prior Art
In today's construction industry, numerous residential structures, and even a significant number of commercial structures such as, for example, apartment buildings, have their exterior surfaces finished with a stucco-type coating applied over a foam insulation board. One such board is, for example, that disclosed in U.S. Pat. No. 4,572,865, and other such boards are well known in the prior art and in the construction industry. Such exterior finishes are generically referred to as Exterior Insulation and Finish Systems, and will be referred to hereinafter as EIFS.
While such EIFS constructions have proved to be quite satisfactory for their relative ease of installation, their insulating properties, and their ability to receive a variety of aesthetically-pleasing finishes, a serious and vexing problem associated with EIFS construction exists. This problem is one of water accumulation behind the exterior wall covering. Such water may be the result of condensation, but is frequently the result of wind-driven water that may enter behind the exterior wall covering at any point where the exterior surface of the coating is penetrated. Such water accumulation may be the result of poor workmanship or design, deterioration of flashing or sealants over time, lesser quality doors or windows, or any other penetration or compromise of the exterior finish.
When such water penetration occurs, absent effective, reliable means for draining the water from behind the EIFS exterior construction, structural damage to the building may occur.
The construction industry has certainly recognized such problems associated with water penetration behind EIFS exteriors, and other insulated building components such as, for example, windows. For example, U.S. Pat. No. 4,569,872 describes an insulating window panel which includes a bottom frame member for draining condensation. According to the disclosure of that patent, a transparent plastic sheet having a number of vertical channels formed therethrough is disposed in face-to-face relationship with a polyethylene closed cell foam sheet. The purpose of the vertical channels is to permit water to flow downwardly, and the lower frame member is dimensioned and configured to provide a drain opening along the bottom thereof. This drain opening is provided by insuring that the composite panel is mounted in spaced apart relation to the bottom of the frame member.
U.S. Pat. No. 2,264,961 discloses a thermal insulation structure having vertical channels formed on one face thereof to provide a ventilating space for the circulation of air to dry out water which may penetrate the insulating material. However, this patent does not disclose or suggest any means for positively draining water from inside the wall.
According to the disclosure of U.S. Pat. No. 4,570,398, concrete may be sprayed onto the exterior of rigid sheet insulation and wire to form a continuous waterproof outer surface. However, one may reasonably question such a statement, for concrete is typically permeable to water.
Finally, U.S. Pat. No. 5,511,346 discloses a rigid, thermoplastic foam board useful in below-grade residential and commercial insulating and drainage applications. According to the disclosure of this patent, the board includes a plurality of vertical channels formed therein to provide for water drainage and to protect a below-grade building wall from excessive moisture.
Without in any way questioning the asserted utility of the devices and structures identified above, any practical study of these devices reveals significant shortcomings. Virtually none of the prior art devices actually provides means for positively draining water away from the building structure. While a drain opening is provided in the panel disclosed by U.S. Pat. No. 4,569,872, establishing that drain opening clearly requires care and precision in fitting the lower frame member to the composite panel. While the other devices discussed above provide means for "ventilating" insulating panels, none provide for water drainage from behind the panels. It is, therefore, clear that there remains a great need in the art of building constructions utilizing EIFS exteriors so as to provide for the drainage of penetrating water from behind the insulation so as to prevent water-related structural damage to the building. Such a device must not only provide for positive water drainage, but also must be of economical manufacture and of relatively simple use and installation so as not to adversely affect building costs.
SUMMARY OF THE INVENTION
The drainage track of this invention is of the type primarily intended for use in combination with exterior insulation and finish systems (EIFS). The principal purpose of the drainage track is to provide positive means for draining water from behind the insulating material so as to prevent water-related structural damage to the building. The drainage track comprises a flashing leg by which the track is attached to the exterior sheathing of the building along the bottom edge of that sheathing. A major portion of the flashing leg overlaps the sheathing, and a minor portion of the flashing leg extends below the sheathing's bottom edge. Extending in angular relation from the bottom edge of the flashing leg is a first structural web. In a preferred embodiment, a second structural web is joined to the first web and extends in angular relation thereto in substantially parallel relation to the flashing leg and upwardly from the first web. A horizontal leg is joined to the second web and extends in angular relation thereto, outwardly from the flashing leg. Thus, in cross-section, the drainage track defines a substantially L-shaped configuration with a drain channel defined by the lower portion of the flashing leg, the first structural web, and the second structural web. The horizontal leg defines a surface for placement of an insulating panel thereon.
A plurality of drain apertures are formed in the first web to provide for positive drainage of water therefrom. A plurality of finish apertures are preferably formed through the horizontal leg so as to permit proper adhesion of the building's stucco-type exterior finish, which finish is applied to the exterior surface of the insulating panel according to known procedures and techniques. Alternatively, the horizontal leg can also incorporate other adhesion promoting means, such as ridges or a combination of ridges and apertures for proper adhesion.
In this preferred embodiment, the drainage track is formed from extruded polyvinyl chloride (PVC). However, the scope of the invention is not to be limited to the use of this material. Any suitable material such as, for example, other plastics or metals, may be used for forming the drainage track. In similar fashion, the cross-sectional configuration described above is nothing more than a preferred embodiment, and alternative configurations will be presented hereinafter.
The invention accordingly comprises an article of manufacture possessing the features, properties, and the relation of elements which will be exemplified in the article hereinafter described, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view, partially in section to show interior detail, of an EIFS wall construction showing use and installation of the drainage track of this invention according to a preferred embodiment.
FIG.2 is a sectional view of the installation shown in FIG. 1.
FIG.3 is a perspective view of a segment of the drainage track used in the installation of FIG. 1.
FIG. 4 is a bottom, plan view of the drainage track of FIG. 3.
FIG. 5 is a front elevation of the drainage track of FIG. 3.
FIG. 6 is a side sectional view of the drainage track of FIG. 3.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Referring first to the views of FIGS. 1 and 2, one sees a perspective and a sectional view of a portion of a standard building construction, the exterior of which is finished with an exterior insulation and finish system (EIFS), generally indicated as 10. The drainage track of this invention is generally indicated as 12. The building segment shown in FIGS. 1 and 2 comprises a slab, or foundation, 14 having a sole or sill plate 16 attached thereto. Using studs (not shown), the exterior of the building is initially formed by sheets of sheathing 18. The EIFS 10, in combination with the drainage track 12 of this invention, is actually attached to sheathing 18.
As seen in the view of FIG. 1, drainage track 12 is attached to sheathing 18 as by staples 20, or any such suitable fastening means such as, for example, nails, brads, or screws. Next, a weather resistant barrier 22 is applied over sheathing 18 such that the lower portion of barrier 22 overlaps flashing leg 24 of drainage track 12. Spacers 26 are next applied over barrier 22, and the bottom portion of spacers 26 also overlaps flashing leg 24. Insulating material 28 is next applied. The bottom portion of insulating material 28 also overlaps flashing leg 24. Referring to the view of FIG. 2, it can be seen that the bottom edge 30 of insulating material 28 actually rests on horizontal leg 32 of drainage track 12. The view of FIG. 1 further illustrates that the exterior of insulating material 28 is provided with a reinforcing mesh 34. Finally, the finish coat 36 is applied over the exterior of insulating material 28 and its mesh 34 to complete the installation. Referring to the view of FIG. 2, it can be seen that finish coat 36 actually "wraps around" the bottom edge 30 of insulating material 28 and onto the bottom surface of horizontal leg 32.
Having thus described a standard installation utilizing drainage track 12 in combination with the EIFS 10, attention is invited to the fact that the subject matter of this invention is directed to drainage track 12. That is to say, drainage track 12 is useful in combination with virtually any EIFS 10, and the individual elements of such an exterior finish may certainly vary from job to job. For purposes of example only, weather resistant barrier 22 is typically a type 15 felt, or an equivalent. Spacers 26 may be 1/4"×31/2" closed-cell polyethylene sill sealers, 1/2" diameter closed-cell backer rods, or their equivalents. Virtually any commercially-available insulating board may be used as the insulating material 28, and the board described in U.S. Pat. No. 4,572,865 is preferred. The finish coat 36 may be any coating/sealant as specified for application to and compatibility with insulating material 28. Sheathing 18 may be plywood, gypsum, cement board, fiberboard, or other equivalents therefore. It is to be understood that local conditions and building codes will, at least to some extent, dictate the individual components of EIFS 10.
Having thus described a typical EIFS 10 used in combination with drainage track 12 of this invention, attention is now invited to the views of FIGS. 3-6 for a more detailed description of a preferred construction for drainage track 12. As previously indicated, drainage track 12 is preferably extruded from PVC. However, drainage track 12 may be formed from any suitable, substantially rigid material such as, for example, other plastics, other synthetics, or metal. As perhaps best seen in the views of FIGS. 3 and 6, drainage track 12 comprises a flashing leg 24 having a top edge 38 and a bottom edge 40. A first structural web 42 is joined to bottom edge 40 and extends in angular relation thereto. In this preferred embodiment, first structural web 42 is substantially normal to flashing leg 24. A second structural web 44 extends from first web 42 in angular relation to first web 42. Again, as shown in this preferred embodiment, second structural web 44 is substantially normal to first structural web 42 and extends upwardly in the direction of top edge 38 such that second structural web 44 is substantially parallel to flashing leg 24. Horizontal leg 32 is joined to the top of second web 44 and extends in angular relation to second web 44, terminating in a distal edge 46.
A plurality of drain apertures 48 are formed in spaced apart relation through first structural web 42. A plurality of finish apertures 50 are formed in spaced apart relation through horizontal leg 32.
Referring to the sectional view of FIG. 6 and the sectional installation view of FIG. 2, it can be seen that a portion of flashing leg 24 adjacent bottom edge 40, first structural web 42, and second structural web 44 effectively define a drain channel for positively draining any water that penetrates the EIFS 10. Referring to the view of FIG. 2, the top of this drain channel is actually defined by bottom edge 30 of insulating material 28, inasmuch as that bottom edge 30 rests on horizontal leg 32.
In the preferred embodiment, drain apertures 48 are about 3/16" in diameter, and finish apertures 50 are about 1/8" in diameter. This size for drain apertures 48 ensures that water will pass therethrough and not be retained in the drain channel as by surface tension, while is of a sufficiently small size to prevent the entry of pests. The smaller size and greater number of finish apertures 50 provide for effective bonding of the finish coat 36 to horizontal leg 32. Though not shown in the drawings, it may be desirable to form the bottom surface of horizontal leg 32 to include a plurality of ridges, further enhancing the bonding between horizontal leg 32 and finish coat 36.
It should also be noted that the distance between flashing leg 24 and second web 44 plus the distance defined between second web 44 and distal edge 46 is less than the thickness of the EIFS 10 used in combination with drainage track 12. Thus, a variety of EIFS 10 constructions may be used in combination with a single drainage track 12 with the exterior of the insulating material 28 extending beyond distal edge 46.
As indicated above, this construction for drainage track 12, as heretofore described and as shown in the drawing figures, is but a preferred embodiment. First structural web 42 need not necessarily be normal to the plane defined by flashing leg 24, and second structural web 44 need not necessarily be normal to the plane defined by first structural web 42. For example, first web 42 and second web 44 could define a V-shaped drain channel, rather than the substantially rectangular channel shown in the sectional view of FIG. 6. The scope of this invention is intended to encompass such a construction, and drain apertures 48 might then be said to be formed through both the first structural web and the second structural web. In similar fashion, the shapes of first web 42 and second web 44 might be altered to define a curved, substantially U-shaped drain channel with drain apertures formed through the bottom of the U. In all instances, however, flashing leg 24 is attached to the building such that the entire EIFS 10 overlaps top edge 38 of flashing leg 24 so that water will necessarily be directed toward the drain apertures 48. Similarly, horizontal leg 32 will always be spaced apart from flashing leg 24 and define a top, planar surface suitable for operatively receiving bottom edge 30 of the insulating material 28.
A key advantage of the drainage track of this invention is that the outer portion of its drainage channel, e.g., structural web 44 of the embodiment shown in the drawings, serves as a block to prevent clogging of the drain apertures. If the drainage track were to simply be an L-shaped device, without an upwardly projecting and blocking member such as web 44, the installer, in applying the coating and reinforcing mesh over the lower edge of the construction, would tend to plug the drainage holes with the coating because there would be no guide limiting how far back his trowel could go. Thus, the track would become ineffective. Structural web 44 or any equivalent step portion therefore plays a key role by serving as a "guide" in limiting how far back the plasterer pushes his trowel with the coating. This guide prevents him from going all the way back to the substrate (slab 14) and filling the vent holes with coating.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and, since certain changes may be made in the above article without departing from the 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.
Now that the invention has been described, | A drainage track useful in combination with exterior insulation and finish systems including a clog-resistant drainage channel so that water collecting behind the exterior insulation and finish may drain from the structure. The drainage track, in a preferred form, is extruded from PVC and defines a substantially L-shaped configuration in cross-section. An elongated, relatively tall flashing leg is provided for attachment of the drainage track to the structure such that all water resistant material and insulation laps over the flashing leg to direct water into the drainage channel. Finish apertures are provided through a portion of the drainage track so that exterior finish such as, for example, stucco, will readily adhere and bond to the drainage track. |
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CROSS-REFERENCE TO PROVISIONAL APPLICATION(S)
This application claims the benefit of U.S. Provisional Application No. 60/260,612, filed Jan. 9, 2001.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to litter sticks and more particularly to a mechanical litter stick provided with a mechanism for cycling an operative pick through a given back-and-forth stroke both for stripping litter off a spike end as well as, in the alternative, affording better manipulation of articles of litter as by plucking or the like.
A number of additional features and objects will be apparent in connection with the following discussion of preferred embodiments and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings,
FIG. 1 is a perspective view of a mechanical litter stick in accordance with the invention;
FIG. 2 is an enlarged scale sectional view taken along line 2 — 2 in FIG. 1 and with intermediate as well as right-end portions broken away, wherein the trigger as depicted in solid lines shows an extreme slack position therefor while as depicted in dashed lines shows the trigger in an intermediate squeezed position;
FIG. 3 is a sectional view comparable to FIG. 2 except showing continuation of the action sequence thereof wherein the trigger as depicted in solid lines shows the dashed-line intermediate-position of FIG. 2 so that the corresponding depiction in solid lines in this FIG. 3 of the spike and an S-form pick show their relatively intermediate activated positions in reaction to the intermediate-position drive input from the trigger, while in this same FIG. 3 the trigger as depicted in dashed lines shows the trigger in an extreme squeezed position;
FIG. 4 is a sectional view comparable to FIGS. 2 and 3 and showing further continuation of the action sequences thereof wherein the trigger as depicted in solid lines shows the dashed-line extreme-position of FIG. 3 so that the corresponding depiction in solid lines in this FIG. 4 of the spike and S-form pick show their relatively extreme activated positions, given their opposite directions of travel, and in reaction to the further drive input from the trigger;
FIG. 5 is an enlarged scale perspective view of the spike end of the litter stick, with the up-staff portions broken away, wherein the spike is depicted impaling an article of litter to show one operative use thereof;
FIG. 6 is a perspective view comparable to FIG. 5 except depicting the spike relatively retracted as the S-form pick is relatively extended to show how the impaled article of litter is wiped or stripped off thereby;
FIG. 7 is a perspective view comparable to FIG. 6 except showing the spike and pick traveled to further opposite states of retraction and extension respectively to afford use of the pick to pluck up an article of litter as shown, wherein the spike has been allowed to drive back down onto and hence pinch the article of litter as shown; and,
FIG. 8 is a perspective view comparable to FIG. 7 except showing the opposite extremes spike-retraction and pick-extension to effect release of the article of litter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a mechanical litter stick 10 in accordance with the invention. The inventive litter stick 10 includes a main staff 12 extending between an upper hand-stock 14 portion and a lower bracket end from which projects a pointed spike 20 . The spike 20 extends through a pair of slide-holes 22 and 24 for it in the lower recurve portions 26 of an S-form pick 30 . The pick 30 terminates in a tip end for picking and/or plucking up litter as will be disclosed more particularly below in connection with FIGS. 7 and 8. The upper hand-stock portion 14 is covered by a resilient sleeve for better grip by a user/operator. At the lower margin of the gripping sleeve, the main staff carries a trigger 40 (or in alternative terms, an ‘operator's lever’) which is also covered in part by a resilient sleeve for better traction.
FIG. 2 provides a sectional view taken along line 2 — 2 in FIG. 1 and in which intermediate as well as upper or hand-stock end portions are broken away. The main staff 12 preferably comprises aluminum channel stock or the like. The channel of the main staff 12 provides for the inset and/or mounting of components as will be more particularly described below. The trigger 40 or ‘operator's lever’ more particularly comprises the stem portion of a T-shaped crank 42 . One end of the crank 42 pivots about a pin. Attachment of the pin is achieved by extending the pin between the opposite flanges of the main staff 12 's channel stock. The pin ends may be mushroomed as in a rivet-style to fix the pin. To return to the crank 40 , it extends from its pinned end to an output end which is connected to a connecting link 44 . Again, the trigger 40 extends or ‘Tees’ off the crank 42 intermediate its pinned and output ends. The connecting link 44 rocks a rocker 50 .
The rocker 50 is mounted on another pin that spans between the opposite flanges of the main staff 12 's channel stock as comparably as described above. The rocker 50 comprises a pair of crooked legs 52 and 56 . An inboard one 52 of the crooked legs is connected to an inboard shaft 54 that terminates in a connection with the pointed spike 20 . The other crooked leg 56 is connected to an outboard shaft 58 that terminates in the S-form pick 30 . The inboard or spike shaft 52 predominantly lies within the confines of the main staff 12 's channel stock. The outboard or pick shaft 58 predominantly extends along the outside of the channel 12 's web. The connecting link 44 attaches to the rocker 50 on the inboard leg 52 at some spacing from the rocker 50 's pivot axis to gain a moment arm on the rocker 50 . The spike and pick shafts 54 and 58 preferably comprise tube stock such as stiffened aluminum tube or the like. The shafts 54 and 58 and rocker legs 52 and 56 can be connected by clevis and pin arrangements as is known in the art.
The majority of materials used to fabricate the mechanical litter stick 10 can be chosen from any appropriate stock material although to date aluminum is preferred for most of the parts. For some parts though, it is preferred if plastic bushings are used to flank and shield the crank 42 and rocker 50 from the flanges of the channel stock 12 . Also, the connecting link 44 can be formed from a suitable steel wire. Moreover, as the rocker 50 is biased in a given direction—ie., as in the extreme clockwise position as shown by FIG. 2 —by a torsion spring 62 , such torsion spring 62 is preferably fashioned from spring steel.
Whereas the drawings show the S-form pick structure 30 formed directly in one end of an aluminum tube (eg., outboard shaft 58 ), it is preferable if the S-form pick structure 30 is produced by any optional means which comparably achieves the functions of the structure as shown. For example and without limitation, the S-form pick structure 30 may optionally be produced as a distinctly different piece which is later assembled onto the blank end of a straight rod or tube (eg., like shaft 58 , though this is not shown). Such a distinctly separate pick head (eg., formed like pick 30 , though this is not shown) can be affixed to the end of a straight rod or tube (eg., like shaft 58 ) by a suitable connection, as for example a telescoping pin which inserts inside the open blank end of a hollow tube. That way, the S-form of the pick structure 30 can be produced in a material different from the aluminum stock of the straight rod or tube 58 , like some alloy of aluminum or the like which although slightly more costly may also be more amenable to being formed into shape without stress fractures and so on. For example, more particularly, such a separate pick head may be produced from a casting of aluminum alloy, including without limitation Al-Mag 35 or the like.
The inboard (‘spike’) and outboard (‘pick’) shafts 54 and 58 are substantially slender and elongated, which is not as evident in FIG. 2 as it is in FIG. 1 . With reference to FIG. 1, the outboard or ‘pick’shaft 58 lies on the outside of the channel 12 as shown between its clevis connection with the rocker 50 and its S-form pick end 30 . To return to FIG. 2, the inboard or ‘spike’shaft 54 is comparably slender (although not in view in FIG. 1 ). The spike end 20 is preferably a sharpened steel rod which gets press fitted into the open end of the spike shaft 54 . The main staff 12 's bracket end holds a plastic bracket 64 which is formed with a slide hole in it for the reversible travel of the spike 20 as shown more particularly in comparing among FIGS. 2, 3 and 4 .
In FIGS. 2 and 3, the trigger/crank 40 and the rocker 50 are depicted prominently in solid lines but are also depicted in dashed lines. With particular reference to FIG. 2, the trigger/crank 40 is depicted in solid lines in an extreme slack or de-activated position. The rocker 50 is likewise shown in an extreme de-activated position, which for it is also an extreme clockwise position given the viewpoint of FIG. 2 . The rocker 50 's further clockwise travel as induced by the unwinding of the torsion spring 62 is stopped by the inboard leg 52 contacting against the web of the main staff 12 's channel stock. In sum, the solid outlines of the trigger/crank 40 and rocker 50 show their positions in the absence of any applied input movement to the trigger 40 .
The dashed outlines in FIG. 2 of the trigger/crank 40 and rocker 50 show a changed position, one in which results from an intermediate applied input to the trigger 40 . Most usually, an intermediate applied input is produced by the partial squeezing of the trigger 40 by the user/operator. That is, in use the user/operator predominantly manipulates the litter stick 10 by a firm grip on the hand-stock 14 . However, the user/operator is afforded the option of extending one, two or three fingers or so over the trigger 40 to alternately squeeze and relax the trigger 40 . Operating the trigger 40 operates the mechanical actions of the inventive litter stick 10 as more particularly described below.
To refer next to FIG. 3, it is comparable to FIG. 2 except it shows a continuation of the action sequence begun by FIG. 2 . That is, the trigger 40 as depicted in FIG. 3 in solid lines corresponds to the dashed-line. intermediate-position of FIG. 2 . The corresponding depiction in solid lines in FIG. 3 of the spike 20 and pick 30 show their relatively opposite travel to their own respective intermediate positions to which they go in reaction to the drive input from the trigger 40 . That is, squeezing the trigger 40 from its slack position (solid lines in FIG. 2) to an intermediate position (eg., solid lines in FIG. 3) causes the following:—(i) upward rotation of the rocker 50 's inboard leg 52 to pull the spike 20 in a retraction stroke, as well as (ii) downward rotation of the rocker 50 's outboard leg 56 to drive the pick 30 in extension. FIG. 3 shows that the spike point 20 is retracted to about even with if not slightly withdrawn in the outermost slide hole 22 for it in the S-form pick 30 . To turn to FIGS. 5 and 6, these views show one example utility for such action.
FIG. 5 shows the spike 20 and pick 30 in their positions at the absence-of-input movement from the trigger 40 . That is, the spike 20 is fully extended as the pick 30 is fully retracted. Those relative positions give the spike 20 its greatest free extension beyond the pick 30 's outer- or lowermost slide hole 22 . That puts the spike 20 in a preferred use position for impaling articles of litter as shown in FIG. 5 . In corresponding FIG. 6, it shows that the cooperative spike-retraction and pick-extension gotten simultaneously by squeezing the trigger 40 to an intermediate position causes the pick 30 to wipe the spike 20 clean, or in alternative phraseology, strip the litter off the spike 20 . Accordingly, FIG. 6 shows the article of litter wiped off loose from the spike 20 and let to fall after that. Again, getting the spike 20 and pick 30 to move from the FIG. 5 position to the FIG. 6 position is achieved by partly squeezing the trigger 40 (not shown) from its extreme slack position to a corresponding intermediate position.
Returning to FIG. 3 the trigger/crank 40 and rocker 50 are depicted in dashed lines to show their extreme activated positions. To refer forward to FIG. 4, it is comparable to FIG. 3 except it shows a further continuation of the action sequences begun by FIGS. 2 and 3.
In FIG. 4, the trigger/crank 40 and rocker 50 are only depicted in solid lines and in positions which correspond to the extreme-activated positions shown by dashed-lines in FIG. 3 . The corresponding depiction in FIG. 4 of the spike 20 and pick 30 shows their extreme activated positions. Since the spike 20 and pick 30 are driven in opposite directions at the same time, the spike 20 is shown in an extreme retracted position as the pick 30 in an extreme extended position. The spike point 20 travels to about even with the inner- or uppermost slide hole 24 for it in the lower recurve portion 26 of the S-form pick 30 .
FIG. 4 shows that the trigger/crank 40 has pulled the connecting link 44 with the rocker 50 onto nearly a direct line with or a diameter of the rocker 50 's pivot axis. In other words, there is no further travel to be gotten by pulling on the connecting link 44 . Thus, FIG. 4 shows the connecting link 44 pulled out so straight as to lie on a diameter of the rocker 50 's axis and hence lose its angle-of-attack or moment arm on the rocker 50 .
With attention to the spike point 20 , the spike point 20 is scaled relative to the innermost slide hole 24 of the pick 30 so as to not quite withdraw clear and free of the last slide hole 24 . If the spike point 20 could get by the last slide hole 24 , then the pick shaft 58 would be free to flop about loosely around its clevis attachment with the rocker 50 (see, eg., FIG. 1 ). And if that were to happen, the user would have to re-thread the spike 20 through the slide holes 22 and 24 for it in the pick 30 to get the litter stick 10 back into its preferred condition. Hence the spike 20 's and pick 30 's relative strokes are designed so as to keep the spike 20 inserted through at least the last slide hole 24 for it in the pick 30 , even at their activated extremes.
To turn to FIGS. 7 and 8, they show one example utility for the further action of the spike 20 and pick 30 that is produced by the changing positions between FIGS. 3 and 4. FIG. 8 shows the spike 20 fully retracted and the pick 30 fully extended, and those relative positions give the lower recurve portion 26 of the pick 30 the greatest clearance of the spike 20 . That affords the pick 30 its advantageous utility to pick or pry at litter and thereafter pick or pluck it up in the manner shown in FIG. 7 . Indeed, FIG. 7 shows the pick 30 inserted inside the mouth of a cup as well as the spike 20 let back down to the extent of pinching on the outside of the cup. This improves the holding power on the cup. If given the position of things in FIG. 7, and then moving things to the position as shown by FIG. 8 where the spike 20 retracts and the pick 30 extends, this ultimately has the spike 20 releasing its pinch on the article of litter (eg., the cup). The cup is free to fall away. Indeed, if the cup in FIG. 7 were to be impaled by the spike 20 , then FIG. 8 shows that the pick 30 would wipe the spike 20 clean here too as was disclosed comparably in connection with FIG. 6 .
Referring back to FIGS. 7 and 8, achieving the fullest combined spike-retraction and pick-extension as shown in FIG. 8 is gotten by the user squeezing the trigger 40 to its activated extreme as shown by FIG. 4 . Reversing the combined extreme spike-retraction and pick-extension of FIG. 8 to an intermediate position as shown by FIG. 7 is gotten by slackening the trigger 40 to an intermediate position such as approximately shown in solid lines in FIG. 3 . Then to go back once more to the fullest spike-retraction and pick-extension of FIG. 8 is gotten by activating or squeezing the trigger 40 to the extreme activated position shown by FIG. 4 . And so on, endlessly, allowing a user to pick and pluck litter at will and then release to deposit it in whatever container.
In brief sum, FIGS. 5 and 6 show successively an inventive impale and then strip mode of use of the inventive mechanical litter stick 10 . FIGS. 7 and 8 show successively an inventive pluck and pinch and then release or strip mode of use of the inventive mechanical litter stick 10 .
Further aspects of the pick structure 30 relate to the following. The pick structure 30 is highly advantageous for inserting inside the mouths of drink cans and bottles as water, soft drinks and/or beer are commonly sold in. Such drink cans and bottles unfortunately constitute as significant source of litter and to date have defied easy pick up and/or plucking by conventional litter sticks. It is thus another object of the invention, in addition to the many others mentioned previously, to provide a litter stick advantageously designed for plucking and retention of such drink cans or bottles.
The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed. | A mechanical litter stick is provided with a mechanism for cycling an operative pick through a given back-and-forth stroke both for stripping litter off a spike end as well as affording better manipulation of articles of litter as by plucking. |
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SUMMARY OF THE INVENTION
Unconsolidated formations, particularly those containing loose sands and soft sandstone strata, present constant problems in well production due to migration of loose sands and degraded sandstone into the well bore as the formation deteriorates under the pressure and flow of fluids therethrough. This migration of particles may eventually clog the flow passages in the production system of the well, and can seriously erode the equipment. In some instances, the clogging of the production system may lead to a complete cessation of flow, or "killing" of the well.
One method of controlling sand migration into a well bore consists of placing a pack of gravel on the exterior of a perforated or slotted liner or screen which is positioned across an unconsolidated formation to present a barrier to the migrating sand from that formation while still permitting fluid flow. The gravel is carried to the formation in the form of a slurry, the carrier fluid being removed and returned to the surface. The proper size of gravel must be employed to effectively halt sand migration through the pack, the apertures of the liner or screen being gauged so that the gravel will settle out on its exterior, with the slurry fluid carrying the gravel entering the liner or screen from its exterior.
Prior to effecting the gravel pack, drilling mud and other contaminants may be washed from the well bore, and the formation treated. Commonly employed treatments include acidizing to dissolve formation clays, and injecting stabilizing gels to prevent migration of formation components and formation breakdown prior to packing.
"Reverse circulation" is a widely employed procedure by which wells are gravel packed. Currently, a liner assembly having a perforated liner or screen is positioned across the unconsolidated formation, commonly referred to as the "zone" to be packed. If the well is to be unlined, the screen is incorporated in the well casing. For purposes of illustration it is assumed that one is packing a lined well. Subsequently, a packer is set above the zone between the liner and the well casing. A tubing string is run inside the liner assembly at the area of the zone, there being created between the liner and tubing string an annulus. Gravel slurry is pumped down this annulus, out into the annulus between the liner and the casing below the packer at a suitable location above the zone where it descends and the gravel is deposited in the area of the screen as the carrier fluid passes through the screen in the liner assembly, being removed from the zone area through the tubing string. A crossover device incorporated in the packing apparatus at the level of the zone being packed routes the upward moving returning fluid back outside the liner assembly, the fluid then traveling up to the surface. A pressure buildup is noted at the surface as the gravel level reaches the top of the screen, indicating that a successful pack has been achieved. Thereafter, the flow of gravel-laden fluid is stopped. If desired the crossover tool may then be closed and pressure applied in the same direction as the slurry flow to squeeze the slurry into the formation, thus consolidating the gravel pack. After squeezing, the crossover tool is opened again, and the circulation of fluid is reversed, a clean fluid being pumped down the inner tubing and back up the annulus between it and the liner assembly in order to flush out this area. Subsequently, the well may be subjected to other treatments if necessary, and produced.
Several different approaches have been taken to effect this reverse circulation method of packing, some of them possessing features which permit the packing of a well with more than one zone.
U.S. Pat. No. 3,710,862, entitled "Method and Apparatus for Treating and Preparing Wells for Production," by Carter R. Young and Henry J. James, assigned to Otis Engineering Corporation, discloses a method and apparatus whereby multiple zones may be packed utilizing a reciprocation-operated crossover tool with an inner operating string for return of fluid to the surface. However, only one zone may be gravel packed per trip in the well, the zones must be isolated and packed from the bottom zone upward, and there is no possibility of revisiting or repacking a zone once the initial trip has been completed. Furthermore, a separate production string must be run back down into the well to seal off the gravel ports in the liner before producing the well, or a similar production seal connnecting member attached to the bottom of the next higher screen assembly must be employed if another, higher zone is to subsequently be packed. Aside from requiring multiple trips for the production string as well as the operating string, the top of the screen assembly in the well and the gravel ports in the liner remain open while the operating string is retrieved and a seal is run down the well.
U.S. Pat. No. 3,952,804, entitled "Sand Control for Treating Wells With Ultra High Pressure Zones," issued to Kenneth E. Smyrl and assigned to Dresser Industries, Inc. discloses a method and apparatus for gravel packing multiple zones, but again involves the use of multiple trips into the well, and is further complicated by the necessity of employing a killing fluid to contain the pressure in the well between zone packs.
The prior art also includes a concentric string gravel packing method and apparatus, disclosed in U.S. Pat. No. 4,044,832, entitled "Concentric Gravel Pack With Crossover Tool and Method of Gravel Packing" issued to Charles A. Richard and Philip Barbee, and assigned to Baker International Corporation. This method and apparatus are only suitable for a single zone pack, however, and results in gravel ports above the pack being left open after the packing operation, with the attendant possibility of flow and sand migration bypassing the gravel pack.
Other methods and apparatus for gravel packing have also been employed in the prior art, as disclosed in U.S. Pat. Nos. 3,637,010, 3,726,343, 3,901,318, 3,913,676, 3,926,409, 3,963,076, 3,987,854, 4,019,592, and 4,049,055. However, all of them are unsuitable for use in packing multiple zones, and possess one or more additional deficiencies with respect to mode of operation and results achieved, as will be enumerated hereafter.
An improved apparatus giving the capability of multiple zone gravel packing in a single trip in the well is disclosed in U.S. Pat. No. 4,105,069, entitled "Gravel Pack Liner Assembly and Selective Opening Sleeve Assembly For Use Therewith" issued to Eugene E. Baker and assigned to Halliburton Company. However, the disclosed apparatus does not possess the capability of packing without disturbing other zones or of reverse circulating without fluid flow across the zone just packed. In addition, the location of the tool string at the zone being packed depends on the balancing of weight to ensure that the gravel packer rests in place on the sleeve of the gravel collar, but does not move the sleeve downward and close the ports in the gravel collar, a delicate operation in deep and highly deviated wells.
Generally, the prior art suffers from a number of deficiencies which prohibit efficient multiple zone gravel packing. From among these is the inability to pack multiple zones with only one trip of the operating string into the well. With the exception noted above, the prior art builds the outer string containing the packing screens from the bottom up in a step-by-step process, and thus the operator must withdraw the operating string between zones in order to add components to the outer string. This also renders it impossible to pack an upper zone before a lower zone, or to set or inflate packers in any order than lowest, first. Because of the order in which the zones are packed, it is also impossible to repack zones below the uppermost. In some instances this is due to inability to place the operating string back in the desired location, due to restrictions placed in the outer string after packing a zone. In other cases, it is due to an inability to relocate the desired zone and the position of the gravel ports with any precision. Additionally, many prior art devices utilize hydraulic operation, which is susceptible to faulty operation or failure. Furthermore, in other prior art devices, connection and disconnection of tools utilizes slots and pins and shear pins, the former of which requires axial and radial alignment, difficult in highly deviated wells, and the latter permits no reconnection or return to a previous tool mode. Finally, there is no procedure in the prior art to assure packing without contamination of adjacent zones, either higher or lower than the zone in question, or to reverse circulate without disturbing the zone being packed.
In contrast, the present invention overcomes all of the previously enumerated disadvantages and limitations of the prior art by providing a new and advantageous method and apparatus for gravel packing multiple zones in a well in any sequence with positive zone isolation from the beginning of the packing operation. The present invention contemplates a concentric two-string tool system. The outer string, preferably referred to as the screen liner assembly, which is hung in the production casing if such is employed, comprises a number of different components. From the bottom of the well, or, if not at bottom, from a bridge plug used to isolate the well bore below the lowermost zone and position the screen liner assembly, there is located a guide shoe, a gravel screen, a concentric string anchor tool, a polished nipple of predetermined length to assure proper positioning of tools in the operating string, a three position full open gravel collar and a suitable casing inflation packer, such as the Lynes External Casing Packer, shown on pages 1 and 2 of the Lynes 1978-79 Catalog for Formation Testing, Inflatable Packer, Inflatable Specialty Tools, and Bottom Hole Pressure and Temperature Sensing Treatments. The screen is, of course, located across the zone of interest, and the gravel collar placed above the zone. The casing inflation packer provides isolation of the zone from those above it. This sequence of tools, augmented with blank pipe between zones to assure proper position of the gravel screens across zones, is repeated up the well bore until all zones of interest have been traversed. At the top of the screen liner assembly is placed a suitable liner hanger tool, such as the Otis Engineering Corporation Type GP Packer, shown on page 70 of the OEC 5120A Catalog, entitled "Otis Packers, Production Packers and Accessories," whereby the screen liner assembly is hung at a predesignated point in the production casing. It is also possible to use the gravel screens, anchor tools, full open gravel collars and casing inflation packers as part of a full string of production casing in lieu of employing a liner.
Employed within the screen liner assembly is an operating string also comprising a plurality of components. Lowermost in this string is a tail pipe, followed by a closing sleeve positioner, a selective release anchor positioner, an opening sleeve positioner and a ball check valve. Above the check valve is run an isolation gravel packer, above which are provided two concentric strings of tubing of suitable length to assure that a crossover tool which may be placed at the top of the operating string will be located above the liner hanger an adequate distance to allow reciprocation of the string while permitting the anchor positioner to engage the lowermost anchor tool in the screen liner assembly. To permit the coupling of the concentric tubing strings into the crossover tool, a tubing swivel and slip joint are provided on the inner tubing immediately below the crossover tool to compensate for variations in length of the two tubing strings.
The operating string is run into the hole inside the screen liner assembly, and the casing inflation packers inflated either on the trip down, or, at the operator's discretion, as the packing proceeds from the lowermost zone of interest through the higher zones. This is not to imply that zones must be packed in this order, or in any order whatsoever, as it is possible to pack the lowest zone first, then the highest zone, then an intermediate zone if so desired. Likewise, the casing inflation packers may be inflated in any order. For the purposes of illustration, however, it is assumed that each packer is inflated as the operating string descends into the well. The operating string is anchored by engagement of the anchor positioner with the anchor tool at that zone, and the packer inflated at each location, the anchor positioner being then released and the operating string lowered to the next zone. After all the packers are inflated and the operating string is at the lowest zone of interest in the well, the full open gravel collar is opened by the opening sleeve positioner, the operating string is anchored in place and gravel packing is begun. Gravel packing and reverse circulation are effected without further manipulation of the operating string or screen liner assembly. After packing is completed, the anchor positioner is released and the operating string raised to the next zone of interest, the closing sleeve positioner closing the gravel collar as it passes. At the location of the next zone of interest, the full open gravel collar at the higher zone is opened and the anchor positioner of the operating string is then engaged in the anchor tool at that zone. From this point, packing proceeds as previously described. If necessary, a previously packed zone may be revisited simply by releasing the anchor positioner and raising or lowering the operating string to the desired location and engaging the anchor tool at that zone. It is thus apparent that all zones in a well may be packed during one trip of the operating string, which is then removed from the well for production. It is also obvious that the disclosed method and apparatus for gravel packing may also be utilized for other types of well treatment, such as acidizing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, 1C and 1D provide a simplified vertical cross-sectional elevation illustrating the operating string and screen liner assembly of the present invention, with components for gravel packing two producing formations in a well.
FIG. 2 is a simplified vertical cross-sectional elevation similar to FIG. 1A, but illustrating the crossover tool of the present invention in the closed mode.
FIG. 3 is a simplified vertical cross-sectional elevation illustrating the isolation gravel packer during reverse circulation after gravel packing has been effected.
FIG. 4 is a simplified vertical cross-sectional elevation illustrating the anchor positioner in its retract mode and the opening sleeve positioner as it is set to open the full open gravel collar of the screen liner assembly.
FIGS. 5A and 5B are developments of the slots of the crossover tool.
FIGS. 6A and 6B are developments of the slots of the anchor positioner.
FIG. 7 is a horizontal cross-sectional elevation of the crossover tool taken on line x--x of FIG. 1A.
FIG. 8 is a cross-sectional view of the pin and ring assembly of the crossover tool.
FIG. 9 is a horizontal cross-sectional elevation of the anchor positioner taken on line y--y of FIG. 4.
FIG. 10 is a cross-sectional view of the pin and ring assembly of the anchor positioner.
FIG. 11 is a simplified vertical cross-sectional elevation illustrating an alternative embodiment of the crossover tool of the present invention in the open mode.
FIG. 12 is a simplified vertical cross-sectional elevation illustrating the alternative embodiment of FIG. 11 in the closed mode with bypass ports closed.
FIG. 13 is a simplified vertical cross-sectional elevation illustrating the alternative embodiment of FIG. 11 in the closed mode with bypass ports open.
FIGS. 14A and 14B are developments of the slots of the alternative embodiment of the crossover tool illustrated in FIGS. 11, 12 and 13.
FIG. 15 is a simplified vertical cross-sectional elevation of a second alternative embodiment of the crossover tool of the present invention in the open mode.
FIG. 16 is a simplified vertical cross-sectional elevation of a second alternative embodiment of the crossover tool of the present invention in the closed mode.
FIG. 17 is a simplified vertical cross-sectional elevation of an alternative embodiment of the anchor positioner of the present invention in the release mode.
FIG. 18 is a simplified vertical cross-sectional elevation of an alternative embodiment of the anchor positioner of the present invention in the retract mode.
FIG. 19 is a development of the J-slot of the alternative embodiment of the crossover tool of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and to FIGS. 1A through 1D in particular, the screen inner assembly and operating string of the present invention are illustrated in simplified form for the sake of clarity. The operating string is generally designated by the reference character 30, while the screen liner assembly concentrically surrounding it is designated by the reference character 32. Disposed about the two concentric strings of the present invention is well casing 34, having perforations therethrough at the levels of two unconsolidated producing formations 26 and 28, through which the well bore passes. Should the method and apparatus of the present invention be employed in a well that does not employ a liner, the components referred to as incorporated in the screen liner assembly 32 may be incorporated in the well casing 34, utilizing a suitably sized operating string within.
Screen liner assembly 32 is secured within well casing 34 by means of a suitable liner hanger 40 with casing packer 42, as illustrated schematically. Liner hanger 40 is positioned in casing 34 by means of slips 44 employed in mechanically setting packer 42. Threaded collar 46 is employed to secure screen liner assembly 32 to a drill string during its installation in the well bore inside the well casing 34.
Moving downwardly from liner hanger assembly 40, the screen liner assembly comprises a length of blank pipe (not shown) to a location just above the highest zone to be packed. At that point is located a casing inflation packer, illustrated schematically at 50. Annular space 52 defined by mandrel 54 and elastomeric outer wall 56 is inflated by pumping fluid through schematically illustrated check valve 58 to a predetermined pressure.
Below packer 50 is located full open gravel collar 60 comprising outer body 62 within which is longitudinally slidably disposed sleeve 64. At the top of body 62 is located necked-down portion 66, bounded by beveled edges. Below necked-down portion 66 is shoulder 68, followed by inner cylindrical surface 70, through which gravel ports 72 and 74 extend (more than two may be employed, if desired). Below inner surface 70 is annular shoulder 76, followed by annular groove 78, cylindrical surface 80 of substantially the same inner diameter as shoulder 76, and annular groove 82. The inner diameter of the lowest extremity 84 of gravel collar 60 is substantially the same as that of polished nipple 106, located immediately below it. Inside body 62 sleeve 64 has disposed thereabout annular seals 86, 88, 90 and 92. At the top of sleeve 64 is located inwardly beveled annular surface 94, below which is downward facing annular shoulder 96. Between annular seals 88 and 90 apertures 98 and 100 communicate with gravel ports 74 and 72 when aligned therewith by longitudinal movement of sleeve 64. At the lowest extremity of sleeve 64 are located a ring of collet fingers 102 having radially outward extending lower ends.
Anchor tool 110 is located below polished nipple 106. At the top of anchor tool 110 an outwardly beveled surface leads to annular recess 112, below which is upward-facing annular shoulder 114, below which an outwardly beveled surface leads to annular recess 116, followed by an inwardly beveled surface leading to cylindrical surface 118, which is of substantially the same inner diameter as blank pipe 120, immediately below.
Gravel screen 122 is disposed across the upper producing formation or zone of interest below blank pipe 120.
Referring to the lower zone of interest, casing inflation packer 130, substantially identical to packer 50, is located below gravel screen 122 to isolate the upper zone of interest from the lower zone. Space 132 defined by mandrel 134 and elastomeric outer wall 136 is inflated by pumping fluid through schematically illustrated check valve 138 to a predetermined pressure.
Below packer 130 is located a second full open gravel collar 140, substantially identical to gravel collar 60. Gravel collar 140 comprises outer body 142 within which is slidably disposed sleeve 144. At the top of body 142 is located necked-down portion 146, bounded by beveled edges. Below necked-down portion 146 is shoulder 148, followed by inner cylindrical surface 150, through which gravel ports 152 and 154 extend. Below inner surface 150 is shoulder 156, followed by annular groove 158, cylindrical surface 160 of substantially the same inner diameter as shoulder 156, and annular groove 162. Below groove 162 an inwardly beveled surface leads to the lowest extremity of gravel collar 140, the inner diameter of which is substantially the same as that of polished nipple 182, immediately below it in the screen liner assembly 32. Sleeve 144 possesses annular seals 164, 166, 168 and 170. At the top of sleeve 144 lies inwardly beveled surface 172, below which is downward facing shoulder 174. Between annular seals 166 and 168, apertures 176 and 178 communicate with gravel ports 152 and 154 when aligned therewith. At the lowest extremity of sleeve 144 are located a ring of collet fingers 180 having radially outward extending lower ends.
Second anchor tool 190 is located below polished nipple 182. At the top of anchor tool 190 an outwardly beveled surface leads to annular recess 192, below which is upward-facing annular shoulder 194, below which an outwardly beveled surface leads to annular recess 196 followed by an inwardly beveled surface leading to cylindrical surface 198, which is of substantially the same inner diameter as blank pipe 200.
Gravel screen 202 is disposed across the lower producing formation or zone of interest. Gravel screens 122 and 202 are fore-shortened in the drawings herein, and actually may be a number of feet in length, the length being determined by the thickness of the producing formation to be gravel packed, all of which is evident to those skilled in the art, it being further evident that the gravel screens may have perforations, as shown, or may employ wire-wrapped slots to form the desired operations.
Another length of blank pipe 204 is attached below gravel screen 202, and the lowest end of the pipe is capped with a float shoe 206.
It should be noted that the proper orientation of operating string 30 with respect to screen liner assembly 32 is dependent upon the polished nipples 106 and 182 being of the appropriate length to position isolation gravel packer and bypass assembly 320 (see FIG. 1C) across either gravel collar 60 or 140 when the operating string 30 is anchored in place at the zone being packed.
The screen liner assembly 32 having been described in detail, the operating string 30 will now be described from the top thereof downward, referring to FIGS. 1A through 1D, 2, 4, 5A, 5B, 6A, 6B, and 7 through 10.
Reference character 230 depicts the lower extremity of a pipe by which the operating string 30 is lowered into the well inside liner assembly 32. Pipe 230 has bore 232 which communicates with bore 242 in the upper part of crossover tool 240. Crossover tool 240 comprises outer sleeve 244 and inner case 246. Outer sleeve 244 is fixed to pipe 230 and slidably disposed about inner case 246, the opening and closing of the crossover tool being effected by reciprocation of outer sleeve 244 through the movement of pipe 230 on the surface. Inner case 246 has two slots, 248 and 250, in its outer surface. Developments of these slots are illustrated in FIGS. 5A and 5B. These slots slidably engage pins 252 and 254, respectively, which are connected to the outer sleeve 244. Pin 252 is fixed to outer sleeve 244 and slides vertically in straight slot 248, a development of which is shown in FIG. 5B. Pin 254 is fixed to ring 256, which is rotationally slidably housed in annular recess 258 in outer sleeve 244, permitting ring 256 to rotate about the axis of the operating string 30. Pin 254 slides within complex slot 250, a development of which is shown in FIG. 5A. FIG. 7, a section taken through line x--x of FIG. 1C, illustrates the manner in which ring 256 is housed between outer sleeve 244 and inner case 246, pin 254 being disposed in slot 250 at the lower end thereof. FIG. 8 shows a section through the assembly of ring 256 and pin 254. The configuration of complex slot 250 permits the crossover tool 240 to be locked in an open or closed mode as will be explained in greater detail hereafter. Briefly, pin 252 in cooperation with slot 248 prevents rotation of the outer sleeve 244 with respect to the inner case 246. Pin 254, when the string is reciprocated, follows the path described by complex slot 250; this can be accomplished because ring 256 permits circumferential movement of pin 254 about case 246, the edges of slot 250 guiding the pin 254 into the several different positions. Outer sleeve 244 possesses annular seals 260, 262 and 264. Seals 260 and 262 bracket circulation ports 266 and 268, which, when the crossover tool 240 is in its open mode, permit communication between upper annulus 270 above the crossover tool 240, and inner bore 272 of the crossover tool 240 via circulation passages 274 and 276 within inner case 246. Inner case 246 possesses vertical passages 278 and 280, depicted by broken lines, which pass from bore 242 to annular bore 282 of the crossover tool. Vertical passages 278 and 280 do not communicate with circulation passages 274 and 276. Inner sleeve 246 also possesses bypass ports 284 and 286, which are bracketed by seals 262 and 264 when crossover tool 240 is in the open mode, as shown in FIG. 1A. When outer sleeve 244 is reciprocated upwardly, and the crossover tool 240 is closed, seal 264 is above bypass ports 284 and 286, thus permitting communication between upper annulus 270 above the crossover tool 240, and the lower annulus 288 between the operating string 30 and screen liner assembly 32. This same motion of outer sleeve 244 isolates circulation passages 274 and 276 via annular seals 260 and 262, as shown in FIG. 2. Bypass ports 284 and 286, when open, allow equalization of pressures in the annulus above and below the crossover tool and, in conjunction with other bypasses in the isolation gravel packer and bypass assembly 320, discussed below, facilitate movement of the operating string 30 within screen liner assembly 32. At the lower end of inner case 246 are disposed packer cups 290 and 292, which face upward, contact the production casing 34 above liner hanger 40, and seal lower annulus 288 below them from greater pressure in upper annulus 270 when reversing circulation after gravel packing. Inner conduit 294 and concentric outer conduit 296 exit from the lower end of crossover tool 240, and mate with inner blank pipe 298 and concentric outer blank pipe 300 which extend downward to isolation gravel packer and bypass assembly 320. Concentric pipes 298 and 300 must be of sufficient length to permit positioning of the isolation gravel packer and bypass assembly 320 (FIG. 1C) across the lowest full open gravel collar 140, while allowing adequate reciprocal motion of the operating string 30 without the crossover tool 240 impinging on liner hanger 240. As the two lengths of pipe cannot be matched exactly, it is of course necessary to include a slip joint and swivel assembly illustrated in simplified form at 302 in the inner string of pipe; inner element 304 slides vertically and rotationally within outer element 306, the two having an annular fluid seal therebetween (not shown).
Referring to FIGS. 1B and 1C, blank pipes 298 and 300 enter the top of isolation gravel packer and bypass assembly 320, at the top of which is located upper body 322, at which point blank pipe 298 communicates with axial circulation passage 324 and the annulus 299 between pipes 298 and 300 communicates with outer passages 326 and 328.
Below outer passages 326 and 328, upper body 322 possesses a constricted area on its exterior upon which is disposed outwardly facing circumferential shoulder 330. Below circumferential shoulder 330 are disposed annular seals 332 and 334, which bracket bypass ports 336 and 338. Continuing downward, annular seals 340, 342, 344 and 346 are disposed about the lower portion of upper body 322. Bypass ports 348 and 350 are located between seals 344 and 346. Slidably disposed about upper body 322 is bypass valve body 352, through which extend bypass ports 354 and 356 at the upper end thereof, and bypass ports 358 and 360 at the lower end thereof. When pipe 230 is moved upward, thereby pulling upper body 322 upward, ports 336 and 338 in upper body 322 become aligned with ports 354 and 356, respectively, in bypass valve body 352. At the same time, bypass ports 358 and 360 become aligned with bypass ports 348 and 350, respectively, in the lower end of the assembly. When the bypass ports are aligned, the upper bypass port sets permit fluid communication between annulus 368 above the isolation gravel packer and packer annulus 370, through inner annular passage 362 and gravel passages 364 and 366, permitting equalization of pressures and eliminating swabbing when the operating string 30 is raised or lowered in the wellbore. Similarly the lower bypass port sets allow pressures to be equalized between the annulus 368 above the isolation gravel packer and annulus 372 below, via outer annulus passage 374, upper vertical bypass passages 376 and 378, upper annular bypass chamber 380, lower vertical bypass passages 382 and 384, lower annular bypass chamber 386 and lateral bypass passages 388 and 390. In the closed position of the bypasses, a ring of collet fingers 392 at the top of bypass valve body 352 engage shoulder 330 on upper body 322. When in the open position, the inward protrusion at the upper portion of collet fingers 392 abuts the lower edge of shoulder 330 positively holding the bypass open until weight is set down on the operating string 30. Reciprocating motion is limited between bypass valve body 352 and upper body 322 by the abutting of a ring of lugged fingers 394 of the lower end of upper body 322 with the annular shoulder 396 of bypass valve body 352, the aforesaid lugged fingers also preventing relative rotation of the two bodies by engagement with groove (not shown) in bypass valve body 352.
Within both bypass valve body 352 and upper body 322 are disposed sleeve 398 and concentric inner mandrel 400. Annular seal 402 provides a fluid seal between sleeve 398 and upper body 322, while annular seal 404 provides a fluid seal between inner mandrel 400 and upper body 322. Seals 402 and 404 both allow reciprocal movement of upper body 322. Disposed about the exterior of the lower portion of bypass valve body 352 are downwardfacing packer cups 406 and 408. Below packer cups 406 and 408, lower body 410 possesses lateral gravel passages 364 and 366 which communicate with inner passage 362 and are aligned with gravel ports 152 and 154 when the isolation gravel packer and bypass assembly 320 is anchored in place at lower zone 28 adjacent gravel collar 140. Annular seal 412 isolates inner annular passage 362 from upper annular bypass chamber 380.
At the lowermost end of isolation gravel packer and bypass assembly 322 are mounted upward-facing packer cups 414, 416 and 418, and downward-facing packer cup 420 upon lower body 410. Between packer cups 416 and 418 are located lateral circulation passages 422 and 424, which communicate with axial circulation passage 324. As noted previously, lower vertical bypass passages 382 and 384 avoid lateral circulation passages 422 and 424 and permit fluid communication between upper annular bypass chamber 380 and lower annular bypass chamber 386, which in turn exits through lateral bypass passages 388 and 390 to annulus 372 below downward-facing packer cup 420.
Immediately below isolation gravel packer and bypass assembly 320 is ball check valve 430, comprising ball 432, housing 434, and valve seat 436. Bypasses 438 in housing 434 permit fluid flow upward into axial circulation passage 324 from tail pipe 440, but seat 436 halts downward flow when circulation is reversed and ball 432 is forced against it.
At approximately the same location as ball check valve 430 is opening sleeve positioner 444, comprising sleeve positioner body 446 and spring arms 448 and 450 as well as two other arms, not shown, disposed on a vertical plane perpendicular thereto. The use of four such arms is for purposes of illustration, and not to be construed as a limitation on the structure of the opening sleeve positioner or the anchor positioner and closing sleeve positioner described hereafter. Each arm possesses a radially outwardly extending shoulder 452 and 454, with beveled edges. At the ends of the spring arms 448 and 450 are located protrusions 456 and 458, each having an upward-facing radially outward extending shoulder at the top thereof, the lower outside face of each protrusion being beveled inwardly in a downward direction. Spring arms 448 and 450 are shown in a slightly compressed position against the interior of screen liner assembly 32 at polished nipple 182.
Below opening sleeve positioner 444 in operating string 30 is located anchor positioner 470, comprising drag block assembly 472 and spring arm collar 474. Drag block assembly is slidably mounted on mandrel 476, in which are located slots 478 and 480, developments of which are shown in FIGS. 6A and 6B, respectively. Pin 482 is fixed to drag block assembly 472, and slides within slot 478. Pin 484 (not shown in FIG. 1D, see FIG. 4), is mounted in ring 486 which encircles mandrel 476 and is rotationally slidably housed in annular groove 488 in drag block assembly 472. FIG. 9, a section across line y--y in FIG. 4, illustrates the housing of ring 486 and pin 484 between drag block assembly 472 and mandrel 476. FIG. 10 is a section of the ring and pin assembly alone. The ring-pin combination permits pin 484 to move circumferentially as well as axially, following the edges of slot 480 to permit drag block assembly 472 to reciprocate up and down on mandrel 476, and to be locked in several different modes, as will be explained in greater detail hereafter. On the exterior of drag block assembly 472 are spring-loaded drag blocks 490 and 492, shown schematically, which press against the inside of screen liner assembly 32, thus centering the anchor positioner 470. The lower face 494 of drag block assembly 472 is frusto-conical in configuration, being inclined inwardly and upwardly from the lowest extremity thereof. Below drag block assembly 472, spring arm collar 474 possesses upward-facing spring arms 496 and 498 (as well as two others on a perpendicular vertical plane), similar to those of opening sleeve positioner 444. Spring arms 496 and 498 possess radially outward extending shoulders 500 and 502, as well as protrusions 504 and 506 at their upper ends. The shoulders 500 and 502 have beveled edges, and the protrusions have downward-facing radially outward extending shoulders at the bottom, and upwardly extending inwardly-beveled faces at the top. The uppermost points of these faces are disposed on a radius less than the lowermost extremity of drag block assembly 472, thus permitting the inclined face 494 to slidably engage and compress the spring arms 496 and 498 when operating string 30 is pulled upward as shown in FIG. 4. Spring arms 496 and 498 are shown engaged with anchor tool 190 in FIG. 1D.
Below anchor positioner 470 is located closing sleeve positioner 510, comprising positioner body 512 on which are mounted downward-facing spring arms 514 and 516 (as well as two others, not shown). Each spring arm 514 and 516 possesses outward radially extending shoulders 518 and 520, the edges of which are beveled. At the lowest end of the spring arms 514 and 516 are protrusions, 522 and 524, having upward-facing outwardly radially extending shoulders at their upper edges, and downward inwardly beveled edges on their lowermost exteriors. Spring arms 514 and 516 are shown in slightly compressed positions against the interior of screen liner assembly 32 at blank end pipe 530.
At the lowest extremity of operating string 30 is tail pipe 440, having bore 532 which communicates with bore 534 extending through anchor positioner mandrel 476 up to check valve 430.
OPERATION
Referring again to the drawings, the operation of the present invention will be described. After the well is drilled and casing 34 inserted it is perforated at the appropriate intervals adjacent formations 26 and 28, washed and possibly treated in some manner. At this point, screen liner assembly 32 is lowered into the well bore and hung within casing 34 by liner hanger assembly 40.
The screen liner assembly 32 as installed in the casing, comprises as many full open gravel collars as there are zones to be packed, as shown in the present instance by reference characters 60 and 140. As stated previously, the gravel collars 60 and 140 are located above their respective zones to be packed, while corresponding gravel screens 122 and 202 are located adjacent to and spanning these zones. Between each gravel collar and its corresponding gravel screen are located polished nipples 100 and 182, and anchor tools 110 and 190, respectively, which accurately position the operating string 30 at each zone when the anchor positioner assembly 470 is engaged in the appropriate anchor tool.
Above the upper zone is located suitable casing inflation packer 50, and below the zone is suitable casing inflation packer 130, which, when inflated isolate the upper zone from the zone below and the well annulus above. If the upper zone is extremely close to liner hanger assembly 40, packer 50 may be deleted as redundant when a liner hanger with a sealing element is employed such as illustrated schematically at 42. If it is desired to isolate zones not only from each other but from the intervals between formations, packers may be employed above and below each zone. For example, if the upper zone in the present instance was far above the lower zone, an additional casing inflation packer might be utilized in the screen liner assembly 32 above packer 130 and yet below the upper zone.
After the screen liner assembly 32 is hung in the casing, the operating string 30 is run into the well bore. The operator has the option of inflating casing inflation packers 50 and 130 as the operating string 30 is going down the well bore, or he may elect to inflate the packers from the bottom as he proceeds upward. He may, in fact, inflate the packers in any order but for purposes of discussion the methods of inflating packers from the bottom up and top down will be more fully described hereinafter.
Before proceeding with the description of inflation packers 50 and 130, however, the operation of the crossover tool 240 and anchor positioner 470 will be discussed in detail.
FIGS. 1A, 2, 5A, 5B and 7 are of particular relevance to the understanding of the operation of crossover tool 240, which utilizes an internal rotating slot mechanism, as previously stated. Outer sleeve 244 being slidably disposed about inner case 246, movement of the outer sleeve 244 by virtue of reciprocation of drill pipe 230 effects changes of mode in crossover tool 240 from open to closed and vice-versa. When crossover tool 240 is in the open mode as shown in FIG. 1A, circulation ports 266 and 268 in outer sleeve 244 are aligned with circulation passages 274 and 276, respectively, which extend through inner case 246 and themselves communicate with inner bore 272. In the open mode, circulation passages are bracketed by annular seals 260 and 262, while seals 262 and 264 bracket bypass ports 284 and 286 in inner case 246 below circulation passages 274 and 276, thus isolating annulus 270 from annulus 288 below crossover tool 240. When crossover tool 240 is in the closed mode, as shown in FIG. 2, circulation passages 274 and 276 are bracketed by annular seals 262 and 264, thus closing them off from annulus 270, while bypass ports 284 and 286 are opened. To ensure positive locking in the open and closed modes of crossover tool 240, the slot mechanisms illustrated in FIGS. 5A, 5B, and 7 are employed. To ensure that outer sleeve 244 will not rotate with respect to inner case 246, fixed pin 252 in outer sleeve 244 slides within straight slot 248 in inner casing 246. A development of straight slot 248 is shown in FIG. 5B. To provide positive locking in each tool mode, complex slot 250 in inner case 246 is utilized with pin 254 and ring 256. Ring 256 is rotationally slidably confined within annulus 258 in outer sleeve 244. Thus, when outer sleeve 244 is reciprocated, pin 254 follows the edges of complex slot 250 and defined by inner case 246 and cam island 251 by virtue of the rotational and axial movement capabilities allowed by ring 256. When crossover tool 240 is in the open mode as illustrated in FIG. 1A, pin 254 is at position 254a in complex slot 250 as shown in FIG. 5A, while pin 252 in straight slot 248 is in position 252a as shown in FIG. 5B. FIG. 7 also illustrates the position of pin 254 in slot 250 when crossover tool 240 is in the open mode. Straight slot 248 is not shown, as the section is taken below it. When drill pipe 230 and therefore outer sleeve 244 are reciprocated upward, pin 254 is guided to position 254b in slot recess 250a by angled edge 251a of cam island 251 and angled perimeter slot edge 246a to position 254b, while pin 252 moves to position 252b, closing crossover tool 240, as shown in FIG. 2. When the drill pipe 230 is set down, pin 254 is guided into position 254c in slot recess 250b by angled cam island edge 251b. Pin 252 also, obviously, moves downward to position 252c in straight slot 248. When it is desired to open crossover tool 240 again, upward reciprocation of outer sleeve 244 causes pin 254 to be guided into location 254d in slot 250 by angled perimeter slot edge 246b, after which downward movement of outer sleeve 244 drops pin 254 down to position 254a. Pin 254 is prevented from returning to position 254c by angled cam island edge 251c, and then follows angled perimeter slot edge 246c to position 254a. Pin 252, of course, goes to position 252b and then 252a in straight slot 248 in the same sequence. It may be noted, should the operator wish to ensure that bypass ports 284 and 286 remain open while running the operating string in the well, whether crossover tool 240 is locked in the closed mode, snap-ring collet mechanism, such as that depicted in FIGS. 14 and 15, may be incorporated in the crossover tool in addition to the complex slot mechanism by elongating both casing and sleeve and placing the snap-ring and collet below the slots. In this manner, even assuming that pin 254 is in location 254d, it will not slide down to position 254a until a predetermined weight (for example, 20,000 pounds as used to close the bypasses in isolation gravel packer 320) focus outer sleeve 244 downward, overcoming the snap-ring, which had previously "propped up" outer sleeve 244. The manner of effecting such modification is, of course, evident to one skilled in the art.
Referring to FIGS. 1D, 4, 6A, 6B and 9, it will now be shown how the reciprocation of the operating string effects the change of mode of the anchor positioner 470 from retract to release. As previously stated, the anchor positioner 470 is activated by an internal rotating slot mechanism. As shown in FIG. 1D, mandrel 476 possesses slots 478 and 480, developments of which are shown in FIG. 6A and FIG. 6B, respectively. Straight slot 478, in conjunction with pin 482, which is fixedly mounted to drag block assembly 472, permits an up and down, or reciprocating, motion of the operating string 30 and hence of mandrel 476 with respect to the drag block assembly 472 while preventing rotational motion of drag block assembly 472. Complex slot 480, on the other hand, is engaged by pin 484 (not shown on FIG. 1D, but shown on FIG. 4) which is fixed to ring 486 which in turn is slidably housed between mandrel 476 and drag block assembly 472 in housing 488. Since rotational motion of the drag block assembly 472 is prevented by pin 482 in slot 478, when the operating string 30 is reciprocated, pin 484 will follow the edges of complex slot 480 defined by mandrel 476 and cam island 481, being permitted to do so by the rotation of ring 486 in housing 488. Referring now to FIG. 6A, it is apparent that the position of pin 484 as shown at 484a in broken lines will coincide with the anchor positioner 470 being in its released position (FIG. 1D), as drag block assembly 472 is held away from spring arms 496 and 498 by drag blocks 490 and 492 and pressing against the wall of anchor tool 190. At the same time, fixed pin 482 is in position 482a in slot 478 as shown in FIG. 6B. To place the anchor positioner assembly 470 in the retract position, the operating string 30 and hence mandrel 476 is pulled upward, thereby moving pin 484 relatively downward in complex slot 480 to position 484b, wherein the inclined face 494 of drag block assembly slidably engages and compresses spring arms 496 and 498. At this instance, fixed pin 482 has moved to position 482b in slot 478. Anchor positioner 470 is now in the retract mode as shown in FIG. 4. Pin 484 is prevented from moving to position 484d by angled cam island edge 481a and is guided to position 484b in slot recess 480a by angled perimeter slot edge 476a. To lock the anchor positioner 470 in the retract mode, operating string 30 and hence mandrel 410 is moved downwardly, whereby pin 484 is guided relatively upward into position 484c in slot recess 480b by angled cam island edge 481b, and pin 482 has moved to position 482c. To release anchor positioner 470 again, operating string 30 need only be moved upward and then downward, to release the pin 484 to position 484d in slot recess 480c (guided by edge 476b) and then back to 484a (guided by edge 476c) where the drag block assembly 472 has disengaged spring arms 496 and 498. Pin 482 returns to position 482b, then to 482a in this sequence. Referring to FIG. 9 for further clarification, a section is shown across line y--y of FIG. 4. Pin 484 is in position 484c at the bottom of complex slot 480, and is rotatably mounted between mandrel 476 and drag block assembly 472 of anchor positioner 470 by its attachment to ring 486. Straight slot 478 is shown at the top of FIG. 9, while complex slot 480 is at the bottom.
The manner in which packers 50 and 130 may be inflated from the lowest upward will now be described, with particular reference to FIGS. 1C and 1D. With anchor positioner 470 in its retract mode, operating string 30 is lowered to the approximate location of the lowest zone and anchor tool 190. The operating string 30 is then reciprocated upward to effect the release mode, and anchor positioner is then lowered to engage anchor tool 190. If the anchor positioner happens to be released below anchor tool 190, it may be raised through it even in the release mode, as the inclined outer edges of protrusions 504 and 506 will guide spring arms 496 and 498 past shoulder 194 of anchor tool 190. Anchor positioner 470 is locked in position when downward-facing shoulders on protrusions 504 and 506 are resting on shoulder 194. At this point, unlike FIG. 1C, full open gravel collar 140 will be closed (as shown in FIG. 4), as no steps have yet been taken to open it. Thus, inflation port 138 of casing inflation packer 130 is spanned by downward-facing packer cups 406 and 408 and upward-facing packer cups 414 and 416 of isolation gravel packer and bypass assembly 320. As the packer cannot be inflated while the bypass ports in isolation gravel packer and bypass assembly 320 are open, it is necessary to set approximately 20,000 pounds of weight on the anchor to close them. When the weight is set, upper body 322 moves downwardly with respect to bypass valve body 352, to the position shown in FIG. 1C, isolating ports 354, 356 and 358 and 360 in bypass valve body 352 from ports 336, 338, 348 and 350, respectively, in upper body 322, annular seals 332, 334, 340, 342, 344 and 346 preventing fluid movement between annulus 368, and packer annulus 370 and annulus 372 below isolation gravel packer and bypass assembly 320. As crossover tool 240 (see FIG. 1A) is in the open mode annular seals 262 and 264 isolate bypass ports 284 and 286, cutting off fluid communication between annulus 270 and annulus 288. However, should crossover tool 240 be in its closed mode (FIG. 2), inflation may still proceed even with bypass ports 284 and 286 open. All necessary bypass ports being closed, the operating string 30 is then pressured to the desired pressure through pipe 230 to inflate casing inflation packer 130. The pressurized fluid reaches packer 130 through annular bore 282, outer blank pipe annulus 299, outer passages 326 and 328, inner annular passage 362, then gravel passages 364 and 366 which exit into packer annulus 370 defined by the interior of screen liner assembly 32, the exterior of operating string 30, packer cups 406 and 408 at the top, and 414 and 416 at the bottom. From annulus cavity 370, fluid enters casing inflation packer 130 through check valve 138, inflating it to a predetermined pressure. The casing inflation packer being inflated, gravel packing may now proceed at the lowest zone as described hereafter. Alternately, if the operator desires to inflate packers 50 and 130 as the operating string 30 proceeds into the well bore, he engages the shoulder 114 of uppermost anchor 110 with spring arms 496 and 498 of anchor positioner 470. The spring arms 496 and 498 will automatically engage if the anchor positioner 470 is in the release mode (as shown in FIG. 1D), the downward-facing shoulders on protrusions 504 and 506 engaging annular shoulder 114 of the anchor tool 110, thereby automatically locating the operating string 30 in the proper position in the well bore. If the anchor positioner is in the retract mode (as shown in FIG. 4) with spring arms 496 and 498 compressed by inclined face 494 of drag block assembly 472, the operating string 30 will pass through anchor tool 110 without engaging it. If this occurs, it is necessary to pick up the operating string to release the spring arms 496 and 498, after which the anchor positioner 470 is lowered to engage the anchor tool 110. If the anchor positioner 470 is released below anchor 110, it will pass up through anchor 110 and the inclined outer edges of protrusions 504 and 506 will guide spring arms 496 and 498 past shoulder 114 of anchor tool 110.
The ports 72 and 74 of full open gravel collar 60 will be closed, as shown in FIG. 1B, with the inflation port 58 of packer 50 being spanned by downward-facing cups 406 and 408 and upward-facing cups 414 and 416 of isolation gravel packer and bypass assembly 320. To close the bypass ports in the isolation gravel packer and bypass assembly, it is necessary to set approximately 20,000 pounds of weight on the anchor, as noted previously. When the weight is set, upper body 322 moves downwardly with respect to bypass valve body 352, thereby isolating ports 354, 356, 358 and 360 in bypass valve body 352 from ports 336, 338, 348 and 350, respectively, in upper body 322, annular seals 332, 334, 340, 342, 344 and 346 preventing fluid movement between annulus 368 and packer annulus 370 and annulus 372. With the bypass ports closed, in isolation gravel packer and bypass assembly 320, the operating string 30 is then pressured to the desired pressure through pipe 230 to inflate casing inflation packer 50. The pressurized fluid reaches packer 50 through annular bore 282, outer blank pipe annulus 299, outer passages 326 and 328, inner annular passage 362, gravel passages 364 and 366 which exit into a packer annular cavity 370 defined by the screen liner assembly 32, operating string 30, and packer cups 406 and 408 at the top and 414 and 416 at the bottom. The fluid then enters casing inflation packer 50 through check valve 58, inflating it to a predetermined pressure. After the packer is inflated, the operating string is ready to proceed down to the next casing inflation packer 130.
To release the anchor positioner assembly 470, the operating string 30 is reciprocated upward by picking up pipe 230 four to six feet, at which time the bypass ports in isolation gravel packer and bypass assembly 320 open as well as those in crossover tool 240, if not already open (that being the case if crossover tool 240 is already in the closed mode) to permit equalization of pressures. As the bypass ports in isolation gravel packer 320 are collet retained, and those in the crossover tool 240 may be by a snap-ring collet abutment (as previously described), they will remain open until the next time weight is set down on the operating string 30.
The operating string 30 is lowered to the approximate location of anchor tool 190, reciprocated again to release anchor positioner 470, and lowered to the point where spring arms 496 and 498 engage annular shoulder 194 and take weight. At this point, 20,000 pounds is set down to close all necessary bypass ports in isolation gravel packer and bypass assembly 320, and the operating string is once again pressured to inflate packer 130 through check valve 138. As shown in FIG. 1C, packer annulus 370 is defined by operating string 30, screen liner assembly 32, packer cups 406 and 408 at the top and packer cups 414 and 416 at the bottom. The cavity 370 is pressured through gravel passages 364 and 366, as previously described. At this point, as all of the inflation packers have been inflated, gravel packing may proceed.
Full open gravel collar 140 is opened by reciprocating operating string 30 to retract the anchor positioner 470, and raising the operating string 30 so that opening sleeve positioner 444 engages sleeve 144 of full open gravel collar 140. Spring arms 448 and 450 of opening positioner 444 expand and the shoulders on protrusions 456 and 458 engage annular shoulder 174 on sleeve 144. A pull of approximately 10,000 pounds will align apertures 176 and 178 of sleeve 144 with gravel ports 152 and 154 of case 142, thereby opening the gravel collar 140. As the open position of full open gravel collar 140 is reached, radially outward extending shoulders 452 and 454 have contacted the beveled edge leading to necked-down portion 146, which contact compresses spring arms 448 and 450, causing them to release from sleeve 144, leaving gravel collar 140 in the open position. The operating string 30 is then lowered to the approximate location of the anchor 190, then picked up again to release the anchor positioner 470, and lowered until the anchor positioner 470 is locked in anchor 190.
At this point, gravel packing may begin, provided that the crossover tool is in the proper position. Crossover tool 240 is also operated by up and down, or reciprocating, motion, as previously described. However, the force required to index the crossover tool 240 from one mode to another is less than that required to index the anchor positioner 470. As the crossover is indexed when the anchor positioner 470 is set in an anchor tool, there is a constraint against upward motion, thereby permitting proper indexing of the crossover tool 240. To ascertain if crossover tool 240 is in the open mode, whereby circulation passages 274 and 276 in inner casing 246 communicate with circulation ports 266 and 268 in outer sleeve 244, the operator pressures down drill pipe 230. If the crossover tool 240 is open, fluid will circulate down pipe bore 232, through crossover bore 242, vertical passages 278 and 280, crossover annulus 282, blank pipe annulus 299, outer passages 326 and 228, inner annulus 362, gravel passages 364 and 366 into packer annulus 370, out through gravel ports 152 and 154 into lower zone annulus 550 between casing 34 and screen liner assembly 32 back into the screen liner assembly 32 through gravel screen 202, into bore 441 of tail pipe 440, mandrel bore 534, check valve 430, axial circulation passage 324, and up to the crossover tool 240 through blank pipe 298, then back to the surface. If crossover tool 240 is closed the circulation path will be the same, but back pressure will result as seals 262 and 264 will prevent fluid from passing through passages 274 and 276 as shown in FIG. 2. If closed, upward and then downward reciprocation of drill pipe 230 will suffice to open crossover tool 240.
Assuming that the operator now has crossover tool 240 in its open mode, gravel packing may now be effected. A slurry of carrier fluid containing gravel is pumped down pipe bore 232 and through crossover tool 240 via vertical passages 278 and 280 into crossover annulus 282, blank pipe annulus 299 into passages 326 and 328, inner annular passage 362 and out through gravel passages 364 and 366 into packer annulus 370, then through gravel ports 152 and 154, of full open gravel collar 140 into lower zone annulus 550, where the gravel is deposited. The carrier fluid returns into screen liner assembly 32 through gravel screen 202, the gravel being retained on the outside of the screen 202 by virtue of the proper sizing of the apertures thereof. The gravel-free carrier fluid then enters tail pipe bore 441, and returns past ball check valve 430 which is unseated by fluid passing in an upward direction. The fluid then proceeds through axial circulation passage 324 in isolation gravel packer and bypass assembly 320, then up through inner blank pipe 298 to inner crossover bore 272, through circulation passages 274 and 276 and circulation ports 266 and 268, respectively, into annulus 270, then to the surface. Circulation of the gravel slurry is continued to build up a gravel pack from below gravel screen 202 to a point above it, thus interposing a barrier to sand migration from the zone into the liner assembly 32. When pressure resistance is noted at the surface, this indicates that gravel in the lower zone has been deposited (packed) higher than the top of gravel screen 202, and the pack has been completed. It is evident that no fluid movement has been induced across upper zone 26, during packing, as both gravel slurry and returns are contained within the operating string 30.
If desired at this point, the gravel pack may be further consolidated by applying pressure to it, referred to as squeezing. To effect this, crossover tool 240 is reciprocated up and then down to close it, or annulus 270 closed at the surface, and pressure applied down the drill pipe 230. This pressure will act upon the pack through the same circulation path as described previously. Fluid is contained below isolation gravel packer and bypass assembly 320 by downward-facing packer cup 420, as during normal circulation with crossover tool 240 open. In order to clear the interior of the operating string 30 of residue, circulation is then reversed using a clean fluid. This operation is illustrated in FIG. 3. No movement in the well bore is required to effect this operation, the only action on the part of the operator being necessary is an upward and downward reciprocation of the drill pipe 230 to reopen crossover tool 240 if a squeeze has been applied to the pack. Clean fluid is sent down annulus 270, through circulation ports 266 and 268, circulation passages 274 and 276, and down inner crossover bore 272 through blank pipe 298 to axial circulation passage 324 in isolation gravel packer and bypass assembly 320. When the fluid reaches check valve 430, ball 432 is seated on valve seat 436 preventing flow downward. At this point, the clean fluid will then exit isolation gravel packer and bypass assembly 320 through lateral circulation passages 422 and 424, and flow upward past collapsed packer cups 414 and 416, and back through gravel passages 364 and 366 into inner annular passage 362, through outer passages 326 and 328 to blank pipe annulus 299 through annular crossover bore 282, vertical passages 278 and 280 to the surface through drill pipe bore 232. When clean fluid is returned to the surface, the packing job is complete. It is noteworthy that the reversing fluid is prevented from circulating below isolation gravel packer 320 by upward-facing packer cup 418, responsive to the pressure of fluid flow through lateral circulation passages 422 and 424, and as a result of this seal as well as the closing of check valve 430, reverse circulation is effected without fluid movement across the zone just packed.
At this point, the operating string may be moved upward to the next zone of interest 26, in this case between casing inflation packers 50 and 130. The operating string 30 is reciprocated upward, thus retracting the anchor positioner 470 and disengaging anchor tool 190. As the operating string 30 is pulled up to the next zone, the passing spring arms 514 and 516 of closing sleeve positioner 510 pulls sleeve 144 of full open gravel collar 140 upward. The upward facing outwardly radially extending shoulders of protrusions 522 and 524 on spring arms 514 and 516 engage downward facing annular shoulder 174 in sleeve 144. As the operating string is pulled up, the spring arms 514 and 516 close gravel collar 140, at which point shoulders 518 and 520 encounter necked-down portion 146 of gravel collar 140, which compresses spring arms 514 and 516, releasing them from shoulder 174 of sleeve 144. At this point, annular seals 168 and 170 bracket gravel ports 152 and 154, sealing them. The operating string 30 is then pulled up to the next zone, where it is reciprocated downward briefly, and then upward again, lowered downward into anchor tool 110. If the casing inflation packer 50 above the upper zone has been previously inflated, this final upward reciprocation can effect the opening of gravel collar 60, by engaging sleeve 64 with spring arms 448 and 450 of opening sleeve positioner 444. As noted previously, when spring arms 448 and 450 have opened the collar 60 by pulling sleeve 64 upward, they will automatically disengage as shoulders 452 and 454 encounter necked-down portion 66 which will in turn compress spring arms 448 and 450.
When the anchor positioner 470 has engaged anchor 110, gravel packing may proceed at this zone, the packer 50 above it having previously been inflated. Crossover tool 240 must, of course, be in the open position, which may be ascertained as previously noted herein. After packing of the upper zone of interest is effected, the operating string 30 is withdrawn and the well may be produced.
DESCRIPTION AND OPERATION OF ALTERNATIVE EMBODIMENTS
Should one wish to have the ability to avoid any circulation across the zone to be packed even before gravel packing, and be able to more quickly and easily ascertain the mode of the crossover tool, an alternative embodiment of crossover tool 240 as shown in FIGS. 11, 12, 13, 14A and 14B may be employed. This crossover tool, designated generally by the reference character 640, is located in the same position in the operating string 30 as crossover tool 240 in lieu thereof, and is connected to drill pipe 230 and the lower portion of operating string 30 in the same fashion. It comprises outer sleeve 644 and inner case 646. Outer sleeve 644 is slidably disposed about inner case 646, and the opening and closing of the crossover tool 640 is effected by reciprocation of outer sleeve 644 through the movement of pipe 230 on the surface. Inner case 646 has two slots, 648 and 650 in its outer surface. Developments of these slots are illustrated in FIGS. 14A and 14B. These slots slidably engage pins 652 and 654, respectively, which are attached to outer sleeve 644. Pin 652 slides axially in slot 648, and is fixed to outer sleeve 644. Pin 654 is fixed to ring 656, which may slidably rotate in annular recess 658 in outer sleeve 644. Pin 654 may also slide axially in slot 650, the rotational ability given by ring 656 permitting it to move laterally (actually circumferentially) in slot 650, which is "wrapped" around inner case 646 in the same manner as slots 248 and 250 on case 246 of crossover tool 240. Slot 650 as slot 250 in crossover tool 240, is of complex design and permits crossover tool 640 to be locked in several different modes, the achievement of which will be described below. Outer sleeve 644 possesses annular seals 660, 662, 664 and 665. Seals 660 and 662 bracket circulation ports 666 and 668, which, when the crossover tool 640 is in its open mode (as illustrated in FIG. 11) permits communication between annulus 270 above crossover tool 640, and inner bore 672 via circulation passages 674 and 676 within inner case 646. Inner case 646 possesses vertical passages 678 and 680, depicted by broken lines, which pass from bore 642 to annular bore 682 of the crossover tool 640. Vertical passages 678 and 680 do not communicate with circulation passages 674 and 676. Inner case 646 also possesses bypass ports 684 and 686, which are bracketed by seals 662 and 664 when crossover tool 640 is in the open mode, and by seals 664 and 665 when in the closed mode (as illustrated in FIG. 12). Thus, unlike crossover tool 240, the bypass ports in crossover tool 640 are not left open until some positive action is taken to do so, as will be explained hereinafter. When bypass ports 684 and 686 are open, they permit communication between annulus 270 above crossover tool 640 and lower annulus 288 below crossover tool 640. Bypass ports 684 and 686, when open, allow equalization of pressures in the space above and below the crossover tool 640 and, in conjunction with the bypasses of isolation gravel packer and bypass assembly 320, facilitate movement of operating string 30 by allowing fluid movement through and past the operating string 30. At the lower end of case 646 are disposed upward-facing packer cups 690 and 692, which contact production casing 34 above liner hanger 40, and seal the area below them from greater pressure in annulus 270 when reversing circulation or performing any other operation where the annulus 270 is pressurized to a greater extent than annulus 288. Inner bore 672 and crossover annulus 682 exit from the lower end of crossover tool 640, mating with inner blank pipe 298 and concentric outer blank pipe 300, respectively, which extend downward to the remainder of the operating string, which is unchanged.
Referring again to FIGS. 11, 12, 13, 14A and 14B, operation of crossover tool 640 is described. As in crossover tool 240, operation is effected by an internal rotating slot mechanism. To ensure that outer sleeve 644 will not rotate with respect to inner casing 646, and thus block circulation passages 674 and 676 even when the tool is in the open mode, pin 652 fixed to outer sleeve 644 slides axially within straight slot 648 of inner case 646. To provide a locking arrangement complex slot 650 in inner case 646 is utilized with pin 654 and ring 656, ring 656 rotationally slidably confined within annulus 658 in outer sleeve 644. Thus, when outer sleeve 644 is reciprocated, pin 654 follows the edges of slot 650 defined by the surface of case 646 and cam island 651. When crossover tool 640 is in the open mode as illustrated in FIG. 11, pin 654 is at position 654a as shown in FIG. 14A while pin 652 in straight slot 648 is in axially corresponding position 652a as shown in FIG. 14B. When drill pipe 230 and therefore outer sleeve 644 are reciprocated upward, pin 654 moves to position 654b being directed thereto first by angled edge 651a of cam island 650, and then by angled edge 646a of case 646. Crossover tool 640 is now in the closed, bypass closed mode shown in FIG. 12. When drill pipe 230 is set down, pin 654 is directed into position 654c in slot recess 650a rather than back to 654a by angled cam island edge 651b. Crossover tool 640 is thus locked in the mode shown in FIG. 12. Pin 652 has also followed the axial portion of the movement of pin 654, as shown at 652b and 652c. At positions 654b and 654c, and points therebetween, crossover tool 640 is in the closed mode, and bypass ports 684 and 686, bracketed by seals 662 and 664 in the open mode are opened briefly as seal 665 passes above them during movement at position 654b, then closed as the drill pipe is set down and position 654c is reached. When it is desired to open the bypass ports again to permit movement of operating string 30 up or down the well bore, drill pipe 230 is once again raised, pin 654 being directed to position 654d by angled edge 646b, and the bypass ports 684 and 686 are then opened as seal 665 is above them. The bypass ports are locked open (FIG. 13) at this position as at position 654b by a collet snap-ring assembly (which has not been shown for the sake of clarity) similar to that illustrated in the second alternative embodiment of the crossover tool shown in FIGS. 15 and 16 and discussed below. As stated previously with respect to crossover tool 240, the collet would be located on the inner casing and the snap-ring disposed thereabout as shown in FIGS. 15 and 16. When bypass ports 684 and 686 are sought to be closed, weight must be set down on the drill pipe 230, which overcomes the snap-ring lock and returns pin 654 to position 654a, and the crossover tool 640 to the open mode illustrated in FIG. 11. Pin 654 is prevented from returning to the position 654c by inclined cam island edge 651c. As before, pin 652 follows the axial segment of the pin 654 movement, going to the 652d position when the bypass ports are open, and then back to 652a when the drill pipe 230 is set down. Thus, the operation of crossover tool 640 is seen to be markedly similar to that of crossover tool 240, but gives the added capability of being able to seal off everything in the production casing 34 below the crossover tool.
When crossover tool 640 is in the closed mode (FIG. 12) and operating string 30 is anchored at lower zone 28, the casing inflation packer 130 may be tested by pressuring down the operating string 30 through drill pipe 230, with full open gravel collar 140 open, being careful to stay below the formation treating pressure for the zone 28 involved. If a packer leak is present (due to an underinflated packer or, in an open hole, fluid communication around the packer), fluid will flow up around packer 130, back inside gravel screen 122, and up the screen liner assembly operating string annulus, past the upward-facing cups 690 and 692 of crossover tool 640, up to the surface. Should a leak be indicated, the casing inflation packer may be re-inflated using the same procedure as initially described for inflation. It is necessary to close the full open gravel collar for packer re-inflation, which may be accomplished by reciprocating the operating string 30 upward to retract the anchor positioner 470, lowering it, raising it again to release the anchor positioner, this time above the gravel collar 140, and lowering it, whereby spring arms 496 and 498 of anchor positioner 470 will engage the top of sleeve 222 and pull it down into the closed position. After repressuring the packer 130, full open gravel collar 140 may be reopened, as previously described, and the operating string 30 repositioned to test the packer seal again. It should be understood that this inflation packer testing procedure may also be employed with crossover tool 240, as well as with crossover tool 740 described hereafter.
Should the test be successful, packing may begin as soon as the crossover tool 640 is in the open mode. Packing is effected in the same manner as described previously with crossover tool 240, utilizing the open mode. After packing, crossover tool 640 may then be closed to squeeze the gravel pack, if desired, and then re-opened to reverse circulate.
In the event that one wishes to eliminate the mode wherein circulation and bypass ports are both closed, to simplify operation of the crossover tool 640, slot 650, in inner casing 646 may be milled below broken line z as shown in FIG. 13A to place bypass ports 684 and 686 in the open position immediately upon closing the circulation passages 274 and 276. Operation of crossover tool 640, as modified, would be the same as that of 240.
In lieu of utilizing any complex slot whatsoever, a second alternative crossover tool may also be employed, which embodiment involves the employment of a single straight slot to prevent rotation of the outer sleeve, and a collet snap-ring locking mechanism to lock the bypass ports in an open position. This embodiment is illustrated in FIGS. 15 and 16. Crossover tool 740 comprises an outer sleeve 744 surrounding an inner case 746. It is connected to drill pipe 230 in the same manner as the other embodiments previously discussed, as well as to the remainder of operating string 30. Outer sleeve 744 is slidably disposed about inner case 746, and the opening and closing of crossover tool 740 is effected by reciprocation of outer sleeve 744 through the movement of pipe 230 on the surface. Inner case 746 has a single straight slot, 748, machined into its outer surface. Slot 748 slidably engages pin 752, which is fixed to outer sleeve 744 and moves axially in slot 748. Inner case 746 also possesses collet 749 on cylindrical surface 747 upon which split snap-ring 745 slides axially. Outer sleeve 744 possesses annular recess 743, in which snap-ring 745 is housed. Annular recess engages snap-ring 745 upon reciprocation, to move it along cylindrical surface 747 and up and over collet 749 in inner case 746. Outer sleeve 744 also possesses annular seals 760, 762 and 764. Seals 762 and 764 bracket circulation ports 766 and 768, which, when the crossover tool 740 is in its open mode (as illustrated in FIG. 14) permits communication between annulus 270 above crossover tool 740, and inner bore 772, via circulation passages 774 and 776 within inner case 746. Inner case 746 possesses vertical passages 778 and 780, depicted by broken lines, which pass from bore 742 to annular bore 782 of crossover tool 740. Vertical passages 778 and 780 do not communicate with circulation passages 774 and 776. Inner case 746 also possesses bypass ports 784 and 786, which are bracketed by seals 762 and 764 when crossover tool 740 is in the open mode, but which are uncovered when crossover tool 740 is in the closed mode, allowing communication between annulus 270 and lower annulus 288, thus equalizing pressures and permitting fluid flow therebetween. At the lower end of casing 746 are disposed upward-facing packer cups 790 and 792, which contact production casing 34 and seal annulus 288 from annulus 270 when reversing circulation or otherwise pressurizing that area. Inner conduit 794 and concentric outer conduit 796 exit from the lower end of crossover tool 740, mating with inner blank pipe 298 and concentric outer blank pipe 300, respectively, which extend down to the remainder of operating string 30, which is unchanged.
Referring again to FIGS. 15 and 16, operation of crossover tool 740 will be described. Unlike crossover tools 240 and 640, operation is effected through the locking mechanism provided by the snap-ring collet combination described above. To ensure non-rotation of outer sleeve 744 with respect to inner case 746, the same type of pin 752 and slot 748 combination as employed in the other disclosed embodiments is again utilized. To provide a means to lock crossover tool 740 in its closed mode, with bypasses open, snap-ring 745 has been provided. When the tool is closed, as illustrated at FIG. 16, snap-ring 745 has been slid up cylindrical surface 747 on inner case 746, and over collet 749. At this point, as snap-ring 745 is constrained within annular recess 743, outer sleeve 744 remains in its upward position, and the crossover tool 740 in its closed mode. When it is desired to open the tool again, an application of weight to the string will cause snap-ring 745 to expand slightly, due to the split therein (not shown), ride back down over collet 749 and permit movement of outer sleeve 744 downward as it slides down cylindrical surface 747. Downward movement of snap-ring 745 over collet 749 may be facilitated by slightly beveling the edge between its inner and lower surfaces. Thus, picking up on drill pipe 230 will close crossover tool 740, and automatically lock it in its closed mode until weight is applied to the operating string 30. As stated previously, the snap-ring locking mechanism may be incorporated in crossover tools 240 and 640 so that when outer sleeves are picked up for the second time in a cycle of operation, the bypass ports may be locked open. Referring to crossover tool 740 again, the determination of whether or not it is in the open or closed mode may be effected in the same manner as that described for tool 240; however, as setting down weight will automatically open the tool, testing would only be necessary to ascertain if the tool is desired to be closed and the operator was uncertain whether he had applied sufficient upward force. With respect to the gravel packing operation itself, it may be effected as described previously for crossover tool 240, as none of the other tools have been changed, and the circulation passage patterns in the two tools are identical. If it is desired to maintain a crossover tool such as 740 permanently open, if a closed mode is not desired, any of the disclosed crossover tools could be modified by increasing the axial distance between the circulation passages and the bypass ports and axially elongating the circulation ports so that reciprocation of the outer sleeve will not result in circulation passages being covered. With this tool, if a squeeze is desired, circulation up the drill pipe casing annulus may be cut off at the surface to permit pressurization.
It should be noted at this point that a crossover tool per se is not absolutely necessary for the performance of the disclosed method. Concentric blank pipes 298 and 300 may be run from the surface to isolation gravel packer and bypass assembly 320, utilizing surface equipment in lieu of a crossover.
In the event that the operator wishes to employ an operational method using rotational as well as reciprocating motion, an alternative embodiment of the anchor positioner of the present invention may be utilized.
Referring now to FIGS. 17, 18 and 19, an alternative embodiment of the anchor positioner of the present invention is illustrated, designated generally by the reference character 870. Anchor positioner 870 comprises a mandrel 876, drag block assembly 872 slidably mounted thereon, and spring arm body 874 mounted below drag block assembly 872. Drag block assembly 872 has mounted thereon drag blocks 890 and 892, and possesses inclined (frusto-conical) lower face 894. Spring arms 896 and 898 mounted on spring arm body 874 possess at their upper ends protrusions 904 and 906, below which are shoulders 900 and 902. Mandrel 876 has machined therein a J-slot 878, with which pin 882, fixedly mounted on drag block assembly 872, cooperates. When anchor positioner 870 is in the release mode, as shown in FIG. 16 anchored in anchor tool 190, pin 882 is at the top of J-slot 878. This is depicted in FIG. 19, a development of J-slot 878, at position 882a. When the operator desires to change the anchor positioner 870 to its retract mode, the drill pipe is reciprocated at the surface, which causes drag block assembly 872 to move downward relative to mandrel 876, retracting spring arms 896 and 898 by their encounter with inclined face 894 in the same manner as previously described with respect to anchor positioner 470. The upward movement of the operating string 30 moves pin 882 into position 882b, due to the inclined lower edge of the J-slot, and, when the string is set down again, pin 882 moves to position 882c, in which it is locked in slot recess 878a until the string is reciprocated upward and turned 30° to the right as it is set down.
Protrusions 904 and 906 have thereon downward facing radially extending shoulders, which engage annular shoulder 194 of anchor tool 190 when anchor positioner 870 passes therethrough and the spring arms 896 and 898 are in the release mode. As described with respect to anchor positioner 470, anchor positioner 870 may be utilized for closing a full open gravel collar, by providing engaging the top of the gravel collar sleeve with spring arms 896 and 898 and moving the operating string downward.
Although the invention has been described in terms of certain embodiments which are set forth in detail, it should be understood that descriptions herein are by way of illustration and not by way of limitation of the invention; as alternative embodiments of the apparatus and operating techniques of the method will be readily apparent to those of ordinary skill in the art in view of the disclosure. For example, the anchor positioner of the present invention might be placed above the isolation gravel packer and bypass assembly and the anchor tool positioned above the gravel collar. Similarly, the check valve could be located at the bottom of the tail pipe. The opening sleeve positioner might be disposed above the isolation gravel packer. Accordingly, modifications such as these and others are contemplated without departing from the spirit and scope of the claimed invention. | A method of gravel packing multiple zones with a single trip of the operating string into a well without inducing fluid movement across zones, and without disturbing the zone being packed in reverse circulation. Apparatus is disclosed to perform the method, comprising a screen liner assembly surrounding a concentric operating string. Mechanical force on the operating string is used to change all tool modes of the apparatus. The operating string is accurately positioned with respect to the screen liner assembly at every zone level and zones may be easily relocated if necessary. Zones may be packed in any order, and a zone may be repacked, if necessary, during the same trip into the well. |
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RELATED APPLICATIONS
This application is a continuation of and claims priority to U.S. provisional Application Ser. No. 61/155,594, filed Feb. 26, 2009, titled “Decking Panel System,” which is incorporated herein by reference.
BACKGROUND & SUMMARY
A decking system comprised of extruded decking panels is provided. A clip attached to a joist receives and retains the outer legs of adjacent decking panels. The clip comprises downwardly-extending legs that grip the sides of the joist and hold the clip in place until a fastener is installed in the clip to permanently attach the clip and the decking panels to the joist. The clips allow an entire deck surface, or portions of the deck surface, to be set in place before the permanent fasteners are installed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
FIG. 1 depicts a decking system according to an embodiment of the present disclosure.
FIG. 2 is a cross-sectional view of the decking system of FIG. 1 , taken along section lines A-A of FIG. 1 .
FIG. 3 is a cross-sectional view of the decking system of FIG. 1 , taken along section lines B-B of FIG. 1 .
FIG. 4 is a side plan view of a clip according to an embodiment of the present disclosure.
FIG. 5 is a top plan view of the clip of FIG. 4 .
FIG. 6 is a cross-sectional view of the clip of FIG. 5 , taken along section lines C-C of FIG. 5 .
FIG. 7 is a cross-sectional view of the clip of FIG. 5 , taken along section lines D-D of FIG. 5 .
FIG. 8 is a cross-sectional view of the clip of FIG. 5 , taken along section lines E-E of FIG. 5 .
FIG. 9 is an enlarged detail view taken along line “F” of FIG. 2 .
FIG. 10 is an enlarged detail view taken along line “G” of FIG. 9 .
FIG. 11 is a side plan view of the decking system 10 according to an embodiment of the present disclosure.
FIG. 12 depicts a method of installing a decking system according to an embodiment of the present disclosure.
FIG. 13 is a side view of a decking system illustrating a step of the method of FIG. 12 , with one a first decking panel installed.
FIG. 14 is a side view of a decking system illustrating a step of the method of FIG. 12 , after a plurality of clips is installed to the first decking panel.
FIG. 15 is a side view of a decking system illustrating a step of the method of FIG. 12 , after a second decking panel is installed.
FIG. 16 is a side view of a decking system illustrating a step of the method of FIG. 12 , after a third decking panel is installed
FIG. 17 is a side view of a decking system illustrating a step of the method of FIG. 12 , after fasteners are installed in the third decking panel.
FIG. 18 is a side view of a decking system illustrating a step of the method of FIG. 12 , after fasteners are installed into the clips.
DETAILED DESCRIPTION
The present invention and its advantages are best understood by referring to the drawings. The elements of the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
FIG. 1 shows a decking system 10 according to one embodiment of the present disclosure. The decking system 10 includes a plurality of substantially identical decking panels 13 disposed upon a plurality of joists 12 . Clips 11 clipped to the joists 12 secure the decking panels 13 to the joists 12 via fasteners (not shown) installed into the clips 11 . The clips 11 further set the spacing of gaps 16 between the decking panels 13 , as is further discussed herein.
The joists 12 are typically fabricated from wood. In one embodiment, the decking panels 13 are extruded aluminum, though in other embodiments may be fabricated from other materials known in the art or hereafter developed, such as composite, other metals, plastic, or the like. In one embodiment, the decking panels 13 have a wall thickness of 0.065 inches. The decking panels 13 are generally rectangular and may be made in any length desired by a user (not shown), and in one embodiment are formed in lengths of 12, 16 and 20 feet.
The width of a decking panel according to one embodiment is 5¾ inches, though other widths may be used in other embodiments. The distance “d” from the center of one clip 11 to the center of an adjacent clip 11 is 6″ in one embodiment, though other distances may be employed in other embodiments.
In the illustrated embodiment, the decking panels 13 are disposed generally perpendicularly to the joists 12 . In other embodiments, the decking panels 13 may be differently angled relative to the joists 12 .
FIG. 2 is a cross-sectional view of the decking system 10 of FIG. 1 , taken along section lines A-A of FIG. 1 . In this embodiment, each decking panel 13 comprises an extruded aluminum platform 51 . The platform 51 is generally horizontal and comprises a top panel surface 14 which forms a walking surface of the decking system 10 .
The top panel surface 14 of the platform 51 comprises protrusions 15 that are raised areas unitarily formed with the platform 51 . The protrusions 15 provide texture to the top panel surface 14 and therefore provide traction for the user (not shown) of the decking system 10 . The protrusions 15 generally run longitudinally down the length of the platform 51 .
The decking panels 13 further comprise outer legs 17 and inner legs 18 . The outer legs 17 and the inner legs 18 extend downwardly from and support the platform 51 spaced apart from (i.e. raised above) the joists 12 . The outer legs 17 and the inner legs 18 extend longitudinally down the length of the decking panels 13 in this embodiment.
The inner legs 18 comprise generally vertical supports 50 extending generally perpendicularly down from a bottom side 52 of the platform 51 . The inner legs 18 further comprise lower side flanges 19 that extend from the generally vertical supports 50 and rest on the joists 12 . The outer legs 17 comprise an angled portion 20 that extends downwardly from an outer edge 53 of the platform 51 and a generally horizontal portion 21 connected to the angled portion 20 . The outer legs 17 thus form a “Z”-shape in conjunction with the platform 51 . In other embodiments, the outer legs 17 of the decking panels 13 are differently shaped, as is further discussed herein.
Each clip 11 has two (2) downwardly-extending legs 22 (one of which is shown in FIG. 2 ) that frictionally grip opposite sides of the joist 12 to hold the clip 11 to the joist 12 until a fastener (not shown) is installed through the clip into the joist, as further discussed herein.
The decking panels 13 are spaced apart from one another by the gap 16 between the panels 13 . The gap 16 is maintained generally uniformly by the clip 11 which fits between the outer legs 17 of adjacent decking panels 13 , as shown. When installed, the clip 11 contacts the outer legs 17 of adjacent decking panels 13 such that when the fastener (not shown) is installed, the clip 11 secures the decking panels 13 firmly in place against the joist 12 , as further discussed herein.
FIG. 3 is a cross-sectional view of the clip 11 of FIG. 1 , taken along section lines B-B of FIG. 1 . The joist 12 has a generally rectangular cross-section in this embodiment, with two generally-straight long sides 23 and a generally straight top and bottom side, 24 and 25 , respectively, that are disposed generally perpendicularly to the long sides 23 . The clip 11 fits over the top short side 24 such that the downwardly-extending legs 22 of the clip 11 extend partially down the long sides 23 , as shown. After the clip 11 is installed on the joist 12 , a fastener 26 is installed in the clip 11 and driven into the joist 12 to secure the clip to the joist 12 .
The fastener 26 may be a typical threaded wood screw that is self-tapping when driven into the joist 12 . In other embodiments, other types of fasteners may be used.
FIG. 4 is an enlarged side view of the clip 11 of FIG. 1 . In this embodiment, the clip 11 comprises an elongated clip body 30 , a top side 32 , two (2) angled side edges 33 (only one of which is shown in FIG. 4 ), two (2) ends 34 , and a bottom side 31 . The downwardly-extending legs 22 extend generally perpendicularly from the bottom side 31 of the clip body 30 . The legs 22 are disposed near the ends 34 of the clip body 30 , as shown.
One or more raised tracks 29 are disposed on the bottom side 31 of the clip body 30 . The raised tracks 29 comprise elongated pointed protrusions integrally formed with the clip body 30 . The tracks 29 “dig into” or grasp the joist 12 ( FIG. 3 ) when the fastener 26 ( FIG. 3 ) secures the clip 11 to the joist 12 . In this regard, the joist 12 is generally formed of wood that is penetrable by sharp or pointed objects. The tracks 29 may thus penetrate the joist 12 and help to secure the clip 11 to the joist 12 .
In this embodiment, the clip body 30 , the legs 22 , and the tracks 29 are integrally formed from a solid material, such as by injection molding of plastic. In other embodiments, other materials and/or processes currently known or hereafter developed may be used to fabricate the clip 11 .
A fastener opening 27 in the clip body 30 extends through the clip body 30 and receives the fastener 26 ( FIG. 3 ). The fastener opening 27 may be a countersunk hole such that when the fastener 26 is installed, the fastener 26 does not protrude above the clip body 30 . Other configurations of openings 27 are usable with other types of fasteners 26 that may be used in other embodiments to attach the clip 11 to the joist 12 .
In the illustrated embodiment, the fastener opening 27 is centrally located within the body 30 (i.e., located equidistant from the ends 34 and the angled side edges 33 ). In other embodiments, the fastener opening 27 may be located elsewhere on the clip 11 .
The illustrated embodiment includes leg openings 28 disposed above each of the downwardly-extending legs 22 . The leg openings 28 comprise hollow rectangular channels formed in the body 30 directly adjacent to (i.e., above) the legs 22 . The purpose of the leg openings 28 is to provide “weak spots” 54 at the juncture of the body 30 and a top end 35 of the legs 22 . These weak spots 54 enable the legs 22 to be readily broken off in the event the user (not shown) desires to use the clip 11 in a configuration where there is no access for the legs 22 to clamp onto the joist 12 . Breaking off one or more legs 22 may be desired, for example, if there are two joists 12 abutted directly together.
FIG. 5 is a top plan view of the clip 11 of FIG. 4 . The body 30 approximates a rectangle when viewed from the top, as shown. The fastener opening 27 is centrally located in this embodiment, as discussed above with respect to FIG. 4 . The leg openings 28 comprise rectangularly-shaped channels that extend into the body 30 . The clip 11 is substantially symmetrical around its x and y axes in this embodiment, as illustrated.
FIG. 6 is a cross-sectional view of the clip 11 of FIG. 5 , taken along section lines C-C of FIG. 5 . In this embodiment, the raised tracks 29 comprise a pair of protrusions that extend along the bottom side 31 of the body 30 , and are integrally formed with the body 30 . The tips 66 of the tracks 29 narrow (i.e., are somewhat sharpened) such that the tips 66 may grip the surface of the joist 12 ( FIG. 2 ).
In this embodiment, the bottom side 31 of the clip body 30 further comprises a pair of channels 37 . The channels 37 are recessions in the bottom side 31 of the clip body 30 that extend longitudinally down the body 30 . The purpose of the channels 37 is to receive and retain the free ends 39 ( FIG. 9 ) of the outer legs 17 ( FIG. 2 ), as is further discussed with respect to FIG. 9 below.
In this embodiment, the side edges 33 angle downward and outward from the top side 32 . The angle of the side edges 33 is substantially similar to the angle of the angled portions 20 of the outer legs 17 ( FIG. 2 ). The similarity in angles of the side edges 33 of the clip 11 and the angled portions 20 of the outer legs 17 enables the edges 33 of the clip 11 to snugly abut the angled portions 20 of the outer legs 17 , as shown in FIG. 2 . In other embodiments, the side edges 33 may be differently shaped to abut differently-shaped outer legs 17 .
Further, in other embodiments of the clip 11 the side edges 33 may not contact the decking panels 13 ( FIG. 2 ) at all, but rather the bottom surface 31 of the clip 11 may be the only portion of the clip 11 that contacts the decking panels 13 .
FIG. 7 is a cross-sectional view of the clip 11 of FIG. 5 , taken along section lines D-D (i.e., the centerline) of FIG. 5 . The fastener opening 27 as shown extends completely through the clip body 30 from the top side 32 to the bottom side 31 , such that the fastener 26 ( FIG. 3 ) can be installed through the opening 27 , as was discussed above with respect to FIG. 3 .
FIG. 8 is a cross-sectional view of the clip 11 of FIG. 5 , taken along section lines E-E of FIG. 5 . The leg opening 28 extends most of the way down through the body 30 , as shown, such that only thin strips 38 of material attach the leg 22 to the body 30 , so that the leg 22 may be broken off of the body 30 as may be desired by the user (not shown).
FIG. 9 is a detail view of the clip 11 of FIG. 2 , taken along detail “F” of FIG. 2 . As illustrated, the body 30 of the clip 11 fits within a somewhat trapezoidal area created by the angled portions 20 of the outer legs 17 of adjacent decking panels 13 . As was discussed above with respect to FIG. 6 , the side edges 33 are disposed at an angle similar to the angle of the angled portions 20 , such that the body 30 may fit snugly between the angled portions 20 of adjacent decking panels 13 . The side edges 33 fitting snugly within the angled portions 20 of adjacent decking panels 13 prevents the clip 11 from moving with respect to the decking panels 13 in the ±x direction and the ±y direction.
In this embodiment, the body 30 fitting within the angled portions 20 sets the width “w” of the gap 16 between adjacent decking panels 13 and further maintains the uniformity of the gap 16 . In one embodiment, the width “w” of the gap 16 comprises approximately ¼ inches. In other embodiments, different widths of the gap 16 may be used.
The free ends 39 of the outer legs 17 comprise protrusions 40 that fit within the channels 37 of the clip body 30 . The channels 37 thus receive and retain the free ends 39 , and in this manner, the clip 11 retains the decking panels 13 in place, as further discussed herein. The protrusions 40 fitting within the channels 37 further aids in preventing the clip 11 from moving with respect to the decking panels 13 in the ±x direction.
The legs 22 of the clip 11 fit in between the free ends 39 of the adjacent decking panels 13 . The tracks 29 of the clip 11 also fit between the free ends 39 , such that the tracks 29 may grip the joist 12 . The tracks 29 gripping the joists 12 further aids in preventing the clip 11 from moving with respect to the decking panels 13 in the ±x direction
FIG. 10 is an enlarged detail view of the clip 11 of FIG. 9 , taken along detail “G” of FIG. 9 . The channel 37 is formed into the body 30 of the clip 11 , and in this embodiment comprises a generally flat top wall 41 and angled side walls 42 and 43 .
The protrusion 40 is integral with and extends upwardly from the horizontal portion 21 of the outer leg 17 , near the free end 39 . In this embodiment, the protrusion comprises a generally flat top wall 60 and angled side walls 61 and 62 . When the clip 11 is installed onto the decking panel 13 , the protrusion 40 is received by the channel 37 . In this regard, the flat top wall 60 of the protrusion 40 contacts the flat top wall 41 of the channel 37 . The angled side walls 42 and 43 help to retain the protrusion 40 within the channel 37 .
FIG. 11 illustrates a different embodiment of the decking panels 13 . In this embodiment, the outer legs 17 of the decking panels 13 are not Z-shaped as in the prior-discussed embodiment. Rather, the outer legs form an “L”-shape, with a generally vertical portion 50 and a generally horizontal lower end 51 . The upper ends 52 of the panel 13 comprise downwardly-curved free ends, as shown.
FIG. 12 depicts a method 100 for installing the decking system 10 according to an embodiment of the present disclosure. In step 100 , which is illustrated in FIG. 13 , a first decking panel 13 a is installed on a joist 12 . Although only one joist 12 is illustrated, it is understood that a plurality of joists 12 are required to support the decking panels 13 , as shown in FIG. 1 . The joist 12 has a first end 71 and a second end 72 . The decking panel 13 a is disposed upon the joist 12 near the first end 71 such that the outer legs 17 a and 17 b and inner legs 18 of the decking panel 13 a rest upon a top surface 70 of the joist 12 .
One or more fasteners 26 a is driven through the outer leg 17 b , which is the leg disposed at a first end 71 of the joist 12 . The fasteners 26 a are typically installed at every joist 12 location. Joists 12 are typically located at 12 ″, 18 ″ or 24 ″ centers, though other spacing configurations of joists 12 may be used.
In step 102 of the method 100 , which is illustrated in FIG. 14 , a plurality of clips 11 a are then clipped on the joists 12 such that the clip(s) 11 a restrain the outer leg 17 a of the decking panel 13 a . Although FIG. 14 shows only one clip 11 a , there may be a plurality of clips 11 a used down the length of the panel 13 a.
In step 103 of the method 100 , which is illustrated in FIG. 15 , a second decking panel 13 b is set on the joist 12 . The outer leg 17 c of the second decking panel 13 b is slid underneath the clip 11 a.
In step 104 of the method 100 , which is illustrated in FIG. 16 , a plurality of clips 11 b are then installed on the joists 12 such that the clip(s) 11 b restrain the outer leg 17 d of the decking panel 13 b.
In step 105 of the method 100 , which is illustrated in FIG. 16 , a third decking panel 13 c is set upon the joists 12 and an outer leg 17 e of the third decking panel 13 c is slid underneath the clip 11 b , as shown.
Referring to FIG. 17 , in the illustrated embodiment, the third decking panel 13 c is the last decking panel, and after it is in place, one or more fasteners 26 b are installed in an outer leg 17 f of the panel 13 c to secure the panel 13 c in place.
In step 106 of the method 100 , which is illustrated in FIG. 18 , fasteners 26 c and 26 d may be installed in the clips 11 a and 11 b to permanently secure the decking panels 13 a , 13 b , and 13 c in place.
Although the method 100 and the accompanying FIGS. 13-18 illustrate a decking system 10 comprising three (3) decking panels 13 a , 13 b , and 13 c , it is understood that a deck will generally comprise many more decking panels, which may be installed with the general method discussed herein. Further, although the method 100 and the accompanying FIGS. 13-18 illustrate and two clips 11 a and 11 b , it is understood that clips will preferably be installed at every intersection of a decking panel and a joist, and therefore multiple clips will generally be used.
This invention may be provided in other specific forms and embodiments without departing from the essential characteristics as described herein. The embodiment described is to be considered in all aspects as illustrative only and not restrictive in any manner. | A decking system comprised of decking panels and clips is provided. Each decking panels comprises a platform and downwardly-extending legs that rest on joists. Clips that clip onto the joists are inserted between adjacent decking panels and define a uniform gap between the panels. The clips further connect to the legs of the decking panels and hold the decking panels in place. Fasteners driven through the clips and into the joists rigidly affix the decking panels to the joists. |
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FIELD OF THE INVENTION
This invention relates to the mining industry and more particularly to the oil-and-gas extracting industry, hydrogeological industry, engineer-geological industry and water-supplying industry, and is intended for the use when cutting slot-shaped key seats by hydro-sandblasting method in the wellside zone of productive bed.
BACKGROUND OF THE INVENTION
The slot relieving of wellside zone of producing beds is known as one of the most effective methods for increasing productivity (output) of oil, gas, fill-in, hydrogeological, engineer-geological or water-supplying well.
This method provides creating of slots in the wellside zone, wherein the width, depth and orientation of the slots are predefined by known methods according to characteristics of the well and productive bed.
Practical cutting of slots having predetermined parameters is a very difficult technical problem, since the cutting is performed in complicated conditions of various rocks, temperatures, at great depth, in the presence of extracted product and/or washing liquids in the welbore, with remote control and monitoring only. One of the most successful techniques for cutting slots is the sandblasting hydro-abrasive perforation, in which the cutting is performed with a jet of water and sand at a very high pressure of liquid. Apparatus for implementing this technique is shown in close-up in FIG. 1 . It comprises a tubing (pipe) 1 which is rigidly joined with a housing tube (housing pipe) 2 , within which an inner tube 4 is moveably mounted coaxially relative to housing 2 (and to a gap 3 ), the inner tube being spring-loaded from below with a cock spring 5 . A ball valve 6 is mounted at the edge of inner tube 4 , and a perforator 7 is mounted above that valve. In the inter tube gap 3 , a hydro-brake 8 is formed comprising two vertical hermetic chambers 9 and 10 constrained by plugs 11 and 12 . The chambers are filled with liquid and separated by a piston 14 having a channel 15 for cross-flow of liquid between the chambers, the top plug 11 being rigidly joined with the case 2 and moveably joined with the inner tube 4 . The piston 14 is rigidly joined with the inner tube 2 and moveably joined with the case 2 . The bottom plug 12 is moveable relative both tubes.
The apparatus in FIG. 1 operates as follows. The outer tube 2 is jointed by means of pipe coupling (like a collar) with the tubing 1 . The second end of tubing 1 is connected to a pump unit of the equipment on the surface. The top chamber 9 is filled with viscous liquid, wherein the amount of liquid for each cutting process is chosen in accordance with the slot length and depth calculated in advance, based on the known parameters of the channel 15 (capillary) connecting the chambers 9 and 10 , temperature dependence of the sizes of the channel and the fluidity of liquid, as well as the pressure of the pump unit.
Then the housing 2 of the apparatus (along with the inner tube 4 , hydro-brake 8 , cock device 5 , hydro-abrasive perforator 7 , and ball valve 6 disposed therein) is lowered to the predetermined depth, so that nozzles of hydro-abrasive perforator 7 are in the place of the well where the top edge of the formed slot should be cut. A ball is dropped into the inner tube 4 (in order to close the ball valve 6 ). The pump unit of the surface equipment is then turned on, and it begins to pump the abrasive mixture with the predetermined (rated) pressure into the inner tube 4 . The mixture passes down to the ball valve 6 and closes it tightly. The hydro-abrasive perforator 7 , via nozzles, begins to cut slots, first in the casing walls, then in the wellside zone. The depth of cutting of a future slot depends, in particular, on the time during which the cutting is performed. Pressure within the inner tube 4 (through which the abrasive liquid is pumped under pressure) pushes the inner tube 4 down and out of the outer tube (housing) 2 rigidly mounted on the tubing 1 . A slow cross-flow of liquid from the top chamber 9 of hydro-brake 8 into the bottom chamber 10 occurs, predetermined by the time of the cross-flow defined by the channel 15 . Thus, the inner tube 4 with the perforator 7 mounted thereon is slowly lowered down, and the rate of its movement defines the depth of (slot) cutting. At that time, only the cock spring 5 pushes from below against the plug 12 of the bottom chamber 10 , which pressure is chosen essentially less than the pressure against the top plug 11 . In other words, the pressure of the cock spring 5 does not impede the liquid to cross-flow from the top chamber 9 into the bottom chamber 10 . This process of slow lowering (in the presence of pressure in the tubing 1 ) lasts until all the oil from the bottom chamber is forced to flow into the top chamber. I.e., the characteristics of liquid poured initially into the bottom chamber 9 define the height of cutting, or the future slot. The duration of the cross-flow defines the rate of lowering of the apparatus for cutting slots, i.e., the depth of cutting of such slot. If the necessary cutting height is achieved before all the oil in the top chamber cross flows into the lower chamber, then at that moment the pressure in the tubing 1 is released, and the process of cutting the slot and the liquid cross-flow is stopped. In doing so, since the pressure against the top plug 11 of hydro-brake 8 is stopped, the cock spring 5 pushes liquid out of the top chamber 9 into the bottom chamber 10 while raising the inner tube 4 into its initial position. The same process occurs after all the oil is squeezed into the bottom chamber 10 , if the pressure in the tubing 1 is withdrawn at that time.
An effective example of such an apparatus for cutting slots by hydro-abrasive perforator, which apparatus being used for developing production columns with a slot and creating vertical relieving slot-shaped cavities in the wellside zone, could be the apparatus 4, the design of << >>[Special Designing Bureau “Sevmorgeologiya”, RU], which operates in the above described manner. Known are another similar apparatuses. The closest analog is the apparatus according the U.S. Pat. No. 6,652,741 issued Nov. 25, 2003.
Now the processes taking place in the process of cutting slots by hydro-abrasion will be analyzed. Essentially in all known apparatuses of this type, a movement of the hydro-abrasive perforator 7 occurs from top to bottom by a pressure in the tube space. The pressure in the tube space is created for operation of a hydro-abrasive jet. Because of the pressure differential between the tube space and the annular space (outside the tube) at hard-alloy nozzles of the hydro-abrasive perforator 7 , an abrasive particle is “charged” with energy (the particle outlet velocity from the hard-alloy nozzle reaches several meters per second). When hitting the production column wall and then the rock, a particle “performs” work: it destroys metal and rock. Hydro-abrasive perforator 7 is lowered into a well on tube 1 . The main part in this apparatus is the hydro-brake 8 , sealed relative to the housing 2 , which is rigidly joined with the column of tube 1 . The inner tube 4 sealed relative to the housing 2 can move a fixed distance limited by top plug 11 and bottom plug 12 . The piston 14 is disposed in the middle of a stroke between the plugs, which piston is implemented as a seal having a capillary through hole, i.e., the channel 15 . The space between the top plug 11 and the piston 14 with the capillary, which is previously referred to as the top chamber 9 of hydro-brake 8 , is filled with viscous liquid. The space between the bottom plug 12 and the piston 14 with the capillary, which is previously referred to as the bottom chamber 10 of hydro-brake 8 , is filled with viscous liquid. Pressure in the tube space causes the displacement of the inner tube 4 relative to the housing 2 due to the cross-flow of viscous liquid from the bottom chamber 10 into the top chamber 9 . The rate of that displacement is adjusted by the length and the cross-section of the capillary, and the selection of the viscosity of the liquid and the cross-section and length of the capillary, so that the displacement rate is predetermined for the optimal operation of hydro-abrasive perforator 7 under the conditions of the face of well (the temperature and working pressure in the tube space).
The bottom seal-plug 12 is made moveable relative to the inner tube 4 and housing 2 , and the bottom plug 12 is spring-loaded relative to the housing by the cock spring 5 . Thus, pressure is created in the bottom chamber 10 of hydro-brake 8 of hydro-abrasive perforator 7 , which pressure ensures the initial position of the bottom plug 12 , and, therefore, the inner tube 4 with the hydro-abrasive perforator 7 , in the upper top position. Pressure of the cock spring 5 in the bottom chamber 10 of the engine of hydro-abrasive perforator 7 (cock force) is chosen such that this force ensures the raising of hydro-abrasive perforator 7 into the upper top position not exceeding 30% of the forward stroke force exerted by the working pressure in the tube space.
More commonly, the back stroke or the cock of the engine of hydro-abrasive perforator 7 occurs due to the straightening the spring 5 which encompasses the inner tube 4 inserted between the housing of hydro-brake 8 and hydro-abrasive perforator 7 . The lower end of the cock spring 5 is pushed against the perforator housing, and spring's upper end is pushed against the bottom plug 12 of the hydro-brake 8 . A displacement of the inner tube 4 relative to the case 2 compresses the spring 5 because of working pressure in the tube space. Once the pressure in the tube space and the annular space is equalized, the spring 5 straightens and pushes out the inner tube 4 with the perforator 7 into the upper top position.
The signaling device 35 ensures control of the rate of displacement of hydro-abrasive perforator and provides information about completion of the working stroke of the hydro-abrasive perforator. This device is, e.g., all upward pin mounted under the ball valve 6 at a holder rigidly jointed with the housing 2 . Said pin opens up the ball valve 6 at the end of the working stroke of hydro-abrasive perforator 7 , at which time the pressure in the tube space drops sharply, informing of the completion of the working stroke.
Using such apparatus, it is possible to open up a production column and create slot-shaped key seats in the wellside zone of the productive bed. During operation of such apparatus in a well, a foreman gets information on the hydro-abrasive perforator displacement rate, the completion of hydro-abrasive perforator engine working stroke, the condition of the hard-alloy nozzles during the operation. There is a possibility to initiate forward or backward washing of the well at any stage of the operation in the well, supply the fraction-treating solution, drive the pressurized solution into a formation, and, when necessary, perform the hydraulic formation fracturing.
In spite of the merits of said apparatus, there are some the common drawbacks:
Unpredicted stoppages and alterations of rate (depth) of slot cutting are unavoidable, since all the known hydro-abrasive perforator engines work on the principle of a hydro-brake: the cross-flow of viscous liquids from one chamber to another through a capillary, i.e., a movement rate is set by the capillary's length and cross-section. The reason for stoppages and alterations is the attenuation of the movement of the liquid movement through the capillary. In the case of such a stoppage or essential alteration of the rate, it is necessary to raise the face equipment and readjust it. This is a very costly and lengthy operation.
Dependence of the slot forming rate on temperature. It is known that the viscosity of a liquid depends on its temperature. In order to set the rate of the movement (displacement) of hydro-abrasive perforator of the apparatus in a well during operation (i.e., under the real conditions), it is necessary to perform a series of complicated operations on the surface. The operations related to simulating the working conditions in a well and to calculating a face temperature changes during stoppages while washing the well, and at various rates of pumping in cycle and during the discharge. In addition, the accuracy of such calculations is rather low, which reflects on operation quality and reliability.
Duration of operation for opening a ball valve at the perforator edge, i.e., the operation of extracting said ball. The ball valve is opened by a backward washing process at a speed permitting to raise the ball up to wellhead and to extract it from the tube space. Depending on the depth of the operation, the operation of extracting the metal ball from the tube space requires from one to three, and sometimes five hours. It is necessary to close the ball valve in order to resume a hydro-abrasive perforator working stroke and to maintain pressure differential at the hard-alloy nozzles in the perforator. This procedure is implemented by repeatedly inserting the metal ball into the tube space. Once reaching the hydro-abrasive perforator, the metal ball blocks the aperture in its edge. Supply of working liquid—the pulp—will occur thereafter only through the hard-alloy nozzles. In order to switch to other operation, such as the forward or backward washing of well, insertion of technological solution, replacement of the pulp by a technological solution, hydraulic fracturing of formation, etc., it is again necessary to have a forward open edge of the hydro-abrasive perforator, or else all the operations having to do with the supply of the liquid into tubing 1 encounters the hydraulic resistance of the hard-alloy nozzles.
Presence of signaling device in the lower part of the face equipment, in fact, shuts off the “forward” flow of the liquid from the hydro-abrasive perforator's edge. It is impossible to perform cleaning of a sump in the well from the accumulated sludge and sand, and it is impossible to place an instrument onto the face in order to packer release it and for other purposes.
In other words, the known apparatuses are insufficiently efficient, insufficiently convenient, reliable, stable in time, and they are temperature dependent.
SUMMARY OF THE INVENTION
The object of the invention is to decreasing the enumerated drawbacks, and specifically, to increase the efficiency of an apparatus for cutting slot-shaped key seats in a well by hydro-sandblasting method, to increase convenience, reliability and temporal stability of that apparatus, as well as to decrease its temperature dependence.
This object is solved by the improvement in the known apparatus for cutting slot-shaped key seats in a well by hydro-sandblasting method. In particular, said apparatus comprised a tube housing rigidly and hermetically joined with an end of the pump-compressor tubing within which an inner tube is moveably and coaxially mounted with regard to a gap. Said inner tube is spring-loaded from below with a cock spring, wherein at the lower end of said inner tube is mounted a hydro-abrasive perforator with a ball valve, wherein the perforator is disposed above the ball. A hydro-brake is disposed inside the gap between the inner tube and the tube housing and includes two vertical hermetic chambers limited by a top plug and a bottom plug, wherein said chambers are filled with a viscous liquid and divided by a piston with a hole for the cross-flow of said viscous liquid between said chambers. The top plug is rigidly joined with the housing and moveably joined with the inner tube, the piston is rigidly joined with the inner tube and moveably joined with the housing, and the bottom plug is moveable relative said both tubes. The essential improvements and additions are the following:
the channel between said chambers of the hydro-brake is made self-adjusting, e.g., in the form of elastically pressed against each other a matrix and a punch which can shift relative to each other. The matrix and the punch have matching recesses and protrusions of the same shape, the protrusions being larger than the recesses;
the recesses and protrusions of said matrix and punch could be chosen in the shape of a trapezoid;
the recesses of said matrix could be chosen in the shape of a trapezoid and the protrusions of said punch could be chosen trianglular;
the matrix of the hydro-brake could be made of elastic material (for example, of caprolactam, a variety of the polytetrafluorethylene rubber, etc.) having the lesser hardness than the punch (for example, aluminum);
the recesses and protrusions of said matrix and punch could be the concentric circles, wherein the inlet of the channel for cross-flow of a viscous liquid is disposed in the center;
the materials of the matrix and the punch of the hydro-brake can have different thermal expansion coefficients, for example, the matrix can be made of caprolactam and the punch can be made of aluminum. Thus, it is possible to decrease the influence of temperature changes by altering the channel cross-section proportionally to the temperature, so that the volume of the cross-flowing liquid remains constant.
Besides, after checking the hermetical tightness of the pumping-compressing tubing column prior to cutting slots and at the completion of work, an upper ball valve could be mounted onto the upper end of the inner tube to eliminate the step of washing out the ball valve, wherein the diameter of the upper ball valve is greater than the diameter of the lower ball valve, A socket for catching the balls is disposed above the valve, which socket is divided by vertical walls into three sectors, the first sector being connected at the bottom only with the second, adjacent sector, the second sector being connected at the top with the upper end of the socket by a passage, wherein the second and third sectors being connected to each other in their upper part by a hole having a diameter greater than the diameter of the largest ball. A reflecting lattice is disposed between the upper end of the inner tube and the pumping-compressing tubing and above the second and third sectors. The cell size of the lattice is smaller than the diameter of the smaller ball. The lattice is made tilted relative to the socket wall, rising to the socket wall at an angle of at least 60°.
Moreover, in order to cut slots not only along the generator line of the tubing column cylinder, but at a given angle (pitch) to the generator line, the apparatus is enhanced with a guiding template disposed above the perforator housing and rigidly connected with the housing, said template being made in the form of a tube with slots into which the heads of the pins mounted on the lower part of the cock housing are inserted. The slots and the pins define a trajectory of the displacement of the hydro-abrasive perforator's nozzles along the cock housing.
Moreover, in order to receive a signal about the completion of the perforator stroke, through openings/orifices could be made in the tube housing above the upper plug, the openings/orifices being normally closed with the differential piston. The moveable gate of the differential piston is implemented with an option to open during a downwards vertical displacement. At the upper end of the inner tube an external protrusion is made for engaging the moveable gate of the differential piston.
BRIEF DESCRIPTION OF THE DRAWINGS
The essence of the invention is explained with the following drawings:
FIG. 1 shows an example of a structural diagram of the apparatus for cutting slot-shaped key seats in a well by a hydro-sandblasting method;
FIG. 2 shows an embodiment of an assembly for a cross-flow of a liquid between the hydro-brake chambers;
FIG. 3 shows an embodiment of the guides for determining the slot cutting trajectory;
FIG. 4 shows an example of construction for catching a ball; and
FIG. 5 shows an example of a device for signaling a completion of a stroke of a tube.
DETAILED DESCRIPTION OF THE INVENTION
The following references are included in the drawings:
1 —the tubing; 2 —the housing, the outer tube; 3 —the gap between tubes of the apparatus; 4 —the inner tube; 5 —the cock device; 6 —the ball valve; 7 —the hydro-abrasive perforator; 8 —the hydro-brake; 9 and 10 —the top and bottom chambers; 11 and 12 —the top and bottom plugs; 14 —the moveable piston between the chambers; 15 —the channel in the piston; 16 —the body of a dosing device; 17 —the punch; 18 —the matrix, 19 —the spring; 20 —the press; 21 —channels of free cross-flowing of a liquid; 22 —the guiding template; 23 —the template slot; 24 —pins; 25 —the socket for catching balls; 26 —dividing walls; 27 —the first sector; 28 —the second sector; 29 —the third sector; 30 —the reflecting lattice; 31 —through openings/orifices; 32 —the differential piston; 33 —the differential piston's moveable gate; 34 —external projections of the inner tube (for engaging the differential piston's moveable gate); 35 —the signaling device.
The structure diagram of the apparatus (as well as the closest analog in FIG. 1 ) comprises a pumping-compressing tubing 1 rigid joined with a housing tube 2 . Within housing 2 an inner tube 4 is mounted moveably and coaxially relative the housing 2 (coaxially also relative to a gap 3 ), the inner tube being spring-loaded from below with a cock spring 5 . A ball valve 6 is mounted at the edge of inner tube 4 , and a perforator 7 is mounted above that valve. In the inter tube gap 3 , a hydro-brake 8 is mounted, the hydro-brake comprising two vertical hermetic chambers 9 and 10 . Said chambers are limited at the top and at the bottom by plugs 11 and 12 , the chambers are filled with a viscous liquid. They are separated by a piston 14 having a through hole 15 for the cross-flow of a liquid between chambers. The top plug 11 is rigidly joined with the housing 2 and moveable joined with the inner tube 4 . The piston 14 is rigidly joined with the inner tube 4 and moveable joined with the housing 2 . The bottom plug 12 is moveable relative both tubes.
Referring to FIG. 2 , an embodiment of the channel for the cross-flow of a liquid between the two hydro-brake's chambers, i.e., the assembly for the cross-flowing of a brake liquid/fluid, comprises the housing 16 with its lower base being the punch 17 . The matrix 18 is overlaid and pressed to the punch 17 with the spring 19 and press 20 threaded into the housing 16 . Channels 21 for the free cross-flowing of the fluid are made through the massive press 20 .
Referring to FIG. 3 , an embodiment of guides for determining the slot cutting trajectory comprises the guiding template 22 jointed rigidly with the housing of perforator 7 ; pins 24 are inserted into the slots 23 of the template 22 , which pins are screwed into the housing of the cock spring 5 . As the perforator 7 moves, it will turn at an angle set by the slot 23 of the template 22 due to the pins 24 screwed into the housing of the cock device 5 . The slope of the slot cut by the perforator 7 will repeat the slope of the slot 23 in the guiding template 22 .
Referring to FIG. 4 , an embodiment of a ball catcher is shown. The socket 25 for catching the balls comprises the socket having inner vertical walls 26 and divided into three sectors. The first sector is connected by a passage only with the second, adjacent sector 28 . The second sector 28 is connected by a passage with the lower end of the socket. The third sector 29 is connected at the top by a passage with the upper end of the socket 25 . In so doing, the second sector 28 and the first sector 27 are connected to each other at the lower part by a hole. The reflecting lattice 30 is disposed above the second sector 28 and the third sector 29 . The lattice has a cell size smaller than the diameter of the smallest ball. The lattice 30 is made inclined and rising to the socket wall.
Referring to FIG. 5 , an embodiment of the device signaling the completion of a stroke comprises openings/orifices 31 disposed above the hydro-brake top plug in the tube housing. The openings/orifices 31 are normally closed by the differential piston 32 having the moveable gate 33 . The moveable gate 33 of the differential piston 32 is implemented with an option to open during a downwards vertical displacement. At the upper end of the inner tube 4 an external protrusion 34 is made for engaging the moveable gate 33 of the differential piston 32 .
The apparatus for cutting slot-shaped key seats operates as follows. The housing tube 2 is jointed by means of pipe coupling with the tubing 1 , the second end of tubing 1 is connected to pump unit of the surface equipment. The top chamber 9 is filled with a viscous liquid. The amount of the liquid for each cutting process is chosen in accordance with the slot length and depth and calculated in advance based on the known parameters of the channel 15 (capillary) connecting the chambers 9 and 10 , temperature dependence of its sizes and the fluidity of liquid, as well as the pressure of the pump unit. Then the apparatus housing 2 (along with the inner tube 4 , hydro-brake 8 , cock device 5 , hydro-abrasive perforator 7 , and ball valve 6 disposed therein) is lowered to the predetermined depth, so that the nozzles of hydro-abrasive perforator 7 are disposed inside the well at the place where the top edge of the slot should be cut. A ball is dropped into the inner tube 4 (in order to close the ball valve 6 ). The pump unit of the surface equipment is turned on, and it begins to pump the abrasive mixture with the predetermined (rated) pressure into the inner tube 4 . The mixture passes down to the ball valve 6 and closes it tightly. The hydro-abrasive perforator 7 , via nozzles, begins to cut slots, first in the casing walls, then in the wellside zone. The depth of cutting of a future slot depends, in particular, on the time during which the cutting is performed. Pressure within the inner tube 4 (through which the abrasive liquid is pumped under pressure) pushes the inner tube 4 down and out the housing 2 rigidly mounted on the tubing 1 . A slow cross-flow of liquid from the top chamber 9 of hydro-brake 8 into the bottom chamber 10 occurs. Thus, the inner tube 4 with the perforator 7 mounted thereon is slowly lowered down, and the rate of its movement defines the depth of (slot) cutting. At that time, only the cock spring 5 pushes from below against the plug 12 of the bottom chamber 10 , which pressure is chosen essentially less than pressure against the top plug 11 . In other words, the pressure of the cock spring 5 does not impede the cross-flow of the liquid from the top chamber 9 into the bottom chamber 10 . This process of slow lowering (in the presence of pressure in the tubing 1 ) lasts until the all of the oil from the bottom chamber is forced to flow into the top chamber. I.e., the characteristics of viscous liquid poured initially into the bottom chamber 9 define the height of cutting, or the future slot. The duration of the cross-flow defines the rate of lowering of the apparatus for cutting slots, i.e., the depth of cutting of such slot. If the necessary cutting height is achieved before all the oil in the top chamber cross flows into the lower chamber, then at that moment the pressure in the tubing 1 is released, and the process of cutting slot and cross-flowing of liquid is stopped. In doing so, since pressure against the top plug 11 of hydro-brake 8 is released, the cock spring 5 pushes viscous liquid out of the bottom chamber 10 into the top chamber 9 while raising the inner tube 4 into initial position. The same process occurs after all of oil is squeezed out into the bottom chamber 10 , if the pressure in the tubing 1 is withdrawn at that time.
Turning again to FIG. 2 , the hydro-brake 8 , which is an device for the cross-flow of a viscous liquid between chambers, operates as follows. It comprises two hermetic chambers 9 and 10 disposed vertically and limited by the top plug 11 and the bottom plug 12 . Said chambers are filled with viscous liquid and divided by the moveable piston 14 . The piston has the channel 15 for the cross-flow of viscous liquid between chambers, the top plug 11 rigidly joined with the case 2 and moveably joined with the inner tube 4 , the piston 14 is rigidly joined with the inner tube 4 and moveably joined with the case 2 , and the bottom plug 12 is moveable relative to the both tubes and pushes against the stop mounted at the inner side of the hydro-brake housing. The displacement of the plug 12 ensures the pressure equal to the pressure outside of tubes, which reduces the requirements to the strength of the housing of hydro-brake 8 . The downwards displacement of the inner tube 4 occurs due to the pressure created in the tubing 1 and inner tube 4 . The rate of that displacement depends on the rate of the cross-flow of viscous liquid through the channel 15 (capillary) in the piston 14 . The pressure within the inner tube 4 (through which the abrasive liquid is supplied under pressure) pushes the inner tube 4 down and out the housing 2 rigidly mounted on the tubing 1 . A slow cross-flowing of viscous liquid from the top chamber 9 of hydro-brake 8 into the bottom chamber 10 occurs, wherein the time this cross-flowing depends on the channel 15 . Thus, the inner tube 4 with the perforator 7 mounted thereon is slowly lowered down, and the rate of its displacement defines the depth of (slot) cutting. At that time, only the cock spring 5 pushes from below against the plug 12 of the bottom chamber 10 . That pressure is chosen to be essentially less than pressure on the top plug 11 , i.e., the pressure of the cock spring 5 does not impede the liquid from cross-flowing from the top chamber 9 into the bottom chamber 10 . This process of slow lowering (in the presence of pressure in the tubing 1 ) lasts until the all of the oil disposed in the bottom chamber is squeezed into the top chamber. The volume of viscous liquid initially filled into the bottom chamber 9 defines the height of the cutting process, or the future slot. The duration of the cross-flowing process defines the rate of lowering of the apparatus for cutting slots, and, therefore, the depth of the slot. If the necessary cutting height is achieved before all the oil in the top chamber is used up, then at that moment the pressure in the tubing 1 is released, and the process of cutting the slot and the cross-flowing of liquid is stopped. When that happens, since the pressure against the top plug 11 of hydro-brake 8 is released, the cock spring 5 pushes viscous liquid out of the bottom chamber 10 into the top chamber 9 while raising the inner tube 4 into its initial position. The same process occurs after the all of the oil is squeezed into the bottom chamber 10 , if the pressure in the tubing 1 is released at that time.
Turning back to FIG. 3 , the guiding device for determining the direction of slot cutting operates as follows. While the perforator 7 moves downwardly due to the working pressure in the inner tube 4 , the guiding template 22 joined rigidly to the perforator 7 . The perforator 7 turns at an angle defined by the slots 23 of the template 22 and the pins 24 threaded into the body of the cock spring 5 . The slope of the vertical symmetry axis of the slot relative to a vertical line will repeat the slope of the slot 23 of the guiding template 22 .
Turning back to FIG. 4 , the socket 25 for catching balls operates as follows. A ball dropped into the tubing passes through the first sector 27 , since the two other sectors 28 and 29 are closed with the reflecting lattice 30 . Then, depending on the diameter of a ball, the ball falls into a socket of one of valves and seals it. After the reverse washing at a speed sufficient to raise the ball valve 6 into the tubing 1 , the ball enters the second sector 28 , hits the reflecting lattice 30 from below and falls into the “dark” third sector 29 . The inner tube 4 is now empty, and all valves are open. That way the unencumbered forward and backward washing of the well can occur.
Turning back to FIG. 5 , the device signaling the completion of a stroke of the inner tube 4 operates as follows. The inner tube 4 is lowered down during the work cycle and reaches the end of the cycle when its upper end reaches the top plug 11 of the hydro-brake 8 . Openings/orifices 31 connecting the inner space of tube with the outside of the tube are disposed above top plug in the tube housing 2 and are closed by the differential piston 32 having the moveable gate 33 in the normal position. In the upper part of the inner tube 4 is arranged the external projection 34 . At the end of the stroke, the projection 34 pushes against the moveable gate 33 and opens the openings/orifices 31 due to the movement of the differential piston 32 . The process goes on in an increasing manner, since after connecting the inside and outside of the tube the differential piston 32 cannot remain in the upper position, and moves into its lower position under its own weight and under the force of the flow incoming into openings/orifices 31 . At the surface, this process can be detected by a pressure drop in the tube space due to the presence of additional circulation between the inside and outside of the tube.
The proposed technical solutions comprise a number of important improvements distinguishing it advantageously from all analogous devices. Let us consider this in more detail.
1) The channel 15 through which viscous liquid cross-flows between the hydro-brake chambers 10 and 9 is formed between the matrix 18 and the punch 17 made as mutually coinciding recesses and protrusions. Since the depth of a recess is greater than the height of a protrusion, their space between them forms the section of the channel (capillary) 15 . The matrix 18 is elastically pressed against the punch 17 with a predetermined force, and the matrix and the punch can be displaced a short distance relative to each other. This displacement occurs if the pressure at one end of the channel 15 becomes greater than the pressure which joins the matrix and the punch together. Once the flow of the liquid through the capillary slows down, the pressure at one end of the channel 15 starts to exceed the shift force, and the moveable matrix 18 moves (shifts) relative to the punch 17 . The channel 15 widens, thereby eliminating the slowing down effect.
2) The shape of the recesses of the matrix 18 is chosen not semispherical, but, for example, as a trapezoid. Therefore, the smallest displacement of the matrix 18 relative to the punch 17 with the triangularly shaped protrusions recess alters significantly the cross-section of the channel, thereby eliminating the effect of slowing down of the flow of liquid through the capillary, and returning the channel into its initial, predetermined position once pressure equalizes.
3) The matrix 18 is made of an elastic material (e.g., of caprolactam, variety of polytetrafluorethylene-rubber, etc.) characterized by the lesser hardness than that of the punch 17 . At a predetermined push of the matrix 18 , the channel 15 has the predetermined cross-section, and the known flow rate of the liquid through the channel. Altering the strength of the push results in altering the cross-section of the channel 15 , therefore, altering (or setting) the speed of the hydro-abrasive perforator.
4) Recesses and protrusions could be made in the shape of concentric circles disposed at the surface of the matrix (or punch). The direction of the flow of viscous liquid is chosen from the center to the outer ends. Thus, the flat channel of a variable cross-section is provided. The flow and consumption of the liquid can be easily determined. The slowing down of the flow of the liquid through the channel can be eliminated.
5) The materials of the matrix and the punch have different thermal expansion coefficients. They are selected in such a way that the temperature variation within a given range proportionally decreases the cross-section of the channel. Then the volume of the liquid cross-flowing through the channel remains constant or at least changes less. For example, the matrix could be made of caprolactam and the punch could be made of duralumin. In practice, such a device flowed through itself 20–50 milliliters of MC oil per minute at the pressure differential 4.0–5.0 MPa in the temperature range from +20 to +70° C.
6) Information about the speed of the hydro-abrasive perforator is received via the signal of the completion of the perforator's stroke. Through openings/orifices are formed in the housing tube 2 that couples the hydro-abrasive perforator's engine with the pumping compressing tubing 1 , which through openings are normally closed by the differential piston. Once the inner tube 4 lowers into the lower bottom position, the inner tube moves the moveable gate of the differential piston by means of a special external protrusion and opens the through openings. Therefore, the inside and outside of the tube are connected via the openings. The completion of the working stroke is ascertained by a drop in the working pressure.
7) In order to shorten a time of washing out metal balls, i.e., valves, the socket 26 for catching balls is introduced into the construction of hydro-abrasive perforator moving device. This socket has an enlarged length as compared with the standard one for the size equal to the sum of diameters of all metal balls assumed to be used during operation. The socket diameter is equal to three diameters of the greatest metal ball assumed to be used plus the socket wall thickness ensuring a safe operation at the predetermined depth with an operation pressure and weight of apparatus for performing work plus eighteen millimeters, i.e., three wall arranged within the socket. The socket 26 is divided by separating walls into three sectors ( 27 – 29 ) for the whole length: the first sector 27 has a communication only with the second sector 28 , the third sector 29 has a communication with the upper socket end, and the second sector 28 has a communication with the lower socket end. In so doing, the first and second sectors connected with the upper and lower socket ends are connected each other in the bottom part by means of a hole having the diameter more than the diameter of the greatest metal ball. The third, “dark”, sector 29 is connected in the upper (“dark”) part by the hole with the second sector 28 having the connection with the lower part of socket by means of a hole having the diameter more than the diameter of the greatest metal ball. Such a device allows one to use a hydro-abrasive perforator with a nose-blade, which, in turn, allows one to perform the face washing and normalizing without additional tripping operation.
EXAMPLE
The present technical solutions were tested repeatedly in practice. It was not difficult to manufacture such an apparatus industrially, since all elements, materials, technologies necessary for the manufacturing of those apparatuses have long been developed. The cost of the claimed apparatus does not differ substantially from the cost of the analog devices.
The claimed apparatuses were tested for increasing the productivity of oil, gas and pressure wells and implemented in practice, particularly in the wells of the Yamburg gas-condensate deposit in January–February 2004, Yamburg, Russia, and in the wells of Yen-Yakhinskoe oil-gas-condensate deposit in July–August 2004, Novy Urengoy, Russia. These tests confirmed the suitability of the proposed apparatus for operation and its ability to achieve the stated tasks. Thus, the present apparatus was used in four productive beds in various wells were treated at the depths of 3060–3870 meters with the average thickness of 8–10 meters. In two cases, key seats were made at the at the 60° between of the vertical symmetry axis of the apparatus and a vertical line. In each case, the spiral-shaped slot was cut through the whole thickness of productive formation with the pitch of 1.2–1.3 meters. In all cases, a clear and unequivocal signal of the completion of stroke was received (32 times—the pressure dropped from 40–20 MPa to 8–12 MPa). In every case, upon completion of the work and then when washing was performed to remove sand and sludge (done twice), the balls were received in the socket of the catcher in 5–7 minutes of the backward washing process. The productivity of the wells was initially 30–60 thousands cubic meters of gas per day. Prior to making key seats in accordance with the present technology, at all of the referenced productive beds the work to increase productivity was performed by using other known methods: hydro-sandblasting perforation and slot cutting. In so doing, none of the known productivity increase methods has demonstrated a significant increase in productivity of those wells. After the wells were treated in accordance with the proposed method, their productivity has increased up to 120–160 thousands cubic meters per day.
Since the analogous devices were used at the same wells prior to the present invention, then it was possible to perform a direct comparison of their productivity. Labor-intensity of the identical operations has been reduced almost by a half (mainly due to accelerating of the extraction of valve balls, reducing the number of stoppages and reinstallations of the cutting equipment), and the productivity of treated wells has increased to 250–300% (due to the more precise cutting of the calculated slot sizes in the wellside zone). Besides, the lifetime of cutting devices and the convenience of their maintenance increased due to ensuring the stable mode of operation, more effective use of the nozzle resource (no cutting of the unnecessary), and operative control of the cutting process. Thus, the stated tasks of the present invention were implemented. | The invention relates to the field of mining, namely, to the oil and gas extraction, hydrogeologic, engineering and the geologic and water supply industry and provides an apparatus for the cutting of slot-like key seats in the well bore zone of productive strata by hydraulic abrasion. |
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This application is a continuation of application Ser. No. 07/186,993, filed 04/27/88, now abondoned.
This invention relates to packoff systems for pressure sealing the annulus between adjacent concentric tubular elements, such as a wellhead housing and a casing hanger in a subsea well, and more particularly to such packoff systems that provide a metal-to-metal seal between the elements.
BACKGROUND OF THE INVENTION
In the oil and gas industry, and especially in subsea or other underwater well drilling procedures, it is well established practice to employe an annular seal assembly, referred to as a packoff, between adjacent concentric wellhead elements, such as the wellhead housing and the casing hangers that support the casing strings in the well, to pressure seal the annuli between these elements. For many years these packoffs have included elastomeric or other non-metallic annular seal elements that, when energized into tight contact with the opposed wellhead and hanger surfaces, provided the requisite pressure barrier. However, the growing trend towards drilling deep wells into relatively high pressure strata, and the frequency encountering in these wells of hydrogen sulfide or other corrosive gases, has led to the development of packoffs with all metal seal elements to establish a metal-to-metal pressure barrier. Although some of the known packoffs with metal-to-metal seals function satisfactorily under certain conditions, there is a growing industry need for such packoffs that can be installed from a remote location without difficulty, that will withstand higher operating pressures than heretofore experienced, and tht will maintain the seal throughout wide fluctuations in pressure.
SUMMARY OF THE INVENTION
Broadly considered, the present invention comprises an improved metal-to-metal seal packoff system for establishing a high pressure metallic barrier between adjacent surfaces of concentric tubular elements, and especially for sealing the annulus between a wellhead housing and a casing hanger located concentrically therein, and for maintaining the metal pressure barrier or seal throughout relatively extreme pressure variations. The packoffs of this invention comprise assemblies of parts, including uniquely configured metal seal elements and seal energizers therefor, that cooperate in a novel manner to produce a significantly improved seal with considerably enhanced ability to withstand unusually high fluctuations in well pressures, that are relatively easy to assemble, and that are capable of installation as an assembled unit into a subsea or other remotely located wellhead without complicated procedures or other detrimental problems.
Each of the below described and illustrated embodiments of a metal-to-metal packoff according to this invention comprises a seal element with a pair of annular metal sealing lips that are energized, i.e. expanded, into pressure-tight contact with opposed annular metal surfaces of, for example, a wellhead housing and an inner casing hanger by the wedging force of an annular expander mandrel that has a cross-sectional configuration resembling that of a tuning fork with depending legs. The legs, actually annular axial flanges, of the mandrel are radially compressed during that wedging-type seal energization action to result in production of bending energy in the legs as well as in the lips of the seal element, which energy maintains the seal lips in pressure-tight engagement with the opposed wellhead and hanger surfaces throughout wide variations in well pressures to which the seal element may be exposed. Each of the described packoff seal embodiments is locked in a retracted, unenergized position while it is being run or otherwise placed in proper position in the wellhead, and activation to expand the metal seal lips into energized contact with the opposed surfaces of the wellhead and hanger cannot occur until purposefully performed by the operator through use of a packoff running tool.
The metal-to-metal seals established by the packoffs of the invention are designed to be backed up by annular elastomeric seals to provide a second sealing function which is desireable under certain circumstances, and when so equipped the secondary elastomeric seal elements preferably are slightly larger in diameter to provide a degree of protection of the metal seal lips during installation and other handling. Thus in tight-fitting locations the elastomeric seal elements can provide a primary or secondary seal between the wellhead and hanger independent of the seal provided by the metal seal element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a subsea wellhead housing surrounding the upper ends of three concentric strings of well casing, with the right half and upper portion of the left half of the drawing in vertical central section to show the packoff assemblies of the present invention installed between the housing and the casing hangers.
FIG. 2 is an enlarged fragmentary isometric view in vertical section of one of the packoff assemblies of FIG. 1.
FIG. 3 is an enlarged fragmentary view in vertical section showing the packoff assembly of FIGS. 1 and 2 in landed position between the wellhead housing and the adjacent casing hanger, but prior to setting it into functional metal-to-metal sealing condition.
FIG. 4 is a view like FIG. 3, showing the packoff set in its metal-to-metal sealing condition.
FIGS. 5-7 are enlarged fragmentary views in vertical section illustrating additional embodiments of the metal seal element of a packoff assembly according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a typical subsea wellhead system for suspending three casing strings at the seafloor, the system generally comprising an outer wellhead housing 10, first, second and third casing hangers 12, 14 and 16 for supporting outer, intermediate and inner casing strings 18, 20 and 22, respectively, in the housing 10, and first, second and third identical packoff assemblies 24, 26 and 28 for pressure sealing the annuli between the housing 10 and the hangers 12, 14 and 16, respectively. As seen best in FIGS. 3 and 4, each of the annular packoff assemblies comprises a two-piece body having upper and lower components 30, 32 rotatably interconnected by threads 34, a lock ring 36 surrounding and carried by the upper body component 30, an annular lock ring expander mandrel 38 also surrounding the upper body component 30 and retained on it above the lock ring by a snap ring 40, that resides partially in an inner groove 42 in the mandrel and around an outer cylindrical surface 44 of the upper body 30, and an annular metal seal element 46 secured to the lower end of the lower body component 32 by a plurality of circumferentially spaced stud and nut retainers 48 (only one shown). Each of the packoff assemblies further includes an anti-rotation ring 47 releasably secured to the upper body component 30 by a plurality of circumferentially spaced shear pins 49 (only one shown) to prevent relative rotation between the upper and lower body components 30, 32 until the packoff assembly is properly positioned and ready for energizing between the housing 10 and the hanger 14.
As shown best in FIG. 2, but also shown in FIGS. 3. and 4, the preferred embodiment of the packoff's seal element 46 comprises an annular metal base portion 50 and a pair of annular metal sealing lips 52, 54 that extend upwardly in a relatively diverging or V-shaped manner from the base 50, a pair of annular elastomeric seals 56, 58 surrounding the outer surfaces of the sealing lips 52, 54, respectively, and a pair of annular wire-mesh or other suitable type of anti-extrusion rings 60,62. The seal element 46 further includes a plurality of segmented spacers 64 having a somewhat tall, slender inverted mushroom shape in cross-sectional configuration, the spacers arranged circumferentially between the retainer studs 48. Each spacer 64 comprises a lower tapered base portion or head 66 that, in the assembled condition shown in the drawings, resides between the seal lips 52, 54, and a central web portion 68 that extends upwardly from the head 66 into a central annular space 70 defined by a pair of annular legs 72, 74 extending downwardly from the lower end portion 32a of the packoff lower body 32.
The annular legs 72, 74 of the packoff lower body 32 are dimensioned to fit tightly between the upper end portions 52a, 54a of the seal element sealing lips 52, 54 as seen in FIGS. 2-4, and their lower outer surfaces are tapered or contoured at 72a, 74a to establish a wedge-like relationship with these lips. Thus as the packoff lower body 32 is forced downwardly from its position shown in FIG. 3 into its FIG. 4 position by rotation of the upper body 30 during the setting procedure, the seal lips 52, 54 are mechanically wedged (spread) apart into pressure tight, metal-to-metal contact with the adjacent surfaces of the housing 10 and the hanger 14. During this seal lip spreading operation bending energy is imparted to the seal lips which functions to maintain them in positive, metal-to-metal contact with the wellhead and hanger over a wide range of well pressures and fluctuations thereof. The annular legs 72, 74 also incur some bending energy during this operation, and the webs 68 of the spacers 64 prevent these legs from experiencing excessive permanent deformation when the well annulus pressure below the packoff pushes up on the seal element from the bottom. The legs 72, 74 will not, however, permanently yield due to loading but will retain some bending energy when subsequent low operating pressures are encountered, thereby maintaining intact the metal-to-metal seal between the hanger and wellhead housing.
INSTALLATION OF THE PACKOFF ASSEMBLY
Each packoff assembly 24, 26, 28 is installed in the wellhead housing 10 by means of a running tool (not shown) attached to the lower end of a pipe string (not shown) that are controlled and manipulated from the surface drilling platform (not shown), a procedure generally well known in the industry. Referring to FIGS. 3 and 4 for illustrative purposes, once the casing hanger 14 has been lowered into position in the housing 10 and its casing string 20 has been cemented in place, the packoff assembly 26 is lowered on the running tool and landed on the hanger as shown in FIG. 3. In this position the packoff lower body 32 is locked against rotation by the cooperative action of an axial groove 14a in the upper outer surface of the hanger 14 and a mating axial rib 32b on the adjacent inner surface of the body 32. Should the rib 32b not be in proper alignment with the groove 14a as the packoff is being lowered, the running tool is rotated by rotation of the running string until the alignment is achieved and the landing step can continue.
The running tool is then rotated to the right, shearing pins (not shown) that releasably secure it to the packoff. As this rotation occurs the tool aligns with vertical slots 80 (FIG. 1) in the packoff and drops further into it, forcing the expander mandrel 38 down behind the lock ring 36 which, in response, expands fully into its wellhead housing groove 82, and causing the packoff anti-rotation ring 47 to shear the pins 49 and drop onto the upper end of the casing hanger 14 (FIG. 4) which thereby frees the packoff's upper body 30 to rotate.
The running tool is then further rotated to the right, causing corresponding right-hand rotation of the packoff's upper body 30. As this occurs the threads 34 between the upper body 30 and the lower body 32 cause these bodies to move in axial opposite directions, resulting in establishing a compressive force contained between the lock ring 36 and the casing hanger 14. This compressive force actuates the packoff seal element 46 to effect the desired metal-to-metal sealing engagement with the wellhead housing 10 and the hanger 14. Low torque is sufficient to achieve this seal element actuation, a highly desireable advantage with packoff assemblies of the present invention.
REMOVAL OF THE PACKOFF ASSEMBLY
The packoff assemblies of this invention can be removed from their set position in the wellhead housing 10 (FIG. 4) by lifting the expander mandrel 38 from behind the lock ring 36, allowing the ring to contract out of the housing groove 82 into its FIG. 3 position against the upper body surface. This releases the packoff from the housing, and frees it for withdrawal by merely lifting it vertically.
THE EMBODIMENTS OF FIGS. 5-7
FIG. 5 illustrates a modification of the packoff seal of FIG. 1-4, wherein annular elastomeric seals 90, 92 with annular surface grooves 90a, 92a are employed with the metal seal element 46 in place of the elastomeric seals 56, 58 and the anti-extrusion rings 60, 62. Also, the spacers 93 of this embodiment do not include a central web as present in the preferred embodiment.
FIG. 6 illustrates another metal seal element 94 with sealing lips 96, 98 of slightly different configuration than the corresponding lips 52, 54 of the FIGS. 1-4 embodiment. This metal seal element 94 also includes a pair of relatively small annular ribs 100, 102 that project upwardly and outwardly from the seal element base 104, and annular elastomeric seals 106, 108 of an undulate surface configuration that reside between the lips and the ribs. In this embodiment, the lower outer surfaces of the seal energizer portion 110 of the packoff lower body have radiused surfaces 112, 114 that bear against the inside surfaces of the legs 96, 98.
In the FIG. 7 embodiment the sealing lips 116, 118 of the uniquely shaped metal seal element 120 extend from near the outer edges of the elements base 122, and annular elastomeric seals 124, 126 with annular anti-extrusion rings 128, 130 are held captive between the ends of the lips and opposed shoulders 132, 134 on the seal energizer portion 136 of the packoff's lower body 138.
Even though the above described embodiments of FIGS. 5-7 differ in geometry from the preferred embodiment of FIGS. 1-4, it should be understood that the several corresponding parts and surfaces of these further embodiments provide the same functions in response to the same energization as that of the preferred embodiment. | An improved metal-to-metal seal packoff system for establishing a high pressure metallic barrier between concentric tubular elements, such as a wellhead housing and a casing hanger, including a seal element with a pair of annular metal sealing lips that are energized by the wedging force of an expander mandrel having a cross-sectional configuration resembling a tuning fork with depending legs. |
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[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application Ser. No. 61/039,864, filed Mar. 27, 2008, the disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to cylinder locks and particularly to pin tumbler cylinder locks with axial sliding detainers that provide a secondary locking mechanism in the cylinders.
[0004] 2. Discussion of the Background
[0005] An ongoing problem for people using locks is other people trying to pick these locks. Pin tumbler locks, a traditional type of lock, are so common that one can buy tools specifically designed to pick a pin tumbler lock. At the same time, pin tumbler technology is well known, and consumers are comfortable with pin tumbler keys. As described below, many have looked to develop an improved lock that is less susceptible to lock picking.
[0006] A. Sohm in U.S. Pat. No. 1,141,215 discloses a cylinder where the plug contains moveable wards, or sliders, that are pushed axially by the insertion of the key. The sliders have a key contact surface and a projecting blade that extends into the shell. The shell contains annular grooves that will accept the projecting blade when the sliders are correctly positioned by the key. When the blades are positioned within the annular grooves, the plug is free to turn.
[0007] The moveable wards or sliders of this invention are primary locking elements in the cylinder. They also directly block the rotation of the plug within the shell.
[0008] B. Perkut in German Pat. No. DE 2 828 343 teaches two locking concepts. The first one (see FIG. 5 ) is of a moveable ward or slider that is very similar to the Sohm patent, but is used as a secondary locking mechanism in a pin tumbler cylinder. The slider 12 ′ has a blade 34 that extends into the shell and must be pushed by the key to an unlocked position, whereupon the blade is located in an annular ring 38 in the shell. This slider directly blocks the rotation of the plug within the shell.
[0009] The second locking concept (see FIGS. 1-4 ) also uses the slider as an auxiliary locking mechanism. The slider 12 , interfaces with a ball 20 that extends from the plug into the shell and blocks the rotation of the plug. The slider has a cavity 18 that will accept the ball when the slider is pushed to a correct axial position. When both the primary tumbler pins 106 a and 106 b and the slider are correctly aligned, the rotation of the plug forces the ball out of the shell into the plug and into the cavity 18 in the slider. Thus the plug can rotate freely. This slider provides an intermediary member, the ball, to block the rotation of the plug within the shell. However the curved shape of a ball will allow the plug to turn even if the slider is not precisely positioned.
[0010] G. Brandt in U.S. Pat. No. 5,615,566 also discloses a cylinder where the plug contains an auxiliary locking element, or slider, in addition to the regular pin tumblers. The Brandt slider 16 has a projecting blade 54 that extends out the back side of the plug and fits into a notch 24 in the shell. When the slider is pushed to the rear-most position by the insertion of the key, the slider is pushed out of the notch in the shell, and if the tumbler pins are also correctly aligned, the plug is free to rotate. The slider directly blocks the plug from rotating within the shell.
[0011] P. Field et al. in U.S. Pat. No. 6,477,875 discloses a cylinder where the plug contains sliders 24 or 24 ′ that move axially and provide tertiary locking mechanisms in the cylinder. The rotating pins must be correctly elevated for the shear line and also be rotationally aligned for the sidebar mechanism 16 or 16 ′ before the cylinder will unlock. Additionally, the sliders in the Field invention have projecting blades 32 or 32 ′ that are used to block the sidebar mechanism. The slider must be positioned at the correct axial location before the sidebar can contact the rotating pins. This slider blocks the motion of the sidebar in the plug.
[0012] Additional detailed specifications of a sidebar cylinder with a P. Field et al. slider and the key interface is provided in U.S. Pat. No. 6,945,082.
[0013] B. Field et al. in U.S. Pat. Application Publication 2007/0137272 teaches a cylinder that contains a sidebar 18 that is axially positioned by the side of a key. When moved to the correct position, the ends of the sidebar are at a location to allow the sidebar to cam into the plug and contact the side of the keyblade. If the key blade is configured with a shape corresponding to the edge of the sidebar 36 , the sidebar can move and allow the plug to rotate. The sliding sidebar directly blocks rotation of the plug in the shell.
[0014] The inventor has found that these lock designs have room for improvement. In particular, these additional mechanisms require valuable space within a traditional pin and tumbler design, and thus require that locks incorporating these features must be large or, alternatively, if a large lock is not possible, these features must be foregone.
SUMMARY OF THE INVENTION
[0015] It is an object of this invention to provide a secondary locking mechanism within a cylinder whereby the primary tumbler pins are left unchanged and the secondary mechanism will provide for additional master keying levels without changing the key hole in the cylinder.
[0016] It is desirable to reduce the size and configuration of the components in a cylinder with an auxiliary slider mechanism, so that the mechanism can be used to key together, in the same key system, cylinders of various sizes and shapes.
[0017] It is desirable to provide a new smaller secondary locking mechanism in a cylinder, so that the key that will operate a slider and sidebar cylinder will also operate in a cylinder without space to accommodate a sidebar mechanism, thus providing expanded keying systems.
[0018] Aspects of the invention are embodied in a lock comprising a cylindrical plug having an axially-extending keyway adapted to receive a conforming key, a plurality of tumbler pins, an auxiliary locking pin, and a slider. The tumbler pins are disposed within radially-oriented tumbler pin holes formed in the cylindrical plug and adapted to control rotation of the cylindrical plug and are constructed and arranged to be engaged by a properly configured key inserted into the keyway and to be positioned by the key within their respective tumbler pin holes so as to permit the cylindrical plug to rotate. The auxiliary locking pin is disposed within the cylindrical plug and is moveable between a first position in which a portion of the auxiliary locking pin extends out of a hole formed in an outer wall of the cylindrical plug and a second position in which the auxiliary locking pin is retracted into the hole. The slider is disposed within the cylindrical plug and is moveable in an axial direction between a first position and a second position. The slider is constructed and arranged to be engaged by a cooperating key inserted into the keyway to move the slider from the first position to the second position, and the slider is operatively inter-engaged with the auxiliary locking pin such that the auxiliary locking pin is in its first position when the slider is in its first position and the auxiliary locking pin moves from its first position to its second position when the slider is moved from its first position to its second position.
[0019] Further aspects of the invention are embodied in a lock comprising a cylindrical plug having an axially-extending keyway adapted to receive a conforming key, a plurality of tumbler pins, and an auxiliary locking pin. The tumbler pins are disposed within radially-oriented tumbler pin holes formed in the cylindrical plug and adapted to control rotation of the cylindrical plug and are constructed and arranged to be engaged by a properly configured key inserted into the keyway and to be positioned by the key within their respective tumbler pin holes so as to permit the cylindrical plug to rotate. The auxiliary locking pin is disposed within the cylindrical plug and is moveable between a first position in which a portion of the auxiliary locking pin extends out of a hole formed in an outer wall of the cylindrical plug and a second position in which the auxiliary locking pin is retracted into the hole. The auxiliary locking pin includes a key contact projection extending into the keyway and constructed and arranged to be engaged by a conforming key to move the auxiliary locking pin from its first position to its second position as the conforming key is inserted into the keyway.
[0020] These and other features, aspects, and advantages of the present invention will become apparent to those skilled in the art after considering the following detailed description, appended claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an exploded perspective view of a cylinder lock with an auxiliary locking mechanism according to one embodiment.
[0022] FIG. 2 is a cross-sectional perspective view of the cylinder lock without a key inserted and with a slider and an auxiliary locking pin both in respective first positions.
[0023] FIG. 3 is an end view of the cylinder lock without a key inserted.
[0024] FIG. 4 is a side cross-sectional view of the cylinder lock along the line 4 - 4 in FIG. 3 with the slider and the auxiliary locking pin both in respective first positions.
[0025] FIG. 5 is a side view of the cylinder lock without a key inserted.
[0026] FIG. 6 is an end cross-sectional view of the cylinder lock along the line 6 - 6 in FIG. 5 with the slider and the auxiliary locking pin both in respective first positions.
[0027] FIG. 7 is a cross-sectional perspective view of the cylinder lock with a key inserted into the lock and with the slider and the auxiliary locking pin both in respective second positions.
[0028] FIG. 8 is an end view of the cylinder lock with a key inserted into the lock with the slider and the auxiliary locking pin both in respective second positions.
[0029] FIG. 9 is a side cross-sectional view of the cylinder lock along the line 9 - 9 in FIG. 8 with the slider and the auxiliary locking pin both in respective second positions.
[0030] FIG. 10 is a side view of the cylinder lock with a key inserted.
[0031] FIG. 11 is an end cross-sectional view of the cylinder lock along the line 11 - 11 in FIG. 10 with the slider and the auxiliary locking pin both in respective second positions.
[0032] FIG. 12 is a perspective view of a key for use in the cylinder lock of the present invention.
[0033] FIG. 13 is a rear perspective view of a slider for use in an auxiliary locking mechanism according to the present invention.
[0034] FIG. 14 is a front perspective view of the slider.
[0035] FIG. 15 is a bottom rear perspective view of the slider.
[0036] FIG. 16 is a top plan view of a cylinder plug of an alternative embodiment cylinder lock.
[0037] FIG. 17 is a bottom plan view of the cylinder plug shown in FIG. 16 .
[0038] FIG. 18 is a side view of a cylinder lock.
[0039] FIG. 19 is an end cross-sectional view of the cylinder lock along the line 19 - 19 in FIG. 18 showing an alternative embodiment without a key inserted and with an auxiliary locking pin in a first position.
[0040] FIG. 20 is a side view of a cylinder lock with a key inserted
[0041] FIG. 21 is an end cross-sectional view of the cylinder lock along the line 21 - 21 in FIG. 20 showing the alternative embodiment with the auxiliary locking pin in a second position.
[0042] FIG. 22 is an end cross-sectional view of the cylinder lock along the line 19 - 19 in FIG. 18 showing the alternative embodiment with the auxiliary locking pin in a third position.
[0043] FIG. 23 is a side view of a key for use in the alternative embodiment.
DETAILED DESCRIPTION
[0044] FIG. 1 illustrates an exploded view of a cylinder lock 10 according to one embodiment of the invention. Cylinder lock 10 includes a cylindrical plug 70 , a control sleeve 20 , a shell 40 , a faceplate 100 , and an auxiliary locking mechanism 120 The cylinder lock 10 shown in FIG. 1 is of the type known as a small format interchangeable core cylinder. This is for the sole purpose of illustrating an embodiment of the inventive lock incorporating an auxiliary locking mechanism and is not intended to be limiting, as the auxiliary locking mechanism could be incorporated into other locks as well.
[0045] The shell 40 includes an upper section 42 and a lower section 52 . Lower section 52 has a hollow, generally cylindrical configuration. The upper section 42 has a solid, generally cylindrical configuration and includes tumbler pin holes 44 which receive conventional tumbler pins 90 (i.e., pin stacks). Upper section 42 includes a recess 46 extending along the axial length of the shell 40 along the bottom of the upper section 42 . The shell 40 further includes a flanged protrusion 50 , configured to interlock with recessed portion 104 (e.g., a dovetail slot) formed in the faceplate 100 . The lower section 52 of the shell 40 is hollow to receive the control sleeve 20 and the plug 70 . Service holes 54 formed in the bottom of the lower section 52 of the shell 40 allow a locksmith to remove tumblers from the tumbler holes 44 to re-key the lock 10 . A cutaway section 56 is formed in the rear of the lower section 52 of the shell 40 .
[0046] The control sleeve 20 is housed inside the shell 40 . Control sleeve 20 has a hollow, cylindrical configuration with a raised portion 22 . Tumbler holes 24 formed in the raised portion 22 of the control sleeve 20 align with tumbler holes 44 formed in the shell 40 when the control sleeve 20 is inserted into the shell 40 , such that tumblers 90 inside may move up and down to control rotation of the plug 70 in a conventional manner. Service holes 30 formed in the bottom of the control sleeve 20 align with service holes 54 formed in the shell 40 . The control sleeve 20 includes a control lug 26 along part of one side of the raised portion 22 . Raised portion 22 of the control sleeve 20 is received within the recess 46 formed in the upper section 42 of the shell 40 , and control lug 26 interlocks with the bottom of the upper section 42 of the shell 40 to lock the control sleeve 20 within the shell 40 . The control sleeve 20 further includes an auxiliary locking pin hole 32 .
[0047] The faceplate 100 includes a guard 102 with a recess 104 (e.g., a dovetail slot) which mates with the flanged protrusion 50 of the shell 40 and a ring 106 which rests against the opening of the lower section 52 of the shell 40 .
[0048] The plug 70 is mounted for axial rotation within the control sleeve 20 , which is disposed within the lower section 52 of the shell 40 . Tumbler holes 72 are formed in the plug 70 and communicate with a keyway 80 formed axially into the plug 70 . Plug 70 further includes an auxiliary locking pin hole 78 . Tumblers 90 disposed within the tumbler holes 72 operate along with a key in a conventional manner to control rotation of the plug 70 . This rotating action is generally used to release a latching mechanism (not shown). A retainer groove 74 formed in the rear end of the plug 70 receives a retainer clip 76 for securing the plug 70 within the sleeve 20 and shell 40 .
[0049] Pin stacks 90 of various bottom pins 92 , master wafers, top pins 96 , and springs 94 are positioned in the tumbler holes 72 , 24 , and 44 . Arrangements of spring loaded pins provide master keying capability and are well known in the lock art.
[0050] The head 86 of the plug 70 has a stepped perimeter which mates with the ring 106 on the faceplate 100 . The head 86 of the plug 70 provides the entry to a keyway 80 . The entry has formed keyway guides 82 which extend across the face of the entry. These guides, formed by the depressions, may be useful in guiding a key (shown later) into the keyway 80 by redirecting the force of the oncoming key along the face of the depression such that the key is aligned with the keyway 80 .
[0051] The cylinder plug 70 of the small format interchangeable core cylinder shown includes two longitudinally extending blind bores 88 (see FIGS. 2 , 4 and 9 ) bored parallel to the keyway 80 from the rear portion of the barrel of the cylinder plug 70 . One bore 88 is formed on each side of the keyway 80 , and the two bores 88 engage with corresponding prongs of a tailpiece (not shown), all of which are rotatably disposed in the cylinder shell 40 , to operate the lock mechanism as the key turns.
[0052] The auxiliary locking mechanism 120 includes an auxiliary locking pin 122 , a pin spring 134 , a pin-actuating slider 136 , and a slider spring 152 . Further details of the auxiliary locking mechanism 120 are shown in FIGS. 2 , 4 , 6 , 7 , 9 and 11 .
[0053] The auxiliary locking mechanism 120 is housed inside the plug 70 . More specifically, the slider 136 and slider spring 152 are disposed within an axially arranged slider cavity 160 , and the locking pin 122 and the pin spring 134 are disposed with a pin cavity 170 formed generally a right angle to the slider cavity 160 (See FIGS. 4 and 9 ). The slider 136 is biased by spring 152 disposed between a back end of the slider 136 and a back end of the cavity 160 opposite the forward end of the slider cavity 160 (i.e., toward the head 86 of the plug 70 ).
[0054] The auxiliary locking pin 122 includes an upper shaft 124 , which is surrounded by the pin spring 134 , and a lower point, or tip, 128 that is in contact with the slider 136 . The auxiliary locking mechanism 120 effects auxiliary locking by the top 126 of the upper shaft 124 extending through auxiliary locking hole 78 and 32 (formed in the plug 70 and the control sleeve 20 , respectively) into gap 48 defined within recess 46 adjacent the raised portion 22 (see FIGS. 4 and 6 ). The locking pin 122 then resists rotation of the plug 70 by contacting the sides of hole 32 . The auxiliary locking pin 122 must provide enough strength to resist a rotational force upon the plug 70 . In particular, if a lock 10 were compromised by aligning the tumblers with the shear line (e.g., by bumping the lock), the auxiliary locking pin 122 ought to be able to resist rotation of the plug 70 . A preferred material for the auxiliary locking pin 122 is stainless steel.
[0055] The top 126 of the auxiliary locking pin 122 is sloped to conform with the peripheral curvature of cylindrical plug 70 .
[0056] The auxiliary locking pin 122 includes a radial shoulder 130 to provide a stop for the pin spring 134 . A shoulder projection 132 protrudes from the shoulder 130 toward the face of the locking cylinder 10 . The auxiliary locking pin spring 134 is disposed around the upper shaft 124 and extends from the shoulder 130 into a counterbore formed coaxially with pin hole 78 to provide a downward biasing force upon the auxiliary locking pin 122 . The shoulder projection 132 is rectangular in cross-section and is sized to conform to the sides of the auxiliary pin cavity 170 , as shown in FIGS. 6 and 11 , to ensure that the auxiliary locking pin 122 does not rotate around its longitudinal axis. Because the tip 126 of the locking pin 122 is sloped to conform to the plug 70 , it is important that the pin 122 maintain a consistent orientation and not rotate about its longitudinal axis. If the auxiliary locking pin 122 were to rotate about its longitudinal axis, the top 126 of the auxiliary locking pin 122 would slope in a direction not conforming with the curvature of the plug 70 .
[0057] The bottom tip 128 of the auxiliary locking pin 122 sits atop the slider 136 .
[0058] As shown in FIGS. 13-15 , slider 136 includes an angled notch 142 which defines angled side walls 144 , a rear body portion 138 , a spring hole 140 formed in the rear body portion 138 in an axial orientation with respect to the plug 70 , and a curved bottom portion 146 having a curvature generally conforming to the peripheral curvature of the plug 70 . Slider 136 further includes a side projection 148 defining a contact surface 150 . When the slider 136 is installed in the slider cavity 160 , the side projection 148 and the contact surface 150 extend into the keyway 80 , and the bottom portion 146 conforms to the curvature of the plug 70 , so the slider 136 is retained within the slider cavity 160 by the control sleeve 120 .
[0059] As shown in FIGS. 2 and 4 , the slider spring 152 , having one end inserted into spring hole 140 , urges the slider 136 toward a first position at the forward end of the slider cavity 160 . As shown in FIGS. 2 , 4 , and 6 , with the slider 136 in this forward position, the pin 122 contacts the top of the rear main body 138 of the slider, thereby holding the pin in a first position with the upper shaft 124 extending through the auxiliary pin locking hole 122 into the gap 48 to prevent rotation of the plug 70 and preventing the pin 122 , which is biased downwardly by the pin spring 134 , from moving from this first position. When engaged by a key (as described in more detail below), the slider 136 is moved, against the bias of the slider spring 152 , to a second position toward the back of the slider cavity 160 . Meanwhile, the tip 128 of the auxiliary locking pin 122 slides along the top of the slider and into the notch 142 , sliding along the angled wall 144 to the bottom of the notch 142 , as shown in FIGS. 7 , 9 , and 11 . With the pin 122 moved into this second position, the upper shaft 124 withdraws from the gap 48 , through the auxiliary pin hole 32 formed in the control sleeve 20 , so that the plug 70 may rotate within the control sleeve 20 .
[0060] When a key is removed, the slider 136 is allowed to move under the force of spring 152 from the second position to the first position toward the front of the slider cavity 160 . The tip 128 of the auxiliary locking pin 122 slides up along the angled wall 144 to the top of the rear main body 138 of the slider 136 . The upper shaft 124 again protrudes through auxiliary locking pin hole 32 into gap 48 , and the plug 70 is again locked against rotation.
[0061] Preferably, the angled side walls 144 of the notch 142 form an angle of about 90°. If the angles of the side walls 144 are too steep, then it will be difficult for the tip 128 of the auxiliary locking pin 122 to slide up the side wall 144 and out of the angled groove 142 as the slider 136 moves from the back, second position to the forward, first position. On the other hand, if the angles of the side walls 144 are too shallow, the linear distance required for the angled notch 142 to reach the necessary depth to permit the upper shaft 124 of the locking pin 122 to fully withdraw from the gap 48 will be too great, which will require an unnecessarily long slider.
[0062] A key 200 configured for use in the cylinder lock 10 is shown in FIG. 12 . Key 200 includes a bow 202 , which may include a key ring hole 204 , a shoulder, or key stop, 206 , and a key blade 208 . Key blade 208 includes a biting edge 210 having teeth 212 . A slider catch 218 is formed in a lower, forward edge of the key blade 208 . The slider catch 218 comprises a slider cut 220 , which is intended to move past the slider (not shown), and a slider contact surface 222 , which is intended to engage the slider contact surface 150 . The distal end of the key blade has a tip stop 224 . Blade profile features, such as longitudinal shelf 214 , may be provided to control access to the keyway by forming a keyblade and keyway to have conforming profiles permit the only the correctly-profiled key to be inserted into a keyway.
[0063] When key 200 is inserted into the keyway 80 , the teeth 214 of the biting 210 engage pin stacks 90 to elevate the tumblers to correct positions to unlock the plug 70 . The depth to which the key 200 can be inserted into the keyway 80 will be determined by the shoulder 206 or the tip stop 224 . Also, the slider contact surface 222 will engage the contact surface 150 of the slider 136 to move the slider from the first, locking position shown in FIGS. 2 , 4 , and 6 to the second, unlocked position shown in FIGS. 7 , 9 and 11 .
[0064] FIGS. 16-23 illustrate components of a cylinder lock according to an alternative embodiment of the invention. The cylinder lock according to this alternative embodiment, like cylinder lock 10 described above, includes an auxiliary locking mechanism which includes an auxiliary locking pin, but does not include a slider which actuates the pin. FIG. 18 shows a side view of a cylinder lock 310 , and FIG. 19 shows a cross-section of the cylinder lock 310 of FIG. 18 . Cylinder lock 310 includes a cylindrical plug 370 , a control sleeve 320 , a shell 40 , a faceplate 100 , and an auxiliary locking pin 422 As with cylinder lock 10 described above, cylinder lock 310 shown in FIGS. 18-22 is of the type known as a small format interchangeable core cylinder. This is merely for the purpose of illustrating this alternative embodiment of the inventive lock incorporating an auxiliary locking mechanism and is not intended to be limiting, as the auxiliary locking mechanism could be incorporated into other locks as well.
[0065] The shell 40 of the alternative embodiment shown in the figures is identical to shell 40 described above, and thus the description will not be repeated.
[0066] The control sleeve 320 is housed inside the shell 40 . Control sleeve 320 has a hollow, cylindrical configuration with a raised portion 322 . Tumbler holes 324 formed in the raised portion 322 of the control sleeve 320 align with tumbler holes 44 formed in the shell 40 when the control sleeve 320 is inserted into the shell 40 , such that tumblers (described above) inside may move up and down to control rotation of the plug 370 in a conventional manner. Service holes 330 formed in the bottom of the control sleeve 320 align with service holes 54 formed in the shell 40 . The control sleeve 320 includes a control lug 326 along part of one side of the raised portion 322 . Raised portion 322 of the control sleeve 320 is received within the recess 46 formed in the upper section 42 of the shell 40 , and control lug 326 interlocks with the bottom of the upper section 42 of the shell 40 to lock the control sleeve 320 within the shell 40 . The control sleeve 320 further includes an upper auxiliary locking pin hole 332 and a lower auxiliary locking pin hole 334 .
[0067] The faceplate 100 of the alternative embodiment and its engagement with shell 40 is identical to faceplate 100 described above, and thus the description will not be repeated.
[0068] The plug 370 is mounted for axial rotation within the control sleeve 320 , which is disposed within the lower section 52 of the shell 40 . Tumbler holes 372 are formed in the plug 370 and communicate with a keyway 380 formed axially into the plug 370 . Tumblers (described above) disposed within the tumbler holes 372 operate along with a key in a conventional manner to control rotation of the plug 370 .
[0069] Plug 370 further includes an auxiliary locking pin hole 378 , which includes an upper pin cavity 472 and a lower pin cavity 470 having a smaller diameter than the upper spring cavity 472 . As shown in FIGS. 16 and 17 —which show top and bottom plan views, respectively, of the cylinder 370 —an area, designated by reference number 382 , between the hole 378 and keyway 380 and one of the tumbler holes 372 is broached. The purpose of this broached area will be described below.
[0070] The auxiliary locking pin 422 is disposed within auxiliary pin locking hole 378 . The auxiliary locking pin 422 includes a shaft 424 , an upper tip 426 , a spring shoulder 430 , a key contact projection 432 , and a lower point, or tip, 428 . A pin spring 434 surrounds the upper shaft 424 . The auxiliary locking pin 422 effects auxiliary locking by the upper tip 426 of the auxiliary locking pin 422 extending from the auxiliary locking pin hole 378 through auxiliary pin hole 332 formed in the control sleeve 320 and into gap 48 defined within recess 46 adjacent the raised portion 322 (see FIG. 19 ). The locking pin 422 resists rotation of the plug 370 by contacting the sides of hole 332 . A preferred material for the auxiliary locking pin 422 is stainless steel.
[0071] The tip 426 of the auxiliary locking pin 422 may be sloped to conform with the peripheral curvature of cylindrical plug 370 .
[0072] The spring shoulder 430 of the auxiliary locking pin 422 provides a stop for the pin spring 434 . More specifically, spring shoulder 430 has a transverse dimension (e.g., diameter) that is greater than that of the upper shaft 424 and the upper tip 426 . The bottom of the spring shoulder 430 forms a radial flange that is substantially perpendicular to the longitudinal axis of the auxiliary locking pin 422 . In the illustrated embodiment, the top 426 has a smaller transverse dimension (e.g., diameter) than the spring shoulder 430 so as to fit within the gap 48 . Also, as seen in FIGS. 19 , 21 , and 22 , the lower pin cavity 470 has a smaller transverse dimension (e.g., diameter) than the upper pin cavity 472 . The change in dimension between the lower pin cavity 470 and the upper pin cavity 472 defines a radial ledge.
[0073] Pin spring 434 surrounds a portion of the upper shaft 424 and resides within the upper pin cavity 472 where it is retained between the radial flange defined at the bottom of the spring shoulder 430 and the radial ledge defined at the transition of the lower pin cavity 470 and the upper pin cavity 472 .
[0074] Pin spring 434 biases the auxiliary locking pin 422 upwardly. Thus, when the locking pin 422 is unengaged by a key, as shown in FIG. 19 , it is in a first position, extending, under the bias force provided by the pin spring 434 , through the upper auxiliary locking pin hole 332 of the control sleeve 320 to prevent the cylindrical plug 370 from rotating.
[0075] The auxiliary locking pin 422 also includes a key contact extension 432 , which extends laterally through the broached area 382 adjacent the lower pin cavity 470 into the keyway 380 . FIG. 20 shows a side view of the cylinder lock 310 with a key 500 inserted into the keyhole thereof. FIG. 21 is a transverse cross section of the cylinder lock 310 and key 500 taken through the auxiliary locking pin 422 . As shown in FIGS. 20 and 21 , when a properly configured key 500 (described in more detail below) is inserted into the keyway 380 , it engages the extension 432 and pulls the auxiliary locking pin 422 down into a second position in which the upper tip 426 of the pin 422 is retracted into the plug 370 to thereby permit the plug 370 to rotate with respect to the control sleeve 320 .
[0076] As shown in FIG. 22 , if the auxiliary locking pin 422 is moved down too far within the auxiliary locking pin hole 378 into a third position (for example, if engaged by the wrong key or if the pin is moved down too far in an attempt to pick the lock), the lower tip 428 of the pin 422 will extend through the lower auxiliary locking pin hole 334 of the control sleeve 320 to again prevent rotation of the plug 370 .
[0077] When the key is removed, the auxiliary locking pin 422 is allowed to move under the force of pin spring 434 from the second position shown in FIG. 21 back to the first position shown in FIG. 19 so that the upper tip 426 again protrudes through upper auxiliary locking pin hole 332 into gap 48 , and the plug 370 is again locked against rotation.
[0078] A key 500 configured for use in the cylinder lock 310 is shown in FIG. 23 . Key 500 includes a bow 502 , which may include a key ring hole 504 , a shoulder 506 , and a key blade 508 . Key blade 508 includes a biting edge 510 having teeth 512 . The key 500 also includes a key stop 516 .
[0079] A pin groove 514 is formed along the key blade 508 . The pin groove 514 comprises a groove, or channel, having a first portion 518 which receives the key contact projection 432 when the key 500 is first inserted into the keyway 380 and the auxiliary locking pin 422 is in its first position. Progressing along the key blade 508 , the pin groove 514 includes a transition 520 , which, in the illustrated embodiment, moves closer to the bottom edge of the blade 508 , to a terminal portion 522 of the groove 514 . As the projection 432 moves along the groove 514 , while the key 500 is inserted into the keyway 480 , it moves from the initial portion 518 , through the transition 520 , and down to the terminal portion 522 . The pin 422 is thus pulled down into the second position, retracted into the plug 370 , thereby allowing the cylinder to rotate, assuming the tumblers are also properly aligned.
[0080] The auxiliary locking pin 422 is installed into the plug 370 by dropping it down into the auxiliary pin locking hole 378 . The broached area 382 allows the pin 422 , with the extending projection 432 , to be inserted into the hole 378 .
[0081] In a further embodiment, a cylinder lock may include an auxiliary locking mechanism comprising more than one auxiliary locking pin of the type shown in FIG. 19 . That is, multiple auxiliary locking pins 422 can be provided along the length of the keyway 380 , each locking pin having a key contact projection 432 at a different height, so that the pins are lowered by different amounts to permit rotation of the cylinder plug. The pin groove provided in a proper key would be shaped to accurately position each locking pin 422 into its respective second position. If the wrong key is used, and one or more pins is(are) moved too little or too much, the upper tip 426 or the lower tip 428 of the locking pin 422 will be engaged in the upper pin hole 332 or the lower pin hole 334 of the control sleeve 320 to prevent the cylinder plug from rotating. Such an arrangement may not, however, be possible if the cylinder includes longitudinal bores (such as longitudinal bores 88 shown in FIGS. 2 and 4 ).
[0082] Thus, a preferred embodiment has been fully described above with reference to the drawing figures. Although the invention has been described based upon this preferred embodiment, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions could be made to the described embodiments within the spirit and scope of the invention. | A tumbler pin lock includes an auxiliary locking mechanism including an auxiliary locking pin to provide enhance locking in addition to the locking provided by the tumbler pins so that the lock remains locked even if the tumblers are picked or bumped into their unlocked positions. |
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BACKGROUND OF THE INVENTION
This invention relates to a bridge plug for use in wells. More specifically, this invention relates to a packer type bridge plug which may be set upon a wireline and retrieved upon a tubing string for use in wells.
In oil and gas wells it is desirable to have a bridge plug which will withstand high differential fluid pressures thereacross, can be set using a wireline and can be easily retrieved from the well.
Such a bridge plug is particularly desirable in wells where multiple formations are to be isolated for completion, testing and/or stimulation.
Some typical prior art retrievable packers and bridge plugs are disclosed in U.S. Pat. Nos. 3,244,233; 3,507,327; 3,584,684; 3,749,166; 4,078,606; 4,427,063 and in U.S. patent application Ser. No. 613,663, filed May 23, 1984, now U.S. Pat. No. 4,545,431.
STATEMENT OF THE INVENTION
The present invention is directed to a packer type bridge plug which will hold differential fluid pressure from either direction and may be set upon a wireline while being easily retrieved upon a tubing string. The easy retrieval of the bridge plug of the present invention is facilitated by the positive retraction of the upper and lower wedge members from beneath the slips during the retrieval process. The packer type bridge plug of the present invention comprises a J-slot retrieving mandrel, release valve sleeve, by-pass body, J-slot mandrel, ratchet body, upper shoe, packer elements, packer element spacer, lower shoe, packer mandrel case, packer mandrel, ratchet blocks, upper wedge member, slips, slip retainer sleeve, lower wedge member, and bottom coupling. Also shown are the bridge plug setting sleeve, adapter, tension stud, and the bridge plug retrieving tool for use in retrieving the bridge plug from the casing in the well bore.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a quarter-sectional view of the bridge plug of the present invention.
FIGS. 2A through 2D are cross-sectional views of the present invention.
FIG. 3 is an unwrapped view of a portion of the J-slot configuration of the J-slot mandrel of the present invention which is used to retrieve the bridge plug.
FIG. 4 is an unwrapped view of a portion of the J-slot configuration in one end of the J-slot mandrel of the present invention which is used to release the ratchets during the retrieval of the bridge plug.
FIG. 5 is a view of a portion of the ratchet thread on the center mandrel of the present invention.
FIG. 6 is a view of the retrieving tool used to retrieve the present invention from a well.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the bridge plug 10 of the present invention is shown.
As shown the bridge plug 10 comprises a tension stud 15, J-slot retrieving mandrel 16, release valve sleeve 18, by-pass body 20, J-slot mandrel 120, ratchet body 130, packer elements 132, packer mandrel case 136, packer mandrel 138, upper wedge member 250, slip retainer sleeve 280, lower edge member 290, slips 300 and bottom coupling 380.
The bridge plug 10 further includes other components and features which will be described hereafter.
Referring to FIG. 2A, a portion of the bridge plug 10 of the present invention is shown. Shown are a portion of the setting sleeve 12, adapter 14, tension stud 15, and a portion of the J-slot retrieving mandrel 16.
The setting sleeve 12 comprises an elongated annular cylindrical member having, on the exterior thereof, a plurality of wrenching flats 22 in exterior surface 24 and, on the interior thereof, first annular recess 26, threaded bore 28, second annular recess 30 and cylindrical bore 32.
The adapter 14 comprises a cylindrical member having, on the exterior thereof, first cylindrical exterior surface 34 and second cylindrical exterior surface 36 and, on the interior thereof, first annular recess 38, first threaded bore 40, second annular recess 42, first cylindrical blind bore 44, a plurality of longitudinal cylindrical bores 46 which allow fluid communication between bore 44 and the exterior of the adapter 14, second cylindrical blind bore 48 and second threaded bore 50. The adapter 14 further includes first threaded aperture 52, a plurality of apertures 54 which allow fluid communication between bore 44 and the exterior of the adapter 14, second threaded aperture 56, and annular recess 58 in the end 60 of the adapter 14.
The tension stud 15 comprises a cylindrical member having a first threaded end 62 which releasably threadedly engages second threaded bore 50 of adapter 14, a reduced diameter portion 64 and a second threaded end 66.
The portion of the J-slot retrieving mandrel 16 shown comprises a cylindrical member having, on the exterior thereof, frusto-conical annular surface 68 and first cylindrical surface 70 having, in turn, a plurality of J-shaped recesses 72 therein and blind bore 78 on one end thereof.
Referring to FIG. 2B, a further portion of the bridge plug 10 of the present invention is shown. Shown is the remaining portion of J-slot retrieving mandrel 16, release valve sleeve 18, by-pass body 20, a portion of J-slot mandrel 120 and a portion of setting sleeve 12.
The remaining portion of the J-slot retrieving mandrel 16 comprises an elongated cylindrical member having, on the exterior thereof, first cylindrical surface 70 having, in turn, a plurality of J-shaped recesses 72 therein, and second cylindrical surface 74 and, on the interior thereof, first threaded bore 76 which releasably, threadedly engages second threaded end 66 of tension stud 15, blind bore 78 and second threaded bore 80.
The release valve sleeve 18 comprises an elongated cylindrical annular member having, on the exterior thereof, cylindrical surface 82, on the interior thereof, bore 84, on one end, a plurality of longitudinal recesses or grooves 86, an annular rib 88 thereon and at least one threaded aperture 90 therethrough.
The by-pass body 20 comprises an elongated cylindrical member having, on the exterior thereof, threaded surface 92, first cylindrical surface 94, second cylindrical surface 96 having, in turn, a plurality of first annular recesses 98 therein containing annular elastomeric seals 100 therein which slidingly, sealingly engage bore 84 of release valve sleeve 18 and second annular recess 99, third cylindrical surface 102 and fourth cylindrical surface 106 and, on the interior thereof, blind bore 108, first bore 110 having, in turn, annular recess 112 therein containing annular elastomeric seal 114 therein and threaded bore 116. The by-pass body 20 further includes a plurality of apertures 118 which allow fluid communication between blind bore 108 and the exterior of by-pass body 20. Installed on first cylindrical surface 94 of by-pass body 20 is elastomeric member 119 which resiliently biases and sealingly engages the interior bore 84 of the end having annular recesses 86 therein of release valve sleeve 18 outwardly when sleeve 18 is retained in a first position on by-pass body 20.
The release valve sleeve 18 is releasably retained on release valve body 20 by a plurality of threaded shear pins 91 having a portion thereof threadedly engaging aperture 90 in sleeve 18 and having a portion thereof extending into annular recess 99 in release valve body 20.
Further shown in FIG. 2B is the upper end 122 of J-slot mandrel 120. The upper end 122 of J-slot mandrel 120 comprises a circular annular member having, on the exterior thereof, first cylindrical surface 124 which slidingly, sealingly engages seal 114 in first bore 110 of by-pass body 20, second cylindrical surface 142, and first threaded surface 126 which threadedly, releasably engages threaded bore 116 of by-pass body 20 and, on the interior thereof, bore 128.
Referring to FIG. 2C, another portion of the bridge plug 10 of the present invention is shown.
Shown are the remaining portion of the J-slot mandrel 120, the ratchet body 130, packer elements 132, packer element spacer 134, packer mandrel case 136, a portion of packer mandrel 138, ratchet blocks 140, a portion of upper wedge member 250, upper packer shoe 170 and lower packer shoe 172.
The remaining portion of the J-slot mandrel 120 shown in FIG. 2C comprises an elongated cylindrical annular member having, on the exterior thereof, second cylindrical surface 142, frusto-conical annular surface 143, third cylindrical surface 144, fourth cylindrical surface 146 having, in turn, a plurality of annular recesses 148 therein containing annular elastomeric seal means 150 therein, and fifth cylindrical surface 152 having, in turn, J-slots 154 formed therein and at least one aperture 156 therein and, on the interior thereof, cylindrical bore 128 therethrough.
The ratchet body 130 shown in FIG. 2C comprises an annular cylindrical member having, on the exterior thereof, first cylindrical surface 160, second cylindrical surface 162, third cylindrical surface 164 and first threaded surface 166 and, on the interior thereof, bore 168 therethrough and a plurality of rectangular shaped apertures 167 therethrough having, in turn, angular bottom and, if desired, top end surfaces 169.
Each packer element 132 comprises an annular elastomeric member having a bore therethrough.
The packer element spacer 134 comprises an annular cylindrical member having a bore therethrough.
The upper packer shoe 170 comprises an annular cylindrical member having, on the exterior thereof, cylindrical surface 174 and, on the interior thereof, threaded bore 176 which releasably threadedly engages threaded surface 166 of ratchet body 130.
The lower packer shoe 172 comprises an annular cylindrical member having a plurality of apertures 178 therein, each aperture 178 receiving a portion of threaded fastener 180 therein.
The packer mandrel case 136 as shown comprises an annular cylindrical member having, on the exterior thereof, first cylindrical surface 182 having, in turn, a plurality of wrenching flats 184 therein, second cylindrical surface 186 and threaded surface 188 and, on the interior thereof, bore 190 therethrough and, in the upper end thereof, a plurality of threaded apertures 192, each aperture 192 releasably, threadedly receiving a portion of threaded fastener 180 therein.
If desired, the lower packer shoe 172 may be made an integral part of the packer mandrel case 136 thereby eliminating threaded fasteners 180 and apertures 178.
The portion of packer mandrel 138 shown in FIG. 2C comprises an elongated annular cylindrical member having, on the exterior thereof, first cylindrical surface 194, a plurality of ratchet groove surfaces 196 and second cylindrical surface 197 and, on the interior thereof, first bore 198, second bore 200, third bore 202 which slidingly, sealingly engages annular elastomeric seal means 150 in J-slot mandrel 120, and fourth bore 204. The packer mandrel 138 further includes a plurality of elongated slots 206 therethrough at least one or a plurality of apertures 208 of any desired shape such as circular, rectangular, etc., therethrough each of which, in turn, releasably receives a portion of threaded studs 210 therein having a portion thereof extending into J-slots 154 in J-slot mandrel 120 and at least one threaded aperture 212 which threadedly, releasably receives a portion of threaded shear pin 214 therein having a portion thereof extending into aperture 156 in J-slot mandrel 120.
Each ratchet block 140 comprises a rectangular shaped member having, on the exterior thereof, outer surface 218 having, in turn, rectangular recess 220 therein containing annular resilient annular garter springs 222 therein and, on the interior thereof, arcuate smooth surface 224 and arcuate ratchet groove surfaces 226 which is complementary to ratchet groove surfaces 196 on the packer mandrel 138. Each ratchet block 140 further includes angular end surfaces 228 which are complementary to bottom and, if desired, top angular end surfaces 169 of rectangular shaped apertures 167 of ratchet body 130.
As shown in FIG. 2C, the upper portion of the upper wedge member 250 comprises an annular cylindrical member having, on the exterior thereof, first cylindrical surface 252 having, in turn, a plurality of wrenching flats 254 therein and second cylindrical surface 312 and, on the interior thereof first bore 256, threaded bore 258 which is threadedly, releasably, complementary and secured to threaded surface 188 of packer mandrel case 136, and second bore 260. The upper wedge member 250 further includes at least one threaded aperture 316 extending through the member 250 from first cylindrical surface 252 releasably, threadedly retaining threaded shear pin 318 therein having, in turn, a portion thereof engaging aperture 320 in packer mandrel 138 and a plurality of threaded apertures 322 extending into the member 250 from second cylindrical surface 312 thereof. Each threaded aperture 322 threadedly, releasably receives a portion of threaded member 324 therein which releasably retains slip retainer sleeve 280 to the upper wedge member 250.
Retained between shoulder 262 of upper wedge member 250 and end surface 264 of packer mandrel case 136 is locking set dog 270. The locking set dog 270 comprises an annular cylindrical member comprising four arcuate segments having a locking set dog spring 272 retained within annular recess 274 in the exterior thereof to bias the locking set dog 270 into slidable engagement with the exterior of packer mandrel 138.
Referring to FIG. 2D, the remaining portion of the upper wedge member 250, the remaining portion of the packer mandrel 138, the slip retainer sleeve 280, the lower wedge member 290, slips 300, slip springs 310, and bottom coupling 380 are shown.
The remaining portion of the upper wedge member 250 comprises an annular circular member having, on the exterior thereof, frusto-conical surface 314 and, on the interior thereof, second bore 260.
The portion of the packer mandrel 138 shown in FIG. 2D comprises an elongated annular cylindrical member having, on the exterior thereof, third cylindrical surface 326, frusto-conical annular surface 328, fourth cylindrical surface 330, and fifth cylindrical surface 332, threaded surface 382 and sixth cylindrical surface 384 and, on the interior thereof, fourth bore 204, and fifth bore 334.
The slip retainer sleeve 280 shown in FIG. 2D comprises an elongated, annular cylindrical member having, on the exterior thereof, cylindrical surface 336 and, on the interior thereof, bore 338. The slip retainer sleeve 280 further includes a plurality of elongated rectangular apertures 340 therethrough and a plurality of apertures 342 each of which receives a portion of threaded member 324 therein to releasably retain slip retainer sleeve 280 to upper wedge member 250.
The lower wedge member 290 shown in FIG. 2D comprises an elongated, annular cylindrical member having, on the exterior thereof, frusto-conical annular surface 344 and first cylindrical surface 346, and second cylindrical surface 386 and, on the interior thereof, bore 348 which slidingly receives fifth cylindrical surface 332 of packer mandrel 138 therein having upper end surface 350 of the lower wedge member 290 abutting shoulder 352 of packer mandrel 138.
The slips 300 each comprise an arcuate rectangular shaped member having a rectangular raised center portion 354 having a plurality of teeth 356 thereon and, on each side of the raised center portion 354, a spring pad 358 having, in turn, a spring recess 360 therein. The upper 362 and lower 364 ends of each slip 30 are formed having frusto-conical arcuate surfaces which are complementary to and slidingly engage the frusto-conical annular surface 314 of upper wedge member 250 and frusto-conical annular surface 344 of lower wedge member 290, respectively. Each slip 300 further includes arcuate surface 366 which slidingly engages third cylindrical surface 326 of packer mandrel 138.
Each slip spring 310 comprises an arcuate resilient member having a middle portion 368 thereof engaging a portion of bore 338 of slip retainer sleeve 280 and the ends 370 thereof retained within spring recess 360 of spring pad 358 of slip 300 to resiliently bias slips 300 inwardly to retain each slip 300 within slip retainer sleeve 290.
The bottom coupling 380 shown in FIG. 2D comprises an elongated, annular cylindrical member having, on the exterior thereof, cylindrical surface 388 and, on the interior thereof, first threaded bore 390 which threadedly, releasably engages threaded surface 382 of packer mandrel 138, annular recess 392 containing annular elastomeric seal 394 therein, first bore 396, second bore 398 and second threaded bore 400.
If desired, the annular recess 392 containing annular elastomeric seal 394 therein may be deleted.
When installed on the end of packer mandrel 138, the bottom coupling 380 has upper end surface 402 thereof abutting bottom end surface 404 of lower wedge member 290 thereby causing upper end surface 350 to abuttingly engage shoulder 352 of packer mandrel 138.
Referring to FIG. 3, the J-shaped recesses 72 in the retrieving J-slot mandrel 16 are shown. Each J-shaped recess 72 is formed having entry portion 410, ramp portion 412, upper portion 414 and lower portion 416.
Referring to FIG. 4, the J-slot 154 in J-slot mandrel 120 is shown. Each J-slot 154 is formed having an upper portion 420, transition portion 422 and lower portion 424.
Referring to FIG. 5, a portion of the threaded ratchet surface 196 on packer mandrel 138 is shown. The ratchet thread may be of any convenient pitch and diameter. A thread having a 30° angle with respect to the vertical plane of the leading face of the thread and a 5° angle with respect to the vertical plane of the trailing face of the thread is preferred. The arcuate threaded surface 226 of the ratchet blocks 140 are similarly formed.
Referring to FIG. 6, the retrieving tool 500 for the retrieval of the bridge plug 10 of the present invention is shown.
The retrieving tool 500 comprises an overshot member 502, upper ring spring holder 504, lower ring spring holder 506 and ring spring 508.
The overshot member 502 comprises an elongated cylindrical annular member having, on the exterior thereof, first cylindrical surface 510, threaded surface 512, and second cylindrical surface 514 and, on the interior thereof, threaded bore 516 and bore 518 having, in turn, a plurality of lugs 520 located thereon. The overshot member 502 further includes a plurality of apertures 522 to allow fluid communication from the exterior thereof to the interior thereof.
The upper ring spring holder 504 comprises an elongated cylindrical annular member having, on the exterior thereof, first cylindrical surface 524, threaded surface 526 and second cylindrical surface 528 and, on the interior thereof, threaded bore 530 which threadedly, releasably engages threaded surface 512 of overshot member 502, first bore 532, second bore 534 and third bore 536.
The lower ring spring holder 506 comprises an elongated cylindrical annular member having, on the exterior thereof, cylindrical surface 538 and, on the interior thereof, threaded bore 540, first bore 542 and second bore 544. The lower ring spring holder 506 further includes a plurality of recesses 546 in one end thereof.
The ring spring 508 comprises an annular ring spring having annular frusto-conical annular surfaces 548 therein. The ring spring 508 is retained within first bore 542 of lower ring spring holder 506 having one end thereof abutting annular shoulder 550 of holder 506 while the other end thereof abuts end 552 of upper ring spring holder 504 when the holder 504 is secured to holder 506.
OPERATION OF THE INVENTION
Referring to FIGS. 1 and 2A through 2D, to set the bridge plug 10 of the present invention a Baker Model "E-4" Wireline Pressure Setting Assembly as sold by the Baker Oil Tool Company, Houston, Tex. is used. The Baker Model "E-4" setting assembly is connected to setting sleeve 12 and adapter 14.
When the Baker Model "E-4" setting assembly is actuated, the setting assembly causes relative motion between the setting sleeve 12 and adapter 14. Initially, upon actuation of the Baker Model "E-4" setting assembly, the setting assembly pulls upwardly on the adapter 14 relative to the setting sleeve 12. Upon shearing of shear pins 318 securing packer mandrel 138 to upper wedge member 250, the upward movement by the adapter 14 causes upper movement of the retrieving J-slot retrieving mandrel 16, by-pass body 20, J-slot mandrel 120, packer mandrel 138, lower wedge member 290 and bottom coupling 380 As the lower wedge member 290 moves upwardly relative to the upper wedge member 250, the slips 300 are cammed or wedged outwardly by the upper wedge member 250 and lower wedge member 290 into engagement with the casing in the well bore.
At this point when the slips 300 engage the casing in the well bore, the Baker Model "E-4" setting assembly causes downward movement of the setting sleeve 12, ratchet body 130, and packer elements 132, relative to the retrieving J-slot mandrel 16, by-pass body 20, J-slot mandrel 120, packer mandrel 138, upper wedge member 250, lower wedge member 290 and bottom coupling 380.
This downward movement of the setting sleeve 12, ratchet body 130, and packer elements 132, causes the packer elements 132 to be compressed into engagement with the casing in the well bore and the ratchet blocks 140 to engage ratchet grooves 196 on the packer mandrel 138.
As the packer elements 132 are compressed into engagement with the casing in the well bore, the stress in the tension stud 15 increases. When the tension in tension stud 15 increases beyond a predetermined level, the stud 15 shears or fractures in the reduced diameter portion 64 of the stud 15. When the stud 15 shears or fractures, the relative movement of the various members or parts of the bridge plug 10 ceases.
When the slips 300 and the packer elements 132 engage the casing in the well bore and the tension stud 15 has sheared or severed, the ratchet blocks 140 which are engaging the ratchet grooves 196 on the packer mandrel 138 prevent any relative movement which would allow the bridge plug 10 to unset or disengage the casing in the well bore of the ratchet body 130, packer elements 132, packer mandrel case 136 and upper wedge member 250 with respect to the retrieving J-slot mandrel 16, by-pass body 20, J-slot mandrel 120, packer mandrel 138, lower wedge member 229 and bottom coupling 380.
After the tension stud 15 has sheared or severed and the bridge plug 10 has been set in the casing in the well bore, the Baker Model "E-4" setting assembly having setting sleeve 12, adapter 14 and a portion of the tension stud 15 secured thereto are removed from the well bore.
To retrieve the bridge plug 10 of the present invention the retrieving tool 500 (shown in FIG. 5) is connected to a tubing string and lowered into the casing in the well bore.
Since the setting sleeve 12 and adapter 14 are not present on the set bridge plug 10 of the present invention in the casing in the well bore, the end of the retrieving tool 500 passes over the top of the J-slot retrieving mandrel 16 with the lugs 520 of the tool 500 engaging entry portion 410 of the J-slot 72 in mandrel 16 until the ring spring 508 passes over and engages the upper surface of annular rib 88 of release valve sleeve 18.
When ring spring 508 engages annular rib 88 of release valve sleeve 18 threaded shear pins 91 retaining sleeve 18 in a first position on release valve body 20 are sheared or severed with the continued downward movement of the retrieving tool 500 causing the sleeve 18 to move downwardly until end 19 of sleeve 18 abuts shoulder 105 at body 20 at which time ring spring 508 expands slightly and passes over annular rib 88. ConcurrentIy with this the plurality of lugs 520 in the retrieving tool 500 have moved through entry portion 410, ramp portion 412 and into lower portion 416 of J-slot 72 (see FIG. 2) in J-slot retrieving mandrel 16.
When the downward movement of the retrieving tool 500 over J-slot retrieving mandrel 16 and release valve body 20 is completed with the ring spring 508 of the resiliently engaging annular rib 88 of sleeve 18, weight is picked up and a right-hand torque is placed on the retrieving tool 500 and tubing string thereby shearing shear pin 214 engaging aperture 156 in J-slot mandrel 120 thereby allowing lug 210 on packer mandrel 138 to move into the transition portion 422 of J-slot 154 of J-slot mandrel 120.
Weight is then set down on the tubing string and retrieving tool 500 thereby causing the J-slot mandrel 120 to move downwardly relative to the packer mandrel 120 thereby, in turn, releasing the ratchet blocks 140 from engagement with ratchet groove 196 on packer mandrel 138 when second cylindrical surface 142 of J-slot mandrel 120 contacts surfaces 224 of the ratchet blocks 140 camming them outwardly from packer mandrel 138 while the studs 210 move upwardly in J-slots 154 of the J-slot mandrel 120.
During the relative movement between ratchet body 130 and packer mandrel 138 when the studs 280 are at the top of J-slots 154 of the J-slot mandrel 120, the packer mandrel 138 then moves downwardly and causes lower wedge member 290 to move downwardly thereby causing the bottom of slips 300 to be positively disengaged from the wedge member 290 and possibly from the casing in the well bore by being biased inwardly by resilient spring members 310.
To insure that the slips 300 are disengaged from the casing in the well bore and the upper wedge member 250 when weight is set down again on the bridge plug 10, this causes the locking set dogs 270 to abut first cylindrical surface 194 of packer mandrel 138 by being resiliently biased thereinto by locking set dog spring 272.
After completion of a predetermined amount of downward travel of the tubing string having retrieving tool 500 connected thereto, the tubing string and retrieving tool 500 are rotated and moved upwardly in the casing in the well bore. This rotation and upward movement causes lugs 520 on retrieving tool 500 to engage upper portion 414 (see FIG. 2) of J-slots 72 in retrieving J-slot mandrel 16 and threaded studs 210 in packer mandrel 138 to engage upper portion 420 (see FIG. 3) of J-slot 154 in packer mandrel 138.
Next, since the locking set dogs 270 now abut shoulder 402 of packer mandrel 138 while remaining in partial engagement with annular recess 404 formed between shoulder 406 of upper wedge member 250 and shoulder 408 of packer mandrel case 136, upon upward movement of the bridge plug 10 by now picking weight up on the tubing string and retrieving tool 500, the packer mandrel 138 causes the upper wedge member to be positively pulled out from under the upper frusto-conical surfaces 362 of the slips 300 thereby insuring the disengagement of the slips 300 from the casing in the well bore.
At this point, continued upward movement of the tubing string and retrieving tool 500 allows the removal of the bridge plug 10 of the present invention from the casing in the well bore.
It should be noted that after release valve sleeve 18 is moved into engagement with shoulder 105 of release valve body 20 any fluid pressure differential across the bridge plug 10 may be equalized by fluid flowing through the bores of bottom coupling 380, packer mandrel 138, J-slot mandrel 120, release valve body 20 through apertures 118 therein, and retrieving tool 500 through apertures 522 therein.
It will be understood that the foregoing disclosure and description of the bridge plug of the present invention are illustrative and explanatory thereof, and various modifications and changes in size, shape and materials as well as details of the illustrated construction may be made without departing from the scope of the invention.
Illustrations of such modifications and changes in the bridge plug 10 of the present invention are integrating or combining the ratchet blocks 140 and ratchet body 130 such that the ratchet body 130 has a plurality of interiorly threaded resilient collet fingers on one end thereof to engage ratchet thread 196 on packer mandrel 138, or integrating or combining the packer mandrel case 136 and upper wedge member 250 into an elongated packer wedge case or integrating or combining the lower wedge member 290, packer mandrel 138 and lower coupling 380 into one member, or by rearranging the order of the components of the bridge plug, etc.
Also, the bridge plug 10 of the present invention could be utilized as a packer by changing the release valve sleeve 18 to a different type actuated valve to permit the selective flow of fluids through the packer. | A packer type bridge plug for use in wells which may be set upon a wireline and retrieved upon a tubing string. The retrieval of the bridge plug is facilitated by the positive retraction of the upper and lower wedge members from beneath the slips during the retrieval process. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. Ser. No. 11/509,718, filed Aug. 25, 2006, which is a continuation of U.S. Ser. No. 10/202,093, which was filed on Jul. 25, 2002, and which is a continuation of Ser. No. 09/534,007, which was filed on Mar. 24, 2000, now U.S. Pat. No. 6,516,579, which was a continuation of Ser. No. 09/356,563, which was filed on Jul. 19, 1999, now U.S. Pat. No. 6,182,410, and which is a continuation of Ser. No. 09/193,687, which was filed on Nov. 18, 1998, now U.S. Pat. No. 6,023,907, which was a continuation of Ser. No. 09/003,499 which was filed on Jan. 6, 1998, now U.S. Pat. No. 5,860,267, and which is a continuation of Ser. No. 08/436,224, which was filed on May 17, 1995, now U.S. Pat. No. 5,706,621, which was a national stage entry of PCT/SE94/00386, filed in Sweden on Apr. 29, 1994. The entire contents of the aforementioned patents and patent applications are incorporated herein by reference.
TECHNICAL FIELD
The invention generally relates to a system for providing a joint along adjacent joint edges of two building panels, especially floor panels.
More specifically, the joint is of the type where the adjacent joint edges together form a first mechanical connection locking the joint edges to each other in a first direction at right angles to the principal plane of the panels, and where a locking device forms a second mechanical connection locking the panels to each other in a second direction parallel to the principal plane and at right angles to the joint edges, the locking device comprising a locking groove which extends parallel to and spaced from the joint edge of one of the panels, and said locking groove being open at the rear side of this one panel.
The invention is especially well suited for use in joining floor panels, especially thin laminated floors. Thus, the following description of the prior art and of the objects and features of the invention will be focused on-this field of use. It should however be emphasized that the invention is useful also for joining ordinary wooden floors as well as other types of building panels, such as wall panels and roof slabs.
BACKGROUND OF THE INVENTION
A joint of the aforementioned type is known e.g. from SE 450,141. The first mechanical connection is achieved by means of joint edges having tongues and grooves. The locking device for the second mechanical connection comprises two oblique locking grooves, one in the rear side of each panel, and a plurality of spaced-apart spring clips which are distributed along the joint and the legs of which are pressed into the grooves, and which are biased so as to tightly clamp the floor panels together. Such a joining technique is especially useful for joining thick floor panels to form surfaces of a considerable expanse.
Thin floor panels of a thickness of about 7-10 mm, especially laminated floors, have in a short time taken a substantial share of the market. All thin floor panels employed are laid as “floating floors” without being attached to the supporting structure. As a rule, the dimension of the floor panels is 200×1200 mm, and their long and short sides are formed with tongues and grooves. Traditionally, the floor is assembled by applying glue in the groove and forcing the floor panels together. The tongue is then glued in the groove of the other panel. As a rule, a laminated floor consists of an upper decorative wear layer of laminate having a thickness of about 1 mm, an intermediate core of particle board or other board, and a base layer to balance the construction. The core has essentially poorer properties than the laminate, e.g., in respect of hardness and water resistance, but it is nonetheless needed primarily for providing a groove and tongue for assemblage. This means that the overall thickness must be at least about 7 mm. These known laminated floors using glued tongue-and-groove joints however suffer from several inconveniences.
First, the requirement of an overall thickness of at least about 7 mm entails an undesirable restraint in connection with the laying of the floor, since it is easier to cope with low thresholds when using thin floor panels, and doors must often be adjusted in height to come clear of the floor laid. Moreover, manufacturing costs are directly linked with the consumption of material.
Second, the core must be made of moisture-absorbent material to permit using water-based glues when laying the floor. Therefore, it is not possible to make the floors thinner using so-called compact laminate, because of the absence of suitable gluing methods for such non-moisture-absorbent core materials.
Third, since the laminate layer of the laminated floors is highly wear-resistant, tool wear is a major problem when working the surface in connection with the formation of the tongue.
Fourth, the strength of the joint, based on a glued tongue-and-groove connection, is restricted by the properties of the core and of the glue as well as by the depth and height of the groove. The laying quality is entirely dependent on the gluing. In the event of poor gluing, the joint will open as a result of the tensile stresses which occur e.g. in connection with a change in air humidity.
Fifth, laying a floor with glued tongue-and-groove joints is time-consuming, in that glue must be applied to every panel on both the long and short sides thereof.
Sixth, it is not possible to disassemble a glued floor once laid, without having to break up the joints. Floor panels that have been taken up cannot therefore be used again. This is a drawback particularly in rental houses where the flat concerned must be put back into the initial state of occupancy. Nor can damaged or worn-out panels be replaced without extensive efforts, which would be particularly desirable on public premises and other areas where parts of the floor are subjected to great wear.
Seventh, known laminated floors are not suited for such use as involves a considerable risk of moisture penetrating down into the moisture-sensitive core.
Eighth, present-day hard, floating floors require, prior to laying the floor panels on hard subfloors, the laying of a separate underlay of floor board, felt, foam or the like, which is to damp impact sounds and to make the floor more pleasant to walk on. The placement of the underlay is a complicated operation, since the underlay must be placed in edge-to-edge fashion. Different under-lays affect the properties of the floor.
There is thus a strongly-felt need to overcome the above-mentioned drawbacks of the prior art. It is however not possible simply to use the known joining technique with glued tongues and grooves for very thin floors, e.g. with floor thicknesses of about 3 mm, since a joint based on a tongue-and-groove connection would not be sufficiently strong and practically impossible to produce for such thin floors. Nor are any other known joining techniques usable for such thin floors. Another reason why the making of thin floors from, e.g., compact laminate involves problems is the thickness tolerances of the panels, being about 0.2-0.3 mm for a panel thickness of about 3 mm. A 3-mm compact laminate panel having such a thickness tolerance would have, if ground to uniform thickness on its rear side, an unsymmetrical design, entailing the risk of bulging. Moreover, if the panels have different thicknesses, this also means that the joint will be subjected to excessive load.
Nor is it possible to overcome the above-mentioned problems by using double-adhesive tape or the like on the undersides of the panels, since such a connection catches directly and does not allow for subsequent adjustment of the panels as is the case with ordinary gluing.
Using U-shaped clips of the type disclosed in the above-mentioned SE 450,141, or similar techniques, to overcome the drawbacks discussed above is no viable alternative either. Especially, biased clips of this type cannot be used for joining panels of such a small thickness as 3 mm. Normally, it is not possible to disassemble the floor panels without having access to their undersides. This known technology relying on clips suffers from the additional drawbacks:
Subsequent adjustment of the panels in their longitudinal direction is a complicated operation in connection with laying, since the clips urge the panels tightly against each other.
Floor laying using clips is time-consuming.
This technique is usable only in those cases where the floor panels are resting on underlying joists with the clips placed therebetween. For thin floors to be laid on a continuous, flat supporting structure, such clips cannot be used.
The floor panels can be joined together only at their long sides. No clip connection is provided on the short sides.
Technical Problems and Objects of the Invention
A main object of the invention therefore is to provide a system for joining together building panels, especially floor panels for hard, floating floors, which allows using floor panels of a smaller overall thickness than present-day floor panels.
A particular object of the invention is to provide a panel-joining system which:
makes it possible in a simple, cheap and rational way to provide a joint between floor panels without requiring the use of glue, especially a joint based primarily only on mechanical connections between the panels; can be used for joining floor panels which have a smaller thickness than present-day laminated floors and which have, because of the use of a different core material, superior properties than present-day floors even at a thickness of 3 mm; makes it possible between thin floor panels to provide a joint that eliminates any unevennesses in the joint because of thickness tolerances of the panels; allows joining all the edges of the panels; reduces tool wear when manufacturing floor panels with hard surface layers; allows repeated disassembly and reassembly of a floor previously laid, without causing damage to the panels, while ensuring high laying quality; makes it possible to provide moisture-proof floors; makes it possible to obviate the need of accurate, separate placement of an underlay before laying the floor panels; and considerably cuts the time for joining the panels.
These and other objects of the invention are achieved by means of a panel-joining system having the features recited in the appended claims.
Thus, the invention provides for floorboards with substantially planar and parallel upper top sides and lower undersides and panel material located between the upper and lower top sides, and a mechanical locking system for locking a first edge of a first floor board to a second edge of a substantially identical second floor board. The mechanical locking system comprising:
a tongue on the first edge; a groove on the second edge; the tongue and groove forming a first mechanical connection locking the first and second edges to each other in a first direction at right angles to a principal plane of the floor boards, the tongue and groove being formed in the panel material which is located between said upper top sides and lower side; and a locking device arranged on an underside of the first and the second edges, the locking device forming a second mechanical connection locking the first and the second edges to each other in a second direction parallel to the principal plane and at right angles to the edges; the locking device includes a locking groove which extends parallel to and spaced from the first edge, the locking groove being formed in the first edge of the panel and being open at an underside of the first edge and including an internal surface; the locking device further includes a strip extending distally beyond an upper part of the second edge, the strip extending throughout substantially an entire length of the second edge and being provided with a locking element projecting from the strip; wherein the strip, the locking element, and the locking groove are configured such that when the first edge is pressed against an upper part of the second edge and is then angled down, the locking element can enter the locking groove; the locking element has a locking surface which faces the second edge and is configured so as to contact the internal surface of the locking groove to prevent substantial separation of the first and second edges when joined together; and wherein, when the first edge and the second edge are locked together, there is space in the locking system between the first and the second edges.
Thus, another embodiment of the invention provides a system for making a joint along adjacent joint edges of two building panels, especially floor panels, in which joint:
the adjacent joint edges together form a first mechanical connection locking the joint edges to each other in a first direction at right angles to the principal plane of the panels, and a locking device arranged on the rear side of the panels forms a second mechanical connection locking the panels to each other in a second direction parallel to the principal plane and at right angles to the joint edges, said locking device comprising a locking groove which extends parallel to and spaced from the joint edge of one of said panels, termed groove panel, and which is open at the rear side of the groove panel, said system being characterized in that the locking device further comprises a strip integrated with the other of said panels, termed strip panel, said strip extending throughout substantially the entire length of the joint edge of the strip panel and being provided with a locking element projecting from the strip, such that when the panels are joined together, the strip projects on the rear side of the groove panel with its locking element received in the locking groove of the groove panel, that the panels, when joined together, can occupy a relative position in said second direction where a play exists between the locking groove and a locking surface on the locking element that is facing the joint edges and is operative in said second mechanical connection, that the first and the second mechanical connection both allow mutual displacement of the panels in the direction of the joint edges, and that the second mechanical connection is so conceived as to allow the locking element to leave the locking groove if the groove panel is turned about its joint edge angularly away from the strip.
The term “rear side” as used above should be considered to comprise any side of the panel located behind/underneath the front side of the panel. The opening plane of the locking groove of the groove panel can thus be located at a distance from the rear surface of the panel resting on the supporting structure. Moreover, the strip, which in the embodiments of the invention, extends throughout substantially the entire length of the joint edge of the strip panel, should be considered to encompass both the case where the strip is a continuous, uninterrupted element, and the case where the “strip” consists in its longitudinal direction of several parts, together covering the main portion of the joint edge.
It should also be noted (i) that it is the first and the second mechanical connection as such that permit mutual displacement of the panels in the direction of the joint edges, and that (ii) it is the second mechanical connection as such that permits the locking element to leave the locking groove if the groove panel is turned about its joint edge angularly away from the strip. Within the scope of the invention, there may thus exist means, such as glue and mechanical devices, that can counteract or prevent such displacement and/or upward angling.
The system according to an embodiment of the invention makes it possible to provide concealed, precise locking of both the short and long sides of the panels in hard, thin floors. The floor panels can be quickly and conveniently disassembled in the reverse order of laying without any risk of damage to the panels, ensuring at the same time a high laying quality. The panels can be assembled and disassembled much faster than in present-day systems, and any damaged or worn-out panels can be replaced by taking up and re-laying parts of the floor.
According to an especially preferred embodiment of the invention, a system is provided which permits precise joining of thin floor panels having, for example, a thickness of the order of 3 mm and which at the same time provides a tolerance-independent smooth top face at the joint. To this end, the strip is mounted in an equalizing groove which is countersunk in the rear side of the strip panel and which exhibits an exact, predetermined distance from its bottom to the front side of the strip panel. The part of the strip projecting behind the groove panel engages a corresponding equalizing groove, which is countersunk in the rear side of the groove panel and which exhibits the same exact, predetermined distance from its bottom to the front side of the groove panel. The thickness of the strip then is at least so great that the rear side of the strip is flush with, and preferably projects slightly below the rear side of the panels. In this embodiment, the panels will always rest, in the joint, with their equalizing grooves on a strip. This levels out the tolerance and imparts the necessary strength to the joint. The strip transmits horizontal and upwardly-directed forces to the panels and downwardly-directed forces to the existing subfloor.
Preferably, the strip may consist of a material which is flexible, resilient and strong, and can be sawn. A preferred strip material is sheet aluminum. In an aluminum strip, sufficient strength can be achieved with a strip thickness of the order of 0.5 mm.
In order to permit taking up previously laid, joined floor panels in a simple way, a preferred embodiment of the invention is characterized in that when the groove panel is pressed against the strip panel in the second direction and is turned angularly away from the strip, the maximum distance between the axis of rotation of the groove panel and the locking surface of the locking groove closest to the joint edges is such that the locking element can leave the locking groove without contacting the locking surface of the locking groove. Such a disassembly can be achieved even if the aforementioned play between the locking groove and the locking surface is not greater than 0.2 mm.
According to the invention, the locking surface of the locking element is able to provide a sufficient locking function even with very small heights of the locking surface. Efficient locking of 3-mm floor panels can be achieved with a locking surface that is as low as 2 mm. Even a 0.5-mm-high locking surface may provide sufficient locking. The term “locking surface” as used herein relates to the part of the locking element engaging the locking groove to form the second mechanical connection.
For optimal function of the invention, the strip and the locking element should be formed on the strip panel with high precision. Especially, the locking surface of the locking element should be located at an exact distance from the joint edge of the strip panel. Furthermore, the extent of the engagement in the floor panels should be minimized, since it reduces the floor strength.
By known manufacturing methods, it is possible to produce a strip with a locking pin, for example by extruding aluminum or plastics into a suitable section, which is thereafter glued to the floor panel or is inserted in special grooves. These and all other traditional methods do however not ensure optimum function and an optimum level of economy. To produce the joint system according to an embodiment of the invention, the strip is suitably formed from sheet aluminum, and is mechanically fixed to the strip panel.
The laying of the panels can be performed by first placing the strip panel on the subfloor and then moving the groove panel with its long side up to the long side of the strip panel, at an angle between the principal plane of the groove panel and the subfloor. When the joint edges have been brought into engagement with each other to form the first mechanical connection, the groove panel is angled down so as to accommodate the locking element in the locking groove.
Laying can also be performed by first placing both the strip panel and the groove panel flat on the subfloor and then joining the panels parallel to their principal planes while bending the strip downwards until the locking element snaps up into the locking groove. This laying technique enables in particular mechanical locking of both the short and long sides of the floor panels. For example, the long sides can be joined together by using the first laying technique with downward angling of the groove panel, while the short sides are subsequently joined together by displacing the groove panel in its longitudinal direction until its short side is pressed on and locked to the short side of an adjacent panel in the same row.
In connection with their manufacture, the floor panels can be provided with an underlay of e.g. floor board, foam or felt. The underlay should preferably cover the strip such that the joint between the underlays is offset in relation to the joint between the floor panels.
The above and other features and advantages of the invention will appear from the appended claims and the following description of embodiments of the invention.
The embodiments of the invention will now be described in more detail hereinbelow with reference to the accompanying drawing Figures.
DESCRIPTION OF DRAWING FIGURES
FIGS. 1 a and 1 b schematically show in two stages how two floor panels of different thickness are joined together in floating fashion according to a first embodiment of the invention.
FIGS. 2 a - c show in three stages a method for mechanically joining two floor panels according to a second embodiment of the invention.
FIGS. 3 a - c show in three stages another method for mechanically joining the floor panels of FIGS. 2 a - c.
FIGS. 4 a and 4 b show a floor panel according to FIGS. 2 a - c as seen from below and from above, respectively.
FIG. 5 illustrates in perspective a method for laying and joining floor panels according to a third embodiment of the invention.
FIG. 6 shows in perspective and from below a first variant for mounting a strip on a floor panel.
FIG. 7 shows in section a second variant for mounting a strip on a floor panel.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b , to which reference is now made, illustrate a first floor panel 1 , hereinafter termed strip panel, and a second floor panel 2 , hereinafter termed groove panel. The terms “strip panel” and “groove panel” are merely intended to facilitate the description of the invention, the panels 1 , 2 normally being identical in practice. The panels 1 and 2 may be made from compact laminate and may have a thickness of about 3 mm with a thickness tolerance of about +/−0.2 mm. Considering this thickness tolerance, the panels 1 , 2 are illustrated with different thicknesses ( FIG. 1 b ), the strip panel 1 having a maximum thickness (3.2 mm) and the groove panel 2 having a minimum thickness (2.8 mm).
To enable mechanical joining of the panels 1 , 2 at opposing joint edges, generally designated 3 and 4 , respectively, the panels are provided with grooves and strips as described in the following.
Reference is now made primarily to FIGS. 1 a and 1 b , and secondly to FIGS. 4 a and 4 b showing the basic design of the floor panels from below and from above, respectively.
From the joint edge 3 of the strip panel 1 , i.e. the one long side, projects horizontally a flat strip 6 mounted at the factory on the underside of the strip panel 1 and extending throughout the entire joint edge 3 . 15 The strip 6 , which is made of flexible, resilient sheet aluminum, can be fixed mechanically, by means of glue or in any other suitable way. In FIGS. 1 a and 1 b , the strip 6 is glued, while in FIGS. 4 a and 4 b it is mounted by means of a mechanical connection, which will be described in more detail hereinbelow.
Other strip materials can be used, such as sheets of other metals, as well as aluminum or plastics sections. Alternatively, the strip 6 may be integrally formed with the strip panel 1 . At any rate, the strip 6 should be integrated with the strip panel 1 , i.e. it should not be mounted on the strip panel 1 in connection with laying. As a non-restrictive example, the strip 6 may have a width of about 30 mm and a thickness of about 0.5 mm.
As appears from FIGS. 4 a and 4 b , a similar, although a shorter strip 6 ′ is provided also at one short side 3 ′ of the strip panel 1 . The shorter strip 6 ′ does however not extend throughout the entire short side 3 ′ but is otherwise identical with the strip 6 and, therefore, is not described in more detail here.
The edge of the strip 6 facing away from the joint edge 3 is formed with a locking element 8 extended throughout the entire strip 6 . The locking element 8 has a locking surface 10 facing the joint edge 3 and having a height of e.g. 0.5 mm. The locking element 8 is so designed that when the floor is being laid and the strip panel 2 of FIG. 1 a is pressed with its joint edge 4 against the joint edge 3 of the strip panel 1 and is angled down against the subfloor 12 according to FIG. 1 b , it enters a locking groove 14 formed in the underside 16 of the groove panel 2 and extending parallel to and spaced from the joint edge 4 . In FIG. 1 b , the locking element 8 and the locking groove 14 together form a mechanical connection locking the panels 1 , 2 to each other in the direction designated D 2 . More specifically, the locking surface 10 of the locking element 8 serves as a stop with respect to the surface of the locking groove 14 closest to the joint edge 4 .
When the panels 1 and 2 are joined together, they can however occupy such a relative position in the direction D 2 that there is a small play Δ between the locking surface 10 and the locking groove 14 . This mechanical connection in the direction D 2 allows mutual displacement of the panels 1 , 2 in the direction of the joint, which considerably facilitates the laying and enables joining together the short sides by snap action.
As appears from FIGS. 4 a and 4 b , each panel in the system has a strip 6 at one long side 3 and a locking groove 14 at the other long side 4 , as well as a strip 6 ′ at one short side 3 ′ and a locking groove 14 ′ at the other short side 4 ′.
Furthermore, the joint edge 3 of the strip panel 1 has in its underside 18 a recess 20 extending throughout the entire joint edge 3 and forming together with the upper face 22 of the strip 6 a laterally open recess 24 . The joint edge 4 of the groove panel 2 has in its top side 26 a corresponding recess 28 forming a locking tongue 30 to be accommodated in the recess 24 so as to form a mechanical connection locking the joint edges 3 , 4 to each other in the direction designated D 1 . This connection can be achieved with other designs of the joint edges 3 , 4 , for example by a bevel thereof such that the joint edge 4 of the groove panel 2 passes obliquely in underneath the joint edge 3 of the strip panel 1 to be locked between that edge and the strip 6 .
The panels 1 , 2 can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again.
The strip 6 is mounted in a tolerance-equalizing groove 40 in the underside 18 of the strip panel 1 adjacent the joint edge 3 . In this embodiment, the width of the equalizing groove 40 is approximately equal to half the width of the strip 6 , i.e. about 15 mm. By means of the equalizing groove 40 , it is ensured that there will always exist between the top side 21 of the panel 1 and the bottom of the groove 40 an exact, predetermined distance E which is slightly smaller than the minimum thickness (2.8 mm) of the floor panels 1 , 2 . The groove panel 2 has a corresponding tolerance-equalizing surface or groove 42 in the underside 16 of the joint edge 4 . The distance between the equalizing surface 42 and the top side 26 of the groove panel 2 is equal to the aforementioned exact distance E. Further, the thickness of the strip 6 is so chosen that the underside 44 of the strip is situated slightly below the undersides 18 and 16 of the floor panels 1 and 2 , respectively. In this manner, the entire joint will rest on the strip 6 , and all vertical downwardly-directed forces will be efficiently transmitted to the subfloor 12 without any stresses being exerted on the joint edges 3 , 4 . Thanks to the provision of the equalizing grooves 40 , 42 , an entirely even joint will be achieved on the top side, despite the thickness tolerances of the panels 1 , 2 , without having to perform any grinding or the like across the whole panels. Especially, this obviates the risk of damage to the bottom layer of the compact laminate, which might give rise to bulging of the panels.
Reference is now made to the embodiment of FIGS. 2 a - c showing in a succession substantially the same laying method as in FIGS. 1 a and 1 b . The embodiment of FIGS. 2 a - c primarily differs from the embodiment of FIGS. 1 a and 1 b in that the strip 6 is mounted on the strip panel 1 by means of a mechanical connection instead of glue. To provide this mechanical connection, illustrated in more detail in FIG. 6 , a groove 50 is provided in the underside 18 of the strip panel 1 at a distance from the recess 24 . The groove 50 may be formed either as a continuous groove extending throughout the entire length of the panel 1 , or as a number of separate grooves. The groove 50 defines, together with the recess 24 , a dovetail gripping edge 52 , the underside of which exhibits an exact equalizing distance E to the top side 21 of the strip panel 1 . The aluminum strip 6 has a number of punched and bent tongues 54 , as well as one or more lips 56 which are bent round opposite sides of the gripping edge 52 in clamping engagement therewith. This connection is shown in detail from below in the perspective view of FIG. 6 .
Alternatively, a mechanical connection between the strip 6 and the strip panel 1 can be provided as illustrated in FIG. 7 showing in section a cut-away part of the strip panel 1 turned upside down. In FIG. 7 , the mechanical connection comprises a dovetail recess 58 in the underside 18 of the strip panel 1 , as well as tongues/lips 60 punched and bent from the strip 6 and clamping against opposing inner sides of the recess 58 .
The embodiment of FIGS. 2 a - c is further characterized in that the locking element 8 of the strip 6 is designed as a component bent from the aluminum sheet and having an operative locking surface 10 extending at right angles up from the front side 22 of the strip 6 through a height of e.g. 0.5 mm, and a rounded guide surface 34 facilitating the insertion of the locking element 8 into the locking groove 14 when angling down the groove panel 2 towards the subfloor 12 ( FIG. 2 b ), as well as a portion 36 which is inclined towards the subfloor 12 and which is not operative in the laying method illustrated in FIGS. 2 a - c.
Further, it can be seen from FIGS. 2 a - c that the joint edge 3 of the strip panel 1 has a lower bevel 70 which cooperates during laying with a corresponding upper bevel 72 of the joint edge 4 of the groove panel 2 , such that the panels 1 and 2 are forced to move vertically towards each other when their joint edges 3 , 4 are moved up to each other and the panels are pressed together horizontally.
Preferably, the locking surface 10 is so located relative to the joint edge 3 that when the groove panel 2 , starting from the joined position in FIG. 2 c , is pressed horizontally in the direction D 2 against the strip panel 1 and is turned angularly up from the strip 6 , the maximum-distance between the axis of rotation A of the groove panel 2 and the locking surface 10 of the locking groove is such that the locking element 8 can leave the locking groove 14 without coming into contact with it.
FIGS. 3 a - 3 b show another joining method for mechanically joining together the floor panels of FIGS. 2 a - c . The method illustrated in FIGS. 3 a - c relies on the fact that the strip 6 is resilient and is especially useful for joining together the short sides of floor panels which have already been joined along one long side as illustrated in FIGS. 2 a - c . The method of FIGS. 3 a - c is performed by first placing the two panels 1 and 2 flat on the subfloor 12 and then moving them horizontally towards each other according to FIG. 3 b . The inclined portion 36 of the locking element 8 then serves as a guide surface which guides the joint edge 4 of the groove panel 2 up on to the upper side 22 of the strip 6 . The strip 6 will then be urged downwards while the locking element 8 is sliding on the equalizing surface 42 . When the joint edges 3 , 4 have been brought into complete engagement with each other horizontally, the locking element 8 will snap into the locking groove 14 ( FIG. 3 c ), thereby providing the same locking as in FIG. 2 c . The same locking method can also be used by placing, in the initial position, the joint edge 4 of the groove panel with the equalizing groove 42 on the locking element 10 ( FIG. 3 a ). The inclined portion 36 of the locking element 10 then is not operative. This technique thus makes it possible to lock the floor panels mechanically in all directions, and by repeating the laying operations the whole floor can be laid without using any glue.
The invention is not restricted to the preferred embodiments described above and illustrated in the drawings, but several variants and modifications thereof are conceivable within the scope of the appended claims. The strip 6 can be divided into small sections covering the major part of the joint length. Further, the thickness of the strip 6 may vary throughout its width. All strips, locking grooves, locking elements and recesses are so dimensioned as to enable laying the floor panels with flat top sides in a manner to rest on the strip 6 in the joint. If the floor panels consist of compact laminate and if silicone or any other sealing compound, a rubber strip or any other sealing device is applied prior to laying between the flat projecting part of the strip 6 and the groove panel 2 and/or in the recess 26 , a moisture-proof floor is obtained.
As appears from FIG. 6 , an underlay 46 , e.g. of floor board, foam or felt, can be mounted on the underside of the panels during the manufacture thereof. In one embodiment, the underlay 46 covers the strip 6 up to the locking element 8 , such that the joint between the underlays 46 becomes offset in relation to the joint between the joint edges 3 and 4 .
In the embodiment of FIG. 5 , the strip 6 and its locking element 8 are integrally formed with the strip panel 1 , the projecting part of the strip 6 thus forming an extension of the lower part of the joint edge 3 . The locking function is the same as in the embodiments described above. On the underside 18 of the strip panel 1 , there is provided a separate strip, band or the like 74 extending throughout the entire length of the joint and having, in this embodiment, a width covering approximately the same surface as the separate strip 6 of the previous embodiments. The strip 74 can be provided directly on the rear side 18 or in a recess formed therein (not shown), so that the distance from the front side 21 , 26 of the floor to the rear side 76 , including the thickness of the strip 74 , always is at least equal to the corresponding distance in the panel having the greatest thickness tolerance. The panels 1 , 2 will then rest, in the joint, on the strip 74 or only on the undersides 18 , 16 of the panels, if these sides are made plane.
When using a material which does not permit downward bending of the strip 6 or the locking element 8 , laying 20 can be performed in the way shown in FIG. 5 . A floor panel 2 a is moved angled upwardly with its long side 4 a into engagement with the long side 3 of a previously laid floor panel 1 while at the same time a third floor panel 2 b is moved with its short side 4 b ′ into engagement with the short side 3 a ′ of the upwardly-angled floor panel 2 a and is fastened by angling the panel 2 b downwards. The panel 2 b is then pushed along the short side 3 a ′ of the upwardly-angled floor panel 2 a until its long side 4 b encounters the long side 3 of the initially-laid panel 1 .
The two upwardly-angled panels 2 a and 2 b are therefore angled down on to the subfloor 12 so as to bring about locking.
By a reverse procedure the panels can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again.
Several variants of preferred laying methods are conceivable. For example, the strip panel can be inserted under the groove panel, thus enabling the laying of panels in all four directions with respect to the initial position. | A thin rectangular laminate floor panel with one pair of long edges and one pair of short edges, the floor panel having an upper decorative wear layer; a core layer arranged beneath the upper decorative wear layer, the core layer being made of a material that is not as hard as the upper decorative wear layer; the floor panel having a substantially planar upper top side and a substantially planar lower underside and which is substantially parallel to the upper side. Also, having a long-side tongue, a short-side tongue, a long-side strip integrally formed with the floor panel, a short-side strip integrally formed with the floor panel, a long-side locking groove, and a short-side locking groove. |
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