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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains generally to lighting fixtures and, more particularly, to a method of manufacturing a lighting bollard assembly that is adaptable to accept varying lengths of lights.
[0003] 2. Background Information
[0004] Lighting bollards (or bollard lights) are so named because in shape they tend to resemble the bollards, i.e., posts, used at wharfs and around which mooring lines are fastened. Outdoor bollard lights are a sophisticated way to illuminate pathways and other areas of a landscape. The unobtrusive design offers a unique way to dress up the exterior of a home or commercial space through soft lighting without detracting from the architectural elements of a building's facade.
[0005] Traditional stacked louvered bollards are manufactured to provide a particular wattage of light within a particular louver stack atop the bollard in which the bollard is configured in a particular tubular shape. Thus, known bollard lights are manufactured as set structures that do not have the flexibility to adjust the configuration of the structures so as to accommodate varying lengths of light fixtures.
[0006] Such typical bollard lights are disclosed in U.S. Pat. Nos. 6,341,877 and 7,182,547, which disclose a bollard light with a diffuser rim retrofitted around the edge of a clear diffuser so as to emit a special light color effect; and a bollard post having a lamp resting atop the post, in which the lamp includes a spaced-apart louver stack, respectively.
SUMMARY OF THE INVENTION
[0007] It therefore would be advantageous to have a bollard light which is adaptable in structure so as to accept light bulbs of varying lengths and thus provide flexibility with respect to the choice of light output.
[0008] Accordingly, an object of the present invention is to provide a method of manufacturing a lighting bollard assembly that provides a choice of light output.
[0009] Another object of the present invention is to provide a method of manufacturing a lighting bollard assembly that is size-adaptable depending on the choice of light output.
[0010] A further object of the present invention is to provide a lighting bollard assembly produced according to the methods of the present invention.
[0011] These objectives are met by the embodiments of the present invention, which provide methods for manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths.
[0012] In an aspect of the present invention, there is provided a method of manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths, comprising mounting a circuit structured to power any one of the different elongated lights atop a base; mounting a first clamp plate atop the circuit and the base; selecting an elongated light from the different elongated lights and affixing the selected elongated light into a light socket; selecting a number of interposed lens rings and a number of light deflectors to correspond to the length of the selected elongated light; interposing the selected number of lens rings among the selected number of light deflectors, wherein each of the selected number of lens rings is inserted into a corresponding one of the selected number of light deflectors; mounting the selected number of interposed lens rings and the selected number of light deflectors atop the circuit; mounting a second clamp plate atop the selected number of interposed lens rings and the selected number of light deflectors; mounting a hood atop the second clamp plate; and connecting together the hood, the second clamp plate, the selected number of interposed lens rings, the selected number of light deflectors, the first clamp plate and the base.
[0013] The elongated lights may include, without limitation, fluorescent bulbs, each having a wattage of, for example, five, seven, nine or thirteen watts. When a five or seven watt fluorescent bulb is selected, three or four lens rings are interposed among two or three light deflectors, respectively. When a nine or thirteen watt fluorescent bulb is selected, five lens rings are interposed among four light deflectors.
[0014] In another aspect of the present invention, there is provided a lighting bollard assembly produced according to the methods of the present invention.
[0015] In another aspect of the present invention, there is provided a method of manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths. The method comprises mounting a circuit structured to power any one of different elongated lights atop a base, in which the base is comprised of a mounting base and an upright tube, the upright tube being of a predetermined length, such as, without limitation, two feet long, four feet long, six feet long or eight feet long. A first clamp plate then is mounted atop the circuit and the upright tube, the first clamp plate having a plurality of openings therethrough. Conductors from the circuit are inserted through at least one of the openings of the first clamp plate, into a lamp cup having a first side and a second side and a plurality of openings therethrough, and into a light socket. An elongated light from the different elongated lights is selected and affixed into the light socket. The lamp cup is mounted atop the first clamp plate. A number of interposed lens rings and a number of light deflectors are selected which correspond to the length of the selected elongated light, in which each of the selected number of lens rings is inserted into a corresponding one of the selected number of light deflectors. The selected number of interposed lens rings and selected number of light deflectors are mounted atop the lamp cup. A second clamp plate having a plurality of openings therethrough is mounted atop the adjusted number of interposed lens rings and light deflectors. A hood having a plurality of openings therethrough is mounted atop the second clamp plate. The hood, the second clamp plate, the selected number of interposed lens rings and selected number of light deflectors, the lamp cup, the first clamp plate and the upright tube and the mounting base then are connected together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
[0017] FIG. 1 is an elevational view of four example lighting bollard assemblies, in which (A) is a five watt lighting bollard assembly, (B) is a seven watt lighting bollard assembly, (C) is a nine watt lighting bollard assembly and (D) is a thirteen watt lighting bollard assembly in accordance with embodiments of the invention.
[0018] FIG. 2 is an exploded isometric view of the components of a lighting bollard assembly, in accordance with embodiments of the invention.
[0019] FIG. 3 is an exploded isometric view of two components of the bollard light assemblies of FIG. 2 : (A) a mounting base, and (B) an upright tube.
[0020] FIG. 4 is an exploded isometric view of four components of the bollard light assemblies of FIG. 2 : (A) a terminal block, (B) a transition strap, (C) a light ballast, and (D) a first clamp plate.
[0021] FIG. 5 is an exploded isometric view of three components of one of the bollard light assemblies of FIG. 2 : (A) a lamp cup, (B) a light socket, and (C) a fluorescent bulb.
[0022] FIG. 6 is an exploded isometric view of two components of the bollard light assemblies of FIG. 2 : (A) a tube ring, and (B) a light deflector.
[0023] FIG. 7 is an exploded isometric view of three components of the bollard light assemblies of FIG. 2 : (A) a second clamp plate, (B) a set of four fasteners, and (C) a hood.
[0024] FIG. 8 is an isometric view of an example thirteen watt lighting bollard assembly, in accordance with embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] A complete understanding of the present invention will be obtained from the following description taken in connection with the accompanying drawing figures, wherein like reference characters identify like parts throughout.
[0026] Directional phrases used herein, such as, for example, “upper” and “lower” and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
[0027] As employed herein, the term “fastener” refers to any suitable connecting or tightening mechanism expressly including, but not limited to, screws, bolts and the combinations of bolts and nuts (e.g., without limitation, lock nuts) and washers and nuts.
[0028] As employed herein, the term “connector” refers to any suitable electrical connection or connection mechanism capable of carrying an electrical current therein.
[0029] As employed herein, the statement that two or more parts are “connected” or “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. Further, as employed herein, the statement that the two or more parts are “attached” shall mean that the parts are joined together directly.
[0030] The invention is described in association with a method for manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths.
[0031] Referring to FIGS. 1 and 2 , the lighting bollard assemblies 10 , 10 ′, 10 ″, 10 ′″ ( FIG. 1 ) is comprised of a base 11 ( FIG. 1 ) in which the base 11 is comprised of a mounting base 12 ( FIG. 2 ) and an upright tube 14 ( FIG. 2 ); a circuit 35 ( FIG. 1 ), in which the circuit 35 is comprised of a terminal block 18 ( FIG. 2 ), a transition strap 20 ( FIG. 2 ) and a light ballast 25 , 25 ′ ( FIG. 1 ); a first clamp plate 48 ( FIG. 2 ), a lamp cup 26 , a light socket 36 ( FIG. 2 ), a plurality of different elongated lights 62 , 64 , 66 ( FIG. 1 ) with different lengths; a plurality of lens rings 40 ( FIG. 2 ); a plurality of light deflectors 42 ; a second clamp plate 50 ( FIG. 2 ); a plurality of fasteners 56 ( FIG. 2 ); and a hood 52 .
[0032] The different elongated lights 62 , 63 , 64 , 65 can include, without limitation, fluorescent bulbs. The different fluorescent bulbs each can have wattages such as, without limitation, five watts (light 62 ), seven watts (light 63 ), nine watts (light 64 ) or thirteen watts (light 65 ).
[0033] Referring to FIG. 3 , the mounting base 12 has a lower end 13 with a plurality of openings 19 therethrough and an upper end 17 with a center opening 37 therein. The upright tube 14 has a lower end 16 and an upper end 15 with a center opening 39 therein.
[0034] Referring to FIG. 4 , the transition strap 20 has a lower end 21 , an upper end 22 , a first side 23 and a second side 24 . The light ballast 25 has an upper end 57 and a lower end 58 . The first clamp plate has an upper end 72 which has an opening 74 therethrough and four peripheral openings therein, and four legs 73 , in which each leg 73 has an opening therein 76 (two openings are shown).
[0035] Referring to FIG. 5 , the lamp cup 26 has an upper end 27 , a lower end 28 , a first side 29 , a second side 30 , a center opening 31 , four peripheral openings 32 at the upper end 27 and four openings 34 (two openings are shown) at the lower end 28 .
[0036] Referring to FIG. 6 , the light deflector 42 has an upper end 44 having four ears 45 therein and a center opening 46 therethrough. Each of the ears 45 has an opening 47 therein.
[0037] Referring to FIG. 7 , the hood 52 has an upper end 51 and a lower end 53 having four openings 54 (one opening is shown) therein. The second clamp plate 50 has an upper end 84 having a center opening 86 therethrough and four peripheral openings 87 therein and two legs 85 (one leg is shown), each leg 85 having an opening therein 88 .
[0038] Referring again to FIGS. 1 and 2 , embodiments of the present invention provide a method of manufacturing a lighting bollard assembly 10 , 10 ′, 10 ″, 10 ′″ ( FIG. 1 ), comprising mounting a circuit 35 ( FIG. 1 ) structured to power any one of the different elongated lights 62 , 63 , 64 , 65 ( FIG. 1 ) atop a base 11 ( FIG. 1 ); mounting a first clamp plate 48 ( FIG. 2 ) atop the circuit 35 and the base 11 ; selecting an elongated light 62 , 63 , 64 or 65 from the different elongated lights 62 , 63 , 64 , 65 , affixing the selected elongated light 62 , 63 , 64 or 65 into a light socket 36 and inserting the light socket 36 into the center opening 31 in the upper end 27 of the lamp cup 26 ; selecting a number of interposed lens rings 40 ( FIG. 2 ) and a number of light deflectors 42 to correspond to the length of the selected elongated light 62 , 63 , 64 or 65 ; interposing the selected number of lens rings 40 among the selected number of light deflectors 42 , wherein each of the selected number of lens rings 40 is inserted into a corresponding one of the selected number of light deflectors 42 ; mounting the selected number of interposed lens rings 40 and the selected number of light deflectors 42 atop the circuit 35 , the first clamp plate 48 and the lamp cup 26 ; mounting a second clamp plate 50 ( FIG. 2 ) atop the selected number of interposed lens rings 40 and the selected number of light deflectors 42 ; mounting a hood 52 atop the second clamp plate 50 ; and connecting together the hood 52 , the second clamp plate 50 , the selected number of interposed lens rings 40 , the selected number of light deflectors 42 , the lamp cup 26 , the first clamp plate 48 and the base 11 .
[0039] Referring to FIGS. 2 and 3 , the method further comprises inserting the lower end 16 of the upright tube 14 ( FIG. 3B ) into the opening 37 in the upper end 17 of the mounting base 12 ( FIG. 3A ).
[0040] Referring to FIGS. 2 and 4 , the method further comprises affixing the terminal block 18 ( FIG. 4A ) to the lower end 21 of the transition strap 20 ( FIG. 4B ) and affixing the lower end 58 of the light ballast ( FIG. 4C ) to the upper end 22 of the transition strap 20 .
[0041] Referring to FIGS. 2-5 , the method further comprises inserting the lower end 28 of the lamp cup 26 ( FIG. 5A ) into the transition strap 20 ( FIG. 4B ) by inserting the first side 29 of the lamp cup 26 into the first side 23 of the transition strap 20 and inserting the second side 30 of the lamp cup 26 into the second side 24 of the transition strap 20 . Conductors 49 ( FIG. 2 ), such as, without limitation, insulated electric wires, are inserted from the terminal block 18 , through the transition strap 20 , the light ballast 25 , the center opening 74 in the first clamp plate 48 , the center opening 31 of the lamp cup 26 , and into the light socket 36 ( FIG. 5B ). The lower end 21 of the transition strap 20 is inserted into the opening 39 in the upper end 15 of the upright tube 14 . Each of the legs 73 of the first clamp plate 48 is inserted into the opening 39 in the upper end 15 of the upright tube 14 .
[0042] Referring to FIG. 7 , the method further comprises attaching together the hood 52 ( FIG. 7C ) and the second clamp plate 50 ( FIG. 7A ) by mounting the hood 52 atop the second clamp plate 50 ; aligning the two openings 54 (only one opening is shown) in the lower end 53 of the hood 52 with a corresponding one of the two openings 88 (only one opening is shown) in the two legs 85 of the second clamp plate 50 ; employing a press nut 81 at each of the openings 88 in each of the legs 85 of the second clamp plate 50 ; and inserting a bolt 82 in each of the openings 54 in the lower end 53 of the hood 52 , each of the bolts screwably attaching into a corresponding one of the nuts in the legs of the second clamp plate 50 .
[0043] Referring to FIGS. 4-7 , the method further comprises connecting together the second clamp plate 50 , the selected number of interposed lens rings 40 ( FIG. 6A ) and the selected number of light deflectors 42 ( FIG. 6B ), the lamp cup 26 and the first clamp plate 48 by inserting a fastener 56 ( FIG. 7B ) into one of four peripheral openings 87 in the upper end 84 of the second clamp plate 50 , into a corresponding one of the four openings 47 in the four ears 45 of the selected number of light deflectors 42 , into a corresponding one of four peripheral openings 32 in the upper end 27 of the lamp cup 26 , and into a corresponding one of the four peripheral openings 75 in the upper end 72 of the first clamp plate 48 .
[0044] Referring to FIGS. 3-5 , the method further comprises attaching the lamp cup 26 and the first clamp plate 48 to the upper end 15 of the upright tube 14 by placing four openings 41 in the upright tube 14 , inserting the four legs 73 of the first clamp plate 48 into the upright tube 14 , mounting the lamp cup 26 atop the first clamp plate 48 , aligning the four openings 34 (two openings are shown) in the lower end 28 of the lamp cup 26 with the four openings 76 (two openings are shown) in the four legs 73 of the first clamp plate 48 and with the four openings 41 in the upright tube 14 , inserting a press nut 81 into each of the openings 76 in the legs 73 of the first clamp plate 48 , and inserting a bolt 82 into each of the openings 34 in the lower end 28 of the lamp cup 26 , into a corresponding one of the openings in the upright tube 14 , and into a corresponding one of the openings 76 in the legs 73 of the first clamp plate 48 , each of the bolts screwably attaching into a corresponding one of the press nuts in the openings 76 of the legs 73 of the first clamp plate 48 .
[0045] Referring to FIGS. 2 and 8 , the method further comprises attaching the lower end 13 of the mounting base 12 to a surface 68 by inserting bolts 82 into each of the four openings 19 in the lower end 13 of the mounting base 12 and fixedly attaching each of the bolts to the surface 68 . The surface may include, without limitation, wood, concrete or asphalt.
[0046] Referring to FIGS. 1 , 2 and 5 , the method further comprises interposing three lens rings 40 ( FIG. 2 ) and two light deflectors 42 when a five watt fluorescent bulb 62 ( FIG. 1A ) is selected for use in the bollard light assembly 10 ( FIG. 1A ); interposing four lens rings 40 ( FIG. 2 ) and three light deflectors 42 when a seven watt fluorescent bulb 63 ( FIG. 1B ) is selected for use in the bollard light assembly 10 ′ ( FIG. 1B ); interposing five lens rings 40 ( FIG. 2 ) and four light deflectors 42 when a nine watt fluorescent bulb 64 ( FIG. 1C ) is selected for use in the bollard light assembly 10 ″ ( FIG. 1C ); and interposing five lens rings 40 ( FIG. 2 ) and four light deflectors 42 when a thirteen watt fluorescent bulb 65 ( FIG. 1D ) is selected for use in the bollard light assembly 10 ′″ ( FIG. 1D )
[0047] In another embodiment of the present invention, there is provided a lighting bollard assembly 10 , 10 ′, 10 ″, 10 ′″ ( FIG. 1 ) manufactured according to the methods of the present invention.
[0048] While specific embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. | The present invention provides methods of manufacturing a bollard light assembly that provides a choice of light output by being size-adaptable depending on the choice of light output. The methods comprise, in pertinent part, selecting an elongated light and interposing a number of lens rings and light deflectors which correspond to the length of the selected elongated light. Also provided is a lighting bollard assembly manufactured according to the methods of the present invention. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. national phase of PCT/EP2008/010667 filed Dec. 10, 2008, which claims priority to DE 10 2008 003 718.4 filed Jan. 9, 2008.
FIELD OF THE INVENTION
The invention relates to a louver blind with louvers that can pivot about a vertical axis and that are held at their two ends by louver holders extending across the louver width so that they can move between an upper and a lower guide track, wherein the louver holders are connected aligned parallel to each other to carriages that can move in the guide tracks and can pivot by means of synchronously driven rotating means arranged in the carriages.
BACKGROUND OF THE INVENTION
Louver blinds are used in architecture to protect buildings and their users from the undesired effects of intense solar irradiation. Simultaneously, however, a high degree of transparency should remain. For this purpose, the louvers must be mounted in carriages so that they can pivot such that, in the state when they are moved apart from each other, these can each be rotated perpendicular to the incident solar irradiation.
Louver blinds of the type named above are known, for example, from DE 75 39 579 U. Here, the louver holders and the gear devices arranged in the carriages are connected rigidly to each other. The production of this connection requires special effort in terms of assembly and also makes any repair work more difficult, for example, when changing out particularly wide louvers, like those being used increasingly for facades with large surface-area glass windows.
The task of the invention is to form the connection between the louvers and the carriages so that both the assembly of the louver blinds and also repair work on the louvers can be performed more easily. In addition, the connections should automatically disconnect when critical tensile forces or torques are exceeded, in order to prevent damage to the connecting parts.
SUMMARY OF THE INVENTION
To achieve this task, it is proposed according to the present invention that the connection between the louver holders and the carriages is produced by permanent magnets that can be decoupled.
This can be achieved advantageously in that the rotating means in the carriage are locked in rotation with a rotary plate projecting from the slot of the guide tracks that is open to the louvers, wherein the magnets are mounted in radial alignment on this rotary plate, and a magnet holder is mounted on the louver holders opposite each rotary plate, wherein this magnet holder is equipped with counter magnets of corresponding strength for producing the connection to the magnets of the rotary plate.
In this way, not only is the assembly made easier, but it can also be achieved that, for the case of the unintentional appearance of torque or tensile stresses that lead to the detachment of the coupling connection, the magnets easily disconnect from each other and automatically rejoin when the disconnection forces are eliminated. Such stresses can then occur, for example, when a window washer inserts his ladder between louvers that are arranged at a right angle for cleaning large surface-area windows, in order to reach the windowpanes, and, in this way, pushes against the louver holders.
BRIEF DESCRIPTIONS OF THE DRAWINGS
Additional features of the invention and their advantages follow from the subordinate claims and the explanation of a preferred embodiment of the invention that is shown in the drawings and that shall be described in detail below. Shown herein are:
FIG. 1 , a louver blind with louvers moved apart from each other and arranged at an angle to the window;
FIG. 2 , the lower guide track with rotary plate when coupled with the magnet plate in a perspective top view;
FIG. 3 , the same picture with a decoupled magnet holder;
FIG. 4 , the upper guide track with carriages and rotary plates in a perspective diagram with a view into the gear;
FIG. 5 , the same picture in side view;
FIG. 6 , the same picture in longitudinal section according to line VI-VI in FIG. 5 ;
FIG. 7 , a front view of FIG. 5 ;
FIG. 8 , the upper louver holder with rotary plates and chocks assembled together in a perspective view from above;
FIG. 9 , the upper louver holder with decoupled rotary plates in longitudinal section according to line IX-IX in FIG. 10 ;
FIG. 10 , a cross section in this respect according to line X-X in FIG. 9 ;
FIG. 11 , an upper rotary plate in top view with a view of the magnets;
FIG. 12 , the rotary plate in section according to line XII-XII in FIG. 11 ;
FIG. 13 , the rotary plate in section according to line in FIG. 11 ;
FIG. 14 , a section through the edge of the plate according to line XIV-XIV in FIG. 11 ;
FIG. 15 , the magnet holder in section according to line XV-XV in FIG. 16 ;
FIG. 16 , the same magnet holder in front view;
FIG. 17 , a chock in side view; and
FIG. 18 , the same chock in front view with view of the projection.
DETAILED DESCRIPTION OF THE INVENTION
The louver blind shown in the figures is equipped with louvers 1 that can pivot about a vertical axis. The louvers 1 are held at their two ends by louver holders 2 that usually extend across the entire louver width. These louver holders 2 are held so that they can move and pivot on their side between an upper and a lower guide track 3 , wherein the louver holders 2 are connected to each other with carriages 4 that can move in the guide tracks 3 in a way still to be described by means of permanent magnets 16 and 18 .
In FIGS. 4-7 , the configuration of a carriage 4 with a gear housed in this carriage for pivoting the louvers 1 is shown clearly and shall be explained in detail below—as much as necessary for understanding the invention.
The carriage 4 is here guided so that it can move in the guide track 3 by means of laterally mounted track rollers 5 . For movement, in the front carriage 4 , a threaded sleeve 6 with large thread pitch is fit in the longitudinal direction, with a threaded rod 7 with the same thread pitch being guided through this sleeve. The threaded rod 7 is driven by a motor arranged at the beginning of the guide track 3 , in order to move the front carriage 4 in the longitudinal direction. The following carriages 4 are then pulled along by typical spacers.
The gear installed in the carriage 4 is made essentially from a toothed wheel 8 that is mounted vertically in the center of the carriage 4 and that projects downward with a rotating rod 9 through an open slot 10 in the guide track 3 , with this rotating rod being locked in rotation, in turn, with a rotary plate 11 or 31 . The toothed wheel 8 engages in vertically mounted pinions 12 that are driven on their side by worms 13 mounted in the carriage 4 at the side of the pinion 12 .
Here it has proven useful to drive the toothed wheel 8 by means of two diametrically opposed pinions 12 and two worms 13 , in order to keep the structural height of the carriage 4 as small as possible.
The worms 13 are provided with a crossed slot 14 through which a rotating rod 15 is inserted that is shaped corresponding to the profile of the slot 14 . This rotating rod 15 is guided through the worms 13 of several carriages 4 arranged one after the other and is connected to a motor at the beginning of the guide track 3 . Therefore, the rotary plate 11 or 31 of all of the carriages 4 can be pivoted in sync by the same angle.
In FIGS. 2 and 3 , the effect according to the invention of the magnet connection between a lower louver holder 2 and a lower rotary plate 11 locked in rotation with the carriage 4 is shown, with this rotary plate having two diametrically opposed permanent magnets 16 in radial alignment relative to the louver holder 2 . On the bottom side of the louver holder 2 , a magnet holder 17 is mounted above the rotary plate 11 , wherein this magnet holder is equipped with counter magnets 18 of corresponding strength for producing the connection to the magnets 16 of the lower rotary plate 11 .
On its edge, the lower rotary plate 11 has—just like the upper rotary plate 31 in FIGS. 8-10 and 11 - 13 —a ring 19 that is directed toward the magnet holder 17 and that is notched in the radial projection of the magnets 16 up to the plate base 20 at the width of the magnet holder 17 . In this way, the notch faces 21 are directed outward at an angle from the plate base 20 , so that the magnet holder 17 can rotate upward along the inclined faces 21 and in this way can be simultaneously decoupled for an unexpected rotating force on the louver holder 2 .
The magnet holder 17 is made from an elongated base body 22 , as can be seen from FIGS. 15 and 16 , in which the two counter magnets 18 are embedded at the same spacing as the magnets 16 in the lower rotary plate 11 . On its bottom side, the base body 22 has a projection 23 that has a T-shaped cross section and that is inserted into a correspondingly shaped groove 24 on its bottom edge for connecting to the louver holder 2 and that is anchored in the center of the louver holder 2 .
In the center of the base body 22 , a circular recess 25 is formed in which engages a round peg 26 fixed on the lower rotary plate 11 in the center between the two magnets 16 in the coupled state. This round peg 26 ensures that, after the appearance of the previously mentioned rotational effect and the decoupling dependent on this effect, the centering of the magnet holder 17 relative to the rotary plate 11 is maintained, so that after the rotational effect is eliminated, the magnet holder 17 can be docked again without a problem. Obviously, the intentional centering effect could then also be achieved when the recess 25 is provided as in FIG. 13 on the upper rotary plate 31 and the associated round peg 26 as in FIG. 15 on the magnet holder 17 .
While just the force of gravity is responsible for the coupling situation at the lower end of the louvers 1 , in which, after the louver holder 2 drifts away, the magnet holders 17 dock on the rotary plates 11 again due to magnetic forces, additional measures must be taken at the upper end of the louvers 1 , as can be seen from FIGS. 8-10 , so that the louver holder 2 does not fall downward due to unexpected appearance of tensile or torque forces after the disconnection of the magnet connection.
Therefore, on the upper louver holders 2 on both sides of the upper rotary plate 31 , chocks 27 are provided with inward-directed projections 28 that have the same T-shaped projections 23 as the magnet holders 17 . These chocks 27 are pushed with their projections 23 on both sides of the rotary plate 31 into the grooves 24 on the lower edge of the louver holder 2 and anchored in the groove 24 shortly before contact on the rotary plate 31 . In this way it is achieved that the projections 28 , as can be seen from FIG. 8 , engage behind the rotary plate 31 in the coupled state of the magnets 16 and 18 with a safety spacing “a”. When the upper rotary plate 31 is decoupled from the magnet holder 17 by the unexpected effect of tensile or torque forces, it can fall downward only by the safety spacing “a” and is then held by the projections 28 ( FIG. 9 ).
The upper edge 29 of the upper rotary plate 31 is here preferably offset inward by a radial step 30 corresponding to the radial dimension of the projections 28 (see FIGS. 10 and 13 ). In order to also achieve the most centered position possible here after the decoupling, the radial step 30 of the upper rotary plate 31 is provided underneath the projections 28 with recesses 32 corresponding to the width of the chocks 27 (see FIGS. 11 and 14 ).
Similar to the notch faces 21 in the ring 19 , here the notch faces 33 are also directed outward at an angle from the base of the recesses 32 , while the projections 28 of the chocks 27 , as can be seen from FIGS. 17 and 18 , have counter faces 35 that are directed inward at an angle corresponding to their engagement edges 34 and that engage in the recesses 32 of the step 30 in the decoupled state of the magnet holder 17 .
In addition it shall be noted that the upper rotary plates 31 differ from the lower rotary plates 11 in shape only by the additional formation of radial steps 30 on the upper edge 29 and recesses 32 in the steps 30 that are provided for the interaction with the chocks.
It is understood that the upper rotary plates 31 can also be used on the lower end of the louvers 1 , in order to eliminate a second shape for the rotary plate 11 or else in order to be able to also insert the same chocks 27 at the lower end of the louvers 1 in the louver holder 2 , if all that matters is protection against decoupling due to the effect of torque forces.
It is further understood that the characterizing features of the invention can also be used in such louver blinds in which the vertically directed louvers 1 are held so that they can move and pivot only at their upper ends with their louver holders 2 on an upper guide track 3 , when a lower guide track can be eliminated or if the upper guide track runs at an angle, because the window frame is beveled at the top.
It is also understood that the connection according to the invention between the louver holders 2 and the carriages 4 can also relate completely generally to louver blinds in which the louvers 1 are held so that they can pivot about their louver axis between two parallel guide tracks 3 , regardless of whether the guide tracks are arranged vertically, horizontally, or at an angle in space. | The invention relates to a louver blind having louvers ( 1 ) that can be pivoted about a vertical axis, displaceably held at both ends thereof by louver holders ( 2 ) extending beyond the louver width between an upper and a lower guide track ( 3 ). The louver holders ( 2 ) are hereby connected to each other by carriages ( 4 ) displaceable in the guide tracks ( 3 ) and aligned in parallel to each other, and can be pivoted by synchronously driven drive device disposed in the carriages ( 4 ). In order to make the installation of the louver blind—or optionally the removal thereof—easier, according to the invention, decoupleable permanent magnets ( 16, 18 ) are provided for connecting between the louver mounts ( 2 ) and the carriages ( 4 ). Said arrangement has the further advantage that the connections can automatically release when critical tension or rotational forces are exceeded, so that damage can be prevented in the connecting parts. |
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is claims the benefit of U.S. provisional patent application No. 60/813,731, filed Jun. 13, 2006, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND
[0002] The general concept of trench drains is well known in the prior art. Trench drains are generally used to transport large amounts of liquid from one location to another. Typically, trench drains are used to collect liquid runoff from residential and commercial structures and deliver the runoff to a sewer system.
[0003] Current trench drains are typically modular in design and constructed of light weight polymers, such as fiberglass reinforced polyester. Typically, the trench drains consist of channels that have two sidewalls separated by a bottom wall. To install the trench drains, a trench is typically dug to a depth twice as deep as the height of the sidewalls, such that the top of the sidewall is about ⅛″ below the surrounding surface. Modular trench drain pieces, typically in about 1 meter lengths, are connected and sealed together. Concrete is poured in the bottom of the trench, the connected trench drain pieces are placed on top, and then concrete is poured around the trench drain up to a height approximately equal to the sidewall.
[0004] Because the top of a trench drain remains level, the slope is typically built into the channel itself. To accomplish this, each section of trench drain, as the drain slopes down, has higher sidewalls than the prior, adjacent section of trench drain. Thus, many different molds are needed to cast and form construct each section of the sloping trench drain. Suppliers will also need to keep a supply of each different section of sloping channel.
SUMMARY OF THE INVENTION
[0005] In one embodiment of the invention, a modular, non-sloping section of trench drain is transformed into a sloping section of trench drain by installing sloping overlay rails. The overlay rails rest on the top of the upper edge of the sidewalls.
[0006] In another embodiment, the sloping overlay rails have a ledge which allows grating, which spans across the channel, to rest on top.
[0007] In yet another embodiment, the channels are held together and in place by a clip with a hole(s) for accepting a support rod, typically rebar, to further secure the channel in place before and after the concrete has cured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a side perspective view of a trench drain with sloping overlay rails according to one embodiment of the invention.
[0009] FIG. 2 is an end view of a trench drain with sloping overlay rails according to one embodiment of the invention.
[0010] FIG. 3 is a trench drain channel without sloping overlay rails according to one embodiment of the invention.
[0011] FIG. 4A is an overhead perspective view of the overlay rails according to one embodiment of the invention.
[0012] FIG. 4B is an overhead perspective view of an anchor clip according to one embodiment of the invention.
[0013] FIG. 5 is a side perspective view of a trench drain with sloping overlay rails and installed grating according to one embodiment of the invention.
[0014] FIG. 6 is a side perspective view of a channel bracket according to one embodiment of the invention.
[0015] FIG. 7 is an overhead perspective view of a channel bracket according to one embodiment of the invention.
[0016] FIG. 8 is and overhead view of the underside of two sections of trench drain channel joined before adding a channel bracket according to one embodiment of the invention.
[0017] FIG. 9 is an overhead view of the underside of two sections of trench drain channel joined with a channel bracket according to one embodiment of the invention.
[0018] FIGS. 10 A-D show various views of the lock device for the grates according to one embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] In one embodiment of the invention, a modular, non-sloping section of trench drain is transformed into a sloping section sloping trench drain by installing sloping overlay rails.
[0020] According to an embodiment of the invention, as shown in FIG. 1 , sloping overlay rails 11 , 12 are mounted on a non-sloping, modular trench drain component 13 to create a sloping trench drain 10 . As shown in FIG. 3 , the non-sloping modular trench drain component 20 , comprises sidewalls 21 and a bottom section 22 . Each sidewall 21 has an upper edge 24 and an inner shelf 23 below the upper edge 24 . There is also a flange with a groove 25 at one end of the modular trench drain component 20 , which flange may correspond to a “female” end and is dimensioned and adapted to receive a corresponding “male” end. The other end of the trench drain component 20 , the “male” end (not shown), is dimensioned and adapted be inserted into the “female” end, to make a tight fitting joint. In an embodiment, the joint is held together with an adhesive and is watertight. The bottom of each overlay rail 11 , 12 has an inverted U-shaped groove. As shown in FIG. 2 , each overlay rail 11 , 12 comprises an inner ledge 11 a , 12 a respectively, and an outer ledge 11 b , 12 b respectively. As shown in FIGS. 2 and 3 , the bottom of the inner ledge 11 f , 12 f rests on the top of the inner shelf 23 of the non-sloping modular trench drain component 20 .
[0021] In another embodiment, the vertical distance from the inner ledge 11 a , 12 a , to the top of the overlay rail 11 d , 12 d is constant throughout the length of the overlay rail 11 , 12 . As shown in FIG. 5 , this allows grating 31 that is level with the top rail 32 to be installed on the sloping trench drain 30 .
[0022] In an additional embodiment, as shown in FIGS. 1 and 2 , the vertical distance from 11 a , 12 a to 11 f , 12 f increases linearly from end A to end B, thereby creating the sloped trench drain 10 . For the outside of the overlay rail 11 , 12 the vertical distance from the top of the rail 11 d , 12 d to the outer ledge 11 b , 12 b increases as the slope increases, and the distance from the outer ledge 11 b , 12 b to the bottom of the outer leg 11 e , 12 e is constant. In one embodiment the rail increases in height at a rate of 0.50% to 1.00%, and in another embodiment it increases in height at a rate of about 0.75%. Thus, for a 1 meter section of trench drain having rails that increase in height at a rate of 0.75%, the increase from end A to end B would be about 0.0075 meters or about 0.295 inches. In another embodiment, fifteen different 1 meter sections of trench drain are connected together with sloping overlay rails having a 0.75% rate of increase in height, yielding a height differential of 0.1125 meters or 4.425 inches between the beginning of the first section and end of the last section. In one embodiment, the overlay rails are 1 mm shorter than the channel section to allow for some linear expansion, although a larger gap may be used.
[0023] According to one embodiment, as shown in FIG. 4A , each rail 41 , 42 in the matched pair 40 is a mirror image of the other. Each section of trench channel will require a different matched pair of overlay rails to create continuously sloping trench drain system. The height at the end of the overlay rail of the previous section of trench drain should correspond to the beginning height of the overlay rail of the next section of trench drain, so as to make a continuously sloping trench drain system. In another embodiment, the outside edge of each rail 41 , 42 contains four anchor lugs 44 , with center openings 45 . Each rail 41 , 42 may contain more or less than four anchor lugs 44 . The lugs 44 enhance positive anchoring during the concrete pour and the center the allows attachment of wire mesh (not shown) prior to the concrete pour. In yet another embodiment, the inside edge of each rail 41 , 42 contains two anchoring tabs 43 with a center hole 46 . Each rail 41 , 42 may contain more or less than two anchoring tabs 43 . In one embodiment, an anchoring clip 50 , as shown in FIG. 4B is inserted into an anchoring tab center hole 46 on a rail 41 and a corresponding center hole 46 on the opposite rail 42 . The anchoring clip 50 assists in maintaining a constant distance between the two rails 41 , 42 . Thus, neither pressure exerted inward from poured concrete, nor pressure exerted outward from the molded draft of the modular channel will significantly change the upper span between the rails 41 , 42 .
[0024] In an embodiment, as shown in FIG. 4B , the anchoring clip 50 comprises a top 47 plate with two pins 48 , and a center hole 49 . In one embodiment, the distance between the two pins 48 corresponds to the distance between the anchor tab center holes 46 , opposite each other on rails 41 , 42 . In yet another embodiment, the center hole 49 is used for a grate locking device and lines up with bolt holes 33 in the grating 31 as shown in FIG. 5 . In one embodiment, the anchoring clip 50 is inserted into corresponding holes 46 with the pins facing down. If it is desired to use a grating lock device, the anchoring clip 50 may be inserted with the pins facing up as discussed below with reference to FIGS. 10 A-D.
[0025] In an embodiment, as shown in FIGS. 6-9 , different sections of the modular trench drain component are joined together with brackets to create longer sections of trench drain. Note that the sloping overlay rails are not shown in FIGS. 8 and 9 because the Figs. show the bottom portion of the trench drain system. As shown in FIG. 8 , one section of modular trench drain channel 81 is joined to another section of trench drain channel 82 . In an embodiment, trench drain channel 81 is the female end with a flange 83 , and trench drain channel 82 is the male end with securing tabs 84 . In one embodiment, trench drain channel 82 has a circular cutout 87 for a round discharge pipe (not shown).
[0026] According to one embodiment, to secure and assist in stabilizing the modular trench drain, channel brackets 60 are used as shown in FIGS. 6 and 7 . In an embodiment, the channel bracket 60 comprises a base 61 , connected to two side walls 66 , and two anchor tabs 64 on the sidewalls 66 . In one embodiment, each sidewall 66 has two grooves 62 , 63 , dimensioned to receive flanges 83 or securing tabs 84 located on modular trench channel sections as shown on FIG. 8 . In another embodiment, only a portion of each sidewall is connected to the base 61 , and one section containing one of the groves 63 is cantilevered from the base 61 . One of the grooves 62 continues from the top of the clip down through the base 61 of the clip. The other groove 63 is only present on the cantilevered portion of the sidewall that is not connected to the base 61 . In another embodiment, the anchor tabs 64 have two center holes 65 which are dimensioned to receive a piece of rebar (not shown).
[0027] In an embodiment, as shown in FIG. 9 , a channel bracket 85 is mounted over a flange (not shown) and a securing tab 84 to secure two sections of trench channel 81 , 82 together. Center holes 85 may receive rebar (not shown) to anchor the secured sections prior to pouring the concrete, as well as after the concrete has cured.
[0028] In one embodiment, as shown in FIGS. 10 A-D, a locking device 100 is used to hold down slotted grates and solid covers and comprises a bolt 101 , a washer 102 , and a threaded flange 103 . In another embodiment, the flange may be used in conjunction with the anchor clip 50 shown in FIG. 4B . The anchor clip 50 would be installed with the pins facing up, and the bolt 101 with a washer 102 would be inserted through a hole in the grating, like hole 33 in FIG. 5 , and the flange 103 would be placed under the anchor clip 50 , so that the bolt 101 may be inserted into the threads 104 of the flange 103 and tightened.
[0029] Various materials may be used for the different components of the trench drain system. In one embodiment, the channel is constructed of fiberglass, polypropylene, polyethylene, polymer concrete, concrete, or combinations thereof In another embodiment, the overlay rails may be constructed of polypropylene, polyethylene, or a combination thereof. In a further embodiment, the rails are constructed of the same material as the channel, fiberglass, polymer concrete, or combinations thereof. In one embodiment, the anchor clips may be constructed of PVC, plastic, steel, aluminum, and combinations thereof. In a further embodiment, polyurethane may be used as a sealer/adhesive between the channel sections, however any commonly known sealer in the art may be used. In an embodiment, the grating lock device is constructed out of stainless steel or galvanized steal, although other materials may be used for various parts such as plastics for the flange.
[0030] While this invention has been described in connection with what are considered to be exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, dimensions, and configurations but, on the contrary, also extends to various modifications and equivalent arrangements. The invention is limited only by the claims and their equivalents. | A modular trench drain system with sloping overlay rails. A non-sloping section of trench drain is transformed into a sloping trench drain by installing sloping overlay rails. The overlay rails rest on the top of the upper edge of the sidewalls and may have a ledge which allows grating, which spans across the channel, to rest on top. The modular channels sections may be held together and in place by a clip with holes for accepting support rods which further secure the channels in place before and after the concrete has been poured and cured around the channels. |
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This application claims the benefit of U.S. Provisional Application No. 60/158,768, filed Oct. 12, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to well casing hangers in petroleum production wells. More specifically, the present invention relates to a full bore wellhead having a retractable load shoulder for suspending a casing.
2. Description of the Related Art
In some types of wellhead assemblies casing is suspended by a casing hanger on a load shoulder formed in the bore of the wellhead housing. Generally the load shoulder is formed integrally or permanently attached to the wellhead housing. The fixed load shoulder results in a reduced diameter in the bore below the load shoulder. Any tools or pipe must be smaller than the fixed shoulder. In some wells, more than one load shoulder is utilized for supporting multiple strings of casing.
Retrievable load shoulders are also known in the art, employing a running tool to deploy and retrieve the load shoulder selectively. Also, the prior art includes retractable load shoulders that are installed with the wellhead housing, but retracted before running casing. Retrievable and retractable load shoulders provide full bore access.
BRIEF SUMMARY OF THE INVENTION
A wellhead load ring constructed in the shape of a C-ring is pre-installed in a wellhead in a storage position that maintains full bore of the wellhead. The load ring is preferably secured in this position by shear pins. The shear pins are sheared by a tool that pushes the load ring into an operational position, where it rests on a landing shoulder of a support ring. The load ring is further secured in this position by one of several latching methods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view of an upper and lower portion of a wellhead housing showing a load shoulder ring in a storage position in accordance with the principles of the invention described herein.
FIG. 2 an enlarged vertical cross section of the wellhead housing shown in FIG. 1, showing the load shoulder ring in a storage position in accordance with the principles of the invention described herein.
FIG. 3 is a vertical cross section of the load shoulder ring of FIG. 2, but showing the load shoulder ring in an operational position in accordance with the principles of the invention described herein.
FIG. 4 is a vertical cross-sectional view of a second embodiment of the invention, showing a load shoulder ring in a storage position in accordance with the principles of the invention described herein.
FIG. 5 is a vertical cross-sectional view of the load shoulder ring of FIG. 4, but showing the load shoulder ring in an operational position in accordance with the principles of the invention described herein.
FIG. 6 is a vertical cross-sectional view of a third embodiment of the invention, showing a load shoulder ring in a storage position in accordance with the principles of the invention described herein.
FIG. 7 is a vertical cross-sectional view of the load shoulder ring of FIG. 6, but showing the load shoulder ring in an operational position in accordance with the principles of the invention described herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, wellhead housing 110 has an axial bore 112 . Axial bore 112 has upper portion 114 and a lower portion 116 , which is an upper portion of a large diameter string of casing. Upper portion 114 has a constant inner diameter and is considered full bore for the purpose of receiving tools and casing during drilling. Lower portion 116 has a diameter larger than upper portion 114 , therefore no portion of bore 112 is less than full bore. Four circumferentially spaced cavities 118 are located at the lower end of the upper portion 114 of axial bore 112 . Cavities 118 are adapted to receive a tool (not shown) as explained later.
A split C-ring 120 is located in bore 112 immediately below cavities 118 . C-ring 120 is initially secured to a support ring 122 by a plurality of shear pins 124 . C-ring 120 is in its free state while in this position, and its inner diameter is greater than or equal to the main diameter of bore upper portion 114 . Support ring 122 is statically secured to bore 112 by means of external threads 126 and by resting on lock ring 128 . Support ring 122 has mating shear holes 130 for receiving shear pins 124 . Shear pins 124 are designed to fail at a predetermined load, at which time the resiliency C-ring 1 20 allows it to contract to a smaller inner diameter. FIG. 1 and FIG. 2 show C-ring 120 in a storage position. Support ring 122 has an internal upward facing shoulder 132 and a profile 134 on its inward facing surface that mates with an outward facing lip or protrusion 136 on the upper end of C-ring 120 , when in the operational position. The inner diameter of support ring 122 is not less than the inner diameter of bore upper portion 114 .
During operation, wellhead housing 110 is installed within a previously installed tubular wellhead on the subsea surface. Casing 116 extends into the well from wellhead housing 110 . When it is desired to install casing within casing 116 , C-ring 120 is moved to the operational position by a tool (not shown) lowered from above. The tool will preferably be simultaneously running the casing. The tool has fingers that protrude outward and locate in cavities 118 and engages C-ring 120 . The tool is moved downward to shear pins 124 and push C-ring 120 downward. As C-ring 120 moves downward, outward facing wedging surface 138 mates with inward facing wedging surface 140 to force C-ring 120 to a smaller diameter so that it can land on landing shoulder 132 . The smaller inner diameter provides an upward facing load shoulder 142 which is used to hang the additional casing string. As C-ring 120 rests on landing shoulder 132 , protrusion 136 mates with profile 134 to secure C-ring 120 to support ring 122 .
FIGS. 4 and 5 show a second embodiment of the present invention. Referring to FIG. 4, wellhead housing 210 has an axial bore 212 . Four circumferentially spaced cavities 218 are located in axial bore 212 . Cavities 218 are adapted to receive a tool (not shown) as explained later.
A load shoulder split C-ring 220 and spring split C-ring 222 are located immediately below cavities 218 . C-rings 220 , 222 respectively, are pre-installed in wellhead 210 as shown in FIG. 4 such that the axial bore 212 remains full bore. Load shoulder split C-ring 220 is located inside spring split C-ring 222 when in a storage position such that the inner diameter of C-rings 220 , 222 in the storage position are not less than full bore. Spring split C-ring 222 locates in a groove 223 in bore 212 . Shear pins 224 extend through load shoulder split C-ring 220 to secure it to spring split C-ring 222 . Spring split C-ring 222 is located on top of a support ring 226 . Support ring 226 is secured to the wellhead housing by external threads 228 , and further supported by a lock ring (not shown). Support ring 226 has a recess 232 on it upper surface that receives a rib 234 on the lower surface of spring split C-ring 222 . As shown in FIG. 4, spring split C-ring 222 is positioned between upper portion 214 and support ring 226 such that rib 234 and recess 232 retain spring split C-ring 222 to the wellhead housing 210 , but allow radial movement.
Load shoulder split C-ring has an outward facing wedging surface 236 on it lower end. Spring split C-ring 222 has a matching inward facing wedging surface 238 below load shoulder split C-rings storage position. Spring split C-ring has a lip 240 below inward facing wedging surface 238 . Load shoulder split C-ring has an upward facing load shoulder 242 on its upper end.
During operation, the wellhead housing 210 is installed in a wellhead previously installed on the subsea surface. When it is desired to install casing within wellhead housing 210 , load shoulder C-ring 220 is moved to the operational position by a tool (not shown) lowered from above. The tool, which preferably is simultaneously running the casing, locates in cavities 218 and engages load shoulder C-ring 220 . The tool is moved downward to shear pins 224 and push load shoulder C-ring 220 downward. As load shoulder C-ring 220 moves downward, outward facing wedging surface 236 mates with inward facing wedging surface 238 to force load shoulder C-ring 220 to a smaller diameter and spring split C-ring 222 to a slightly larger diameter, allowing load shoulder split C-ring 220 to pass lip 240 on spring split C-ring 222 . Once pass lip 240 , the smaller inner diameter of load shoulder split C-ring 220 provides an upward facing load shoulder 242 which may be used to hang additional casing string. As C-ring 220 rests on landing shoulder 244 , lip 240 overlaps the top of load shoulder C-ring 220 slightly to secure load shoulder C-ring 220 to support ring 226 . FIG. 5 shows load shoulder C-ring 220 in an operational position, resting on landing shoulder 244 and secured by lip 240 .
FIGS. 6 and 7 show yet another embodiment of the present invention. Referring to FIG.6, wellhead housing 310 has an axial bore 312 . Four circumferentially spaced cavities 318 are located in axial bore 312 . Cavities 318 are adapted to receive a tool (not shown) as explained later.
A split C-ring 320 is located in bore 312 immediately below cavities 318 . A C-ring 320 is initially secured to a support ring 322 by a plurality of shear pins 324 . C-ring 320 is in its free state while in this position, and its inner diameter is greater than or equal to the main diameter of bore upper portion 314 . A support ring 322 is statically secured to bore lower portion 316 by means of external threads 324 and resting on lock ring 326 . Support ring 322 has mating shear holes 328 for receiving shear pins 324 . Shear pins 324 are designed to fail at a predetermined load, at which time the resiliency C-ring 320 allows it to contract to a smaller inner diameter. FIG. 6 shows C-ring 320 in a storage position. Support ring 322 has an internal upward facing shoulder 330 . Support ring 322 has a recess 332 on its inward facing surface that mates with a retainer ring 334 . Retainer ring 334 is located so that it aligns with a seat or notch 336 on the upper end of C-ring 320 when in the operational position. The inner diameter of support ring 322 is not less than the inner diameter of bore upper portion 314 .
During operation, the wellhead housing 310 is installed in a wellhead on the subsea surface. When it is desired to install casing within wellhead housing 310 , C-ring 320 is moved to the operational position by a tool (not shown) lowered from above. The tool locates in cavities 318 and engages C-ring 320 . The tool is moved downward to shear pins 324 and push C-ring 320 downward. As C-ring 320 moves downward, outward facing wedging surface 338 mates with inward facing wedging surface 340 to force C-ring 320 to a smaller diameter so that it can land on landing shoulder 330 . The smaller inner diameter provides as an upward facing load shoulder 342 which is used to hang an additional casing string. As C-ring 320 comes to rest on landing shoulder 330 , retainer ring 334 snaps into notch 336 securing C-ring.
The embodiments described above all provide the same advantages. The load shoulders are fully retracted when in the storage position. This allows full bore tools to pass. The design also allows the shoulder operation to be performed simultaneously with running the casing or separately so that the shoulder may be tested prior to running the casing.
While the invention has been shown in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. | A wellhead load ring constructed in the shape of a C-ring is pre-installed in a wellhead in a storage position that maintains full bore of the wellhead. The load ring is secured in this position by shear pins. The shear pins are sheared by a tool that pushes the load ring into an operational position where it rests on a landing shoulder of a support ring. The load ring is further secured in this position by one of several latching methods. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to tools and methods for installing replaceable blades onto moldboards, bowls and the like, and removing them therefrom.
BACKGROUND OF THE INVENTION
Road graders and scrapers often have replaceable cutting blades that are attached to a moldboard or bowl, and which need to be replaced when worn out from contact with the ground surface. These blades are generally elongate metal bars that are mounted onto the moldboard or bowl, by bolting them thereto using a number of bolts that pass through corresponding apertures in the moldboard or bowl, and the blade.
Graders and scrapers are quite large and the blades are therefore large and heavy, making them difficult to replace. Not only must the blade be lifted to abut the moldboard or bowl but it must also be positioned properly such that the relatively small apertures in the moldboard or bowl and the blade line up. Then, it must be held in that position until at least a few of the bolts are in place. The blade replacement process is a difficult task that often requires the coordinated efforts of two or more persons, to ensure that the blade is not accidentally dropped before it is secured.
Often, one person operates a grader or scraper in a remote area. When the blade needs to be replaced the person must either replace it themselves, if possible, or call for another person to come to the site to assist in the replacement. What is needed in the art is a means for enabling one person to remove a used blade, and then lift, line up and securely bolt, a new blade to a moldboard or bowl in a manner that is easy, quick and avoids injury.
SUMMARY OF THE INVENTION
There is provided herein an apparatus and method by which one person can lift, line up and securely hold a blade to a moldboard, or to a bowl, until the blade is fastened to the moldboard.
In one aspect, this invention is an apparatus for moving an elongated blade that has a plurality of apertures, towards a support, that has a plurality of apertures that correspond with the apertures on the blade, said apparatus comprising:
(a) a frame; (b) two flexible hoisting means, each having a free end and a fixed end, the free end and the flexible hoisting means being capable of passing through an aperture in the support and through a corresponding aperture in the support, and the free end being capable of being reversibly modified to prevent the slippage of the free end through the aperture in the blade after it has been inserted therethrough; (c) a drum rotatably connected to the frame, to which the fixed end of each flexible hoisting means is attached, and around which the flexible hoisting means may be wound; and (d) a stabilizing means fastened to the apparatus, said stabilizing means being capable of stabilizing the apparatus when in use on a support.
In one embodiment, the apparatus additionally comprises a rotation control means for controlling the rotation of the drum. In one embodiment the rotation control means controls the rotation of the drums in one direction. In another embodiment the rotation control means controls the rotation of the drum in a selected one of two directions.
In yet another embodiment the apparatus comprises two drums, each said drum being positioned on the apparatus such that it will be above an aperture on the support when the apparatus is being used.
In one embodiment the stabilizing means is a stud. In another embodiment the apparatus comprises two studs, each said stud being positioned on the apparatus such that it will securely engage an aperture on the support when the apparatus is being used. In another embodiment, the apparatus comprises both two drums, and two studs.
In another embodiment, the studs are comprised of two parts, a fixed part and a removable adapter part. In this embodiment, the adaptor part can be changed, so that the apparatus may be used with supports that have apertures of different diameters.
In another aspect, this invention is a method for lifting an elongated blade that has a plurality of apertures from the ground to a support that has a plurality of apertures that correspond with the apertures on the blade, said method comprising:
(a) providing two flexible hoisting means, each said hoisting means comprising a free end and a fixed end; (b) inserting the free end of each flexible hoisting means through an aperture on the support, said apertures being different from one another; (c) inserting the free end of each flexible hoisting means through a corresponding aperture on the blade; (d) modifying the free end of each flexible hoisting means so that it is no longer capable of passing through the aperture on the blade; (e) providing a drum to which each fixed end is attached, and onto which each flexible hoisting means can be wound; (f) winding the flexible hoisting means onto the drum until the blade abuts the support; and (g) securing the blade to the support.
In one embodiment, this method involves the creation of a sling in which the blade can be cradled, so that the angle of the blade can be adjusted to ensure that it abuts the support at a selected angle.
In another aspect, this invention is a method for lowering an elongated blade from a support to the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of an embodiment of the apparatus of this invention.
FIG. 2 is a front perspective view of an embodiment of the apparatus of this invention.
FIG. 3 is a front perspective view of an embodiment of the apparatus of this invention.
FIG. 4 is a front elevation view of an embodiment of the apparatus of this invention.
FIGS. 5A–C are side elevation views of embodiments of the stud of this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made to FIGS. 1 to 4 , which show various embodiments of the invention. Although described herein as being used to lift or lower a blade of a grader to a moldboard, it is apparent that the apparatus could be used to lift or lower a replaceable blade of a scraper, of a snow wing, or other types of machines, to a support, such as a bowl, to which the blade will be attached.
FIG. 1 shows apparatus 10 mounted onto a moldboard 12 and supporting a blade 16 . Moldboard 12 has a plurality of apertures 14 that correspond with a plurality of apertures 18 on blade 16 . Apparatus 10 comprises a frame 20 , two drums 22 , a drive shaft 24 , a rotation control means 26 , which in this embodiment is a ratchet, a lever 28 and studs 30 . Studs 30 securely engage apertures 14 , and correctly position apparatus 10 for use. Each drum 22 has a flexible hoisting means 32 , which in this embodiment is a strap, and which is capable of passing through apertures 14 and 18 . The drums 22 are fixed to and coaxially disposed about shaft 24 , which shaft is driven to rotate about its longitudinal axis by pivotally mounted operating lever 28 . The rotation of shaft 24 causes the drums 22 to rotate, and therefore straps 32 will wind onto or off of the drum, depending upon the direction of rotation. Rotation control means 26 is also fixed to and coaxially disposed about shaft 24 , and functions to prevent uncontrolled rotation of the shaft, when the apparatus is in use. Apparatus 10 may include a handle 34 and stud storage means 36 .
Frame 20 is an elongate support member that must be strong enough to support the various components of apparatus 10 , when the apparatus is being used to lift or lower a blade 16 . A blade 16 can weigh 125 pounds or more, and therefore frame 20 must be able to withstand this weight. The inventors have found that a frame 20 made from iron will provide the required support. However, other metals, or wood, or synthetic materials, such as plastic and plexiglass, may be used to make frame 20 , provided that they have sufficient strength to withstand the lifting of a blade.
Frame 20 rests upon the upper surface of moldboard 12 when apparatus 10 is being used to lift or lower blade 16 , as shown in FIG. 1 . Frame 20 is designed so that the drums 22 are able to rotate about their axes, in order to lift or lower the blade. Therefore the ends of the frame 20 have vertical spacing members 21 , as shown in FIG. 1 , which function to provide sufficient space between the moldboard and the drums 22 , to allow the drums to rotate. As is apparent, the vertical spacing members 21 could be elsewhere disposed on the frame, for example towards, or at, the middle of the longitudinal axis of frame 20 . There can be more than two vertical spacing members 21 , for example as shown in embodiment 10 b in FIG. 3 , wherein there is a central vertical spacing member provided near rotation control means 26 , which provides support for the center part of frame 20 .
Shaft 24 is attached to, and supported by, frame 20 in such a manner that the shaft is capable of rotation about its longitudinal axis. In the embodiment shown in FIG. 1 , shaft 24 is functionally attached at each end to the vertical spacing member 21 . Shaft 24 passes through drums 22 , and rotation control means 26 , as shown in FIG. 1 , and is fixed to the drums and the rotation control means so that, as shaft 24 is rotated by lever 28 , the drums and the rotation control means rotate therewith to the same degree. One means of attaching drums 22 and rotation control means 26 to shaft 24 is by welding.
Shaft 24 must be sufficiently strong to withstand the forces applied to it when bit 16 is being hoisted toward moldboard 12 . In this regard, 1″×¼″ and 1¼″×¼″ cold roll flat bar, a solid hexagonal shaft, or a round cold bar may be useful, depending upon the length of shaft 24 , and other features of the apparatus.
Instead of comprising a one-piece unit as shown in FIG. 1 , shaft 24 may comprise several portions 24 a that are functionally joined together to rotate in unison with one another, as shown in embodiment 10 a , in FIG. 2 . In this embodiment, drums 22 and rotation control means 26 comprise independent units that are carried within separate frames, 38 and 40 respectively, that are welded to frame 20 . Each of the drums 22 or the rotation control means 26 rotate within their respective frames, and can be activated to rotate via an activator 42 , that functionally connects drum 22 or rotation control means 26 to shaft portion 24 a , so that they rotate therewith. In one embodiment, the activator 42 is two ½ moon pieces of key stock separated by ¼″, and mounted to the sides of the frame 38 or 40 .
Shaft portions 24 a , must be sufficiently strong to withstand the forces applied to them when blade 16 is being lifted or lowered. In this regard, 1″×¼″ and 1¼″×¼″ cold roll flat bar have been found to be useful. The pieces of cold roll flat bar are cut to the appropriate length, so that they extend the distance between, and functionally interconnect, the activators 42 of frames 38 and 40 .
In the embodiment shown in FIGS. 1 and 2 , the rotation control means 26 is a ratchet, which is a wheel or other structure with teeth on its outer surface that interact with a loose, pivoted pawl 27 . The pawl is a pivoted catch, latch or cog that is yieldingly urged, as by a spring, to engage the teeth on the ratchet to prevent the rotation of the ratchet, and therefore shaft 24 . Therefore, the ratchet and pawl prevent uncontrolled rotation of the shaft when the blade is being lifted or lowered. In one embodiment of this device, the ratchet is a Klingspor™ PS33 150 Klingon Disc, which comprises a substantially square metal frame with a toothed wheel on either side of the frame, and a pivoted spring-activated pawl 27 that engages the teeth on both of the toothed wheels simultaneously. This rotation control means 26 is shown in FIG. 2 or 4 . The embodiment of the apparatus shown in FIG. 4 includes a latch 29 , that can be used to disengage the pawl 27 from the ratchet 26 , and thereby allow free rotation of the shaft 24 .
In one embodiment the rotation control means 26 functions to prevent the unrestricted rotation of the shaft 24 in one direction only, and can be used therefore, to prevent the blade from falling when it is being lifted towards the moldboard. In an alternative embodiment, the rotation control means 26 functions to prevent the unrestricted rotation of shaft 24 in a selected one of both directions of rotation, and can therefore be used to control both the lifting and the lowering of blade 16 . Although shown and disclosed herein as a ratchet, any device or combination of devices that would control the rotation of shaft, is intended to be included herein.
An example of the assembly of embodiment 10 a that the inventors have used, is herein provided. Frame 20 comprises 4″ channel iron, cut to an appropriate length, to which is welded the frames 38 and 40 . One source of the drums and rotation control means, in a frame, is the Klingspor™, PS33 150 Klingon Disc. In order to make the drums 22 on either end of apparatus 10 a , the pawl 27 on the PS33 150 Klingon Disc is removed. The shaft portions 24 a comprise 1¼″×¼″ cold roll flat bar, inserted into the ¼″ space between the two ½ moon pieces of key stock on the PS33 150 Klingon Disc, and bolted thereto.
Lever 28 is pivotally mounted and functionally connected to shaft 24 , such that it will cause shaft 24 to rotate when actuated. Other means of causing shaft 24 to rotate are intended to be included herein, for example, lever 28 may be replaced by an electric or hydraulic device that rotates shaft 24 . Note that, depending upon what type of means are used to rotate the shaft 24 , the apparatus of this invention may or may not need to have a rotation control means 26 . For instance, if the shaft is rotated by an electric device, rather than a lever, the device may lift the blade in one continuous and controlled motion, and therefore the rotation control means 26 may be dispensed with, as there will be little risk of uncontrolled rotation.
The drums 22 rotate in unison, as they are both securely fixed to shaft 24 and therefore move in coordination therewith, as lever 28 is pivoted. Wound around the drums is a flexible hoisting means 32 , such as a cable, rope, chain, strap or belt, as shown in the embodiments disclosed in FIGS. 1–4 . In these embodiments, drums 22 are positioned on shaft 24 at such a location that they are substantially above an aperture 14 on moldboard 12 . In this position the flexible hoisting means will be easily and accurately wound onto drum 22 , as blade 16 is being lifted towards moldboard 12 .
The distance between drums 22 corresponds to the distance between apertures 14 of the moldboard on which apparatus 10 will be used. In one embodiment of this invention, shown in FIGS. 1 and 2 , drums 22 are separated by a distance that is four times the distance between apertures 14 . In conventional moldboards, the distance between two apertures 14 is about 6 inches, and therefore in this embodiment drums 22 would be separated by about 24 inches. As is apparent, drums 22 could be separated by a distance that is a multiple of about one, two, three, or more than four times, the distance between apertures 14 . The present invention is not intended to be limited by the distance between drums 22 , provided that the apparatus will still function as intended herein at whatever distance is selected.
Although FIGS. 1 to 4 show an apparatus in which drums 22 are positioned at either end of shaft 24 , this invention is intended to include embodiments in which the drums 22 are positioned closer to the middle of the apparatus, but still substantially above apertures 14 .
In another embodiment, the drums 22 are not positioned substantially above an aperture 14 in the moldboard. Rather, only the flexible hoisting means 32 are positioned substantially above the apertures 14 . This could be accomplished, for instance, by directing the flexible hoisting means 32 from the drums through a guide means, which guide means positions the flexible hoisting means 32 substantially above the apertures 14 . What is important with regard to the positioning of the flexible hoisting means 32 , is that the flexible hoisting means 32 be able to pass through at least two different holes in the moldboard, and this is easily accomplished by placing the drums 22 above the apertures 14 . If the flexible hoisting means 32 pass through only one aperture 14 , the blade will be capable of pivoting around that point as it is being lifted or lowered, and may cause damage to equipment or injury to workers. By passing through at least two apertures 14 , the ability of blade 16 to pivot is thereby reduced.
The flexible hoisting means 32 is comprised of material that, recognizing that at least two flexible hoisting means 32 are used in this invention, is strong enough to support blade 16 while it is suspended. Each flexible hoisting means 32 comprises a free end 45 . In order to use apparatus 10 , free end 45 is passed through apertures 14 and 18 , and then modified in some manner so that it will not slip out of aperture 18 when the user is lifting or lowering blade 16 . In this regard then, free end 45 must be capable of being reversibly modified in some manner, to prevent it from slipping out of aperture 18 , after it is inserted therethrough.
In one embodiment, flexible hoisting means 32 is a strap. After insertion of the strap through aperture 14 as shown in FIGS. 1 and 2 , free end 45 is brought back up to the drum 22 . At drum 22 , the free end is modified by winding it around the drum in such a manner that, when the drum is turned to lift the blade, the free end will turn therewith. This can be accomplished, for example, by inserting the free end 45 between the drum 22 and the flexible hoisting means 32 , such that when the drum is turned, the free end becomes trapped between the drum and flexible hoisting means, and turns therewith.
In another embodiment, the free end 45 may be reversibly secured to the moldboard, the blade, or to some part of the apparatus itself in order to prevent it from slipping out of an aperture 18 after it is inserted therethrough. One way of accomplishing this is to increase the diameter of the free end, for example by tying a knot in it, which will, for example, secure the free end to the underside of the blade. Alternatively, as shown in FIG. 3 , free end 45 may be modified to include a terminal 47 to which a fastening device 49 that is larger than aperture 18 , can be attached, as by threading onto the terminal. This fastening device will be incapable of passing through the aperture in the bit, or through another aperture that can be formed on the apparatus itself.
It is preferred to restrain the free end 45 at or near the drum, so that the flexible hoisting means 32 forms a sling 33 that cradles the blade, as seen in FIGS. 1 and 2 . If this means of securing the free end is used, the angle of blade 16 can be adjusted while it is in the sling, before it abuts moldboard 12 . This will help to ensure that the moldboard and blade meet at an angle that will enable them to be bolted together easily and efficiently.
While the invention has been described herein as having two drums 22 and two flexible hoisting means 32 , it is understood that more drums and more flexible hoisting means may be used. As is also apparent, both flexible hoisting means may be rolled onto one drum 22 , if they are otherwise appropriately positioned for insertion into apertures 14 .
Studs 30 are longitudinal members oriented so that they will engage apertures 14 in moldboard 12 . Studs 30 function to align apparatus 10 with respect to apertures 14 , and to prevent apparatus 10 from moving out of alignment with apertures 14 when it is being used. Additionally, studs 30 assist in preventing the apparatus from flipping about its longitudinal axis when it is being used. Therefore studs 30 are sufficiently long, and of a suitable diameter to securely engage apertures 14 , and perform these functions. As is apparent, studs 30 are longer than vertical spacing members 21 , in order to be able to be received in apertures 14 . Studs 30 may also be of a length sufficient to enable them to be received in apertures 18 of blade 16 .
Studs 30 may be of any shape in cross-section, including round, oval, square and rectangular, that will permit them to securely engage apertures 14 . The studs are comprised of a material that will provide sufficient strength to prevent them from breaking when apparatus 10 is being used. In one embodiment, studs 30 are made of iron, however, other metals, or wood, or synthetic materials, such as plastic and plexiglass may be used, provided that they have sufficient strength. The studs 30 are fastened to frame 20 , for example by welding to frame 20 , or by threading into a nut that is welded to frame 20 .
In one embodiment shown in FIGS. 5A–C , studs 30 are comprised of two parts, fixed part 46 and adaptor 48 , that are connected together to form the studs 30 . Fixed part 46 has a spacer 50 and connector 52 . Spacer 50 is fastened, as by welding, to frame 20 . Connector 52 comprises a means of securely and reversibly connecting fixed part 46 to adaptor 48 . In the embodiment shown in FIG. 5 , connector 52 comprises a nut, that is partially threaded onto spacer 50 and welded thereto.
Adaptor 48 comprises a connector 54 and an aperture-engaging portion 56 . Adaptor 48 securely and reversibly connects to fixed part 46 , for example by threading connector 54 into connector 52 . Aperture-engaging end 56 is sized so as to securely engage an aperture on a moldboard. In one embodiment shown in FIG. 5B , aperture-engaging end 56 has a ¾ inch diameter, whereas in another embodiment, 48 a , shown in FIG. 5C , aperture-engaging end 48 a has a ⅝ inch diameter. Both of these diameters are the diameter of standard apertures in moldboards. The end user of apparatus 10 would have access to both adaptors 48 and 48 a , and therefore could select an adaptor depending upon the size of the apertures in the moldboard. Therefore, one apparatus 10 could be used with moldboards that have a different aperture size.
As is apparent, the diameter of aperture-engaging end 56 is not limited to ¾″ or ⅝″ but could be any diameter that will securely engage an aperture of a moldboard, or bowl. Additionally, other means of securely connecting fixed part 46 and adaptor 48 to one another may be devised by those skilled in the art, and these means are intended to be included in the scope of this invention.
As mentioned above, studs 30 perform two functions, namely to position the apparatus before and during use, and to stabilize the apparatus so that it does not flip about its longitudinal axis, during use. The studs 30 may be replaced by other means for stabilizing the apparatus, for example magnets or clamps that clamp the apparatus to the moldboard. Alternatively the width of the base of the apparatus, being the part that contacts the moldboard, may be increased, for example by adding skis thereto. In one embodiment, the studs are dispensed with altogether, as the apparatus is stabilized by some other means, and the positioning function of the studs is provided by the flexible hoisting means 32 .
One embodiment of this invention, shown in FIGS. 1 and 2 , provides a stud storage means 36 , which stores adaptors 48 when they are not being used or when they are not connected to fixed part 46 . In this embodiment, adaptor 48 is threaded, via its connector 54 , into the stud storage means, which is shown in FIGS. 1 and 2 as a nut. As is apparent, the stud storage means 36 may be designed to co-operate with whatever means is used to securely connect fixed part 46 and adaptor 48 together.
In the embodiment shown in FIG. 1 , studs 30 are attached to frame 20 at two positions that lie between drums 22 . However, the two studs 30 could be positioned anywhere along the longitudinal axis of frame 20 , including on the outside (as in FIG. 1 ) of drums 22 , provided that apparatus 10 will still function as indicated herein.
In one embodiment of this invention apparatus 10 comprises only one stud 30 , and in yet another embodiment, three or more studs. These studs can be positioned anywhere along the longitudinal axis of frame 20 , provided they are able to engage the apertures 14 . The present invention is not intended to be limited by the number of studs 30 , provided that the apparatus will function as intended herein, using the selected number of studs.
The distance between studs 30 will correspond to the distance between apertures 14 of the moldboard on which apparatus 10 will be used. In one embodiment of this invention, shown in FIGS. 1 and 2 , studs 30 are spaced apart a distance that is twice the distance between apertures 14 . For conventional moldboards therefore, the studs in this embodiment would be separated by about 12 inches. In other embodiments, the studs 30 may engage adjacent apertures, or they may be separated by more than twice the distance between apertures 14 . The present invention is not intended to be limited by the distance between studs 30 , provided that the apparatus will still function as intended herein at the selected distance.
In one embodiment apparatus 10 comprises a handle 34 that is used to carry the apparatus.
Having thus described various embodiments of the apparatus 10 , a method of lifting a blade to a moldboard will now be disclosed. The first step of this method is to position apparatus 10 on the top face of moldboard 12 by inserting studs 30 into apertures 14 of the moldboard. The moldboard will have any blades previously attached thereto removed.
A moldboard may require only one blade, or it may require two or more blades. In one embodiment of this method, apparatus 10 is positioned above the apertures 14 that would correspond with the apertures 18 that are approximately in center of the particular blade that is to be installed. An aperture 14 on the moldboard and an aperture 18 on the blade “correspond” when they are the apertures that are connected by the same bolt, after the blade is bolted to the moldboard. By selecting apertures 14 that would correspond with apertures 18 that are in approximately the center of the particular blade 16 , the blade will remain essentially level when it is being lifted upwards. As an example, a 12-foot moldboard generally requires two blades, each a length of six feet. Each blade will usually comprise thirteen apertures 18 , of which the 7 th aperture is the center. Therefore, to mount the blade on the moldboard, using for example the embodiment of the apparatus 10 shown in FIG. 1 , the apparatus would be positioned so that the studs 30 are in the 6 th and 8 th apertures 14 from one end of the moldboard, and the rotation control means 26 is positioned above the 7 th aperture.
The method described herein is not limited to the insertion of studs 30 into apertures 14 that correspond with apertures 18 positioned approximately in the center of the particular blade that is to be installed on the moldboard. Other apertures 14 can be used.
Upon insertion of the studs 30 into the apertures 14 , the free ends 45 of the flexible hoisting means 32 will line up with apertures 14 through which they will be inserted. The next step of the method is to insert the free ends 45 through the apertures 14 .
In another embodiment of the method of this invention, the first and second steps noted above are reversed. Therefore, the apparatus is approximately positioned over top of the apertures 14 , and the flexible hoisting means are inserted through their respective apertures 14 before the studs 30 are inserted into the selected apertures 14 on the moldboard.
The next step is to insert the free ends 45 through the apertures 18 on the blade that correspond with the apertures 14 on the moldboard through which they were previously passed. The free ends are then secured to the drum, blade, moldboard or apparatus, as described above, to prevent them from slipping back through the apertures 18 .
The next step is to rotate shaft 24 by actuating lever 28 . Drums 22 will rotate, and the flexible support members 32 will be wound around drums 22 and thereby move the blade towards the moldboard. If free end 45 is secured in such a manner that a sling 33 is formed, the angle of the blade may be adjusted at any time before it abuts the moldboard. When blade 16 abuts moldboard 12 , apertures 14 and 18 will be aligned. The user will then bolt together two or more apertures 14 and 18 that do not have a stud 30 or flexible hoisting means 32 extending therethrough.
The free ends 45 are then released, the flexible hoisting means 32 are removed from the apertures 14 and 18 . The apparatus 10 is removed from the moldboard and any remaining apertures 14 and 18 are bolted together.
If the apparatus is to be used to remove a moldboard, the steps in the method described above are essentially reversed. This method would use an apparatus that has a rotation control means that controls the rotation of shaft 24 while the blade is being lowered.
While the invention has been described in conjunction with the disclosed embodiments, it will be understood that the invention is not intended to be limited to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. For example, to be used to mount a blade onto a snow-wing, the apparatus may be adapted in order to enable the studs 30 to securely engage the apertures on the snow-wing. Such adaptations are intended to be included herein. | An apparatus for lifting and aligning a blade to a support, such as a grader moldboard or a scraper bowl. In one aspect the invention is an apparatus with a frame, flexible hoisting means for holding the blade, a drum to which each flexible hoisting means is attached, a stabilizing means for stabilizing the apparatus, and a drive means for rotating the drums. In another aspect, the invention is a method for lifting a blade to a support, which involves inserting flexible hoisting means through different apertures of a support and the corresponding apertures in the blade, and providing means to controllably reduce the length of the flexible hoisting means while holding the blade. The apparatus and method can be used by one person to lift, line up, and securely bolt a blade to a support. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to submersible artificial lift devices, and in particular to a single or multi-device system provided with a barrier to deter an ingress of well fluids into the device to reduce or prevent development of corrosion, formation of scale or asphaltenes or other problems in an idle device within a wellbore.
[0003] 2. Background
[0004] Submersible artificial lift devices are widely used to pump fluid from a wellbore, particularly for purposes of hydrocarbon recovery. Examples of submersible artificial lift devices include an electrical submersible well pump (ESP) and an electrical submersible progressing cavity pump (ESPCP). Typically, an artificial lift device is suspended within a well from a flow conduit. The artificial lift device is submerged in well fluids. Prolonged inactivity and exposure to well fluids may damage motor and pump components of a typical artificial lift device. Therefore, it is desirable to protect the internals of an inactive artificial lift device when the device is submerged in wellbore fluids.
[0005] For example, U.S. Pat. No. 2,783,400 to Arutunoff teaches a protecting unit for an oil field submergible electrical motor. The protective unit provides a pathway for a lubricating and protecting fluid to expand or contract as a result of heating or cooling due to the electric motor. Additionally, the protecting unit essentially doubles the length of a path traveled by moisture or any contaminating fluid before such fluid can reach the pumping unit. One potential drawback of the protecting unit of Arutunoff is that the lengthened moisture path delays rather than prevents moisture migration to the pumping unit.
[0006] In some cases, it has been desirable to deploy multiple pumping units within a wellbore. Examples of multiple pumping units include the following:
[0007] U.S. Pat. No. 3,741,298 to Canton teaches a multiple well pump assembly wherein upper and lower pumps are both housed in a single wellbore hole and the pumps are connected in parallel so as to supplement each other's output. The pumps may be provided with different flow capacities and may couple with power means for running each pump individually or both simultaneously to provide a well pump system capable of selectively delivering three different effective flow rates from a single wellbore hole to satisfy varying flow demands.
[0008] U.S. Pat. Nos. 4,934,458 and 5,099,920 to Warburton et al. teach a small diameter dual pump pollutant recovery system. The system includes a water pump assembly and a pollutant pump assembly mounted at the lower end of piping, which serves to suspend the pumps in a well and also as an exhaust conduit for transporting pump water to the surface. The pollutant pump is used to recover lower density immiscible pollutants from the surface of the underground water table using the cone of the pressure method. The water pump may be raised and lowered to the position at the pollutant/water interface. A method of relocating the pollution intake and resetting the height of the cone of depression when conditions vary the height of the pollutant/water interface is also disclosed.
[0009] U.S. Pat. No. 5,404,943 to Strawn teaches a multiple pump assembly for wells. Strawn teaches a design to allow multiple submersible pumps in a single borehole. The multiple pump assembly provides flexibility in use of multiple pumps by allowing the user to avoid multiple well requirements through the use of standby or peak loading pumps.
[0010] U.S. Pat. No. 6,119,780 to Christmas teaches a wellbore fluid recovery system and method for recovering fluid from a wellbore that has at least one lateral wellbore extending out therefrom. The system includes a first electrical submergible pumping system for recovering fluids from a first zone of a wellbore and a second electrical submergible pumping system for recovering fluids from a second zone of a wellbore, such as a from a lateral wellbore. The fluid recovery system allows fluid recovery from each lateral wellbore to be independently controlled and also to provide adequate draw down pressure for each lateral wellbore.
[0011] U.S. Pat. No. 6,250,390 to Narvaez et al. teaches a dual electric submergible pumping system for producing fluids from separate reservoirs. A first submergible pumping system is suspended from deployment tubing and a second submergible pumping system is suspended from deployment tubing. The first submergible pumping system is connected to a fluid transport such that fluid may be discharged into the first fluid flow path, and a second submergible pumping system is connected to the fluid transport such that the fluid may be discharged into the second fluid flow path.
[0012] Typically, once an ESP is located below the static fluid level during deployment of the ESP into the well, wellbore fluid is free to enter into and fill the pump. If a blanking plug is installed, e.g. in a Y-Tool crossover, wellbore fluid is free to fill the open path in the pump and compress the air cap in the pump having a blanking plug in place. Depending on submergence pressure, the wellbore fluid may partially or substantially fully fill the pump.
[0013] A difficulty with having an idle unit that is at least partially filled with well fluid is that the idle unit is subject to the possibility of degradation of internal components including scale or asphaltenes precipitating out in the unit, which can cause either plugging of flow passageways and/or interference or locking of rotating components. Therefore, it is desirable to provide a protective environment for internals of the pump(s) that are held in backup or that have a delayed start-up. A protective environment increases the reliability of starting and running the pumps.
SUMMARY OF THE INVENTION
[0014] The present invention features an artificial lift device that is suspended on a flow conduit within a well. The artificial lift device is submerged in well fluids. A barrier is provided to prevent ingress of well fluids into the artificial lift device.
[0015] In many instances it is desirable to use multiple artificial lift devices in a single borehole. One advantage is that one device may be used as a primary pump and a second device may be used as a backup pump. One difficulty is that the static, or backup, unit sits idle and soaks in the wellbore environment, where the backup unit may be exposed to pressure cycles and possibly small temperature cycles. Possibilities exist for scale or asphaltenes to precipitate out in the unit. This can cause plugging of flow passageways and/or interference or locking of rotating components. By providing a barrier to protect the internal components of a backup unit or units from well fluid, the probability of damage to internal components is reduced.
[0016] In one embodiment, a multi-unit system of the invention is suspended on a tubing string into the wellbore. The multi-unit system has a junction, such as a Y-tool, T-connector or other type of junction having an upper end that communicates with production tubing and has a lower end having an operating unit port and a backup unit port. An operating unit communicates with the junction via the operating unit port and a backup unit communicates with the junction via the backup unit port. A barrier, such as a valve, blanking plug or other type of barrier is provided in the junction for selectively blocking off either the operating unit port or the backup unit port, thereby blocking fluid communication with either the operating unit or the backup unit. The backup unit is also provided with an intake barrier that deters ingress of well fluids into the backup unit. Therefore, the backup unit may remain submerged within well fluids for an extended period of time without experiencing degradation of the backup unit internals. The intake barrier may include a plug, burst disk, soluble material, a selectively openable intake barrier such as a sleeve or a spring biased member or other member that is capable of providing a suitable barrier.
[0017] In one embodiment, a pressure sensor is provided in communication with the interior of the backup unit. The pressure sensor communicates with a pressure producing device, such as a compressor, pump, or other device that may be activated to maintain a positive pressure within the backup unit to assist in preventing well fluids from entering the backup unit. A pressure sensor may also be provided in communication with the interior of the primary unit to detect a failure of the primary unit and to send a signal to an automated system to auto-activate the backup unit. Alternatively, the pressure sensor may be used to send a warning to the surface, e.g., to a workstation, so that an operator may intervene to take appropriate action, such as starting the back-up unit in the event of primary unit failure.
[0018] The invention further includes a method of preserving pump integrity of an idle unit in a well, e.g., as a backup unit in a multiple unit system in a common wellbore. The method includes locating a multi-unit system in a wellbore wherein the multi-unit system includes an operating unit in communication with a junction and the backup unit in communication with a junction. A fluid barrier is provided in an output port output passageway, the junction, an intake port, or both ports or other combination of locations to deter ingress of well fluids into the backup unit. The backup unit is preferably filled with a protective fluid. The backup unit may be filled with protective fluid prior to deploying the multiple unit system within the wellbore or the backup unit may be filled, e.g., via a hydraulic communication line after the multiple unit system is deployed within the wellbore.
[0019] In one embodiment, a bubbler gage system may be used to deliver a fluid, such as an inert gas, to the backup unit. Typically, a bubbler gage system includes a fluid line extending from the surface to a location below the fluid level in a well, in this case to a submerged artificial lift unit. Fluid is then continuously delivered to the interior of the unit to maintain a positive pressure therein, which deters ingress of fluids into the unit. The bubbler gage also provides an additional benefit in that the well fluid level may be determined by noting when the pressure required to deliver additional fluid into the fluid line ceases to increase as a function of volume of fluid delivered.
[0020] To facilitate operation of the idle unit, the barrier is removed. The barrier may be removed by the application of additional pressure in the backup unit to push out a barrier or to burst a burst disk type barrier or by activating the unit to “pump out” a barrier. Additionally, if the barrier is comprised of a soluble material, then a solvent may be delivered to the backup unit to dissolve the fluid barrier. A selectively openable member may also be activated to open a flapper type valve, to slide a sliding sleeve, or to manipulate other types of selectively openable members. Examples of activators include, but are not limited to, a hydraulic line, an electric line in communication with a servo or an electric line to deliver a one time electrical pulse to activate a charge, a pneumatic line, or other means. Further, the barrier may be a spring-biased member that opens automatically by activation of the backup unit. Additionally, the barrier may be activated to open by rotation of the shaft in the unit. The barriers may also be opened to allow the fluid barrier to drain or flow out of the unit. Other types of barriers may also be used. Although the invention is described primarily as it relates to a protection scheme for a backup unit, it should be understood that the invention is also applicable to a single ESP unit that is to remain idle for a period of time while submerged in well fluids.
[0021] A better understanding of the present invention, its several aspects, and its advantages will become apparent to those skilled in the art from the following detailed description, taken in conjunction with the attached drawings, wherein there is shown and described the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated for carrying out the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a schematic view of a multiple unit artificial lift system deployed in a wellbore.
[0023] [0023]FIG. 2 is a cross-sectional view of a Y-Tool having a blanking plug installed therein.
[0024] [0024]FIG. 3 is a cross-sectional view of a Y-Tool having a flapper valve installed therein.
[0025] [0025]FIG. 4 is a perspective view of a barrier plug obstructing a pump intake port.
[0026] [0026]FIG. 5 is a perspective view of a burst disk obstructing a pump intake port.
[0027] [0027]FIG. 6 is a perspective view of a soluble plug obstructing a pump intake port.
[0028] [0028]FIG. 7 is a perspective view of a spring-biased member obstructing a pump intake port.
[0029] [0029]FIG. 8 is a perspective view of a sliding sleeve obstructing a pump intake port.
[0030] [0030]FIG. 9 is a perspective view of a hydraulically actuated flapper valve obstructing a pump intake port.
[0031] [0031]FIG. 10 is a cross-sectional view of a multi-unit in-line artificial lift system deployed in a wellbore.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Before explaining the present invention in detail, it is important to understand that the invention is not limited in its application to the details of the embodiments and steps described herein. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.
[0033] Referring now to FIG. 1, shown is a multiple unit system designated generally 10 . The multi-unit system 10 is deployed within wellbore 12 . Wellbore 12 is lined with casing 14 . A tubing string 16 carries the multiple unit system 10 . Typically, the multiple unit system 10 is utilized to lift wellbore fluids 18 that enter the wellbore 12 through perforations 20 . Wellbore fluids 18 are directed upward through tubing string 16 , through wellhead 22 , and to a production line 24 . A junction, designated generally 23 , such as Y-Tool crossover 26 , is affixed to the lower end of the tubing string 16 . As can be seen in greater detail in FIGS. 2 and 3, Y-Tool crossover 26 has an upper end 28 and a lower end 30 , which is provided with a first unit port 32 and a second unit port 34 . Typically, a junction 23 , such as the Y-Tool crossover 26 , is provided with an output barrier 35 in either the first unit port 32 or second unit port 34 . Examples of output barriers 35 include a blanking plug 36 (FIG. 2) and a flapper valve 38 (FIG. 3). Flapper valve 38 is preferably capable of 180° rotation to selectively seal either the first unit port 32 or the second unit port 34 . Further examples include a traveling ball used to selectively close a selected side. Although blanking plug 36 and flapper valve 38 are specifically shown in FIGS. 2 and 3, it should be understood that other types of output barriers may be suitable for use to selectively seal off either the first unit port 32 or the second unit port 34 . Additionally, in some cases it may be desirable to directly seal off a discharge port 39 (FIG. 1) of the unit 42 , or to locate a barrier in a first unit passageway 40 , which extends upwards from the unit 42 .
[0034] Referring back to FIG. 1, first unit passageway 40 communicates with first unit port 32 of Y-Tool 26 . First unit passageway 40 delivers output from first unit 42 through Y-Tool 26 and up tubing string 16 to the surface. As shown, first unit 42 is an ESP having a centrifugal pump 44 , a rotary gas separator 46 , a seal section 48 , and an electric motor 50 . Typically, rotary gas separator 46 is provided with pump intakes 52 . The electric motor 50 receives power from a cable, which transmits electric power to electric motor 50 from the surface.
[0035] The multiple unit system 10 of the invention is provided with a second unit 60 , which may be used as a primary unit or as a back-up unit as desired. Second unit 60 communicates with the second unit port 34 of Y-Tool 26 via a second unit passageway 62 . Second unit passageway 62 communicates with discharge port 61 of second unit 60 . The second unit 60 and the second unit passageway 62 are preferably affixed to the first unit 42 via a series of clamps 64 . As shown, second unit 60 is an ESPCP having a progressing cavity pump 66 , a flex shaft section 68 , a seal section 70 , a gear reducer 71 and an electric motor 72 . The electric motor 72 receives power from the surface via a cable. Second unit 60 is also provided with a fluid intake 74 .
[0036] It should be understood that although FIG. 1 shows first unit 42 as an ESP and second unit 60 as an ESPCP, this arrangement is shown for example purposes only. Other combinations are possible and fall within the scope of the invention. For example, first unit 42 and second unit 60 may both be an ESP unit or may both be an ESPCP unit. First unit 42 may be an ESPCP unit and second unit 60 may be an ESP unit. Additionally, other types of artificial lift devices may be substituted for either or both the first unit 42 and second unit 60 . Moreover, additional units 42 , 60 may be provided in combination with additional junctions 23 so that three or more artificial lift devices may be provided in any combination of ESPs, ESPCPs, or other artificial lift devices. Finally, as shown in FIG. 1, the terms “first unit” and “second unit” are used for convenience only and it should be understood that either or both of the units may be operated or held as a backup as required. Still referring to FIG. 1, wherein first unit 42 is shown as an ESP and second unit 60 is shown as an ESPCP, it may be desirable to operate one or the other of units 42 and 60 depending upon well conditions or process preferences.
[0037] Referring now to FIGS. 4 - 9 , in the preferred embodiment, first unit 42 and second unit 60 are provided with an intake barrier designated generally 100 , which may be located in the pump intake 52 of the first unit 42 and in pump intake 74 of second unit 60 or intakes 208 and 238 (FIG. 10), discussed below, to prevent wellbore fluids 18 from entering the units 42 , 60 when units 42 , 60 are not in use. Although units 42 , 60 are specifically referenced, it should be understood that FIGS. 4 - 9 are equally applicable to a stand-alone artificial lift unit or to an artificial lift unit in any multi-unit system configuration. A pressure sensor 101 may be provided to sense pressure within a unit 42 , 60 . Pressure information is communicated to the surface where a pressure producing device, such as compressor or pump 104 (FIG. 1), may be selectively operated to maintain pressure within the unit 42 , 60 at a pressure above that of the wellbore fluids 18 . The pressure producing device, such as compressor 104 , communicates with the unit 42 , 60 via a communication line, such as hydraulic line 106 . Hydraulic line 106 is connected to the multiple unit system 10 at a location below the junction 23 .
[0038] Examples of intake barrier 100 include plug 108 (FIG. 4), burst disk 110 (FIG. 5), soluble plug 114 (FIG. 6), and a selectively openable member designated generally 116 (FIGS. 7 - 9 ). Selectively openable member 116 includes a spring biased member 118 as shown in FIG. 7, a sliding sleeve 120 , actuated by a hydraulic system and hydraulic piston 121 , as shown in FIG. 8, or flapper valve 122 actuated by hydraulic piston 123 , as shown in FIG. 9. Other selectively openable members may also be used as required.
[0039] In practice, a method of preserving pump integrity of an idle unit, such as second unit 60 of a multiple unit system 10 is as follows. It should be understood that the method of preserving pump integrity is equally applicable to first pump 42 or to a stand alone artificial lift device, secondary back-up unit or other artificial lift device and that second unit 60 is used herein for purposes of example only. An intake barrier 100 is provided in pump intake 74 of the second unit 60 to deter ingress of well fluids 18 into the second unit 60 . The second unit 60 is filled with a protective fluid to inhibit contamination of the second unit 60 within the wellbore 12 . Examples of suitable protective fluids include but are not limited to a range of fluids having a generally lighter specific gravity, e.g. diesel, to protective fluids that have a generally heavy specific gravity, e.g. “Beaver Lube”. Preferably, the protection fluids are inert with respect to component materials of the unit. Second unit 60 may be filled with protective fluid prior to deployment of multi-unit system 10 within the wellbore 12 or may be filled with protective fluid via hydraulic communication line 106 after multiple unit system 10 reaches setting depth. In one embodiment, pressure within the second unit 60 is at least periodically maintained at a level that is equal to pressure external of the second unit 60 in the wellbore. Pressure within the second unit 60 may be maintained via hydraulic communication line 106 , which is operatively connected to a pressure producing device, such as compressor 104 . Additionally, periodic flushing of the second unit 60 may be undertaken to assure continued protection over the time.
[0040] If a protective fluid is used that has a heavier specific gravity than well fluids, then the unit 60 may be sealed with an intake barrier 100 since the protective fluid will tend to settle to the lower portions of the unit. Conversely, if a protective fluid is used that has a lighter specific gravity than well fluids, then a barrier may located in the junction 23 , as shown in FIGS. 2 and 3, in passageway 40 , 62 , in output ports 39 , 60 or at another location in the upper regions of units 42 , 60 . Such a barrier shall be referred to herein as an “output barrier”. The lighter protective fluid will float on any well fluid present in the unit and, when held in place with an output barrier, will serve to prevent ingress of well fluids into the unit. Therefore, it can be seen that a protective fluid may prevent ingress of well fluids when used in conjunction with one of an intake barrier and an output barrier. Of course, barriers may be provided at both the intake and output regions and used with or without a protective fluid.
[0041] In operation, if an operating unit, e.g. first unit 42 , fails or if it is desired to run first unit 42 and second unit 60 simultaneously, an intake barrier 100 and/or output barrier 35 must be removed from the pump intake 74 and/or the output region of the second unit 60 . Similarly, if unit 60 is a stand alone unit in a well, e.g., if for some reason it is desirable to install the unit 60 and leave the unit idle for some period of time, then intake barrier 100 and/or output barrier 35 will be removed from pump intake 74 before operating unit 60 .
[0042] One method of removing an intake barrier is to apply additional pressure within the backup unit 60 via hydraulic line 106 to push out the intake barrier 100 , such as plug 108 (FIG. 4 ). Additionally, pressure may be delivered to the second unit 60 via hydraulic line 106 to burst a burst disk 110 (FIG. 5).
[0043] Further, in one embodiment, intake barrier 100 and/or output barrier 35 may be a soluble plug 114 (FIGS. 2 and 6). To remove soluble plug 114 , a solvent is introduced through a passageway such as hydraulic line 106 into the unit 42 , 60 . Examples of suitable materials for a soluble plug include gels, solids, or other suitable materials. The solvent acts to dissolve soluble plug 114 , thereby opening the pump intake 74 or pump output. Examples of suitable solvents include acids, e.g. hydrochloric acid, hydrofluoric acid, or other fluid treatments that are preferably not damaging to the unit or to the reservoir and which are preferably not soluble to well fluids. Hydraulic line 106 may be used to selectively activate a selectively openable member 116 (FIGS. 7 - 9 ). For example, pressure may be delivered to move a sliding sleeve 120 to expose the pump intake 74 (FIG. 8) or hydraulic pressure may be applied to open flapper valve 122 (FIG. 9), thereby opening pump intake 74 . A pressure differential across pump intake 74 when the pump is running may be sufficient to open a spring biased member 118 to open pump intake 74 (FIG. 7). Additionally, sliding sleeve 120 (FIG. 8) and flapper valve 122 (FIG. 9) may be opened by internal pump pressure rather than by pressure via hydraulic line 106 .
[0044] Although, second pump 60 has been shown as part of a multi-unit artificial lift system 10 , the protection schemes of the invention could be utilized on multi-unit artificial lift systems having multiple backup pumps or the protection schemes of the invention could be utilized on a single artificial lift device deployed downhole, particularly where the single artificial lift device may not be started immediately.
[0045] Referring now to FIG. 10, an additional embodiment of a multi-unit system is shown. In particular, an in line POD system 200 is suspended from tubing 202 within a wellbore 204 . An upper artificial lift device 206 has an intake port 208 and an output port 210 . Upper artificial lift device 206 may be an ESP or an ESPCP or other types of submersible artificial lift devices. A passageway 212 communicates the output port 210 with the tubing 202 . Passageway 212 has an upper selectively openable member 214 thereon. In one embodiment, the selectively openable member is a sliding sleeve 216 that may be positioned to selectively block fluid flow. Other types of selectively openable members may be used to allow selective flow from an outside to an inside passageway 212 . Additional selectively openable members may include but are not limited to spring biased members similar to spring biased member 118 shown in FIG. 7 or may employ a hydraulic system and hydraulic piston similar to the hydraulic system and piston shown in FIG. 8, a flapper valve similar to the flapper valve 122 shown in FIG. 9, or other types of selectively openable member.
[0046] A shroud 218 surrounds the upper artificial lift device 206 . Shroud 218 defines an annulus 220 between the upper artificial lift device 206 and the shroud 218 . An upper closure member 222 is positioned on an upper end of shroud 218 . The upper closure member 222 preferably has a first electric cable aperture 224 and a second electric cable aperture 226 . A first cable 228 extends down through wellbore 204 through the first electric cable aperture 224 and provides power to the upper artificial lift device 206 . A lower closure member 230 is provided on the lower end of shroud 218 . The lower closure member 230 preferably has an aperture 232 located therein. The upper closure member 222 and the lower closure member 230 seal off ends of annulus 222 and define a sealed annular space 234 .
[0047] A lower artificial lift device 236 is located below the upper artificial lift device 206 . Lower artificial lift device 236 has an input port 238 that it is in communication with wellbore fluids in wellbore 204 . Lower artificial device 236 additionally has an output port 240 . The output port 240 is in communication with the aperture 232 and the lower closure member 230 . Preferably, a passageway 242 communicates the output port 240 of the lower artificial lift device 236 with the annular space 234 by passing through aperture 232 in the lower closure member 230 . Passageway 242 is additionally provided with a lower selectively openable member 246 , which may be of the type described above with respect to upper selectively openable member 214 . A second electric cable 250 extends through the second electric cable aperture 226 in the upper closure member 222 . The second electric cable extends within annular space 234 and provides power to the lower artificial lift device 236 . Second electric cable 250 may also extend through an aperture in lower closure member 230 similar to second electric cable aperture 226 in upper closure member 222 , as required.
[0048] In operation, lower artificial lift device 236 may be provided with intake barriers 100 (FIGS. 4 - 9 ) to prevent well fluid from entering into the lower artificial lift device 236 . The intake barriers may be of the type described above in reference to FIGS. 4 - 9 . When lower artificial lift device 236 is used as a backup unit, intake ports 238 are provided with intake barriers 100 . Lower selectively openable member 246 is opened to allow output fluid from lower artificial lift device 236 to pass through passageway 242 and into sealed annular space 234 . Upper artificial lift device 206 then is able to draw wellbore fluids in through lower selectively openable member 246 through passageway 242 and into the annular space 234 where the fluids pass into intake port 208 of the upper artificial lift device 206 . The upper artificial lift device 206 then forces wellbore fluids to the surface through passageway 212 .
[0049] If upper artificial lift device 206 fails, or if it is desirable to run lower artificial lift device 236 while using upper artificial lift device 206 as a backup, then upper selectively openable member 214 is opened to allow wellbore fluids to pass therethrough. In this mode of operation, lower artificial lift device 236 intakes wellbore fluids through input ports 238 . The wellbore fluid is driven out of output port 240 and through passageway 242 into the annular space 234 between the shroud 218 and upper artificial lift device 206 . The wellbore fluid then flows past the upper artificial lift device 206 and through the open selectively openable member 214 and through passageway 212 and into tubing 202 where it can pass through the surface. Advantages of the POD system 200 include the ability to install dual or multi-unit systems in well casing having a smaller diameter as compared to multi-unit systems utilizing a junction, as shown in FIG. 1. The in-line POD system 200 permits multi-unit installation having larger pumps than does a Y-type multi-unit system in the same diameter of well casing. Additionally, a larger motor may be used for the lower artificial lift device 222 than is used for the upper artificial lift device 206 due to the pressure containment shroud 218 , which surrounds the upper artificial lift device 206 .
[0050] While the invention has been described with a certain degree of particularity, it is understood that the invention is not limited to the embodiment(s) set for herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled. | A protection system for an artificial lift device including but not limited to electrical submersible pump (ESP) and an electrical submersible progressing cavity pup (ESPCP). The artificial lift device is suspended on a tubing string into a wellbore where the artificial lift device contacts well fluids. The artificial lift device is provided with a barrier such as an intake barrier or output barrier that deters an ingress of well fluids into the artificial lift device. As a result, the artificial lift device may remain idle and submerged within well fluids for an extended period of time without experiencing degradation of the artificial lift device internals. The intake barrier may include a plug, burst disk, dissolvable material, a selectively openable barrier such as a sleeve or a spring biased member or other member that is capable of providing a suitable barrier. The barrier may be removed once the artificial lift device is ready for operation. The artificial lift device may be filled with a protective fluid. An optional pressure sensor may be provided that is in communication with the interior of the backup unit for communicating with a compressor that may be activated to maintain a positive pressure within the artificial lift device to prevent well fluids from entering the unit. The protection system of the invention is desirable for protecting an idle artificial lift device, including when the artificial lift device is a backup unit in a multi-artificial lift device deployment. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/831,911, filed Jun. 6, 2013, which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0003] The extraction of hydrocarbons from deepwater oil and gas reservoirs requires the transportation of a production stream from the reservoirs to facilities for processing. Water, along with oil and gas, may be included in these production streams. During transportation, if the temperature of the production stream is low and the pressure is high, the system can enter the hydrate region where gas hydrates form. Gas hydrates are solids and behave like ice and, if formed in large quantities, may plug the pipeline. Hydrates may also plug or cause malfunction of other units, such as valves, chokes, separators, and heat exchangers.
[0004] Jumper lines are flowlines that are commonly used to connected subsea units together. Conventional jumper line configurations often incorporate a valley and a bend in order to provide flexibility to the jumper line. During shut ins, liquids may settle and segregate in the lower middle section of these jumper lines. During shut in restart cycles, these jumper lines are often at risk of forming gas hydrates.
[0005] It is desirable to develop a jumper line configuration that aids in preventing the formation of gas hydrates.
SUMMARY
[0006] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0007] In one embodiment, the present disclosure provides a jumper line system comprising: a first subsea device; a second subsea device; and a jumper line providing fluid communication between the first subsea device and the second subsea device, wherein the jumper line does not comprise a valley.
[0008] In another embodiment, the present disclosure provides a method of transporting hydrocarbons from a subsea well comprising: providing a subsea well; providing a manifold; connecting the subsea well to the manifold via a jumper line, wherein the jumper line does not comprise a valley; and flowing hydrocarbons from the subsea well to the manifold via the jumper line.
[0009] In another embodiment, the present disclosure provides a method of connecting two subsea devices comprising: providing a first subsea device; providing a second subsea device; providing a jumper line, wherein the jumper line comprises a first end section and a second end section and does not comprise a valley; connecting the first end section of the jumper line to the first subsea device; and connecting the second end section of the jumper line to the second subsea device.
[0010] The features and advantages of the present disclosure will be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the invention
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the above recited features and advantages of the disclosure may be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are, therefore, not to be considered limiting of its scope. The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0012] FIG. 1 is a side view illustration of a typical M-shaped jumper line geometry.
[0013] FIG. 2 is a side view illustration of a jumper line geometry in accordance with an embodiment of the present disclosure.
[0014] FIGS. 3A and 3B are top and side view illustrations of a jumper line geometry in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0015] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0016] The description that follows includes exemplary apparatuses, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
[0017] Referring now to FIG. 1 , FIG. 1 illustrates a conventional jumper line configuration 100 . As can be seen in FIG. 1 , conventional jumper line configuration 100 may comprise a first subsea device 110 , a second subsea device 120 , and a jumper line 130 . Jumper line 130 may comprise one or more straight sections 131 , one or more elbows 132 , one or more peaks 133 , one or more valleys 134 , and one or more end sections 135 . In certain embodiments, the one or more peaks 133 are comprised of one or more elbows 132 . In certain embodiments, the one or more peaks 133 define the one or more valleys 133 .
[0018] In this conventional configuration, the valleys 134 and elbows 132 may provide flexibility to the jumper line. However, during shut ins, liquids may settle and segregate in the valleys 134 , as well as end sections 135 , of the jumper lines 130 thus increasing the risk of hydrates forming in the valleys 134 during shut in-restart cycles.
[0019] In certain embodiments, the present disclosure provides jumper line configurations that aid in the prevention of hydrate blockages. Examples of such jumper line configurations are illustrated in FIG. 2 and FIGS. 3A and 3B .
[0020] Referring now to FIG. 2 , FIG. 2 illustrates jumper line configuration 200 . As can be seen in FIG. 2 , jumper line configuration 200 may comprise a first subsea device 210 , a second subsea device, and a jumper line 230 .
[0021] In certain embodiments, first subsea device 210 and second subsea device 220 can comprise any type subsea equipment. Examples of suitable subsea devices include subsea Christmas trees, well heads, and manifolds. In certain embodiments, first subsea device 210 may comprise a well head. In certain embodiments, second subsea device 210 may comprise a manifold.
[0022] Jumper line 230 may be constructed out of any material suitable for use as a jumper line. Examples of suitable materials include carbon steel, allows of titanium and chrome, flexible pipes, or composite materials.
[0023] Jumper line 230 may comprise one or more straight sections 231 , one or more elbows 232 , peak 233 , and one or more end sections 235 . In certain embodiments, the one or more straight sections 231 may be horizontal or vertical along a primary axis. In certain embodiments, the primary axis is defined as the horizontal line that is in line with the overall flow of hydrocarbons from first subsea device 210 to second subsea device 220 . In certain embodiments, the one or more straight sections 231 may be inclined from 0 degrees to 90 degrees from the primary axis. In certain embodiments, the one or more straight sections 231 may be straight along the primary axis while incorporating a number of straight sections and elbows along a perpendicular axis. In certain embodiments, peak 233 is comprised of the one or more elbows 232 . In certain embodiments, the one or more elbows 232 may comprise one or more connectors. Unlike jumper line configuration 100 of FIG. 1 , jumper line configuration 200 does not comprise a valley defined by one or more peaks 233 . Rather, in certain embodiments, the maximum elevation of jumper line configuration 200 occurs at peak 233 , and no local maximum elevation occurs on either side of peak 233 .
[0024] In certain embodiments, jumper line 230 may further comprise one or more injection ports 236 wherein a hydrate inhibitor may be injected into the jumper line 230 . In certain embodiments, the one or more injection ports 236 may be disposed on the one or more end sections 235 .
[0025] In certain embodiments, jumper line 230 may further comprises one or more valves 237 that allow the end sections of jumper line 230 to be drained or provide means to move gas from the first subsea device 210 to the second subsea device 220 . In certain embodiments, the one or more valves 237 may be disposed on the one or more end sections 235 above the one or more injection ports 236 . In other embodiments, the one or more valves 237 may be disposed on the one or more ends sections 235 below the one or more injection ports 236 . In certain embodiments, the one or more valves 237 may be tree valves.
[0026] In certain embodiments, during shut ins, gas may segregate into the one or more peaks 233 of the jumper lines 230 and water may segregate into the one or more end sections 235 of jumper lines 230 . The one or more valves 237 may be manipulated to drain the water from the one or more end sections 235 , thus lowering the risk of forming hydrates when the lines are restarted.
[0027] Referring now to FIG. 3 , FIG. 3A illustrates a side view of jumper line configuration 300 and FIG. 3B illustrates a top view of jumper line configuration 300 . As can be seen in FIG. 3A , jumper line configuration 300 may comprise a first subsea device 310 , a second subsea device 320 , and a jumper line 330 . Jumper line 330 may comprise straight section 331 , one or more elbows 332 , peak 333 , and one or more end section 335 . Jumper line 330 may further comprise one or more injection ports 336 and one or more valves 337 .
[0028] In certain embodiments, straight section 331 may be inclined with respect to the primary axis. In FIG. 3 , peak 333 is comprised of a single elbow 332 . Similar to jumper line configuration 200 , jumper line configuration 300 does not comprise a valley defined by one or more peaks 333 . Rather, in certain embodiments, the maximum elevation of jumper line configuration 300 occurs at peak 333 , and no local maximum elevation occurs on either side of peak 333 . However, as shown in FIG. 3B , jumper line 330 may comprise one or more secondary elbows 338 . The one or more secondary elbows 338 may be arranged in a configuration that does not result in the formation of a valley in jumper line 330 along the primary axis. For example, in certain embodiments, the one or more secondary elbows 338 may be in an axis perpendicular to the primary axis and produce one or more bends 339 in jumper line 330 in the same plane as the flow within the jumper line 330 . In certain embodiments, the one or more secondary elbows 338 may provide flexibility to the jumper line configuration 300 .
[0029] The jumper line configuration discussed herein may have several advantages. One advantage is that the jumper line configurations discussed herein are able to provide bends without having valleys, thus increasing the flexibly while limiting the formation of hydrates. Another advantage is that using the jumper line geometry discussed herein, gas may segregate into the higher part so of the jumper line and water may segregate in the low sections, thus allowing water to be drained during shut ins.
[0030] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
[0031] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter. | A jumper line system comprising: a first subsea device; a second subsea device; and a jumper line providing fluid communication between the first subsea device and the second subsea device, wherein the jumper line does not comprise a valley. |
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to European patent application No. 05075058.7, filed 11 Jan. 2005, which is hereby incorporated by reference as if fully disclosed herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a holder for a vane of a vertical venetian blind assembly used, for instance, for covering an architectural opening, such as a window or door.
2. Description of the Related Art
Vertical venetian blinds have generally been provided with horizontally-extending head rails, holding a plurality of carrier or travellers that can be moved in spaced apart relationship along the longitudinal length of each head rail. Each carrier has typically supported a vertically-extending louver, slat or vane by a vane holder in such a manner that the user of the vertical blind can move the vane along the length of the head rail (e.g. by pulling on a first operating cord or pull cord) and also can rotate or tilt the vane about its vertical axis (e.g. by pulling on a second operating cord or tilt cord). For this purpose, each carrier has typically included a main body with a vertically oriented drive hub or worm wheel, which is drivingly connected to a worm gear. The bottom of each drive hub has supported a depending vane holder, adapted to hold securely the top of a vane. A horizontally-extending tilt rod or drive shaft has been provided in the head rail, extending through the carriers and engaging their worm gears, whereby rotation of the tilt rod about its longitudinal axis has caused the drive hubs of the carriers to rotate about their vertical axes so as to make the vane holders and the attached vanes tilt together.
A problem in mounting a vertical venetian blind in a slanted or sloped architectural opening is that, for each slope angle, different vane holders are required. Specifically, a suitable length has to be chosen for each related slope under which the blind is mounted, since the length of the vane holder influences the space the vane of the blind has for rotating and thus tilting. The steeper the slope, the longer the vane holder has to be. When the vane holder is too short, the upper marginal portion of the vane hits the head rail when rotated. When the vane holder is too long, it negatively influences the look of the blind, because light will leak into the room even when the blind is closed. Generally, a blind manufacturer will offer a limited number of different length vane holders. For slopes that are not covered in the assortment of vane holders, a compromise can be made by using a vane holder of a length that comes closest to the ideal one. So in practice, vane holders of a specific length will be used for a range of slope angles. This is not ideal and will lower the quality of the product. The same problem occurs with blinds that are to be mounted in arched or curved architectural openings.
U.S. Pat. No. 6,000,456 solves a different problem, based on a difficulty that can be encountered when mounting a vertical blind assembly adjacent an architectural opening. In particular, where the vanes of the vertical blind assembly are of a particular length, it is necessary that the head rail is positioned and mounted accurately relative to the architectural opening. If the head rail is mounted too high or too low, it becomes necessary to remount it, possibly causing undesirable damage to the architectural opening surrounding. As a solution to this problem, U.S. Pat. No. 6,000,456 proposes a vane holder having an adjustable length. The vane holder has a vane clasp and a clasp holder, the vane clasp having a first end, to which the vane of the blind is attached, and a second end which can be attached to the clasp holder. The holder, in turn, can be attached to a carrier of a vertical blind. The second end of the clasp has ratchet grooves, each of which can co-operate with a single locking tooth in the holder, such that a resilient ratchet-type mechanism is created. The clasp can be moved resiliently between engaging consecutively one of the securing points or ratchet grooves to the locking tooth in the holder so as to vary the height of the vane.
The length adjustable vane holders of U.S. Pat. No. 6,000,456 could theoretically solve the problem of for sloped vertical blinds. Unfortunately, this is not the case since such holders were originally designed only for correcting small inconvenient differences in length. Also a drawback of the adjustable ratchet of such holders is that it is difficult to control their adjustment. In order to overcome the connection between the operably engaged ratchet parts of these holders, one generally has to pull on them, but it is not uncommon that too much force is used and thereby the desired length of the holders is exceeded. This is because the correct amount of force is difficult to control.
SUMMARY OF THE INVENTION
In order to provide an adjustable length holder that can support a vane from a carrier of a vertical blind assembly and that can be more easily and reliably adjusted, the holder of this invention comprises:
a length adjustable mounting extending from a top end connectable to the carrier to a bottom end connectable to a hook member for suspending the vane, the length adjustable mounting comprising a first part and a second part which are operably interconnected to allow displacement of the two parts upwardly or downwardly relative to each other, by which the vertical length of the vane holder between the top end and the bottom end can be adjusted, the first and second parts being rotatably interconnected such that the rotation of one of the first or second parts relative to the other of the first or second parts results in the adjustment of the vertical length of the vane holder.
Advantageously, the first part comprises one of a threaded spindle element or a spindle nut and the second part comprises the other of a threaded spindle element or a spindle nut and wherein the spindle thread and the nut thread are rotatably interconnected. It is especially advantageous that the threaded spindle comprises an elongated body with an outer surface having a screw thread and wherein the spindle nut comprises a nut body with an inner surface having a screw thread.
Also advantageously, the bottom end of the vane holder is rotatable relative to the top end of the vane holder. It is especially advantageous that: the first part comprises a threaded spindle element forming the top end of the holder and the second part comprises a spindle nut forming the bottom end of the vane holder and wherein the threaded spindle element and spindle nut are rotatably interconnected and rotation of the spindle nut causes the nut and the bottom end of the vane holder to move vertically; or the first part comprises a spindle nut which forms the top end of the vane holder and wherein the second part comprises a threaded spindle element which forms the bottom end of the vane holder and wherein the threaded spindle element and the spindle nut are rotatably interconnected and rotation of the spindle nut causes the threaded spindle element and the bottom end of the vane holder to move in a vertical direction towards or away from the top end of the vane holder.
Advantageously, a locking arrangement is provided between the top end and the bottom end of the vane holder which, in a locked position, prevents inadvertent rotation of the bottom end relative to the top end. It is especially advantageous that the locking arrangement comprises a vertically extending groove in the thread of the spindle element and a locking pin that is on the inner surface of the spindle nut and that can cooperate with the groove such that at one point in every 360 degree rotation of the bottom end relative to the top end, the locking pin lodges in the groove to lock the spindle element and spindle nut.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the invention will be apparent from the following description and the accompanying drawings, in which:
FIG. 1 is a perspective view of a vertical blind assembly including a vane holder of this invention;
FIG. 2 is an exploded perspective view of a first embodiment of the vane holder of the invention;
FIG. 3 is an exploded perspective view of a second embodiment of the vane holder of the invention;
FIG. 4 is a plan view of a fourth embodiment of the vane holder of the invention, attached to a carrier;
FIG. 5 is an exploded perspective view of the third embodiment of the vane holder of the invention;
FIG. 6 is a plan view of a fourth embodiment of the vane holder of the invention; and
FIG. 7 is an exploded perspective view of the fourth embodiment of the vane holder of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a vertical blind assembly 1 which includes a plurality of vertical vanes or louvers 3 suspended from a generally longitudinally-extending head rail 5 that is mounted at an upward slope or angle (from left to right in FIG. 1 ). The vanes 3 may be conventional metal, plastic or fabric slats, each having an upper marginal portion 7 securely suspended vertically from a holder 15 . Each holder is attached to a conventional carrier or traveller (not shown) that extends downwardly for, is carried by, and can be moved longitudinally along, the head rail 5 .
As shown in FIG. 1 , the head rail 5 may also be provided with a conventional pull cord 9 for moving a plurality of the carriers along the head rail and a conventional bead chain 11 which serves as a tilt cord for rotating a grooved tilt rod (not shown) of the head rail 5 so as to tilt the vanes 3 .
FIG. 2 shows the vane holder 15 with a carrier 13 , which can be carried by the head rail 5 . The vane holder 15 has a top end 15 A that is connectable to the carrier, a bottom end 15 B which carries a hook member 17 , and a length adjustable mounting 19 which provides the possibility of changing the vertical length of the vane holder between the top end 15 A and the bottom end 15 B. The length adjustable mounting 19 includes a top or first part 21 forming the top end 15 A of the holder 15 for attachment to the carrier 13 and a bottom or second part 23 forming the bottom end 15 B of the holder 15 for carrying a hook member 17 . The first part 21 has a threaded spindle element 25 , and the second part 23 has a threaded spindle nut 51 carrying the hook member 17 , so that the two parts can be displaced vertically relative to one another.
As shown in FIG. 2 , the first part 21 of the length adjustable mounting 19 , which includes the threaded spindle element 25 , includes an elongated body 27 with a top base 29 a bottom base 31 and a threaded outer surface 33 . The threaded outer surface 33 has a circumferential screw-thread 35 of multiple windings 37 . Extending from the top base 29 vertically down to the bottom base 31 of the outer surface 33 is a groove 39 . The groove cuts through the windings 37 of the thread 35 and is part of a locking arrangement 75 which is explained further below. Extending upward from the top base 29 is a connector 41 for attachment to the carrier 13 ; for sloped blinds, the attachment of the vane holder 15 to the carrier 13 is preferably by a conventional intermediate gimbals mounting (not shown).
The second part 23 of the length adjustable mounting 19 , which includes the spindle nut 51 , is suitable for carrying the hook member 17 . The spindle nut 51 has an elongated body 53 with a top base 55 , a bottom base 57 and a threaded inner surface 59 (not visible). The threaded inner surface 59 has a circumferential screw-thread 61 (not shown) of multiple windings 63 (not shown).
As also shown in the FIG. 2 , the spindle nut 51 is vertically at least as long as, and preferably longer than, the threaded outer surface 33 of the spindle element 25 . The vertical lengths of the nut 51 and the spindle element 25 determine the maximum possible vertical length of the vane holder 15 which is reached when the top base 55 of the nut 51 is at the bottom base 31 of the spindle element 25 . Means for preventing the disengagement of the parts 21 , 23 at this point can be provided, such as by closing the last thread winding on the bottom base 31 of the spindle thread 35 or the last thread winding on the top base 55 of the nut thread 61 or both.
In accordance with the invention, the spindle element 25 and the nut 51 are operably interconnected in that the nut 51 is rotatably placed about spindle element 25 and the nut thread 61 co-operates with the spindle thread 35 . In use rotation of the nut relative to the spindle results in a vertical displacement of the bottom end 15 B and the hook member 17 it carries either towards or away from the top end 15 A of the vane holder, depending on the type i.e. left or right handed screw-threads that are chosen. At the same time rotation of the nut 51 will also rotate the hook member 17 and change its orientation relative to the threaded spindle 21 , relative to the top of the vane holder 15 A and when the vane holder 15 is installed in a blind also relative to the carrier 13 . Thus in practice when the desired length of the vane holder is determined and even when the vane holder is assembled into a vertical venetian blind, only rotations of integers of 360 degrees can than be used to adjust the vertical position of the hook member. Rotations of less then 360 degrees would be unacceptable since they would change the angle of the hook member relative to the top end of the vane holder, while a change of the angle of the hook member should only be a direct result of the normal tilting action and only relative to the carrier to which the vane holder is attached. The length resulting from the adjustment per 360 degree turn, depends on the pitch of the thread of the spindle and nut. The length of the vane holder 15 and the vertical position of the hook member 17 relative to the top end 15 A of the vane holder 15 can thus be adjusted.
FIG. 3 shows a second embodiment 115 of the adjustable length holder of the invention which is similar to the holder 15 of FIGS. 1-2 and for which corresponding reference numerals (greater by 100) are used below for describing the same parts or corresponding parts.
The vane holder 115 has a top end 115 A that is connectable to the carrier, a bottom end 115 B which carries a hook member 117 , and a length adjustable mounting 119 which provides the possibility of changing the length of the vane holder between the top 115 A and the bottom 115 B. The length adjustable mounting 119 of the second embodiment also comprises two-parts including a first part 121 having a top 115 A for attachment to the carrier and a second part 123 having the bottom 115 B for carrying a hook member 117 . The first and second parts 1211 , 123 can be displaced vertically relative to each other.
As shown in FIG. 3 , the first part 121 has a spindle nut 151 which includes an elongated nut body 153 with the top nut base 155 , the bottom nut base 157 and a the nut thread 161 on the inner surface 159 (not shown). The nut thread 161 comprises multiple windings 163 (not shown). Extending upward from the top nut base 155 is a connector 141 for attachment to the carrier 113 (not shown); for sloped blinds preferably attachment to the carrier 113 is preferably realized by an intermediate gimbals mounting (not shown).
The second part 123 includes a threaded spindle element 125 and carries a hook member 117 . The threaded spindle element 125 comprises an elongated body 127 with a top base 129 a bottom base 131 and a threaded outer surface 133 . The threaded outer surface 133 comprises a circumferential screw-thread 135 of multiple windings 137 . Extending from the top base 129 vertically down to the bottom base 131 of the outer surface is a groove 139 . The groove cuts through the windings 137 of the thread 135 , and is part of a locking arrangement 175 between the spindle and the nut of the adjustable mounting 119 which is explained further below. The spindle thread 135 is of course chosen to co-operate with the nut thread 161 .
As also shown in the FIG. 3 , the spindle nut 151 is vertically, at least as long as, and preferably longer than, a threaded outer surface 133 of the spindle element 125 . The length of the nut 151 and the spindle element 125 determine the maximum possible length of the vane holder 115 which is reached when the bottom or free base 167 of the nut 151 is at the base 129 of the spindle element 125 . Means for preventing the disengagement at this point can be added such as closing the last thread winding on the top base 131 of the spindle thread 135 or the last thread winding on the free base 167 of the nut thread 161 or both.
In use, the first part 121 which includes the nut 151 , and the second part 123 which includes the spindle element 125 are operably interconnected in that the spindle element 125 is rotatably placed within the nut 151 . Rotation of the spindle element 125 relative to the nut 151 results in a vertical displacement of the bottom 115 B and the hook member 117 it carries either towards or away from the top 115 A of the vane holder. At the same time rotation of the spindle element 125 will also rotate the hook member 117 and change its orientation relative to the threaded nut 151 , the top of the vane holder 115 A and the carrier 113 . Thus, as in the first embodiment, in practice when realizing the desired length for the vane holder 115 and or adjusting it even when the vane holder 115 is assembled into a vertical venetian blind, integers of 360 degree rotations can than be used to adjust the vertical position of the hook member.
In the vane holders 15 and 115 of FIGS. 1-3 , a locking arrangement 75 , 175 is provided to ensure that during normal tilting action each vane holder 15 , 115 rotates as a single unit, and thus prevents the threaded parts 25 , 51 , 125 , 151 of the adjustable mountings 19 , 119 from inadvertently rotating relative to each other during the normal tilting action, which could result in an undesired vertical displacement of the hook member 17 , 117 as well as an undesired radial lagging behind the desired tilt. The locking arrangement is provided between the threaded spindle element 25 , 125 and the nut 51 , 151 to prevent this undesired displacement and ensures rotation of the vane holder 15 , 115 during normal tilting as single body. The locking arrangement 75 , 175 comprises the vertically extending groove 39 , 139 in the thread 35 , 135 of the threaded spindle element 25 , 125 , and a lock pin 65 , 165 (not shown) on the inner surface 59 , 159 of the threaded nut 51 , 151 at a free base 67 , 167 of the nut body 53 , 153 . The free base 67 , 167 is the top nut base 55 in the first embodiment and the bottom nut base 157 in the second embodiment. The lock pin 65 , 165 (not visible) provides a locking action in the groove 39 , 139 such that during normal tilting the vane holder 15 , 115 acts as a single body.
For initially choosing and adjusting to the desired length of the vane holder 15 , 115 or for adjusting the length later, relative easy un-locking of the lock pin 65 , 165 from the groove 39 , 139 is realized by the lock pin being positioned on a relative flexible leg 69 , 169 of the nut body 53 , 153 . The leg portion 69 , 169 is realized between two parallel, adjacent slits 71 , 73 ; 171 , 173 in the nut body 53 , 153 . When the hook member 17 , 117 is rotated relative to top 15 A, 15 A of the vane holder 15 , 115 , the flexible leg portions 69 , 169 of the nut 51 , 151 flexes outward and the latch pin 65 , 165 disengages from the groove 39 , 139 of the spindle element 25 , 125 .
FIGS. 4 and 5 show a preferred, third embodiment 215 of the adjustable length holder of the invention which is similar to the holder 15 of FIGS. 1-2 and for which corresponding reference numerals (greater by 200) are used below for describing the same parts or corresponding parts.
The vane holder 215 can be vertically adjusted between the top and bottom ends 215 A, 215 B without affecting the radial orientation of the bottom end 215 B and hook member 217 relative to the top end 215 A. Thus, this arrangement allows length adjustment by rotational movement of the second part 223 of the length adjustable 219 mounting relative to the first part 221 by less than 360 degree turns. This means that a more precise length adjustment can be realized.
FIG. 4 shows a carrier 213 with the vane holder 215 . The connection of the vane holder 215 to the carrier 213 can be of any desired arrangement for suspending the vane holder. FIG. 4 shows a preferred gimbals mounting 216 for connecting the vane holder to the carrier in a sloped blind.
The vane holder 215 has a top end 215 A that is connectable to the carrier 213 , a bottom end 215 B which is suitable for connection to a hook member 217 , and a length adjustable mounting 219 which provides the possibility of changing the vertical length of the vane holder between the top 215 A and the bottom 215 B. The length adjustable mounting 219 includes a top or first part 221 comprising the top 215 A for attachment to the carrier 213 and a bottom or second part 223 comprising the bottom 215 B for connection to the hook member 217 , and these parts can be displaced relative to each other.
As shown in FIG. 4 , the top part 221 of the length adjustable mounting 219 has a threaded spindle element 225 and the bottom part 223 comprises a threaded spindle nut 251 carrying the hook member 217 . The spindle element 225 and the nut 251 are operably interconnected in that the nut 251 is rotatably placed about spindle element 225 . The top part 221 , which has the threaded spindle element 225 , includes an elongated body 227 with a top base 229 , a bottom base 231 and a threaded outer surface 233 . The body 227 further has a plurality of outwardly extending wings 277 . The wings extend radially outwards from the vertical axis of the body 227 and are part of a locking arrangement 275 . Each of the radial or locking wings 277 ends in an outer surface 277 A. The outer surfaces 277 A of the wings 277 together shape the circumferential, discontinuous outer surface 233 of the spindle element 225 and comprise the spindle thread 235 . The spindle thread 235 has multiple windings 237 .
The bottom part 223 has the spindle nut 251 and a nut holder 391 , and the nut 251 is rotatably mounted on a nut holder 291 , which in turn carries the hook member 217 . The spindle nut 251 comprises an elongated body 253 with a top base 255 a bottom base 257 and a threaded inner surface 259 . The threaded inner surface 259 comprises a circumferential screw-thread 261 of multiple windings 263 .
The nut holder 291 comprises a bottom base 287 and at least one locking arm 285 . The bottom base 287 coincides with the bottom end 215 B of the vane holder. The bottom base 287 comprises a circumferential channel portion 283 and the at least one locking arms 285 extends vertically upwardly from the bottom base 287 . When there are more than one locking arms, they are parallel and spaced apart on the bottom base 287 . The channel portion 283 is a circumferential waist like portion. The nut holder bottom base 287 extends outwardly in circumferential direction beyond the channel portion 283 both above and below it. The at least one locking arm 285 thus extends upwardly from above the channel portion 283 . The locking arms 285 each have an outer surface 285 A which together form a circumferential, discontinuous outer surface 297 of the nut holder 291 which is smooth and not threaded. The threaded nut 251 is mounted about the locking arms 285 of the nut holder 291 , and is rotatable about the circumferential, discontinuous outer surface 297 of the nut holder 291 . The at least one locking arm 285 of the nut holder 291 is part of a locking arrangement 275 which prevents rotation of bottom end 215 B of the vane holder and of the hook member 217 it carriers relative to the top end 215 A of the vane holder. The locking arrangement 275 is described further below.
The nut 251 of the third embodiment further comprises at the bottom nut base 257 of the cylindrical nut body 255 , at least one radially inwardly projecting flange portion or foot 279 for attachment to and rotatable co-operation with the circumferential channel portion 283 on bottom base 287 of the nut holder 291 . The bottom nut base 257 of the cylindrical nut body 255 can additionally be provided with a number of slits, dividing the body into a plurality of lower legs 281 , each including one of the inwardly projecting feet 279 , that can flex slightly in and out for assembly to the circumferential channel portion 283 on the nut holder bottom base 291 . Since as described above the hook member 271 is carried by the nut holder bottom base 287 , which coincides with the bottom end 215 B of the vane holder, the nut 251 when assembled to the nut holder 291 carries the hook member 217 while being rotatable relative to the hook member 217 . As in the previous embodiments the nut thread 261 is of course chosen to co-operate with the spindle thread 235 .
The locking arrangement 275 comprises the at least one locking arm 285 on the nut holder 291 in slidable co-operation with the at least one locking wing 277 of the threaded spindle 223 . Adjacent radial wings 277 of the spindle body 227 are at angles to each other, such that between each pair of adjacent radial wings one locking arm 285 can be slidingly accommodated. The locking arm 285 of the locking arrangement 275 does not project radially beyond the outer radial wing surfaces 277 A or outer spindle surface 233 of the spindle element 225 and does not hinder rotation of nut 251 relative to the spindle element 225 . This arrangement of the co-operating locking arms with the wings prevents the rotation of the bottom end 215 B relative to the top end 215 A of the vane holder 215 and ensures that the vane holder 215 once assembled into a vertical venetian blind acts as a single element during operation of the blind.
In the third embodiment of the vane holder 215 there are four locking wings 277 on the spindle body 227 and four locking arms 285 on the nut holder 291 . The arms are spaced apart along in a general circular manner. The locking arms 285 are preferably of the same length as the nut 251 to ensure operation of the locking arrangement in any length of the vane holder 215 . If the locking arms where shorter than the nut 251 they could at a certain length of the vane holder be disengaged from the locking wings 277 of the spindle element 225 rendering the locking arrangement inoperable.
As shown in the FIGS. 4 and 5 , the spindle nut 251 is at least as long as or longer than the threaded outer surface 233 of the spindle element 225 . The length of the nut 251 and the spindle element 225 determine the maximum possible length of the vane holder 215 which is reached when the top or free base 255 , 267 of the nut 251 is at the bottom base 231 of the spindle element 225 . Means for preventing the disengagement at this point can be added, preferred it to close the last thread winding 263 (not visible) at the free base 267 of the nut 251 .
When assembled, the adjustable mounting 219 comprises as top part 221 the threaded spindle element 225 and as bottom part 223 the nut 251 and the nut holder 291 . The hook member 217 is carried by the nut holder 391 as part of the bottom part 223 of the adjustable mounting 219 . The spindle nut 251 is rotatably mounted relative to the hook member 217 by the inwardly projecting flange 279 to the channel portion 283 on the nut holder 291 and relative to the threaded spindle element 225 by the connection between the nut thread and the spindle thread. The locking arrangement 275 between the hook member 217 and the spindle element 225 , including at least one locking arm 285 of the nut holder 391 in sliding co-operation and between two adjacent locking wings 277 of the spindle element 225 , ensures that the vane holder 215 rotates as a single element when it is mounted in a vertical blind assembly and during normal tilting of the vanes of the vertical blind assembly. The spindle nut 251 is rotatably placed about the outer surface of the spindle element 225 , and at the same time about the locking arms 285 .
In use, when the length of the vane holder 215 is chosen and set or needs to be adjusted, the nut 251 is rotated in clockwise or counter clockwise direction. This clockwise or counter clockwise rotation of the nut 251 translates into an upward or downward movement of the nut 251 relative to the spindle 223 depending on the sort of thread that is used. The upward or downward movement of the nut 251 directly causes an identical vertical movement of the hook member 217 because of the connection of nut 251 by the inwardly projecting flange 279 to the channel portion 283 on the nut holder 291 . Thus by rotation of the nut 251 the length of vane holder 215 between the top 215 A and the bottom 215 B reduces or increases, and the vertical position of the hook member 217 relative the top 215 A of the vane holder 215 is changed. The radial orientation of hook member 217 relative to the top 215 A of the vane holder remains unchanged due to rotational connection between the nut 251 and the hook member 217 and the due to locking arrangement 275 which prevents rotation of the hook member 217 relative to the spindle element 225 .
FIGS. 6 and 7 show a preferred, fourth embodiment 315 of the adjustable length holder of the invention which is similar to the holder 15 of FIGS. 1-2 and for which corresponding reference numerals (greater by 300) are used below for describing the same parts or corresponding parts. The vertical length of the vane holder 315 can be adjusted between the top and bottom 315 A, 315 B without effecting the radial orientation of the hook member 317 .
The vane holder 315 has a top end 315 A that is connectable to a carrier (not shown), a bottom end 315 B which is suitable for connection to a hook member 317 , and a length adjustable mounting 319 which provides the possibility of changing the vertical length of the vane holder between the top 315 A and the bottom 315 B. The length adjustable mounting 319 includes a top or first part 321 comprising the top end 315 A of the vane holder 315 for attachment to a carrier and a bottom or second part 323 comprising the bottom end 315 B of the vane holder 315 for connection to the hook member 317 , and the two-parts can be displaced relative to each other.
The top part 321 has a spindle nut 351 , and the bottom part 323 has a threaded spindle element 325 carrying the hook member 317 . The spindle element 325 and the nut 351 are operably interconnected in that the nut 351 is rotatably placed about spindle element 325 . The top part 321 also has a nut holder 391 on which the nut 351 is rotatably mounted. The nut holder 391 includes a top base 393 , one or more parallel and spaced apart vertically locking arms 385 extending vertically downwardly from the top base 393 and ending in a bottom base 395 . The nut holder 391 and the locking arms 385 are part of a locking arrangement 375 which prevents rotation of the bottom end 315 B of the vane holder and of the hook member 317 relative to the top end 315 A of the vane holder. The locking arms 385 each have an outer surface 385 A which together form a circumferential, discontinuous outer surface 397 of the nut holder 391 which is smooth and not threaded. The threaded nut 351 is mounted about the locking arms 385 of the nut holder 391 , and is rotatable about the circumferential, discontinuous outer surface 397 of the nut holder 391 . The bottom base 395 of each locking arms 385 has outwardly flared edges preventing the nut 351 from detaching from the nut holder. Extending upwardly from the top base 393 of nut holder 391 is a connector 341 for connection of the vane holder 315 to a carrier.
The nut 351 includes a cylindrical nut body 353 which is shorter in length then the spindle element 325 and having an outer surface 354 and an inner surface 359 . The inner nut surface 359 comprises a screw thread 361 of multiple windings 365 . The nut body 353 can be cylindrical with a smooth or knurled outer nut surface 352 or it can be hexagonal.
The bottom part 323 of the length adjustable mounting 319 has the threaded spindle element 325 and is suited for carrying the hook member 317 . The threaded spindle 323 includes an elongated body 327 with a bottom base 331 which carries the hook member 317 . The spindle body 327 is in the shape of two parallel vertically locking wings 377 extending upwardly from bottom spindle base 331 . Each spindle locking wing 377 having with a top base 329 and a threaded outer surface 377 A. The threaded outer surfaces 377 A of both wings 377 together form a circumferential but discontinuous outer surface 333 of the spindle, with a circumferential but discontinuous spindle thread 335 of multiple windings 337 .
The locking arrangement 375 has at least one locking wing 377 on the hook member 317 that is in slidable co-operation with at least one locking arm 385 of the nut holder 391 . Adjacent locking wings 377 of the spindle element 325 are at angles to each other, such that between the adjacent locking wings 377 one locking arm 385 can be slidingly accommodated. The locking wings 377 of the locking arrangement 375 project radially beyond the outer radial arm surfaces 385 A of the nut holder 391 and its outer threaded surface 333 provides a suitable connection with the inner threaded surface 359 of the nut 351 . The at least one locking wing 377 is fixedly connected to the hook member 317 . It extends from a top hook base 387 of the hook member 317 . In the fourth embodiment of the vane holder 315 there are two locking arms 385 on the nut holder 391 and two locking wings 377 on the hook member 217 .
The cross-sectional shapes of both the locking wings 377 and the locking arms 385 and their relative positions on the top hook base 387 and the top nut holder base 393 are chosen to allow a slidable interaction between the nut holder 391 and the spindle element 325 . As can be best seen in FIG. 7 , the locking wings 377 of the spindle element 325 and the locking arms 385 of the nut holder 391 have a general pie-point shaped cross-section. The wings and arms having a outer curved wall 377 A, 385 A and left and right inner walls 377 B, 377 C, 385 B, 385 C projecting radially inwards. The locking wings 377 are placed relative to each other at certain angles, such that between the two wings 377 between opposite inner walls 377 B, 377 C one of the locking arms 385 can be accommodated. This arrangement of the co-operating locking arms with the wings prevents the rotation of the bottom end 315 B relative to the top end 315 A of the vane holder 315 and also ensures that the vane holder 315 once assembled into a vertical venetian blind acts as a single element during operation of the blind.
The locking arms 385 of the nut holder 391 do not project radially beyond the outer circumferential threaded surface 333 of the locking wings 377 of the spindle 323 . Ensuring that the inner threaded surface 359 of the nut 351 comprising the nut thread 361 can co-operate with the outer radial threaded surfaces 333 of the spindle 323 . As is partly visible in FIG. 7 , the inner nut thread 361 comprises a plurality of windings 363 .
When assembled, the adjustable mounting 319 comprises as top part 321 the threaded nut 351 and the nut holder 391 and as bottom part 323 the threaded spindle element 325 . The hook member 317 is carried by the bottom part 323 , the threaded spindle element 325 of the adjustable mounting 319 . The spindle nut 351 is rotatably mounted relative to both the nut holder 391 and to the threaded spindle element 325 . The locking arrangement 375 between the hook member 317 and the nut holder 391 , including the locking arms 385 of the spindle 325 in sliding co-operation with the locking wings 377 of the nut holder 391 , prevents rotation of the bottom end 315 B and of the hook member 317 relative to the tope end 315 A of the vane holder. The spindle nut 351 is rotatably placed about the outer surface of the spindle element 325 , and at the same time about the locking wings 377 of the nut holder 391 .
As shown in the FIGS. 6 and 7 , the spindle nut 351 has a short ring like nut body 353 , and the nut holder 391 is at least as long as or longer than threaded outer surface 233 of the spindle element 325 . In stead of the nut 351 , in this embodiment the length of the nut holder 391 and the length of the spindle element 325 determine the maximum possible length of the vane holder 315 . The maximum length is reached when the top base 329 of the spindle element 325 is moved to the bottom base 357 of the nut 351 . In this respect the position of the nut 351 nearest the bottom portion 395 on the nut holder 391 is also determinative for the maximum length of the vane holder 315 . Means for preventing the disengagement of the spindle element 325 from the nut 351 can be to close the last thread winding 363 (not visible) at the bottom base 357 of the nut 351 or the last thread winding 337 at the top base 329 of the spindle element 325 .
In use, when the length of the vane holder 315 is chosen and initially set or when it needs to be adjusted, the nut 351 is rotated in clockwise or counter clockwise direction. This clockwise or counter clockwise rotation of the nut 351 translates into an upward or downward movement of the spindle element 325 and associated hook member 317 depending on whether a right or left handed the thread is used. Thus by rotation of the nut 351 the length of vane holder 315 between the top 315 A and the bottom 315 B reduces or increases, and the vertical position of the hook member 317 relative the top 315 A of the vane holder 315 is also changed. The locking arrangement 375 ensures that radial orientation of hook member 317 relative to the top 315 A of the vane holder remains unchanged during adjustment of the length of the vane holder as well as during operation of the blind when it is assembled to a blind.
Additionally, to prevent inadvertent vertical sliding displacement of the nut 351 along the nut holder 391 , protrusions 399 are placed on the outer surface of the locking wings 377 of the nut holder 391 . The protrusions 399 and the bottom flanges 395 of the nut holder 391 confine the nut 351 to its vertical position on the nut holder. Alternatively, the nut 351 can comprise an inner screw thread comprising a single winding instead of a plurality of windings.
All the vane holders 15 , 115 , 215 , 315 include an additional locking arrangement for ensuring that the vane holder will act as a single body during normal tilting operation of the vanes in a blind. The locking arrangement either preventing inadvertent rotation during tilting, or preventing all rotation between the top end and the bottom end of the vane holder. However, other solutions to ensure that the vane holder will act as a single element during tilting are also possible. Such solutions include the choice of a nut thread and a spindle thread that allow relative rotation only by exerting a relative large rotational force on one or both of the parts, e.g. by ensuring a relative high friction between the threads. The force needed for rotation should be significantly larger than the force that would be caused by the normal tilting action. The length of a vane holder of such an embodiment could preferably only be set before assembly into a blind, i.e. during assembly of the various elements of the vane holder. Later length adjustment would be possible but less easily realized and could require dismounting the vane holder from the blind.
Alternatively during assembly of the various elements of the vane holder, the desired length could be set and fixated. The fixation can e.g. be realized by adhesive. The advantage of an easily set length is still there, less parts are still needed because any desired length can be produced by the top and bottom parts of the vane holder elements that are in stock. But once the length is set for a blind that will be mounted under a specific slope, it cannot be adjusted later.
This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “vertical”, “horizontal”, “upward”, “downward”, “upper”, “lower”, “inward”, “outward”, “longitudinal” and “lateral”, have been used only as relative terms to describe the relationships of the various elements of the spindle-type adjustable length vane holder of the invention. For example, when the vane holder is being assembled or when it is sold as a separate part of a vertical venetian blind, it can be in a generally horizontal position, and the holder in such a position would be within the scope of this invention. Also, the hook member 17 , 117 , 217 , 317 can either be integrally formed with the bottom end 15 B, 115 B, 215 B, 315 B of the vane holder 15 , 115 , 215 , 315 or it can be connected thereto by any suitable means. The type of hook member is also not critical, so long as it is suited for carrying a vane. | A vertically adjustable holder for interconnecting a carrier in a control system for a vertical vane covering for an architectural opening and a suspended vane includes two component parts which are rotatably adjustable relative to each other to increase or decrease the length of the holder and thus the spacing between the carrier and the suspended vane. |
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BACKGROUND
[0001] 1. Related Applications
[0002] This application is a divisional of U.S. application Ser. No. 11/279,069, filed Apr. 7, 2006.
[0003] 2. Background of the Invention and Related Art
[0004] Research has shown that, on average, more than 200,000 children are treated in U.S. hospital emergency rooms for playground-equipment-related injuries, many of which result from falls. To minimize the risks associated with playgrounds, a number of guidelines are established which require surfaces under the playgrounds to attenuate the impact of a fall.
[0005] While the primary function of a surface is often safety, the Americans' with Disabilities Act (“ADA”) also requires playgrounds be wheelchair accessible. Thus a surface must be soft enough to sufficiently attenuate the impact of a fall, while at the same time be firm, stable and slip resistant enough to comply with the ADA. Oftentimes, these two apparently conflicting requirements are reconciled by placing a solid access path to the playground structure. While such a path complies with ADA requirements, it also poses the risk that anyone falling onto the surface could result in serious injury or even death.
[0006] A combination of guidelines promulgated from both government and independent bodies tackle the tricky issue of providing surfaces at play grounds that are soft enough to prevent most fall injuries but that are also firm and stable enough for wheelchair maneuvering. For example, the guidelines, based on American Society for Testing and Materials (ASTM) standards, state that wheelchair access, surfaces are required to be “firm, stable and slip resistant” as specified in Americans with Disabilities Act Accessibility Guidelines (ADAAG). Another example is the amount of force required to rotate the caster wheels of a wheel chair as set for in ASTM standard F-1951, which is based on a measurement of the physical effort to maneuver a wheelchair across a surface. Accessible surfaces within the use zone (the ground level area beneath and immediately adjacent to a play structure) are also required to be “impact attenuating” in compliance with ASTM F-1292 requirements for drop testing.
[0007] Materials currently used as impact-absorbing surfaces under playgrounds include sand and gravel, shredded tires, poured rubber to name a few. Sand and gravel have been traditionally used because of their impact attenuation properties, wide availability and low cost. However, such a surface is not wheelchair accessible. In addition, sand and gravel tends to lump and harden when wet or frozen. In addition, the critical fall height for sand and gravel is merely nine feet, which is reduced to five feet when the sand or gravel is compressed. Furthermore, such a surface can cause abrasions when a playground patron falls, can cause a patron to trip when running, is tracked indoors and can cause scratches on floors, can be thrown, can be blown away with wind, as well as be an attraction for cats and other animals. Thus, sand and gravel are not ideal materials to use for playground purposes.
[0008] Alternatively, shredded tires are used, however, these pose additional problems of becoming very hot when in direct sunlight, being flammable, and containing steel belts that were part of the original tire. Additionally, shredded tire installations, when properly installed to attenuate falls, do not meet the requirements for accessibility as defined in ASTM F-1959.
[0009] Similarly, poured rubber is used because it is wheelchair accessible, however, it is expensive to purchase and install. In addition, as the rubber wears out under high traffic areas such as swings, the rubber cannot be replaced without significant additional expense. Furthermore, several obstacles arise during installation such as bonding the rubber to the cement base or ground and requiring completely level ground when the rubber is poured. Poured rubber is also prone to cracking and mechanical failure if exposed to ultraviolet light, extreme temperatures or water. There is evidence that, when exposed to environmental factors over time, a poured surface may deteriorate to the point where it will fail ASTM F-1292 testing.
[0010] Matching the appropriate surface and application can also pose problems. For example, a pool and its surround deck are often made of cement which can get very slick when wet, and a fall thereon may cause a serious injury. Similarly an injury may result from a person diving into and hitting the bottom of a cement pool. Alternatively a cement surface can be so abrasive so as to cause blisters or cuts on swimmers' feet.
[0011] Given the known hazards and limitations of existing surfaces, an impact-attenuating surface, which is also firm, stable, and slip-resistant in accordance with the ADA, would be beneficial.
SUMMARY AND OBJECTS OF THE INVENTION
[0012] Certain exemplary embodiments shown herein comprise an impact attenuating tarmac that may be used in conjunction with an impact attenuating base such as loose fill or poured rubber. Alternatively, the tarmac may be used in wet environments to improve surface traction, reduce blisters and scrapes on patrons' feet and also to attenuate the impact of a patron falling. The tarmac further provides a firm, stable and slip resistant surface in accordance with the ADA.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0014] In order that the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0015] FIG. 1 illustrates an exemplary play ground area for children according to some embodiments of the invention.
[0016] FIG. 2 illustrates a partial side, cross-sectional view of an impact attenuation system of the play ground area of FIG. 2 .
[0017] FIG. 3 illustrates a partial, top perspective view of a mat that may form a tarmac of the impact attenuation system of FIG. 2 .
[0018] FIG. 4 illustrates a partial, bottom perspective view of two linked mats that may form the tarmac of the impact attenuation system FIG. 2 .
[0019] FIG. 5 illustrates a partial top view of two linked mats that may form the tarmac of the impact attenuation system FIG. 2 .
[0020] FIG. 6 illustrates a partial bottom view of two linked mats that may form the tarmac of the impact attenuation system FIG. 2 .
[0021] FIG. 7 illustrates an exemplary tarmac used under water according to some exemplary embodiments of the present invention.
[0022] FIG. 8 illustrates an exemplary embodiment of an underwater mat.
[0023] FIG. 9 illustrates an exemplary cut-away view of a mat having a plurality of tabs and slots fit together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments of the invention.
[0025] This specification describes exemplary embodiments and applications of the invention. The invention, however, is not limited to these exemplary embodiments and applications or to the manner in which the exemplary embodiments and applications operate or are described herein.
[0026] The Head Injury Criterion (“HIC”) is a measure of the severity of an impact and takes into account its duration as well as its intensity. The criterion is based on the results of research into the effects of impacts on the human head. HIC is defined by the following integral formula
[0000]
HIC
=
[
(
t
2
-
t
1
)
{
1
(
t
2
-
t
1
)
∫
t
1
t
2
a
·
t
}
2.5
]
[0027] Where “t” is defined as time and “a” is defined as deceleration at time t.
[0028] G-max is the maximum deceleration experienced by the head (or headform) during an impact. It is a measure of the peak forces that a likely to be inflicted on the head as a result of the impact. It is measured in standard units of G, acceleration due to gravity −9.8 m/s/s.
[0029] Critical fall height is the minimum free fall height resulting from all test drops of an instrumented head onto a surface for which an HIC less than 1000 or a G-max value less than 200 is obtained. Thus, for example, if the instrument is dropped from a fall height of X feet onto a non-impact attenuating surface the force of the impact may be HIC of 1500 and a G-max of 210. Such force may lead to injury in a person. In contrast if the same instrument were then dropped from the same fall height onto an impact attenuating surface the HIC might be 500 and the G-max might be 100, and accordingly the probability of an injury resulting is much less.
[0030] FIG. 1 illustrates an exemplary play ground area 50 for children such as may typically be found in school yards, parks, etc. The play ground area 50 includes play ground equipment 56 (e.g., one or more swing sets, slides, climbing bars, etc.) and an impact attenuation system 12 . As will be seen, impact attenuation system 12 is designed to absorb energy from an impact and thus protect children from falls from playground equipment 56 , and impact attenuation system 12 may also be configured to have a sufficiently firm surface to allowed rolling equipment (e.g., a wheel chair, a baby stroller, etc.) to be pushed across the tarmac 15 of impact attenuation system 12 . The exemplary play ground area 50 shown in FIG. 1 is surrounded on three sides by a lawn area 52 and on one side by an asphalt or concrete area 4 . A small ramp 6 is provided between asphalt area 4 and tarmac 15 .
[0031] FIG. 2 shows a partial side, cross sectional view of an exemplary configuration of impact attenuating system (see FIG. 1 ) according to some embodiments of the invention. As shown in FIG. 2 , the impact attenuating system 12 includes fill material 14 , which is disposed on the ground 2 under play ground area 50 . Tarmac 15 is formed of a plurality of interlocking mats 5 , which cover fill material 14 . The fill material 14 may be loose or a solid-fill material such as those commonly used in the art for impact attenuation. Examples of such materials include wood chips, sand, gravel, shredded tires, poured rubber or other similar materials suitable for absorbing an impact from a child's fall. As shown in FIG. 2 , each mat 5 includes a surface structure 10 and legs 20 , which may rest on an upper surface of fill material 14 or, as shown in FIG. 2 , may extend at least partially into fill material 14 . Each mat 5 also includes a linking tab 24 that interlocks a mat 5 with an adjacent mat by sliding into slot 25 (see FIG. 4 ). A plurality of mats 5 can thus be interlocked to form tarmac 15 in just about any desired shape and size.
[0032] FIG. 2 also shows part of an asphalt area 4 and ramp 6 , which may be formed of a plurality of sloped mats that interlock with a linking tab 24 of a mat 5 as shown. Ramp 6 provides a sloped ramp structure from the asphalt area 4 to the tarmac 15 .
[0033] Although fill material 14 shown in FIG. 2 is loose, allowing legs 20 to sink into the fill material 14 , a landscape fabric (not shown) may be placed between fill material 14 and legs 20 , preventing legs 20 from sinking into fill material 14 . Such a landscape fabric (not shown) may additionally protect the fill material 14 from, for example, ultra violet light from the sun.
[0034] Because the exemplary tarmac 15 shown in FIG. 2 is modular, that is, formed of a plurality of interlocking mats 5 , individual mats 5 may be replaced as specific areas wear out. This may occur under swings or other high traffic areas or through damage and vandalism. Similarly as particular mats 5 of the tarmac 15 are adversely affected by weather or ultraviolet degradation from exposure to sunlight, or have a mechanical failure such mats 5 can be replaced. The upper surface of the tarmac 15 may comprise an undulating surface to improve traction, and to provide flex, which will attenuate an impact. The undulating upper surface of the tarmac 15 may optionally comprise a plurality of small flexible arches, the elasticity of the ach being determined by the materials from which the tarmac 15 is made.
[0035] Mats 5 can be made from a number of different materials, including but not limited to, synthetic polymers such as PVC, as well as a variety of other polymers commonly known in the art. Furthermore, mats 5 can be formed in molds, using extrusion techniques, etc. An edging (e.g., comprising one or more ramps 6 ) can also be used to couple the tarmac 15 to another surface such as a cement or asphalt surface, or to reduce the amount of energy needed to get a wheelchair onto the tarmac 15 surface. The edge thus may be an extension from the tarmac 15 surface to another surface, or it may be tapered to provide a ramp from another surface up to the tarmac 15 surface (e.g., like ramp 6 shown in FIG. 2 ).
[0036] Extending from the bottom of each mat 5 are legs 20 . As mentioned above, the legs 20 may sit on top of the fill material 10 , or the fill material may work its way to fill the interstitial spaces between the legs 20 . Legs 20 may be a variety of different lengths. If the legs 20 have different lengths, each leg 20 will make contact with the fill material 14 at different times and thus increase energy impact dissipation and attenuation of an impact of a fall. Furthermore, the legs 20 further improve the impact-attenuation properties of the energy absorption system by concentrating force onto certain areas, and allowing the tarmac 15 surface to flex. The mats may also be used to reduce erosion in high traffic areas, or to promote growth of vegetation in high traffic areas.
[0037] Mats 5 may be tethered to ground 2 to prevent the tarmac 15 from sliding off the fill material 14 . In addition, the tethers (not shown) may help anchor the fill material 10 in a stationary position. Any tethering structure suitable for anchoring mats 5 to ground 2 may be used. For example, rigid steel spikes may be driven through mats 5 and into ground 2 . As another example, mats 5 may be tied using string, wire or rope to spikes that are driven into ground 2 below tarmac 15 .
[0038] FIGS. 3-6 illustrate an exemplary mat 5 or mats 5 that may be used to form the tarmac 15 covering over fill material 14 . FIG. 3 illustrates a partial, top perspective view of a mat 5 ; FIG. 4 illustrates a partial, bottom perspective view of two interlocked mats, each like the mat shown in FIG. 3 ; and FIGS. 5 and 6 show top and bottom views, respectively, of two interlocked mats 5 each like the mat 5 shown in FIG. 3 .
[0039] The exemplary mats 5 shown in FIGS. 3-6 comprise a relatively thin surface structure 23 supported by a grid structure comprising an array of legs 20 that are connected one with another by rib structures 42 . As also shown, surface structure 23 includes a plurality of arches 35 each located generally between four legs 20 and four rib structures 42 .
[0040] The exemplary embodiments teach at least three impact attenuation techniques which may be used either separately or in combination with each other. The mat 5 structure illustrated in FIGS. 3-6 absorbs the impact of a child's fall in several ways. First, arches 35 are flexible and absorb or attenuate at least some of the force from a child's fall. Second, the rib-grid structure (formed by legs 20 and rib structures 42 ) allows the mat 5 to flex horizontally with respect to the top surface of the mat 5 . The rib-grid thus dissipates some of the force from the child's fall horizontally through mat 5 . Third, the mat 5 transfers some of the energy from the child's fall through legs 20 to fill material 14 , which as discussed above, itself is soft and readily absorbs at least part of the energy from the child's fall.
[0041] As a result, when a child falls onto the tarmac 15 , three separate energy attenuating features aid in reducing the adverse effects of such a fall. First the impact causes the arches 35 to flex, absorbing energy. Second the entire tarmac 15 flexes horizontally dissipating some of the impact from the child's fall horizontally (e.g., generally level with ground 2 ). Third, the fill material 14 absorbs some of the force from the child's impact with the tarmac 15 .
[0042] The amount of flex in the arches 35 depends on the radius of curvature in the arch, the height of the arch, as well as the material from which the mat 5 is made. The amount of flex provided by the grid structure depends on several factors, including the materials that form the legs 20 and rib structures 42 , and the size, spacing, and number of legs 20 and the size and thickness of the rib structures 42 .
[0043] The arches 35 of mats 5 form an undulating pattern on the outer surface of the tarmac 15 , which may improve the tarmac 15 's traction by allowing increased surface contact between a patron's foot or shoe and the tarmac 15 . In addition, there are a number of pores 40 formed in a mat 5 , which allow water to drain through mats 5 . A seam 22 between two adjacent mats 5 also provides improved flex upon impact by spreading under a force, as well as the convenience of replacing the surface in a particular area for low cost and as needed.
[0044] As best seen in FIG. 6 , which shows the bottom side of two interlinked mats 5 , linking tabs 24 couple adjacent mats 5 by sliding into slot 25 (see FIG. 9 ). Tab 24 is designed to provide a secure link and may also be designed to flex to absorb energy from an impact, such as a falling child. In addition to the linking tabs 24 , the mats 5 are secured using both an adhesive such as glue and a heat source where two adjacent mats 5 are configured to overlap. In such a case the mats 5 are bonded together using both an adhesive and a heat source to melt the contacting plastic and further improve the bond. For example, the linking tab 24 may be coupled to an adjacent mat, a heat gun may be used to melt and fuse the tab to the adjacent surfaces, and an adhesive such as a glue may then be used to bond the two adjacent mat surfaces. Of course the heat treatment can only be used on thermoplastics such as PVC.
[0045] The combination of an impact attenuation fill material 14 and an impact attenuation tarmac 15 overlaying the fill material 14 , as shown in FIG. 2 , has been found to provide greater impact attenuation than the sum of the impact attenuation of the fill material 14 by itself and the impact attenuation of the tarmac 15 by itself. That is, the impact attenuating system of FIG. 2 absorbs more energy from an impact-and thus provides greater protection to a falling child-than the sum of the energy absorbed by the fill material 14 alone and the tarmac 15 alone. This unexpected, synergistic increase in the impact attenuation properties of the combination of tarmac 15 overlaying fill material 14 is believed to be due to the multiple ways in which the system absorbs energy from an impact.
[0046] As discussed above, the impact attenuation system 12 of FIG. 2 attenuates an impact in three ways. First, referring to the mat 5 depicted in FIGS. 3-6 , the arches 35 deform generally vertically with respect to the top surface of surface structure 10 (which is generally in the direction of the impact force) and thereby attenuate energy from an impact. Second, as discussed above, the grid structure comprising the array of legs 20 and interconnecting rib structures 42 allows mats 5 to flex generally horizontally with respect to the top surface of surface structure 10 and thereby attenuate energy from an impact. Third, as also discussed above, energy from the impact is transferred through legs 20 to fill material 14 , which also attenuates energy from the impact. The energy from the impact is attenuated by the fill material 14 as individual pieces of fill material 14 move closer together and flex under the force of the impact.
[0047] The performance of the exemplary system can meet the gmax<200 and Head Impact Criterion<1000 requirements from a critical fall height of 13 feet.
[0048] In addition to absorbing energy from an impact (e.g., a falling child), the grid structure comprising the array of legs 20 and interconnecting rib structures provides mats 5 with a sufficiently firm surface to allow rolling equipment to be used on tarmac 15 . Generally speaking, the less a wheel sinks into a surface, the less effort and energy is required to roll the wheel across the surface and to turn the wheel on the surface. As one example, the grid structure formed by legs 20 and interconnecting rib structures 42 may be configured to provide tarmac 15 with a sufficiently firm surface for a baby stroller to be pushed on the tarmac 15 surface and the wheels turned on the tarmac 15 surface by a typical adult without requiring an uncomfortable effort from the adult. As another example, the grid structure formed by legs 20 and interconnecting rib structures 42 may be configured to provide tarmac 15 with a sufficiently firm surface to meet ADA standards for use of a wheel chair on the surface of tarmac 15 .
[0049] Thus, as discussed above, the tarmac 15 shown in FIG. 2 is able to meet both the impact attenuation requirements for protecting a child from a fall of the ASTM guidelines and the ADA requirements for wheelchair accessibility. That is, the combination of tarmac 15 and fill material 14 , as shown in FIG. 2 , is sufficiently impact absorbing to protect a child from a fall while at the same time provide a sufficiently firm surface to allow the use of a wheel chair on the tarmac 15 .
[0050] Referring now to FIG. 7 , there is illustrated an exemplary embodiment of the present invention, wherein a tarmac 15 having legs 20 is used in a wet environment. Thus, the pores 40 allow water to leave the surface of the tarmac 15 and drain to the ground below. As discussed above, legs 20 may have a variety of different lengths and thus increase the impact attenuating properties of the tarmac 15 .
[0051] The alternative exemplary embodiment of FIG. 8 may also include using the tarmac 15 underwater, such as at the bottom of a pool. Oftentimes pools made of concrete are very rough and may cause blisters. To cure this problem, pool owners often need to acid wash their pools which is not only expensive, but also requires the pool to be fully drained and then refilled. The present invention allows the tarmac 15 to be placed in direct contact with the cement to provide a smoother surface for the bottom of the pool. In addition, the tarmac 15 increases the pool's safety by attenuating the impact of a diver hitting the bottom of a shallow end of the pool. Such protection is important because an impact with the concrete could result in a serious or fatal injury.
[0052] Finally FIG. 9 illustrates a exemplary embodiment of a cut-away view of the seam connecting two adjacent mats 5 . In this exemplary embodiment a plurality of tabs 24 from a first mat 5 are fit into a plurality of receiving slots 25 to secure the two mats. Additionally glue and/or a thermal bond may be formed between the mats so as to further strengthen the couple holding the mats 5 together.
[0053] Although specific embodiments and applications of the invention have been described in this specification, there is no intention that the invention be limited these exemplary embodiments and applications or to the manner in which the exemplary embodiments and applications operate or are described herein. | A system and method of providing a wheelchair accessible path through a variety of impact attenuating surfaces including loose fill materials. The combination of a tarmac and loose fill material provides an ASTM compliant impact attenuating surface for playgrounds and other activities. The modular tarmac 15 is also used in wet conditions to improve the traction and impact attenuation over traditional materials used in water parks, and also for reducing wear to park patrons' feet. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates to discs for cleaners of liquid-containing vessels and more particularly to automatic pool cleaners having fluted discs for improved performance in swimming pools.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,351,077 to Hofmann and U.S. Pat. No. 4,642,833 to Stoltz, et al., incorporated herein in their entireties by this reference, disclose automatic, water-interruption-type suction swimming pool cleaners having flexible annular discs. These discs are typically mounted near the inlets of the suction cleaners and designed to contact pool surfaces when in use. By doing so, the discs decrease the tendency of the cleaners to disengage from pool surfaces, particularly when the cleaners are negotiating transition regions between walls and floors.
U.S. Pat. No. 4,193,156 to Chauvier, also incorporated herein in its entirety by this reference, describes (at column 4, lines 5-55) an annular disc having numerous "concertina-like," "circumferentially spaced folds." These folds extend when their associated swimming pool cleaner encounters a transition region, purportedly "keeping the inflow of water into the mouth opening to a minimum." Other existing discs similarly are designed for improved adhesion to surfaces to be cleaned, thereby reducing fluid flow into the mouth of the cleaners.
SUMMARY OF THE INVENTION
The present invention provides alternative flexible discs for devices such as automatic swimming pool cleaners. Unlike the discs described above, the present invention incorporates one or more flutes, or curved raised areas (arched protrusions), therein. Each such flute extends generally radially from adjacent the central portion of the disc to its periphery, creating a direct fluid flow path from the periphery of the disc to the mouth of the associated cleaner. Doing so expands the cleaning area of the disc without concurrently enlarging its physical area, enhancing performance over conventional discs.
In particular, fluid flow rates into the cleaner mouth increase significantly in the fluted areas. This accelerated flow reduces the pressure (according to Bernoulli's equation) not only in the fluted areas themselves, but also beyond the periphery of the disc in the regions surrounding the openings provided by the flutes. This larger area of low pressure results in a greater area of the vessel being subject to cleaning for a given-sized disc, since the low pressure region draws debris toward the disc (the source of low pressure).
Certain embodiments of the present invention include dual flutes symmetric about a radius of the disc. Fewer or greater flutes may be included, however, consistent with the scope of the invention. Moreover, such flutes need not be of uniform width or depth, but rather may taper toward the central portion of the disc (thereby effectively funneling fluid from the periphery) and simultaneously decrease in depth. The boundaries of the flutes additionally may be either straight or curved as suitable or desired.
Additional features of the present invention include a curved, or upturned, lip between flutes. The lip, forming the leading edge of the disc, supplies an inclined surface for and sufficient rigidity to the disc to enable it to ride over various objects, including many drains, lights, valves, and nozzles, projecting from internal surfaces of pools. The disc underside also contains an integrally-formed ramped segment surrounding its (nominally circular) central aperture. This ramp likewise assists the pool cleaner in negotiating obstacles, supplying a smooth progression from the disc bottom to the bottom of the cleaner footpad (which the disc surrounds in use), which too may include a ramp.
Multiple openings through the disc enable fluid to pass from one surface of the disc to the other, maintaining a boundary fluid layer between the lower surface of the disc and the adjacent surface of the pool. These openings facilitate movement of the disc relative to the pool cleaner and allow dirt and debris to be entrained in the flow of fluid through the openings and in the boundary layer. Another embodiment of the present invention includes a multi-featured periphery and a non-circular central aperture.
It is therefore an object of the present invention to provide a disc incorporating one or more generally radial flutes extending to its periphery.
It is a further object of the present invention to provide a disc enhancing the performance of an automatic swimming pool cleaner through increasing its cleaning area by providing a larger low pressure region.
It is an additional object of the present invention to provide a disc having one or more upturned lips to facilitate negotiating obstacles.
It is yet another object of the present invention to provide a disc having an underside containing a ramped segment surrounding its central aperture.
It is, moreover, an object of the present invention to provide a disc including multiple openings therethrough, enabling fluid to pass from one surface of the disc to the other.
Other objects, features, and advantages of the present invention will become apparent with reference to the remainder of the text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a disc of the present invention.
FIG. 2 is a top plan view of the disc of FIG. 1.
FIG. 3 is a cross-sectional view of the disc of FIG. 1 taken along lines 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view of the disc of FIG. 1 taken along lines 4--4 of FIG. 2.
FIG. 5 is a cross-sectional view of the disc of FIG. 1 taken along lines 5--5 of FIG. 2.
FIG. 6 is a top plan view of an alternate embodiment of a disc of the present invention.
DETAILED DESCRIPTION
FIGS. 1-5 illustrate disc 10 of the present invention. Disc 10 defines a central aperture 14, nominally circular, in which a footpad of an automatic swimming pool cleaner may be received, for example. Disc 10 also defines a generally planar upper surface 18, a periphery 20 and, as shown in FIG. 3, a lower surface 22. Extending upward from upper surface 18 are curved raised areas (arched protrusions), or flutes 26, which effectively expand the cleaning area of disc 10 without concurrently enlarging its physical area. Each flute 26 extends generally radially from adjacent the reinforced area 28 of disc 10 surrounding central aperture 14 to periphery 20, creating a direct path from the periphery 20 to the mouth of the associated cleaner for debris-laden fluid.
FIGS. 1-3 also detail the raised lip 30 of periphery 20. Located intermediate adjacent flutes 26, lip 30 provides a ramped portion of disc 10 (which may be of increased rigidity) to facilitate the disc 10 negotiating obstacles often projecting from interior pool surfaces. Pins or stops 32, which may be integrally formed with and project upward from the reinforced area 28 of disc 10, cooperate with portions of a footpad or other component to inhibit misorientation of disc 10. In use, lip 30 forms the leading edge of disc 10 as it and associated equipment move throughout a pool or other vessel, enabling the disc 10 to ride over objects encountered therein. Openings 34 through disc 10 enable fluid to pass between upper and lower surfaces 18 and 22 of disc 10 when in use, maintaining a boundary fluid layer between the lower surface 22 of disc 10 and the adjacent surface of the pool or other structure to be cleaned.
Shown in FIGS. 3-4 is ramp 38, projecting from lower surface 22 of disc 10 and positioned concentrically about central aperture 14. Ramp 38 promotes a smooth transition between lower surface 22 and the bottom of a footpad (or other component) received by central aperture 14, facilitating unobstructed movement of a swimming pool cleaner associated with the footpad. FIG. 3 similarly discloses radius 42 existing between lip 30 and lower surface 22 of disc 10, providing a smooth transition therebetween and, as noted above, an inclined surface, or ramp, for negotiating obstacles.
In an embodiment of the invention consistent with FIGS. 1-5, flutes 26 are positioned symmetrically about a radial axis 46 extending through disc 10 from central aperture 14 to periphery 20. As shown in these figures, flutes 26 need not be of uniform width (W) or height (H), but rather may be widest and highest (i.e. protrude further) at periphery 20 and taper in width while decreasing in height toward reinforced area 28. As noted earlier, fluid flow rates into the cleaner mouth increase substantially in the fluted areas of disc 10. This accelerated flow creates a region of low pressure extending beyond periphery 20, increasing the effective cleaning area of the cleaner.
Although two flutes 26 are illustrated in FIG. 1, the number of flutes 26 is not necessarily critical to the invention. Consequently, disc 10 may include more or less than two flutes 26 as necessary or desired. Those skilled in the art will recognize, however, that including vast numbers of flutes 26 on disc 10 may ultimately diminish the effectiveness of the associated cleaner by reducing the quantity of the increased fluid flow through each to a negligible amount.
FIG. 5 details selected characteristics of a portion of flute 26 near periphery 20. Whereas upper surface 18 and lower surface 22 generally define parallel planes, at flute 26 each extends upward above the plane formed by upper surface 18. These upwardly-extending surfaces 18A and 22A, while remaining approximately parallel at any particular location, no longer are planar but rather are curved. The result is an approximately semi-conical structure for flute 26 that, as shown in FIGS. 1-2, may be truncated adjacent reinforced area 28.
FIG. 6 illustrates an alternate disc 50 of the present invention. Although including flutes 54 similar to disc 10, disc has a multi-featured periphery 58 differing in shape from periphery 20. Central aperture 62 of disc 50 additionally is configured differently than central aperture 14 of disc 10, with reinforced area 66 being more triangular than circular in nature. Defining central aperture 62 in this manner permits suitable attachment to the style of footpad 70 shown in FIG. 6. Doing so also alleviates any need for including stops 32 or other external orientation means to be present on disc 50.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those of ordinary skill in the art and may be made without departing from the scope or spirit of the invention. | Discs for devices such as automatic swimming pool cleaners are disclosed. The discs incorporate one or more flutes, or raised areas (arched protrusions), extending generally radially from adjacent their central portions to their peripheries. The peripheries themselves, moreover, may include upturned areas (lips) between flutes, and both the discs and footpad may include ramped segments facilitating movement over obstacles extending from swimming pool surfaces. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a continuation-in-part of my co-pending patent application Ser. No. 06/372,134, filed Apr. 27, 1982 abandoned.
BACKGROUND
This invention pertains to valves and in particular to dual valve devices utilizing a sleeve valve and a cooperating ball valve, a valve positioner and an operator for the valves.
PRIOR ART
When operating earth wells, it is highly desirable to have apparatus in the well which may operate to maintain pressure control and prevent "blowouts" by closing off well outflow near the producing formation and providing means to introduce heavy fluid into the well to "kill" the well.
One such system, herein incorporated by reference, is shown on p. 813 of the 34th revision of the "Composite Catalog of Oilfield Equipment and Services" and described as a "block-kill" system. This system requires numerous downhole devices such as a block-kill actuator, an actuator mandrel, control line, and a block-kill valve, which are operated by pressure in the well annulus.
The valve devices of the present invention replace all the numerous devices required in the above described system and operate to close formation outflow and open wall flow passages to allow killing fluid to flow into the tubing from the well annulus.
A valve device of this invention is installed in well tubing, above a packer and lowered into the well casing, where the packer is set above a producing formation, creating an annulus in the well and sealing between the formation and annulus. The formation is then in pressure communication with the tubing and flow passage through the valve device, and the well annulus is in pressure communication with flow ports in the valve device wall.
Two embodiments of the invention devices utilize a ball valve controlling flow through the device, connected to a sleeve valve, controlling flow through wall flow ports between the annulus outside the valve and the flow passage through the valve, and include a lock, locking the sleeve valve closed and the connected ball valve open. The lock is releasable in response to predetermined pressures. As the ball valve is opened and the sleeve valve is closed mechanically, an operating spring is compressed to furnish operating force.
The lock release in one of these embodiments is a spring loaded differential piston which is moved by greater pressure outside the valve device to compress a spring and release a collet type lock.
The lock release in the other embodiment utilizes a number of precharged bellows which respond to higher pressure outside the valve and operate to release a ratchet type lock.
One of these valves is then installed at the desired depth in the well and when annulus pressure outside the valve exceeds formation pressure inside the valve by a preset amount, the lock is released and the compressed spring closes the ball valve, closing off flow through, and opens the sleeve valve and wall flow passages to flow pumped in from the well annulus to kill the well.
A third embodiment of the valve device of this invention contains cooperating ball and sleeve valves, a lock locking the ball valve closed, a piston responsive to pressure, which is movable to compress an operating spring, release the lock, open the ball valve and close the sleeve valve. Pressured fluid is conveyed from the surface through a conduit to a sealed chamber above the piston. This device is operated in a well by increasing or reducing pressure in the conduit at the surface. This embodiment includes structure similar to that shown in U.S. Pat. No. 3,384,337 to N. F. Brown, herein incorporated for reference. When the ball valve of this embodiment of the present invention is locked closed, higher pressure in the valve body above or below the valve ball biases the seat away from the higher pressure into sealing engagement with the valve ball. Structure in the Brown patent biases the seat nearer the high pressure into sealing engagement with the valve ball.
The chamber in the third embodiment valve device could be pressured sufficiently on the surface and sealed to move the piston to compress the operating spring, release the lock, open the ball valve and close the sleeve valve. If this valve is installed in well tubing above a packer set in well casing, the piston would respond automatically to a predetermined higher pressure in the well annulus and release the compressed operating spring, to close the ball valve and tubing flow and open the sleeve valve to killing fluid flow, from the well annulus.
A ball valve device of the type shown in U.S. Pat. No. 4,140,153 to Deaton, herein incorporated by reference, is utilized in embodiments of the present invention. The ball valve could be of the type disclosed in U.S. Pat. No. 4,289,165 to Fredd.
All embodiments of the invention valve device may be reset to operate repeatedly while in place in a well.
An object of this invention is to provide an improved safety and kill valve which automatically operates when well annulus pressure is increased a predetermined amount.
An object of this invention is to provide an improved safety and kill valve wherein operating pressures may be preset.
An object of this invention is also to provide an improved block and kill valve which may be reset to operate repeatedly without retrieving from the well.
Also an object of this invention is to provide a safety and kill valve operable by conduit from the surface.
BRIEF DRAWING DESCRIPTION
FIGS. 1A and 1B together show an elevational view of an embodiment of the invention valve device, half sectioned, showing the valves positioned to operate after installation in a well.
FIGS. 2A and 2B together show a view of the valve device of FIGS. 1A and 1B after operation.
FIGS. 3A and 3B together show another embodiment of the dual valve device of the present invention in elevation, half sectioned, wherein the two valves are positioned to operate.
FIGS. 4A and 4B together show the valve device of FIGS. 3A and 3B after operation.
FIG. 5 is a fragmentary enlarged view of the lock mechanism of the embodiment of FIG. 3 in the locked position.
FIG. 6 is a fragmentary enlarged view of the lock mechanism of the embodiment of FIG. 3 in the unlocked position.
FIGS. 7A, 7B, 7C, 7D and 7E together show a half section elevation view of a third embodiment of the dual valve device of this invention, wherein the valves are in operating postion.
FIGS. 8A, 8B, 8C, 8D and 8E together show the valve device of FIGS. 7A, 7B, 7C, 7D and 7E after operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an invention valve device 10, locked in position for installation in a well, whereon is provided an appropriate top connection 11 and bottom connection 12 for connecting the valve 10 into a well pipe string to be lowered into a well. An internal profile 13 is provided in upper connector 14. The upper end of operator tube 15 is slidably received in upper connector bore 16. A downward facing shoulder 15a is provided on operator tube 15 to compress operating spring 17, and a longitudinal bore and flow passage 15b is provided therethrough. Upper connector 14 is connected to upper housing 18 at thread 19 and sealed with seal 20. Housing 18 is provided with internal shoulder 21 on opposite sides of which press operator spring 17 and piston spring 22. The lower end of piston spring 22 presses through ring 23 on the upper end of piston 24. A seal 25 is provided in internal shoulder 26 in lower housing 27 slidably sealing piston 24 to housing 27. At least one port 27a is provided in housing 27. A seal 28 is also provided for sealing upper housing 18 to lower housing 27 above their connecting threads 29. Another seal 30 in piston 24 slidably seals it to the outside of operator tube 15. An internal bore 31 is provided in the lower end of piston 24, and groove 32 is formed in the outside of operator tube 15. Collet 33 with arm lug portions 34 is installed over the upper end of insert 35 and retained thereon by set screws 36. Seal 37 slidably seals insert 35 to operating tube 15. Lower connector 38 is connected to lower housing 27 at threads 39 and sealed to insert 35 with seal 40. At least one port 41 is provided in operating tube 15. A chamfered shoulder 42 is formed on the lower end of insert 35, engageable by secondary valve surface 43a formed on seat member 43. Seat member 43 is connected to operator tube 15 with threads 44.
The construction and operation of ball valve device 45, housed in lower connection 38, is described in U.S. Pat. No. 4,140,153. The ball valve device 45 includes shoulder 42, seat member 43, control arms 46 fitted to ball member 47 in frame 48, seat 43b formed on the lower end of seat member 43, and shoulder 49 in lower connector 38.
FIG. 3 shows another embodiment of the invention valve device 50 utilizing a pair of bellows 51 with lower ends joined to body connector 52. The upper ends of bellows 51 are joined to ring 53. Ring 53 is secured to latch tube 54 with screws 55 when bellows 51 are in slots 56 provided for the bellows in latch tube 54. Bellows 51 and ring 53 may be gas pressure charged internally by loosening screw seals 57, opening passages 58 to admit pressured gas into bellows 51 and ring passage 53a, and tightening seals 57 to seal the charge in the bellows and passages. Slots 59 are cut near the lower end of latch tube 54 through which pawls 60 may engage teeth 61 on operating tube 65 (see also FIGS. 5 and 6). Pawls 60 are positioned in opposed slots 62 in the lower end of body connector 52 and are retained by and pivot around pins 63. Camming surfaces 64 and 66 are formed at either end of slots 59 to cam pawls 60 into and out of engagement with teeth 61. The lower end of latch tube 54 is enlarged to extend camming surface 66. A longitudinal flow passage 67 is provided through operating tube 65. An operating spring 68 biases operator tube 65 upwardly. At least one port 69 is provided in tube 65. A seal 70 slidably seals tube 65 in connector 72. At least one port 71 is provided in lower housing 73.
FIG. 7 depicts a third embodiment 74 of the block and kill valve device of this invention, preferred by the inventor, shown in ball valve open position and having an appropriate thread 75 in top connection 76. The top connection has an internal profile 77, a thread 78 for connection of a control conduit from suface or a plug and connecting flow passages 79 and 80. The lower end of the top connection is provided with a thread 81 connecting the top connection to upper housing 82. Resilient seal 83 seals the top connection to the upper housing. The upper end of upper operator tube 84 is slidably received in bore 85 in the top connection and sealed to it with resilient seal 86. Formed on the upper operator tube is a piston 87 slidably received in bore 88 in the upper housing and sealed to it with resilient seals 89. A variable volume chamber C, in communication with flow passage 80, is formed by seal 83, bore 88, seal 89, piston 87 and seal 86. A compressed spring 90 is positioned in the upper housing bore around the upper operator tube between lower piston surface 87a and internal shoulder 82a in the upper body.
An intermediate housing 91 is connected to the lower end of the upper housing with thread 92 and has at least one flow port 93. Upper operating tube 84 extends through a bore in the lower end of the upper housing and is connected to lower operator tube 94 with threads 95 and is sealed to the lower tube with resilient seal 96.
The larger outside of the lower operator tube is slidable into bore 91a in the intermediate housing and is sealed to the intermediate housing when inside by resilient seal 97. Also slidably mounted in bore 91a is dog carrier 98 to which are pivotally connected a number of dogs 99 by pins 100. Interrupting bore 91a is a recess 91b. The lower tube has a groove 94a and is provided with at least one port 94b. Carrier 98 is connected to an upper seat 102 with thread 103. The upper seat is slidably sealed in the upper housing by resilient seal 104. Bore 97a houses a spring 105 which receives an expander 106. An annular seat 102a is formed at the lower end of the upper seat and the annular upper seat is held in slidable contact with the outside sealing surface 107a on valve ball 107 by an opposed pair of control connections 108, each having a pin portion 108a protruding into holes 107b centered in flats on opposite sides of the valve ball. Control connections 108 are slidably housed in frames 109.
Connected to the intermediate housing with thread 110 is a lower housing 111. These housings are sealed together by resilient seal 112. Lower seat 113 has a annular seat 113a, formed in its upper end, which is also held in slidable contact with the outer sealing surface on the valve ball by the control connections. Connected to the lower housing with thread 114 is a lower connector 115, having an appropriate lower thread 116 for connecting into well tubing. Each frame is positioned in lower housing 111 between the lower end of intermediate housing 91 and the upper end of lower connector 115. Each frame has a pin 109a which protrudes into a slot 107c in each ball flat, eccentric to the holes for connector pins 108a. Longitudinal movement of the upper seat slides the valve ball, control connectors and lower seat in the frames, and the valve ball is rotated about pins 108a by stationary frame pins 109a, between open and closed positions. Resilient seal 117 slidably seals the lower seat in lower connector bore 115a and seal 118 seals the lower connector to the lower housing. The upper and lower seat diameters sealed by seals 104 and 117 are equal and smaller than the equal seal diameters of ball 107 on annular seats 102a or 113a. Longitudinal flow passage 119 extends through valve device 74.
One embodiment of the present invention may be preferred by a well operator depending on conditions in a particular well.
To utilize the embodiment of this invention shown in FIGS. 1 and 2, the valve 10, if not in running and operating position shown in FIG. 1, is placed in position on the surface by pushing down on the upper end of operating tube 15, to move operating tube 15 downwardly (disengaging valve 43a from shoulder 42), compressing spring 17, rotating ball valve 45 to open flow passage 15b to flow while moving ports 41 below seal 37 to close flow through ports 41. When groove 32 on tube 15 is opposite lugs 34, spring force in the collet arms 33 moves lugs 34 into groove 32 and compressed spring 22 moves ring 23 and piston 24 down and bore 31 over lugs 34 to lock lugs 34 in groove 32 and operator tube 15 and the valve 10 in running and operating position.
The valve 10 is then connected into a well tubing string above a packer and lowered to desired depth in the well where the packer is set in the well casing, sealing between the well annulus and formation. As ball valve 45 is open, two-way formation flow may occur freely through tubing and flow passage 15b, and no flow may occur through ports 41 as they are below seal 37. In the event pressure in the well annulus outside the valve 10 acting through ports 27a on the sealed differential piston area between the inside of seal 30 and the outside of seal 25 produces an upward force on piston 24 sufficient to overcome the combined downward forces of compressed spring 22 and force produced by pressure in flow passage 15b acting down on sealed differential piston area from the outside of seal 25 to the inside of seal 30, piston 24 moves up compressing spring 22. The rate of spring 22 may be preselected to determine a desired pressure difference between well tube pressure in valve flow passage 15b and greater well annulus pressure outside of valve 10 to move piston 24 up. Upward movement of piston 24 continues until bore 31 is above the upper end of lugs 34 unlocking lugs 34 to be moved out of groove 32. Compressed spring 17 maintains an upward bias on operating tube 15 sufficient to cam lugs 34 outward from groove 32 with cam surface 32a, releasing the tube 15 to be moved up until ports 41 are above seal 37 and in pressure communication with ports 27a, and ball valve 45 has rotated to close flow passage 15b and well outflow (FIG. 2). If required, fluid may be pumped down the well annulus through ports 27a and 41 into flow passage 15b and up in the well tube to a level sufficient to overcome well pressure on the lower side of the closed ball valve 45, "killing" the well.
To reposition the valve 10 to operating position, reopening ball valve 45 and closing ports 41 to flow, an appropriate tool may be lowered in the well tubing to contact the upper end of operator tube 15 and push it down to reposition valve 10 in locked operating position.
To utilize the embodiment shown in FIGS. 3 and 4, bellows 51 are pressure charged and sealed to a predetermined pressure and will automatically operate the valve device 50 in the well when pressure outside the valve is greater by a predetermined amount than pressure in bellows 51. If valve 50 is in the operated position as shown in FIG. 4, it must be repositioned to run and operate position as shown in FIG. 3 by pushing down on the upper end to move operator tube 65 down, "ratcheting" teeth 64 by pawls 60, compressing spring 68, moving ports 69 below seal 70, and rotating ball valve 45 open. The pressure charge in bellows 51 maintains the bellows extended and exerting a constant upward pull on latch tube 54. Cam surfaces 66 on tube 54 are constantly urging pawls 60 into engagement with teeth 64 on tube 65. Operator tube 65, therefore, is automatically locked in down position by pawls 60 engaging a tooth 64 (see FIG. 5). Ports 69 are now below seal 70 and closed to flow, and ball valve 45 is open for flow through flow passage 67, as shown in FIG. 3. The valve 50 is then connected in well tubing above a packer and lowered into the well to the desired depth at which the packer is set, sealing between the formation and well annulus. When well annulus pressure outside the valve 50, acting through ports 71 in housing 73 up through clearances between outside latch tube 54 and inside housing 73 and connector 52, overcomes the pressure charge in bellows 51, the well annulus pressure compresses and shortens the bellows and moves latch tube 54 down. Cam surfaces 66 are moved out of engagement with pawls 60 and cam surfaces 64 contact and cam pawls 60 around pins 63 out of engagement with teeth 61 (FIG. 6), unlocking tube 65 to be moved up by compressed spring 68. Upward movement of tube 65 moves ports 69 above seal 70 and rotates ball valve 45. Valve 45 has closed flow passage 67 to upflow and ports 69 are above seals 70 and open to flow through ports 71 into and up flow passage 67 as shown in FIG. 4.
An appropriate tool may later be lowered in the well tubing to engage the upper end of and move operating tube 65 down repositioning the dual valve 50 for repeated operation.
To install and use the block and kill valve embodiment 74 shown in FIG. 7 and 8, the variable volume chamber C of an operated valve (FIG. 8) may be pressure charged at the surface through flow passages 79 and 80 with a predetermined pressure and sealed by screwing an ordinary pipe plug into thread 78. The pressure charge acting on piston 87 operates and positions the dual valves for automatic operation in a well, when pressure exterior of the valve is sufficiently greater than pressure in valve device flow passage 119. If surface control of the operation of the valve device 74 is desired, chamber C is not pressure charged at the surface and a control conduit is connected to thread 78. The control conduit may be pressured at the surface to increase pressure in chamber C and operate the valve device.
The pressure charged or control conduit valve device 74 is then connected in well tubing above a packer and lowered into the well to the desired depth, where the packer is set to anchor and seal with well casing above a producing formation in the well and form a tubing-casing annulus above the packer.
Pressure in the well tubing-casing annulus, exterior of the pressure charged valve device 74, enters ports 93 and acts downwardly on the annular sealed area between seals 96 and 97 and also acts upwardly on the annular sealed area between seals 96 and 89. Seal 89 is larger than seal 97, so the net force is upward on operator tubes 84 and 94. Compressed spring 90 exerts an upward force on piston 87 and the operator tubes and the charged pressure in chamber C exerts a downward force on the piston. When annulus pressure exterior of the valve device is increased sufficiently to overcome downward forces on the operating tubes, the operating tubes move upwardly compressing the charge in chamber C, moving dogs 99, carrier 98, upper seat 102, control connections 108 and lower seat 113 while rotating valve ball 107 closed. The upward travel of the dog carrier, upper seat, control connectors and lower seat is stopped when the upper end of the connectors contact the lower end of intermediate housing 91 and valve ball 107 has rotated to close flow passage 119 to flow. At this time, dogs 99 are aligned with intermediate housing recess 91b and on continued upward movement of the operating tubes, the lower end of lower operating tube 94 disengages the upper end of expander 106 and releases spring 105 to push the expander inside the dogs expanding and locking them into engagement in recess 91b and valve ball 107 closed. Upward movement of the upper operator tube is stopped by the top side of piston 87 contacting the lower end of top connection 76. The lower operator tube has moved out of sealing engagement with intermediate housing seal and ports 94b are in pressure communication with intermediate housing ports 93 and the well annulus exterior of the valve device 74, as shown by FIG. 8. Well fluid of a gradient sufficient to overcome formation pressure may now be pumped from the well annulus through ports 93 and 94b into valve device flow passage 119. Closed valve ball 107 seals on annular seat 102 a or 113a effectively preventing higher pressure leakage in flow passage 119 from above or below the closed valve ball 107.
When the ball valve is locked closed, higher pressure in flow passage 119 above the valve ball acting on the sealed annular area between the larger upper seat seal diameter on valve ball 107 and smaller seal 104 biases the upper seat up. As there are very small operational clearances between movable parts, the upper seat is moved upwardly by the bias, out of sealing engagement with the ball, and minute flow may now occur through operational clearances between seat 102a and ball seal surface 107a and connectors 108 and ball 107, increasing pressure on the lower seat annular area between the larger lower seat seal on valve ball 107 and seal 117 and biasing the lower seat upwardly to sealingly engage lower seat seal surface 113a and ball seal surface 107a. The control connectors now prevent downward movement of the valve ball and lower seat, and forces tending to distort the valve ball are greatly reduced. If the higher pressure is below the locked closed valve ball in flow passage 119, the upper seat is biased into sealing engagement with the valve ball in a like manner, and the valve ball seals on the seat away from higher pressure and valve ball distorting forces are reduced. The pressure charged valve device will be automatically repositioned to operate on sufficient reduction of pressure exterior of the valve in the well annulus.
If surface operational control is desired for valve device 74, a control line is connected to thread 78 and the valve device with control line extending to the surface is installed in the well. With no pressure in chamber C, spring 90 closes valve ball 107 and opens ports 93 and 100 to flow between flow passage 119 and the valve device's exterior. Valve 74 may be placed in operating position as shown in FIG. 7 by pressuring the control line at surface. When pressure in chamber C and down forces are sufficient, the operating tubes are moved downwardly by piston 87, opening the ball valve for flow through passage 119 and closing ports 93 and 100 to flow between passage 119 and the valve device exterior. When operation of the control line valve device is desired, pressure in the control line is reduced or annulus pressure increased sufficiently for spring 90 to move the operating tubes upwardly, opening ports 93 and 100 to flow and closing passage 119 to flow and locking valve ball 107 closed. The control line valve device may be repositioned to operate by repressuring the control conduit at the surface or reducing pressure in the annulus. | Disclosed is a safety and kill valve device useful in tubing above a packer set above a producing formation in a well, operable to shut off tubing flow and open wall flow passages to the well annulus through which heavy formation killing fluid may be pumped into the tubing. A lower ball valve is used to shut off tubing flow and an upper sleeve valve, cooperable with the ball valve, controls flow through the wall flow passage. An operating tube moves downwardly, opening the ball valve and closing the sleeve valve while compressing a spring. The compressed spring furnishes operating force to move the operating tube upwardly, closing the ball valve and opening the sleeve valve. Two embodiments operate automatically in response to higher well annulus pressures. Another embodiment may be controlled through conduit from the surface or operate automatically in response to higher annulus pressures. All embodiments may operate repeatedly without retrieving from a well. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of Provisional U.S. Patent Application 62/230,133 under 35 U.S.C. Section 119(e).
[0002] Pat. No. 5,572,768 P, Daul teaches a rotary friction damper in a device, external to the door, such as a hinge, for connecting a door to an adjacent structure, including a helical spring operatively connected to the door and the structure.
[0003] Pat. No. 5,787,549 P, Soderlund, is a hinge system for attaching a hinged element to a base forming a hinged unit. The hinge system included first and second torsion rods fixed directly to the hinged element and to the base.
[0004] Pat. No. 7,195,300, Austin, teaches an automotive tailgate hinge assembly that counterbalances the weight of the tailgate storing energy in a torsion bar connected at one end to the tailgate and at the other end directly connected to the frame of the automobile.
[0005] Pat. No. 7,219,391 B1, Luca, teaches a door assembly and a door closer arranged and constructed so as to be wholly concealed within the associated door. The apparatus consists of a standard piston or rack and pinion style door closer disposed within the upper or lower hollow door rail and an arm connected at one end to the piston of the door closer. The arm protrudes through the pivot side door edge to receive a mounting bracket attached to the door jamb.
[0006] Pat. No. 8,732,094 B2, Busch, teaches a cam based hydraulic door closer with a helical spring for energy storage. Busch delineates non-linear torque vs door angular displacement relationships that are typical for door closer applications.
BACKGROUND OF INVENTION
[0007] This invention relates to the field of commercial, industrial and residential swing doors, gates and windows that rotate about a pivot axis. The invention is applicable to pivot hung doors that are displaced in one direction and subsequently self restore to their nominal or at rest positions, being driven by spring potential energy stored during the displacement of the door from its nominal position. It is also applicable to special security or fire doors that serve as a means of egress and can move rapidly, without external power, from nominal, spring energized position to a second, displaced position, upon receipt of an external stimulus such as a fire alarm, emergency signal, or the activation of a panic device.
[0008] The current invention overcomes inherent limitations of the existing art for self-closing doors that, including those that rely on surface mounted door closers that are operatively engaged by means of external connecting arms, slide tracks, or both. The complete concealment of the control system of the current invention offers benefits of cost, safety, security, ease of installation and improved aesthetics over the existing art. Some of the primary limitations of the prior art are exemplified in the following referenced citations.
[0009] Pat. No. 5,572,768 P, Daul, teaches a helical spring and friction device contained in a door hinge. This invention is limited in the magnitude of the torque that can be transferred to the door. Also, the angular displacement at the spring is identical to that of the door and this relationship cannot be altered. The use of this invention for pivot mounted doors is not taught.
[0010] Pat. No. 5,787,549 P, Soderlund teaches the use of a torsion bar in the hinge to replace the helical spring taught by Daul and is also not applicable to pivot mounted doors.
[0011] Pat. No. 7,219,391 B1, Luca, relies on the offset of the door hinge with respect to the vertical middle plane of the door as a moment arm to cooperate with a piston force and thereby produce a torque on the door. This invention relies on a mechanical connection between the door closer within the door, and the door jamb, and is not applicable to pivot hung doors. There are many examples in the prior art in which door closers are disposed within the door. All of these require an operative connection to the structure around the door.
[0012] Pat. No. 8,732,094 B2, Busch discloses torque vs. displacement curves that are typical for surface mounted door closers. These curves reveal that the desired torque on the door decreases in a non-linear fashion as the door opens. This contrasts the approximately linearly increasing torque vs door angular displacement that would be inherent if a spring, whether helical or torsion, were connected directly between the door and a fixed reference.
[0013] Pat. No. 7,195,300, Austin, teaches a counterbalanced tailgate mechanism with a torsion bar mounted between the tailgate at one end and the fixed frame of the automobile at the other end. This system does not provide for a non-linear relationship between the angular displacement of the tailgate and the twist angle of the torsion bar. The fixed relationship between the torsion bar windup and tailgate position limits the quality of the counterbalancing effect of the torsion bar, since perfect balancing of the tailgate would require a sinusoidal increasing torque on the tailgate as it moves from the latched position to the open position.
[0014] As is evident from the cited art, mechanical systems to facilitate the self closing of swing doors are well known. Absent, however, in the prior art, is a system disposed within a self restoring pivot hung door; connected, or in contact with, the surrounding structure around the door only at the pivots; providing non-linear modulation of stored torque and selective energy dissipation.
BRIEF SUMMARY OF THE INVENTION
[0015] The control system of this invention overcomes the cited limitations of the prior art by means of the serial disposition of a new and novel torsion means and rotary dampener. Elongated torsion means, such as torsion bars, disposed within a door, benefiting from the volume of the hollow chamber in the door and not just from the cross sectional area thereof, can deliver large torques at acceptable working stress levels. The invention makes use of torsion bars disposed in door stiles and rails operatively engaged with the door to impart, on the door, a torque that is decreasing in a non-linear fashion as the door is displaced from its nominal position. Furthermore, the invention employs a new and novel rotary dampening device disposed within the door and operatively engaged with said torsion means to provide energy dissipation to control the restorative angular velocity of the door.
[0016] The invention teaches the apparatus and method of field adjusting the restorative torque on the door in its nominal position using the door as a convenient lever to manually energize the torsion bar to an initialized torque, or angle of twist.
[0017] The control system of this invention provides new and novel improvements over the existing art with the following benefits:
[0018] said control system is entirely concealed within the door and does not require connections to the structure around the door other than at the pivots,
[0019] said control system provides increased efficiency by reducing the complexity of the operative hardware between the energy storage component and the door.
[0020] said control system eliminates the ubiquitous rack and pinion drive of existing self contained door closers,
[0021] said control system provides for easy installation and initialization of the torque on the door in its nominal position,
[0022] said control system provides enhanced safety by the elimination of finger pinch points inherent in hinge and pivot mounted doors.
[0023] said control system provides enhanced security since the hardware, installed within the door, is tamperproof, and
[0024] said control system can be manufactured to meet the most stringent domestic and foreign guidelines for door safety such as ANSI A156.4.
[0025] It is an object of this invention to teach a new and novel door control system that is disposed within a hollow cross section of a door that provides all the functionality of an ANSI A156.4 Grade 1 door closer without the necessity of an operative connection, or arm, that is connected between the structure around the door and the door closer.
[0026] It is an object of this invention to teach a new and novel method of energizing a self restoring door by use of a torsion bar disposed within the door itself.
[0027] It is an object of this invention to teach a control system for controlling the motion of a self restoring pivot hung door when said door includes a panel, such as a solid glass plate, and a hollow pivot side stile in which the control system is disposed.
[0028] It is an object of this invention to teach a control system for controlling the motion of a self restoring pivot hung door when said door is a hollow door such as the hollow metal doors used in many commercial applications, having at least a hollow pivot side stile and one hollow rail in which to dispose the control system.
[0029] It is an object of this invention to teach the means by which a torsion bar disposed within a door is indirectly coupled to the door so that the manual opening of the door results a resistive torque on the door that is either increasing, constant, or decreasing; either linearly or non-linearly.
[0030] It is an object of this invention to improve the efficiency of the existing door closer art by eliminating sliding friction losses including those inherent in the rack and pinion elements of the existing art.
[0031] It is an object of this invention to teach a new and novel rotary dampener or dashpot, disposed within the stiles and rails of a self restoring pivot hung door, consisting of a housing and a rotor, within the housing, to control the closing speed of the door.
[0032] It is an object of this invention to teach a self restoring pivot hung door which maintains a small, consistent gap between pivot side door stile and the pivot side door jamb throughout the allowable motion of the door, thereby eliminating pinch points that are a safety concern on existing doors.
[0033] The benefits of this invention are improved efficiency, aesthetics, safety, security, cost, and ease of installation compared to the prior door closer art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0034] FIG. 1A —Top plan view of the door header indicating Section A-A.
[0035] FIG. 1B —Section view A-A of door and header. The door is shown in the closed position. The door pivots on the right side and the moving wing rotates out of the page as the door opens.
[0036] FIG. 1C —Detail view, A, of the torque modulator of this invention, disposed within the upper rail and the pivot side stile of the door.
[0037] FIG. 1D —Detail view, B shows the preferred location of the rotary dampener of this invention as well as the adjustable bottom pivot of this invention.
[0038] FIG. 1E —Enlarged perspective view of Detail A.
[0039] FIG. 2A —Front plan view of the alternate embodiment of the invention disposed within the hollow pivot side stile of the door. The pivot side door stile and corresponding pivot side door jamb are shown displaced to the right to reveal the apparatus of this invention.
[0040] FIG. 2B —Top plan view of the alternate embodiment with the door stile and door jamb displaced to the right of their actual position
[0041] FIG. 2C Detail view, C, of the torque modulator.
[0042] FIG. 2D —Detail D enlarged to illustrates the unique cross sections of the door stile and the mating door jamb.
[0043] FIG. 2E —Perspective view of Detail C showing the key components of the torque modulator operatively disposed between the fixed header, 10 , above the door, and the rotating end of the torsion bar, 45 .
[0044] FIG. 3A —Top view of the rotary viscous dampener of this invention, indicating Section B-B.
[0045] FIG. 3B —Section view B-B showing the rotor, 22 , and housing, 21 , of the rotary viscous dampener.
[0046] FIG. 3C —Section view C-C indicated in FIG. 3D illustrating the disposition of the rotor in the housing.
[0047] FIG. 3D —Side plan view of the rotary viscous dampener of this invention showing sweep and latch adjustment ports and Section C-C.
[0048] FIG. 3E —Perspective view of the rotary viscous dampener of this invention
[0049] FIG. 4A —Exploded view of the adjustable bottom pivot of this invention.
[0050] FIG. 4B —Side plan view of torsion lock plate, 26 , of the adjustable bottom pivot
[0051] FIG. 4C —View D-D of the torsion lock plate, 26 , of the adjustable bottom pivot
[0052] FIG. 5A —Depicts the restorative torque vs angle of displacement for the main embodiment of this invention.
[0053] FIG. 5B —Depicts the restorative torque vs angle of displacement for the alternate embodiment of this invention.
LIST OF FIGURE REFERENCES
[0000]
1 torsion bar
2 torque modulator
3 cam pulley
4 cable
5 crank link
6 coupler link
7 follower link
8 rotary dampener
9 bottom pivot
10 header
11 shaft
12 mounting bracket
13 cam pulley
14 crank shaft
15 latch port
16 sweep port
17 rotor
18 bearing
19 bearing
20 void
21 housing
22 shaft end
23 shaft end
24 elongated boss
25 check valve
26 locking torque plate
27 flat head screws
28 socket head screw
29 gap
30 socket head screw
31 thrust bearing
32 bearing, outer race
33 locking sleeve
34 central bore
35 door stile
36 torque converter
37 four bar linkage
38 chaises
39 shaft
40 door bearing
41 bracket
42 crank
43 coupler
44 follower
45 free end of torsion bar
46 coupling
47 door jamb
48 cable
49 cam pulley
50 cam pulley
51 control ports
52 region A
53 region B
54 sealing surfaces
55 o ring seal
56 alt torque modulator
57 door panel
58 door frame
59 right angle drive
60 torque transfer drive
DETAILED DESCRIPTION OF THE INVENTION
[0114] For purposes of illustration, the nominal position of the door is assumed to be the closed position, however, the specification is not intended to be limited by this assumption. The structure of the invention includes a torsion means for storing and controllably releasing potential energy and a dampening means to dissipate, as waste heat, kinetic energy of a moving door. The torsion means consists of an elongated member capable of storing elastic strain energy in torsion, such as a torsion bar, and a torque modulator. The torque modulator defines the relationship between angular displacement of the door and the corresponding angular displacement of the torsion bar as the door oscillates between the limits of its motion. The torsion means is disposed in a hollow chamber within the pivot hung door.
[0115] Referring to FIG. 1B , the torque modulator, 2 , of the main embodiment includes a four bar linkage with moving links, 5 , 6 , and 7 , shown in FIG. 1E . The pivot hung door is the fourth link and is fixed relative to the links 5 , 6 , and 7 . It is well known to those skilled in the art of kinematic synthesis of linkages that any four bar linkage can be equivalently represented by a pair of cams in rolling contact. These cams, one fixed and one moving are derived from the fixed polode and moving polode of the four bar linkage, respectfully. Thus, the torque modulator linkage, embodied herein, could equally be embodied by an equivalent system consisting of two cams or two cam shaped pulleys fixedly connected by a cable, belt or chain so as to maintain their relative rolling contact kinematics. However, because of the high torques and bearing loads associated with the self restoring pivot hung door application, the linkage itself is the best known embodiment of this invention.
[0116] FIG. 1A shows a top view of the pivot hung door and indicates Section A-A. Referring to Section A-A in FIG. 1B , the energy storage is accomplished by means of a torsion bar, 1 . The torsion bar of this invention consists of one or more elongated members suitable for storing elastic strain energy in torsion, disposed in a parallel arrangement an connected at each end with common end plates. Working in unison, multiple elongated members can, for a given length, provide the same torque as a single torsion bar while at the same time significantly reducing the maximum torsional stress in each individual elongated member with respect to that of a single torsion bar. The parallel arrangement of multiple torsion bars can optimize energy density while at the same time minimizing the working stresses of the torsion bars. In a practical example of a medium size swing door with a preload torque of 36 ft-lb, six torsion bars of diameter 0.176 inches working in parallel have a working shear stress 70% lower than that which would exist in a single torsion bar at the same torque and angular displacement, of diameter 0.55 inches, or 15 mm.
[0117] A novel feature of this invention is the concealed torque modulator, 2 . Detail view A, FIG. 1C , shows the torque modular, 2 and its connection to the header, 10 , or jamb above the pivot hung door by means of the right angle drive, 59 , and its connection to the free end of torsion bar, 45 , below it, by means of the transfer drive, 60 . Referring now to FIG. 1E which shows a perspective view of the torsion means consisting of:
[0118] The right angle drive, 59 , of this invention consisting of parts 3 , 4 , 11 , 12 , 13 ; torque modulator, 2 , of this invention consisting of parts 5 , 6 , 7 ; torque transfer drive, 60 , of this invention, consisting of parts 48 , 49 , 50 ; and torsion bar, 1 .
[0119] The right angle drive, 59 , provides the operative connection between the fixed header, 10 , and the crank link, 5 of the torque modulator, and includes elements, 3 and 13 which may be circular or cam shaped and either concentrically or eccentrically mounted with respect their axes of rotation, hereinafter cam pulleys, and non endless cable, 4 , fixedly attached at each end to one of cam pulleys 3 , and 13 . The operative profiles of said cam pulleys, whether circular, cam shaped, concentric or eccentric are determined by the specific requirements of the application under consideration. Said non endless cable, 4 , may be constructed of rope, wire, belt or braided cable of material to suitable transfer torque from cam pulley to cam pulley. The torque modulator crank link, 5 , is fixedly attached to cam pulley, 13 , at proximal end by means of crank shaft, 14 , and pivotably constrained to the door at said end. The distal end thereof is pivotably engaged with the proximal end of coupler link, 6 . The distal end of coupler link, 6 , is pivotably engaged with the proximal end of follower link, 7 . The distal end of follower link, 7 rotates about a fixed point on the door and is fixedly attached to cam pulley, 50 .
[0120] The torque transfer drive, 60 , provides the operative connection between follower, 7 of the torque modulator, 2 , and the free end of the torsion bar, 45 , and consists of cam pulleys, 49 , and 50 , which may be circular with respect to their rotation axis or cam shaped, and non endless cable, 49 , fixedly attached at each end to one of cam pulleys 49 , and 50 .
[0121] Selective removal of kinetic energy from during the restorative cycle of the pivot hung door is accomplished by the rotary dampener, 8 , of this invention, shown in FIG. 1D . The adjustable bottom pivot of this invention, 9 , also depicted in FIG. 1D , allows for ease of installation and setting of the torque on the door in its nominal position.
[0122] Referring to FIG. 1B , the pivot hung door, 58 , is shown in the closed or nominal position. As the door opens the latch side edge of the door rotates out of the page as shown. It should be apparent to those skilled in the art that the locations of the torsion means, 2 , shown in Detail A and the rotary dampener, 8 , shown in Detail B of FIG. 1D , can be interchanged without altering the function thereof. Referring now to FIG. 1E , as the door wing rotates, cable, 4 , winds up on non-rotating cam pulley, 3 , which is fixedly attached to the header, 10 , via shaft, 11 , and mounting bracket, 12 . Cam pulley, 13 , begins to rotate. Cam pulley, 13 , is fixedly attached to crank link, 5 , which therefore rotates clockwise as viewed in the figure. Each unit of rotation of the crank, 5 , results in a unique, non-constant rotation of the follower link, 7 whereby the relative displacement of the follower link, 7 is small at the beginning of the opening cycle and larger at the end of the opening cycle. Coupler link, 6 , connects crank link, 5 and follower, 7 , and moves in general coplanar motion as it rotates with respect to links 5 and 7 . The four bar linkage, 5 , 6 , 7 serves to decrease the torque in torsion bar, 1 , as the door opens, while the motion of the door itself tends to increase the torque of the torsion bar. The superposition of these motions, as the door opens, results in cable, 48 , being taken up by cam pulley, 49 , as it is released from cam pulley, 50 . The resulting angular displacement at the torsion bar moving end, 45 , is larger near the door closed position and smaller near the door open position. As the door moves between these two positions, the angular displacement relationship between the door and the torsion bar varies in a non-linear fashion with respect to a unit angular displacement of the door itself. As would be apparent to those skilled in the art, each of the cam pulleys described herein could be non-circular in design. This would allow further enhancement of the non-linear relationship between the door rotation and the torsion bar angular displacement. This is possible because the cables are not endless, they are fixedly attached to the cam pulleys, and because the relative angular displacement of the cam pulleys is a limited oscillation and not a continuous rotation. The non-circular cam pulleys would in this case act as cams capable of providing further non-linear enhancement between the door angular displacement and that of the torsion bar. When the door is released from its displaced position, the potential energy of the system, stored as elastic strain energy in the torsion bar is released in a prescribed fashion to deliver an appropriate torque on the door at each position during the restorative motion of the door.
[0123] A novel feature of this invention is rotary dampener, 8 , which provides all of the energy dissipation capability and adjustability of the modern door closer and accomplishes this with a fixed housing element and a pivotably disposed element. The rotary dampener or dashpot, selectively dissipates excess energy during the closing cycle of the door and contains at least one field adjustable means to set the magnitude of the energy removed at a specific angle during the door closing cycle. The rotary dampener, shown in FIG. 1B , is disposed near the bottom of the door, mating with adjustable bottom pivot, 9 , of this invention on the lower end of the dampener and to the torsion bar, 1 , at the upper end of the dampener.
[0124] FIG. 3D is a plan view of the rotary dampener with latch port, 15 , to control the speed of the door during the last approximately 15 degrees of door closing, and the sweep port, 16 , to control the speed from the fully open position to approximately 15 degrees of opening. Section B-B is identified in FIG. 3A and shown in FIG. 3B . The elongated hatched area, 17 , is a cross section view of the pivotably operative rotor, constrained by bearings, 18 and 19 . Fluid, either pneumatic or hydraulic, in the void, 20 , between the rotor, 17 , and the housing, 21 , is constrained within the housing by seals concentric with bearings, 18 , and 19 . Spring energized lip seals and o-rings seals are commonly used for this purpose. The void, 20 , is defined by two regions, region A, 52 , and region B, 53 , as illustrated in FIG. 3C . Fluid is exchanged between the two regions via the check valve, 25 , during door opening and via the ports, 51 and the latch valve, 15 and the sweep valve, 16 , as the door closes. The indicated surfaces, 54 in Section view C-C, are in close proximity. Sealing between the two regions, A and B is accomplished by o-ring seal, 55 , is indicated between the rotor, 17 , and the boss, 24 . Referring to FIG. 3C , the boss, 24 , contains openings and pathways for the oil to travel past one or both of the latch and sweep valves as it travels from one side of the chamber defined by the rotor and boss to the other side of the chamber. The rotating rotor of the rotary dampener functions analogously to the sliding piston in the ubiquitous rack and pinion designs currently in use in the industry. The relative port locations and pathways are similar to those of the existing rack and pinion door closer art and are therefore not detailed herein. A check valve in the rotor, 25 allows the oil to bypass the latch and sweep pathways and instead flow directly from one chamber to the other for ease of manual door opening. The function of the rotary dampener mirrors that of the linearly constrained piston of common rack and pinion door closers. However, the dampening function facilitated for a door application in a device for which there is only relative rotation among the constituent parts is heretofore unknown in the art. The rotary dampener, offers efficiency benefits over the rack and pinion design because the rotary to linear motion conversion stage is eliminated. In addition, the rotary dampener, disposed within the door pivot stile and concentric with the central axis of rotation of the door further enhances efficiency, security, safety, reliability, cost and ease of door installation. As the door rotates, the rotary dampener housing rotates with the door, while the rotor is constrained by its connections to the bottom pivot and the torsion bar.
[0125] The adjustable bottom pivot of this invention, illustrated in FIG. 4A, 4B, and 4C , provides a very simple and safe means for commissioning the door with the proper torsion bar preload, i.e. the proper force of the door on the door surround, in its nominal position. Door pivots are commonly used in commercial and industrial swing doors. Those skilled in the art are familiar with the means of installation of a swing door between upper and lower pivots. Once the door is properly installed on its pivots it is necessary to set the torque of the door on the door surround. In commonly used, rack and pinion style door closers, this is accomplished with a tool used to set the initial displacement of a compression spring that pushes directly against the sliding piston of the closer. Since spring forces are very high it can be difficult and cumbersome for the installer to make significant changes to the factory setting of the compression spring. The adjustable bottom pivot of this invention makes this process very simple and safe because the door itself is used as a lever to set the initial displacement of the torsion bar. Given the large leverage that can be realized by pushing on the latch end of the door, even very large torques can be effortlessly set with the adjustable bottom pivot of this invention. Referring to FIG. 4A , an exploded view of the adjustable bottom pivot, the locking torque plate, 26 , is securely fastened to the floor with screws, 27 , preferably flat head screws, and screw, 28 , preferably a socket head screw, engaged to allow subsequent compression of the gap, 29 , facilitated by turning screw, 30 , preferably a socket head screw. Thrust bearing and thrust washer assembly, 31 , and roller bearing, 32 , slide onto sleeve, 33 , with preferably a close clearance fit. The sleeve inserts in the central bore, 34 of the locking torque plate, 26 . The outer race of bearing, 32 , mates with a bore in the door stile to define the axis of rotation of the door. With the adjustable bottom pivot in place, and the rotor pre-positioned in the rotary dampener housing to correspond to the nominal position of the door, the door is set in place and the screw, 30 , is tightened to fix the rotor and prevent its rotation. The door is then opened to either a pre-specified position, or to a position for which the measured resistive torque on the door corresponds to the desired nominal door torque. The door is chocked in this position and a suitable retainer wrench is placed on the flats of sleeve, 33 , to lock the torsion bar to the door. Access to the concealed hardware is easily accomplished by means of a small removable cover preferably located on the door edge nearest the door pivot. With the retainer in place, screw, 30 , is loosened so that the sleeve, 33 , now rotates with the door as it is manually returned to the nominal position. Screw, 30 , is again tightened to secure the torsion bar to the bottom pivot. The retainer between the door and the torsion bar is then removed. The door is now ready for the final set up of the latch and sweep valves, accessible through said removable cover, to match the required closing times from fully displaced to approximately 15 degrees and from approximately 15 degrees to the nominal position, respectively.
[0126] An alternate embodiment is illustrated in a partially exploded view in FIG. 2A , in which the vertical stile, 35 , and door jamb, 47 have been displaced to the right in the illustrated figure to reveal the apparatus of the alternate embodiment. The apparatus of this embodiment requires neither the right angle drive, 59 , nor the transfer drive, 60 , disclosed earlier in this specification. The four bar linkage of the alt torque modulator, 56 , in the alternate embodiment is redesigned with unique link lengths and a serial assembly of links with vertical rotation axes as seen in FIG. 2E . The alternate embodiment requires a non standard pivot side stile. The unique pivot side stile, 35 , of the alternate embodiment can be used in conjunction with numerous types of door panels. It is particularly beneficial for the all glass door panel, 57 , which can be readily attached to the stile by means known to those skilled in the art. Hinged doors as well as pivot hung doors, especially those with offset pivots, present a safety hazard since the gap between the pivot side door edge and the vertical, pivot side door jamb increases as the door opens. A finger, trapped in this gap would be injured as the door returns to its nominal position. The unique cross section profiles of the vertical stile of this invention and that of the door jamb are seen in a top plan view in FIG. 2D . The close proximity and the concentric disposition of the relative concave and convex sections provide a unique and attractive safety enhancement. FIG. 2E , a perspective view, illustrates the gap, 14 , the unique stile, 35 and the unique jamb, 47 of this invention. The gap, 14 , does not open as the door is displaced. The gap can be as little as ⅛″ and still allow for weather-stripping between the stile and the jamb to seal the building from the exterior environment.
[0127] Referring to FIG. 2E , the moving links, 42 , 43 , and 44 of four bar linkage, 37 , are stacked vertically and connected at one crank end, 42 , to the door stile, 35 , by means of bracket, 41 , and at the follower end, 44 , coupled to the moving end of the torsion bar, 45 , by means of coupling, 46 , which prevents relative rotation between the follower, 44 , and the torsion bar, 1 . Chaises, 38 , fixedly mounted to the top door jamb or alternately to the header, 10 , provides the bearing supports for four bar linkage, 37 . Shaft, 39 , fixedly attached to both of bracket, 41 , and crank, 42 , rotates in chaises bearing, 40 . Bracket, 41 , is fixedly attached to door stile, 35 with suitable fasteners. Coupler, 43 , is pivotably constrained to both of crank, 42 , and follower, 44 . Torsion bar, 45 , is fixedly attached to follower, 44 , by way of coupling, 46 . The door is shown in the nominal position in FIG. 2A . As the door is displaced from this position, the moving wing of the door rotates into the page of FIG. 2A . As the door begins its motion from the nominal position, the four bar linkage, 37 , imposes relatively larger angular rotation on the moving end of the torsion bar, 45 . As the door continues to move toward the fully displaced position, the angular rotation imposed upon the moving end of the torsion bar becomes relatively smaller. The reduction in the imposed rotation of the torsion bar is not a linear decrease as the door is displaced, but rather a steep decrease at the beginning of the cycle and a very small decrease at the end of the opening cycle.
CONCLUSION
[0128] The invention herein consists of a new and novel concealed control system disposed in a pivot hung door, connected to the door surround only at the pivots; including a torsion bar, a means to modulate the torsion bar torque, a rotary dampening means, and an adjustable bottom pivot for ease of commissioning of the door. The main and alternate embodiments of this invention illustrate how the ubiquitous rack and pinion door closers of the existing art can, to advantage, be replaced with an efficient system that stores energy in a torsion bar disposed within a hollow chamber of a pivot hung door and comprising serially disposed elements that are pivotably engaged to one another. The versatility of the control system of this invention is illustrated in FIGS. 5A and 5B . The curves depicted in the graphs represent practical solutions for commercial doors. FIG. 5A shows the non-linear drop in torque on the door as the door is displaced from its nominal position, indicated as zero on the horizontal axis of the graph. The vertical axis is given in units of inch-pounds. The minimum torque on the door is achieved at about 80 degrees of displacement, after which the torque increases. This increase at 80 degrees of displacement is desirable for exterior doors in windy environments to resist wind forces while at the same time still providing a very desirable torque during the manual opening, which is typically less than 90 degrees of opening. The result shown in FIG. 5A is that of the main embodiment of this invention, however, the same result can be achieved by the alternate embodiment. For purposes of illustration FIG. 5B depicts a second torque profile that would be suitable for interior doors. The result shown in FIG. 5B is that of the alternate embodiment of this invention, however, the same result can be achieved by the main embodiment. Those skilled in the art will recognize that an almost limitless variety of torque vs displacement curves can be achieved by well known methods of kinematic linkage synthesis. The advantages of the control system of this invention include:
[0129] the entirely concealed hardware provides added safety;
[0130] the entirely concealed hardware is secure and tamper proof;
[0131] the design is aesthetic and architecturally innovative;
[0132] the simplified design efficiently converts the potential energy stored in the torsion bar into the useful work of self closing the door; and the installation in both new construction and retrofit applications is straightforward and easily accomplished by those skilled in the art. | This invention teaches a motion control system for self-closing or self-opening pivot hung doors, gates and windows being disposed within a hollow chamber of a pivot hung door, gate or window connected to the door surrounding structure only at the door pivots. The system stores elastic strain energy as the door is displaced from its nominal position and controllably releases that energy to self restore the system to its nominal position. The system consists of serially connected torsion means and dampening means wherein torsion means includes a torsion bar and a torque modulator, and dampening means includes a housing and a rotor operatively rotational in housing. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device for moving a slidable body forward or backward and a method of controlling the position of the slidable body. More particularly, it is concerned with a device for moving a nozzle in a part cleaning device for washing the anus and functioning as a bidet and a method of controlling the position of the nozzle. The term "part cleaning device" as herein used means an apparatus including a tank for cleaning water, a cleaning nozzle which is movable between its retracted position and its cleaning position, a system for heating the cleaning water, a system for supplying the heated cleaning water, a system for moving the nozzle and devices for controlling those systems, and provided at the rear end of a water closet for directing a jet of heated cleaning water toward the private parts through the nozzle in its cleaning position.
2. Description of the Prior Art
In the part cleaning device, it is usually the case that the nozzle has two cleaning positions, i.e., the position for cleaning the anus and the position for functioning as a bidet.
There are known two arrangements for moving the nozzle forward from its retracted position to its cleaning positions and backward.
One of them relies on the pressure of cleaning water for moving the nozzle forward. The nozzle is slidably disposed in a cylinder and the cleaning water is introduced into the cylinder to push the nozzle out of the cylinder to either of its cleaning positions. A spring is connected to the nozzle for urging the nozzle back to its retracted position in the cylinder.
The other arrangement employs a motor which is rotatable in either direction for moving the nozzle out of, or into, a cylinder. This arrangement will hereunder be described with reference to FIG. 16.
The cylinder 101 is secured in a casing 100 located adjacent to the rear end of a toilet stool (not shown). The nozzle 102, which comprises a tubular body, is axially slidable in the cylinder 101. The electric motor 103 is provided adjacent to the proximal end of the cylinder 101 for moving the nozzle 102 forward or backward. The motor 103 has an output shaft 104 to which a cylindrical drum 105 is secured. A leaf spring 106 has one end wound on, and fastened to, the outer cylindrical surface of the drum 105. The other end of the spring 106 is connected to the proximal end of the nozzle 102. The output shaft 104 of the motor 103 is rotatable in two directions and the manner of the rotations of the output shaft 104 causes the reciprocal motion of the nozzle 102 in the cylinder 101. When the nozzle 102 is brought to its cleaning position, it directs a jet of cleaning water toward the private parts of a person using the toilet through its end openings 107. The positioning of the conventional nozzle 102 structure is effected by a feedback control system including a sensor of, for example, the magnetic or optical type which is located in a position for monitoring the motion of the nozzle 102. The sensor detects the amount of motion of the nozzle 102 and transmits a corresponding signal to the motor 103 to turn the power circuit of the motor 103 on or off.
The system relying on the pressure of the cleaning water for positioning the nozzle has the disadvantage that if the water pressure is lower than a predetermined level, the nozzle fails to reach its designated cleaning position and accomplish its proper cleaning function. If the nozzle is of the type having two cleaning positions for the anus and for the use as a bidet, respectively, its internal water passages formed in the nozzle 102 itself are complicated and the size of the nozzle 102 is undesirably enlarged.
The system employing the motor 103 for moving the nozzle 102 and the sensor for detecting and positioning it has the disadvantage that its nozzle positioning accuracy depends on the performance of the sensor. If the sensor fails to function accurately, the nozzle 102 fails to reach its designated cleaning position and also to accomplish its proper cleaning operation as mentioned above.
The sensor requires a complicated job of assembly including wiring connection between the motor 103 and the control system and mounting in a predetermined narrow space, and the control system also becomes complicated. The drum 105 has, as shown in FIG. 17, formed on its outer cylindrical surface a shoulder 108 and threaded holes 110 provided in the vicinity of the shoulder 108 for receiving screws 109 for securing the leaf spring 106. Thus, the outer cylindrical surface of the drum 105 on which the leaf spring 106 is wound does not have a uniform curvature. As the drum 105 is rotated alternately in the opposite directions, the leaf spring 106 is wound on the surface of the drum 105 and unwound therefrom repeatedly. Insofar as the surface of the drum 105 does not have a uniform curvature, with the passage of time the fatigue of the leaf spring 106 is not uniform along its length, and this causes stress concentration or buckling in the leaf spring 106 which leads to failure in driving the nozzle 102. The fastening of the leaf spring 106 to the drum 105 by the screws 109 adds to the amount of labor required for the fabrication of the apparatus and hence the cost thereof.
Another problem that the conventional part cleaning device involves is due to the fact that the distal end portion of the nozzle 102 which is provided with the openings 107 projects from the cylinder 101 even when the nozzle 102 is in its retracted position. The projecting distal end portion of the nozzle 102 is always liable to contamination by dirty liquid or matter, whether the nozzle 102 may be in its cleaning or retracted position. The dirty liquid and matter are likely to form powder on the projecting end portion of the nozzle 102 and in its openings 107 and thereby to block the openings 107. They have an objectionable odor, and contaminate cleaning water.
SUMMARY OF THE INVENTION
It is an object of this invention to solve the problems hereinabove pointed out in connection with the movement of a slidable body and more particularly the positioning of a cleaning nozzle in a part cleaning device, and to improve the accuracy of the nozzle positioning by employing an open-loop control system not relying on any kind of sensors.
It is another object of this invention to improve the slidable body moving device which includes a drum secured to the output shaft of an electric motor and a leaf spring, so that the connection of the spring to the drum may be simplified, and so that the smooth and proper function of the spring may always be ensured.
It is still another object of this invention to enable the self-cleaning of the exposed distal end portion of the nozzle in a part cleaning device and at the same time the cleaning of the head of its extensible nozzle member both before and after its use to keep it always clean.
The first object of this invention is attained by a device for driving a slidable nozzle in a part cleaning device which comprises an electric motor adapted for rotation synchronously with the frequency of a power source or a pulse, such as a synchronous motor, pulse motor or servomotor, means for counting the number of cycles of the frequency of the power source for the motor, means for determining the actual position of the nozzle based on the counted number of cycles, and means for comparing the actual position of the nozzle with its predetermined cleaning or retracted position, the output of the comparing means being transmitted to a power circuit for the motor to effect the ON-OFF control thereof for moving the nozzle to its cleaning or retracted position.
The output shaft of the motor has a specific rotating speed or angle relative to the frequency of its power source. Therefore, the nozzle has a specific amount of axial direction movement in either direction depending on the direction of the rotation of the output shaft of the motor. It is, therefore, possible to determine the actual position of the nozzle if the number of cycles of the frequency of the power source is counted simultaneously with the rotation of the output shaft of the motor. The actual position of the nozzle is compared with its predetermined cleaning or retracted position stored in the comparing means, and as soon as the former coincides with the latter, the power circuit for the motor is turned off so that the nozzle may be stopped in its predetermined cleaning or retracted position.
The second object is attained by an improved device for driving a slidable nozzle in a part cleaning device which comprises a cylinder, a nozzle having at a distal end thereof openings through which cleaning water is directed outwardly, an electric motor for moving the nozzle axially in either direction in the cylinder, a drum secured to the output shaft of the motor and a leaf spring connecting the drum and the nozzle, and characterized in that the drum comprises a main body portion having a sectoral recess and a sectoral insert portion fitted in the sectoral recess and having an arcuate outer peripheral surface defining a precision cylindrical drum surface with the outer peripheral surface of the main body portion, and that one end of the leaf spring is secured between the mutually fitting surfaces of the main body and sectoral insert portions.
As the drum surface is precision round, the amount of the spring which is wound or unwound reflects the amount and angle of the rotation of the output shaft of the motor correctly, and the amount and angle of the rotation of the output shaft are transmitted to the nozzle highly accurately.
The third object is attained by a device including a nozzle having a flattened nozzle head and adapted for its complete retraction into a cylinder, a first packing member provided in the cylinder for sealing the peripheral surface of the nozzle when it is in its retracted position, a second packing member provided between the first packing member and the distal end of the cylinder and surrounding the nozzle head portion, and a cleaning water feed line connected to the cylinder between the first and second packing members, the nozzle head being temporarily stopped in a position projecting out of the distal end portion of the cylinder immediately before its arrival at its cleaning position and immediately after its departure therefrom so that the cleaning water may be discharged through an annular passage between the second packing member and the nozzle head portion for cleaning the distal end portion of the cylinder and the nozzle head.
Switches for starting the cleaning operation of the anus and the fucntion as a bidet are provided in a control panel for a part cleaning device. If either of those switches is turned on, the nozzle is temporarily stopped in a position suitable for the self-cleaning of the nozzle head. The electromagnetic valve or pump disposed in the cleaning water feed line works for a brief period of time to supply water from a hot water storage tank to the annular passage so that it may clean the nozzle head and the distal end of portion the cylinder before it is discharged into a toilet stool. Then, if the stop switch provided in the control panel is turned on, the nozzle starts retracting into the cylinder and stops temporarily at its self-cleaning position on its way again. The electromagnetic valve or pump works briefly and water is supplied from the hot water storage tank to the annular passage for cleaning the nozzle head itself and the distal end portion of the cylinder before the nozzle is moved to its completely retracted position in the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a water closet provided with a part cleaning device embodying this invention;
FIG. 2 is a schematic top plan view showing the interior of the device shown in FIG. 1;
FIG. 3 is a sectional view taken along the line I--I of FIG. 2 and showing the longitudinal section of a nozzle device in a retracted position;
FIG. 4 is a top plan view, partly in section, of the nozzle device;
FIG. 5 is an exploded perspective view of a drum and a leaf spring;
FIG. 6 is a perspective view showing the proximal end of the leaf spring secured to the drum;
FIG. 7 is a fragmentary longitudinal sectional view of the nozzle in its self-cleaning position;
FIG. 8 is a perspective view showing a nozzle distal end and a first and a second packing members;
FIG. 9 is a block diagram showing a control circuit for an electric motor;
FIG. 10 is a flow chart showing the operation of the motor;
FIG. 11 is a top plan view, partly in section, of the nozzle device of which the positioning is effected by lead switches and a magnet;
FIG. 12 is a sectional view taken along the line II--II of FIG. 11;
FIG. 13 is a longitudinal sectional view of the nozzle device of which the positioning is effected by Hall ICs and a magnet;
FIG. 14 is a top plan view, partly in section, of the nozzle device shown in FIG. 13;
FIG. 15 shows the principle of nozzle position detection by a magnet and Hall ICs;
FIG. 16 is a longitudinal sectional view of a conventional nozzle device; and
FIG. 17 is a perspective view of a conventional drum for driving the nozzle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A water closet provided with a part cleaning device A embodying this invention is shown in FIG. 1 and comprises a toilet stool B, a flushing water tank C, a lavatory seat D and a lid E. The part cleaning device A comprises a base 1, a tank F for heating and storing cleaning water, a valve unit G for supplying the cleaning water, a hot air fan H for drying after cleaning and a nozzle device N located approximately in the center of the device and connected to the tank F by a cleaning water supply pipe P. The nozzle device N comprises a cylinder 2 secured on the base 1 and having a base end to which an electric motor 3 is integrally mounted, and a tubular nozzle body 4 provided axially movably in the cylinder 2, as shown in FIGS. 3 and 4. The motor 3 is a synchronous motor having an output shaft adapted for rotation synchronously with the frequency of a power source.
The cylinder 2 is provided at the distal end thereof with an elbow 5 for connection to the cleaning water supply pipe P. When the nozzle body 4 has been moved forward to its cleaning position, the elbow 5 communicates with a water passage formed in the nozzle body 4 so that a jet of cleaning water may be directed outwardly through a plurality of first and second end openings 6a and 6b.
A cylindrical drum 10 is secured to the output shaft 11 of the motor 3. A thin leaf spring 12 has its proximal end fastened to the drum 10 and the distal end of the leaf spring 12 is connected to the proximal end portion of the nozzle body 4. The drum 10 is formed from a synthetic resin. It comprises a main body portion 15 and an insert portion 16 for securing the leaf spring 12 integrally to the main body portion 15, as shown in FIG. 5. The main body portion 15 has a central boss 17 secured about the output shaft 11, and a major arc-shaped cylindrical outer peripheral or rim surface 18 formed with a sectoral recess 19. The recess 19 defines a pair of radial walls 20 and 21 which is substantially equal in length to the width of the rim surface 18. The wall 20 has a groove 22 and the wall 21 also has a groove 23. Both of the grooves 22 and 23 are in parallel to the axis of the drum 10. The groove 23 has a positioning projection 24 approximately at the middle thereof.
The insert portion 16 has a sectoral cross section and can be fitted in the sectoral recess 19. The insert portion 16 has an arcuate outer peripheral or rim surface 25 and a pair of radial walls 26 and 27. The rim surface 25 has a radius of curvature which is equal to that of the rim surface 18 of the main body portion 15, and the rim surfaces 18 and 25 form a precision cylindrical surface when the insert portion 16 is fitted in the main body portion 15. The wall 26 is formed on its outer surface with a pair of projections 28 for engaging the leaf spring 12, as shown in FIG. 6. The wall 27 is provided at its radially inner edge with an outwardly directed flange 29 having approximately at the middle thereof a recess 30 in which the positioning projection 24 can be received.
The leaf spring 12 is so bent prior to assembly as to closely fit the wall 26 of the insert portion 16 and the rim surfaces 18 and 25, and has the bent end portion 31 formed with a pair of holes 32 for receiving the projections 28 on the wall 26, as shown in FIG. 6. The projections 28 extending through the holes 32 are fitted in the groove 22 of the wall 20 and the flange 29 is fitted in the groove 23 of the wall 21, as is obvious from FIG. 5. The other end of the leaf spring 12 is connected by a pin 33 to the proximal end portion of the nozzle body 4, as shown in FIG. 3.
If the output shaft 11 of the motor 3 is rotated in one direction, the leaf spring 12 is unwound from the rim surfaces 18 and 25 of the drum 10 to enable the nozzle body 4 to move forward to its cleaning position, and if the output shaft 11 of the motor 3 is rotated in the reverse direction, the leaf spring 12 is wound on the drum to enable the nozzle body 4 to return to its retracted position. Insofar as the drum 10 has a precision cylindrical surface defined by the rim surfaces 18 and 25, the leaf spring 12 is subjected to uniform compression or tensile stress along its entire length when it is being either wound or unwound around the drum 10. The leaf spring 12 always works smoothly without being subjected to any localization of stress concentration or buckling, and therefore has long life and good durability. The leaf spring 12 is easy to be secured to the drum 10, as it is sufficient to fit the insert portion 16 in the main body portion 15.
The nozzle body 4 is of the double-walled construction and comprises an outer tube 40 and an inner tube 41 disposed in the outer tube 40 coaxially therewith. Therefore, the nozzle body 4 has a first water passage 44 defined between the outer and inner tubes 40 and 41, having an annular cross section and leading to a nozzle head 43 at the outer end of the outer tube 40, and a second water passage 45 extending through the inner tube 41 and leading to the nozzle head 43. The nozzle head 43 is provided at its top with three or five first jet openings 6a and second jet openings 6b, though the number of those openings may have to be selected to provide the force of water required for cleaning the anus or the function for a bidet. The nozzle head 43 is flattened on the top and the bottom by a pair of shoulders 46 dividing it from the rest of the nozzle body 4.
The cylinder 2 is provided inwardly of its outer distal end portion with a first packing member 47 and a second packing member 48 both having a Y-shaped cross section and surrounding the nozzle head 43 therebetween when the nozzle body 4 is in its completely retracted position. The packing members 47 and 48 and the shoulders 46 on the nozzle head 43 define an annular passage 49 in the cylinder 2. The annular passage 49 is connected to the passage 51 in the elbow 5 which is connected to the cleaning water supply pipe P leading to the tank F. The outer tube 40 has first and second water inlet openings (not shown) through which the annular passage 49 is connected to the first and second water passages 44 and 45 to supply cleaning water into the nozzle body 4 when it is in its cleaning position.
The nozzle device N including the nozzle body 4 is secured to the base 1 in a casing W in such a way that the nozzle body 4 may be axially movable into the bowl B-1 of the toilet stool B. The jetting of the cleaning water from the nozzle device N is started by a cleaning start switch 53 and a start switch for a bidet 55 provided on a control panel 52 and stopped by a stop switch 54 also provided on the control panel 52.
The nozzle body 4 can be stopped at three cleaning positions, i.e., the anus cleaning position S-1, the position for functioning as a bidet S-2 and self-cleaning position S-3. When the nozzle body 4 is in its first stop position S-1 by the operation of the cleaning start switch 53, cleaning water flows from the annular passage 49 to the first jet openings 6a through the first inlet opening (not shown) and the first water passage 44 for cleaning the anus. When the nozzle body 4 is in its second stop position S-2 by the operation of the start switch for a bidet 55, water flows from the annular passage 49 to the second jet openings 6b through the second inlet opening (not shown) and the second water passage 45 for the use as a bidet. The supply of cleaning water from the tank F may be effected by a known device, i.e., by an electromagnetic valve in the valve unit G if water is supplied directly, or by an electromagnetic pump (not shown) if it is supplied indirectly.
According to a salient feature of this invention, the electromagnetic valve or pump is in operation for a brief period of time immediately after the nozzle body 4 has been temporarily stopped at its self-cleaning position S-3, and immediately after it has been retracted toward the cylinder 2 and stopped temporarily at its self-cleaning position S-3 again. This is a very short period of, say, one to several seconds required for cleaning the nozzle head 43 and the adjacent end of the cylinder 2.
If the nozzle body 4 stops at its self-cleaning position S-3, the nozzle head 43 is displaced outwardly relative to the packing members 47 and 48 and projects from the cylinder 2, as shown in FIG. 7. The second packing member 48 leaves the shoulders 46 on the nozzle head 43. The annular passage 49 communicates to the atmosphere through the annular opening between the second packing member 48 and the nozzle head 43 and water is discharged at a reduced pressure for cleaning the nozzle head 43 and the adjacent end of the cylinder 2 to keep them clean both before and after the toilet is used. As the pressure of the discharged water for self-cleaning is reduced, water flows along the nozzle head 43 and the adjacent end of the cylinder 2 slowly and does not undesirably jet out from the annular passage 49 into the bowl B-1 or splash out of the water closet B.
The nozzle body 4 does not necessarily need to be of the type having two water supply routes for cleaning the anus and for the use as a bidet, respectively, as hereinabove described. The first and second packing members 47 and 48 defining the annular passage 49 in the cylinder 2 do not necessarily need to have a Y-shaped cross section, but may have another cross sectional shape, for example, a U-shaped cross section.
A method of controlling the position of the nozzle body 4 will now be described with reference to FIG. 9. The block diagram of FIG. 9 includes a pushbutton or other operating device 60 provided in the vicinity of the part cleaning device, a nozzle position setting device 61 connected to the operating device 60, a commercial frequency clock converter 62 provided in the vicinity of the power source for the motor 3, a nozzle position detector 63 connected to the converter 62 and a nozzle position comparator 64 connected to the devices 62 and 63. The anus cleaning position S-1, the functioning position as a bidet S-2 and the self-cleaning position S-3 of the nozzle body 4 are stored in the nozzle position setting device 61 and each compared with the actual position of the nozzle body 4 which is detected by the nozzle position detector 63. The power circuit for the motor 3 is connected to the nozzle position comparator 64 through a motor controller 65 which turns on or off the supply of power to the motor 3 in response to the output of the comparator 64.
The flow chart of FIG. 10 showing a system for controlling the movement of the nozzle body 4 includes an actual nozzle position timer MT and a set nozzle position timer PT. If the operating device 60 is actuated to turn on the power circuit for the motor 3, its output shaft 11 is rotated to unwind the leaf spring 12 from the drum 10 and move the nozzle body 4 forward to its cleaning position. The number of cycles of the frequency of the power source starts to be counted simultaneously with the turning on of the power circuit. When the nozzle body 4 has reached one of its cleaning positions, the power circuit is turned off to discontinue the rotation of the motor 3 and stop the nozzle body 4 as its designated anus cleaning position S-1 or functioning position as a bidet S-2, as shown in FIG. 3.
When the nozzle body 4 is moved back to its retracted position S-4 in the cylinder 2, the motor 3 is kept in operation for several more cycles even after the counted number of cycles indicating the actual position of the nozzle body 4 has coincided with a set value representing its retracted position S-4. This ensures the return of the nozzle body 4 to its completely retracted position S-4 and eliminates its inaccurate positioning which might otherwise result from the repeated operation of the motor 3. A similar control system is used for positioning the nozzle body 4 relative to its self-cleaning position S-3.
The motor 3 is a synchronous type and therefore, the nozzle body 4 may be accurately positioned if the frequency of the power source is counted. However, because incorrect positioning is possible, a pair of stop members 70 and 71 are provided in the cylinder 2 to ensure that the nozzle body 4 is stopped at its retracted position S-4 or at its functioning position as a bidet S-2.
If required, a semiconductor control device may be employed to enable the motor 3 to start when the voltage of the power source is zero. This arrangement eliminates any error in the counting of the number of cycles and improves the accuracy of nozzle positioning control.
The use of the precision cylindrical drum 10 and the leaf spring 12 for converting the rotation of the motor 3 to the axial reciprocating movement of the nozzle body 4 enables the accurate conversion of the amount and angle of rotation of the output shaft 11 to the amount of movement of the nozzle body 4. This feature permits the use of a nozzle position sensor for the accurate positioning of the nozzle body 4 as shown in FIG. 11.
Referring to FIG. 11, a frame 72 is secured along one side of the cylinder 2 and has an inner surface on which lead switches 73, 74 and 75 are provided for detecting each position of the nozzle body 4 when it is in its anus cleaning position S-1, functioning position as a bidet S-2, and retracted position S-4, respectively. The cylinder 2 is formed on the one side thereof with a recess 76. A magnet 77 which faces one of the lead switches 73 to 75 depending on the position of the nozzle body 4 is secured to the nozzle body 4 and exposed through the recess 76. When the magnet 77 has come to one of the lead switches 73 to 75 during the movement of the nozzle body 4, a corresponding signal is transmitted to the control system for the motor 3 to enable the detection of the nozzle position and its accurate positioning.
Another arrangement for positioning the nozzle body 4 is shown in FIGS. 13 and 14. It employs Hall ICs for detecting the position of the nozzle body 4 in motion instead of the lead switches as mentioned above. Such arrangement includes a magnet 80 mounted on the proximal end of the nozzle body 4 in such a way that the directions of both poles thereof may be perpendicular to the direction of axial movement of the nozzle body 4. Three Hall ICs H 1 , H 2 and H 3 are provided for detecting the position of the nozzle body 4 in cooperation with the magnet 80. The Hall ICs H 1 to H 3 are mounted on the inner surface of the upper plate 81 of the cylinder 2 in parallel to the nozzle body 4 and in a way forming a perpendicular magnetic field with the magnet 80. The first to third Hall ICs H1 to H 1 to H 3 are so situated as to face the magnet 80 when the nozzle body 4 has reached its retracted position S-4, anus cleaning position S-1, and functioning position as a bidet S-2, respectively.
The Hall ICs are turned on or off by a magnetic field as is known in the art. The Hall ICs H 1 to H 3 are switched on or off when the magnet 80 creates a magnetic field of intensity above a certain level. They produce a low output voltage when switched on, and a high output voltage when switched off.
FIG. 15 shows the principle of nozzle position control by the Hall ICs H 1 to H 3 and the magnet 80. The system of FIG. 15 includes a central processing unit (CPU) 82 in a system 83 provided in the part cleaning device A for controlling all of the electrical components thereof, and a solid-state relay 84 for controlling the supply of power to the motor 3, a cleaning water heater, a heater for warming the toilet seat, a heater for the hot air fan H and the electromagnetic valve in the piping. The Hall ICs H 1 to H 3 are connected to the CPU 82 by position signal lines 85 to 87, respectively. Lead wires 88 and 89 are connected to the upper plate 81 of the cylinder 2 for supplying an electric current to the Hall ICs H 1 to H 3 .
In order to move the nozzle body 4 forward from its retracted position S-4 as shown in FIG. 13 to its anus cleaning position S-1, the cleaning start switch 53 on the control panel 52 is turned on and the motor 3 is started in response to a signal from the CPU 82 to release the leaf spring 12 from the drum 10, whereby the nozzle body 4 is moved forward. If the nozzle body 4 reaches its anus cleaning position S-1, the second Hall IC H 2 faces the magnet 80 and is turned on at a low output voltage as shown by graph (2) in FIG. 15. Its output is fed back to the CPU 82 and the CPU 82 determins the Hall IC from which it has received the output signal. If it determines the signal as having been received from the second Hall IC H 2 , it discontinues the supply of power to the motor 3. The nozzle body 4 is held at its anus cleaning position S-1 and the electromagnetic valve, or the like is opened to jet out cleaning water. If the anus has been cleaned, the stop switch 54 is operated. The CPU 82 transmits a signal to the motor 3 to rotate it in the opposite direction to retract the nozzle body 4 into the cylinder 2. When the magnet 80 has come to face the first Hall IC H 1 , it produces a low output voltage as shown by graph (1) in FIG. 15 and in response to the output of the Hall IC H 1 , the CPU 82 stops the rotation of the motor 3, whereby the nozzle body 4 is held in its retracted position within the cylinder 2.
The start switch for a bidet 55 is turned on to move the nozzle body 4 to its functioning position as a bidet S-2. The magnet 80 cooperates with the third Hall IC H 3 to position the nozzle body 4 in its functioning position as a bidet S-2. The stop switch 54 may be depressed to retract the nozzle body 4 into the cylinder 2.
An additional Hall IC or ICs may be employed to provide an additional cleaning position or positions. The use of Hall ICs is convenient for enabling the detection of the nozzle body in a plurality of cleaning positions. Moreover, the Hall ICs, which do not have any contact, are easier to handle, assemble and mount than the lead switches.
According to this invention, the use of lead switches 10 or Hall ICs does not present any problem in the position control of the nozzle body 4, since the leaf spring 12 on the precision cylindrical surface of the drum 10 converts the rotation of the output shaft 11 of the motor 3 accurately to the axial movement of the nozzle body 4.
In addition to the various advantages of this invention as hereinabove set forth, it is also useful to remove cold water from the cleaning water supply pipe and wet the first and second packing members 47 and 48 prior to the use of the device for its primary purposes in order to reduce their frictional resistance to the movement of the nozzle body 4 and prolong the life of the packing members 47 and 48. | A device for moving a cleansing nozzle connected to a water supply system includes an elongated nozzle, a cylinder in which the nozzle is axially slidable, a motor having an output shaft, a drum body mounted on the output shaft, the drum body having a cylindrical rim surface and a sectoral recess extending from the surface, a sectoral insert disposed in the recess and having a partial cylindrical surface conforming to and forming a continuation of the cylindrical rim surface, and a leaf spring having one end connected to the nozzle and the other end held between the drum body and the sectoral insert such that rotation of the drum body extends and withdraws the nozzle longitudinally as the leaf spring unwraps and wraps around the drum body. The method includes counting the number of cycles of the frequency of the electric power supplied to the motor, determining the actual position of the nozzle on the basis of the counted pulses, establishing a predetermined position of the nozzle, comparing the actual position with the predetermined position, and transmitting the results of the comparison to a power circuit for the motor to turn the motor on and off so that the motor thereby positions the slidable nozzle at the predetermined position. |
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to valves for use in the wall of a string of tubulars, such as casing that is placed in wells. More particularly, a valve is provided that can be opened by a selected pressure inside the tubular and that may remain open.
[0003] 2. Description of Related Art
[0004] To produce hydrocarbons from some reservoirs in the earth, long, horizontal holes are drilled through productive rock. To prevent collapse of the surrounding rock into the horizontal wellbore, casing must be placed in the holes before fluids can be withdrawn. The casing is normally pushed along the horizontal hole, but the frictional resistance between casing and the wall of the wellbore limits the distance that casing can be placed in horizontal wells using standard methods. One way that has been used to allow longer horizontal sections of casing in wells is to float the casing into the horizontal section using a low-density fluid inside the casing. In all wells, horizontal, deviated and vertical, openings in the wall of the casing must be provided for injection of fluids or production of fluids through the well.
[0005] After casing is placed in a well, in some wells cement is pumped down the casing and up the annulus between the casing and the wall of the wellbore. Openings for fluid flow through the wall of the casing are commonly made by perforating guns, which shoot a hole through the casing wall, the cement layer and a short distance into the surrounding rock. In other wells, an “open hole” is left outside the casing (no cement) and packers, made of a rubber sleeve that can be inflated or swellable material are placed at selected distances along the wellbore to prevent flow along the annulus outside casing. In this case, valves in the casing wall that can be opened by a mechanical device or by pumping balls down the casing are normally provided between the packers.
[0006] European Patent EP 0 681 088 discloses an annulus pressure-responsive valve that can be locked in the open position and then closed. The valve uses a power piston in a housing with an actuating piston. European Patent Application 2 458 139 discloses a valve that can be inserted into the wall of casing in a well by using the valve body to drill through the casing wall. UK Pat. App 2464009 discloses a method of using inflow control devices, which are commonly used to control the rate of flow into casing when there are multiple points of entry. The inflow control devices do not stop flow. U.S. Pat. Nos. 5,957,197 and 6,820,697 disclose downhole valves. It is common to place valves such as sliding sleeves in casing, which can be operated by mechanical tools inside the casing. Such device is disclosed in WO 2012/080487. Valves in casing operated mechanically by running tools or coiled tubing inside casing are often used in connection with hydraulic fracturing of multiple zones in a well. Many patents disclose downhole safety valves, which serve primarily the purpose of effecting a reliable positive closure of the bore of a production tubing string in the event of an emergency.
BRIEF SUMMARY OF THE INVENTION
[0007] A valve is provided that can be opened by a selected increase of pressure inside casing or other tubular followed by a selected value of pressure reduction in the tubular. The valve may be used in operations to float a casing into a horizontal section of wellbore, to open a casing at selected locations for production or injection (including hydraulic fracturing operations), and for any other uses where a valve that is opened by internal pressure in the tubular and remains open is needed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0008] FIG. 1 is an isometric view of the valve disclosed herein and a section of the tubular where it is to be installed.
[0009] FIG. 2 is a cross-section view of the valve installed in a tubular.
[0010] FIG. 3 a is a view of the proximate end of the valve. FIG. 3 b is a cross-sectional view of the valve in the closed position.
[0011] FIG. 4 is a cross-sectional view of the valve in the open position while mounted in a tubular.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Referring to FIG. 1 , inflow control valve 10 is shown in position to be inserted into the wall of tubular sub 12 , having a wall thickness, t, which may be a coupling for a string of tubulars. Alternatively, the sub may have any selected length. The wall thickness t is effective to provide the mechanical strength of a tubular string to be placed in a well with valve 10 in place. Receptor hole 13 is sized to receive valve 10 and may include internal threads adapted to receive external threads on valve 10 . Alternatively, valve 10 may be held in place in receptor hole 13 by a clip ring and indexed so as to be held in a selected direction in hole 13 and to align ports to increase flow area when the valve is opened. The indexing may be provided by a protrusion or indentation on body 30 or marking on the proximate end of body 30 such that the valve can be aligned in receptor hole in a selected direction. O-ring 30 b provides a seal outside body 30 . Inner port 14 is drilled to intersect receptor hole 13 at a selected position and extend through the inner wall of sub 12 . Plug 14 a is placed in the outer portion of inner port 14 . Outer port 16 is drilled through the outer surface of sub 12 to intersect receptor hole 13 at a selected position. A screen may be placed over outer port 16 to prevent particles entering the port and valve and plugging a flow channel after the valve opens. Screens outside flow control valves in casing are well known in industry.
[0013] Referring to FIG. 2 , valve 10 is shown installed in receptor hole 13 of sub 12 . Threads 22 may be used to fasten valve 10 into hole 13 of sub 12 , or a clip ring may be used. Torque may be applied to valve 10 by use of hexagonal key hole 20 to align or make up the threads. When the valve is installed, distal hole 24 of the valve intersects outer port 16 and proximate hole 26 of the valve intersect inner port 14 . The holes in the tubular may be drilled or milled with a CNC machine or a conventional machine.
[0014] Referring to FIG. 3 a , a view of the proximate end of valve 10 is shown. Shuttle 33 is preferably centered around the axis of the valve. Referring to FIG. 3 b , valve body 30 has distal hole 24 and proximate hole 26 , which are disposed in body 30 so as to intersect inner port 14 and outer port 16 of sub 12 when valve 10 is installed in sub 12 , as shown in FIG. 2 . Outside threads 30 a match inside threads in sub 12 . O-ring 31 seals around the proximal end of shuttle 33 with a sealing area A 1 . O-ring 32 , having a larger diameter than o-ring 31 , exerts a force in the distal direction when differential pressure exists from inside to outside the tubular. Split retainer ring 36 is compressed to fit inside body 30 and sized to spring out when it passes shoulder 30 d so as to hold shuttle 33 in the valve-open position. Shear pin 34 , selected to shear at a selected axial force on shuttle 33 , is inserted in body base 30 c and shuttle 33 before base 30 c is inserted into valve body 30 . Body base 30 c may be fastened in place by threads or other fastening method. Pressure inside sub 12 is applied between o-ring 31 and o-ring 32 . This pressure exerts an axial force on shuttle toward the distal end of the shuttle. Shear pin 34 is selected such that it is sheared at a force corresponding to a selected differential pressure between the inside and outside of sub 12 . After shear pin 34 has failed, shuttle 33 moves to place the distal end of shuttle 33 in contact with the end of the inside opening in base 30 c. The valve is still closed when pressure inside sub 12 is at or above the pressure to shear pin 34 .
[0015] As pressure inside sub 12 is decreased, a value is reached such that spring 35 moves shuttle 33 toward the proximal end of the valve. The spring constant of spring 35 may be selected to control the pressure inside sub 12 at which shuttle 33 moves. FIG. 4 shows the position of shuttle 33 after shear pin 34 has been sheared and pressure has decreased inside sub 12 to allow shuttle 33 to move toward the proximal end of the valve. In FIG. 4 , shuttle 33 has moved past the position where o-ring 32 and retaining ring 36 pass shoulder 30 d. This allows equalization of pressure across o-ring 32 . Distal hole 24 intersects outside port 16 and proximal hole 26 intersects inside port 14 . [The valve is open when o-ring 32 passes 26 . In this position, split ring 36 insures that the valve is permanently open, independent of pressures inside and outside sub 12 . Turkey button 40 , which may be a bright color, may be placed on the proximal end of shuttle 33 to allow easy inspection to determine if the valve is open. Alternatively, turkey button 40 may be replaced with a sensor to indicate if the valve is open. A signal from the sensor may be communicated to surface using known communication technology or the sensor may be read by a device run on slick line, coiled tubing or logging cable.
[0016] The force required to shear a pin can be selected over a wide range. For example, valves may be placed in a tubular string and adapted to shear the pin in different valves over a range of differential pressures across the valve. All valves in a tubular string remain closed until the shear pin in one valve is caused to fail, so selected valves can be opened by increasing pressure in the tubular only to the value required to open a selected valve or valves. When some valves are open and other valves requiring pressure are to be opened, open valves may be temporarily closed by dropping one or more ball sealers to close the entrance to inside port 14 of open valves or degradable solid particles may be pumped into the well to plug open valves, using technology known in industry.
[0017] Multiple valves can be placed around the circumference of a tubular at about the same axial distance along the tubular. This may be required to achieve a desired flow rate into or out of the tubular at the same depth or distance along a horizontal section of a well.
[0018] Valve body 30 may be constructed from standard coupling stock. The valves in a tubular string, such as a casing string, may be inserted at the surface in drilled ports that are threaded to receive the valves or that are adapted to a clip ring. Beans may be inserted with the valves or inside the valves to control flow rate. The beans or valves may be constructed of erosion-resistant materials. Flow from the valves enters the casing tangentially to the inside wall, minimizing erosion of a tubular inside the casing. Grooves in the outside surface of sub 12 (not shown) may be used to increase flow area if an outside port is in contact with a wellbore.
[0019] One application of the valve disclosed herein is to allow a casing to be floated during installation in a horizontal section of a wellbore. A horizontal casing string may have valves placed at selected locations along the casing. Packers may be placed between the valves to isolate flow in the annulus to different valves. The packers may be swell packers or mechanically expanded packers, using technology known in industry. Light fluid, usually nitrogen gas, is placed inside the casing, using technology known in industry. After the casing has been “landed” at the selected location, the gas may be partially or completely displaced with liquid. Pressure inside casing is increased to shear the pins in selected valves along the casing, Pressure in the casing is then reduced to allow the valves to open. All valves may be opened at substantially the same time. Alternatively, valves having different pressures to shear the shear pins in the valves may be used, such that valves may be selectively opened at different distances along a casing string, Open valves may be temporarily plugged to allow application of pressure across closed valves for their opening.
[0020] The valves disclosed here may be used in a well that is to be acidized or hydraulically fractured. Valves may be opened selectively at different locations, if desired. The method and apparatus described here may be used in vertical or horizontal wells. When wells are hydraulically fractured, fluid is injected at a high rate. Then fluid containing solid particles, called a “proppant” is injected. It may be desirable to increase the area of the flow channel through the valves for production or injection of fluids. For such applications, it may be desirable for the flow path through a valve to increase over that shown in FIG. 4 at the beginning of a fracture treatment. To facilitate increase in flow area, shuttle 33 and spring 35 .may be constructed of materials that erode quickly. Even valve body 30 may be made partially or completely of material that is easily eroded, such as a soft metal like brass or bronze. After fluid has been pumped through an open valve it may erode completely, increasing the area for flow of fracturing fluid or produced fluids. In wells to be produced through the valves, it may be desirable to use materials that are quickly eroded by fluid flow.
[0021] In another application, multiple valves may be placed along a horizontal wellbore or at different depths in a vertical well and some valves in the casing opened to allow production for a period of time while other valves remain closed. When it is desirable to open new zones or intervals for production, open valves may be temporarily plugged by injecting balls or degradable particles into the well before increasing pressure to a higher value to open additional zones. Alternatively, open valves may be permanently plugged by a resin that solidifies in the valves or by other methods before new zones are opened by increasing pressure in the casing sufficient to shear the pins in other valves.
[0022] Locations of ends, openings and holes are identified by the terms “proximate” and “distal.” In the figures, proximate is leftward and distal is rightward. It should be understood that these terms are used for identification, and the directions can be reversed in defining the terms to achieve the same results.
[0023] Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims. | A valve and valve assembly are provided to allow opening of flow channels through the wall of a tubular by increasing and then decreasing pressure in the tubular. Slidable seals having different areas are used to apply an axial force to a shuttle in the valve in response to differential pressure across the valve when in the closed position. The axial force shears a pin, releasing the shuttle. A decrease of pressure in the tubular can allow the valve to open in response to a spring force. Multiple valves may be placed along a tubular string and the valves may be opened all at substantially the same time or at time intervals determined by pressures applied inside the tubular. |
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BACKGROUND OF THE INVENTION
This invention relates to an improved window construction, and more particularly, to an improved method and assembly, including a frame expander receptor, for the cladding of the existing, exterior frame of a window.
With the increasing consciousness of the desirability of older buildings and the heat loss caused by poorly insulated windows, a need has arisen for insulated replacement window components. As disclosed in U.S. Pat. No. 3,815,285, metal clad, wooden windows have long been considered highly desirable for their ease of maintenance, superior insulation, pleasing appearance and long life. Exterior cladding of all window components, including both the sash and trim, has been most preferred. To date, however, the cladding of the exterior trim or frame has not been satisfactorily accomplished, where the original exterior trim of a window is retained after replacement of the sash. Previous attempts at cladding the exterior trim have all involved the fastening of cladding to the trim with fasteners such as nails or screws, the heads of which are left exposed. The exposed heads have caused an unsightly appearance, marring the visual integrity of many buildings. The entry points for the fasteners have also acted as entry points for moisture, which moisture, after entry, has been retained against evaporation along the fasteners and behind the cladding. This water retention has speeded deterioration of the wooden trim, damaging the soundness of the trim and weakening the hold of the fasteners. Since repair of a window by replacement of only the sash is widely preferred, the satisfactory cladding of the existing exterior frame of a window has become widely desired.
SUMMARY OF THE INVENTION
It is thus an object of the present invention to provide an improved method and assembly for the cladding of the existing, exterior trim or frame of a window.
Another object of the present invention is to provide an improved method and assembly for cladding an exterior window frame which provide for metal or plastic cladding over wooden exterior trim.
Another object of the present invention is to provide an improved method and assembly for cladding an exterior window frame which complement the architectural beauty of existing buildings while providing ease of maintenance and long life.
Another object of the present invention is to provide an improved method and assembly for cladding exterior window trim which substantially eliminate moisture entry into the trim.
Another object of the present invention is to provide an improved assembly for cladding exterior window trim which is economically manufactured and utilized.
Thus, in a principal aspect, the present invention is a window frame expander receptor for cladding a window frame. The receptor includes fastener flange means and flexible receptor flange means. The fastener flange means is for receiving fasteners therein. The flexible receptor flange means is for (a) defining a frame expander receiving zone, and (b) retaining a frame expander received in the frame expander receiving zone. With such a receptor, the window frame may be clad, the fasteners covered by the frame expander, and a moisture barrier created between the environment and the fasteners.
In a second principal aspect, the present invention is an assembly for cladding a window frame, where the frame has a head frame member and two jamb frame members. The assembly comprises a head frame expander, a head frame expander receptor, two jamb frame expanders and two jamb frame expander receptors. The receptors are formed in accordance with the first aspect of the present invention. The head frame expander and the jamb frame expanders each include a generally planar cladding portion for overlying the fastener flange means of the head frame expander receptor and the two jamb frame expander receptors, respectively, and for substantially cladding the head frame member and the two jamb frame members. Each expander has a back surface for disposition adjacent a frame member and a front surface for display to the environment. Together, the expanders and receptors define means for creating a moisture barrier between the fasteners and frame. With such an assembly, the window frame may be clad, the fasteners may be covered by the expanders and a moisture barrier created between the environment and the fasteners and frame.
In a third principal aspect, the present invention is a method of cladding a window frame by utilization of the assembly of the second principal aspect of the invention. The receptors are fastened to the frame members with the head frame expander receptor fastened to the head frame member and the jamb frame expander receptors fastened to the jamb frame members. The jamb frame expanders are then mounted on the jamb frame expander receptors, and the head frame expander mounted on the head frame expander receptor.
These and other objects, advantages and aspects of the present invention will become apparent from the Detailed Description of the Preferred Embodiments, which follows.
BRIEF DESCRIPTION OF THE DRAWING
The preferred embodiments of the present invention are described in the Detailed Description of The Preferred Embodiments with reference to the accompanying drawing. The eleven figures of the accompanying drawing are briefly described as follows:
FIG. 1 is a pictorial view of a window as clad and rehabilitated utilizing the preferred embodiments of the present invention;
FIG. 2 is an exploded view of the preferred apparatus of the present invention, as adapted to the window of FIG. 1 according to the preferred method of the present invention;
FIG. 3 is a cross-section view of a head frame receptor expander taken along line 3--3 of FIG. 2;
FIG. 4 is a cross-section view of a head frame expander taken along line 4--4 of FIG. 2;
FIG. 5 is a cross-section view of a sill frame expander taken along line 5--5 of FIG. 2;
FIG. 6 is a broken cross-section view of the rehabilitated window of FIG. 1, taken along line 6--6 of FIG. 1;
FIG. 7 is a broken cross-section view of the rehabilitated window of FIG. 1, taken along line 7--7 of FIG. 1;
FIG. 8 is a view similar to the upper half of FIG. 6, showing an alternative use of the head frame expander receptor of the present invention;
FIG. 9 is a broken pictorial view of the window of FIG. 1, during an early stage of rehabilitation;
FIG. 10 is a pictorial view of the window of FIG. 1, during a stage of rehabilitation subsequent to the stage of FIG. 9; and
FIG. 11 is a broken, pictorial view of the window of FIG. 1, during a stage of rehabilitation subsequent to the stages of FIGS. 9 and 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-11 of the accompanying drawing, the preferred embodiments of the present invention are an exemplary frame expander receptor 12, shown in cross-section in FIG. 3; an assembly 14, shown exploded in FIG. 2; and a method of cladding a window by utilization of the assembly 14, as hereinafter described. As shown in FIG. 1, the utilization of the assembly 14 in the preferred method results in a rehabilitated window 16 having, among other advantages, a most pleasing appearance. Contrasting FIG. 9 with FIG. 1, the window 16 prior to application of the assembly 14 may have had a most displeasing appearance, as a result of peeling or blistered paint, breakage or damage due to rot.
As should be understood, the window 16 includes an existing window frame 18 which is a part of an existing building or structure 20. Be definition, the term "existing" includes new and old construction permanently erected prior to utilization of the preferred method and assembly 14. A head frame member 22 extends horizontally across the top of a window opening 24 and defines the top of the window frame 18. The jamb frame members 26, 28 of the window frame 18 extend along opposite sides of the window opening 24. A sill 30 juts outward from the structure 20 along the bottom of the window opening 24 to complete the window frame 18. The sill 30 may be relatively thick and outwardly tapered as illustrated, or uniform in thickness and relatively thin. The sill ends 32, 34 overlie the ends 36, 38, respectively, of the jamb frame members 26, 28. The upper ends 40, 42 of the jamb frame members 26, 28 abut the lower side edge 44 of the head frame member 22 along the ends 46, 48 of the head frame member 22. The front or outer surfaces 50, 52, 54 of the frame members 22, 26, 28 are planar, rectangular and coplanar with each other. The surfaces 50, 52 and 54 may project outward of the siding or like material of the structure 20 as shown, or be flush therewith.
As further shown in FIG. 9, a replacement sash 56 is installed in the window opening 24 as a part of the window 16. The sash comprises two sash side members 58, 60, a sash top member 62 and a sash bottom member 64 (FIG. 1). The sash 56 contains a glass panel 66 and is a part of a replacement assembly including side molding members 68, 70, top molding member 72 and bottom molding member 74 (FIG. 1). Referring to FIGS. 6 and 7, the side molding members 68, 70 and the upper molding member 72 each include an outward facing, cross-sectionally rectangular groove or channel recess 76 for receiving components of the assembly 14, as hereinafter described.
Referring to FIG. 2, the assembly 14 is comprised of the following: a head frame expander 78, the head frame expander receptor 12, two jamb frame expanders 82, 84, two jamb frame expander receptors 86, 88, a sill frame expander 90, and a sill nose cover 92.
Referring to FIG. 3, the head frame expander receptor 12 is exemplary of all three receptors 12, 86, 88. A fastener and abutment flange 94 of the receptor 12 is elongated in a longitudinal direction (perpendicular to the plane of FIG. 3), and extends in a transverse direction (the vertical direction in FIG. 3) from a joined end 96 to a free end 98. A longitudinally elongated, transversely extending fastener receiving area 100 is defined on the flange 94 adjacent the free end 98. The area 100 has a thickness in a direction perpendicular to the transverse direction (the horizontal direction in FIG. 3) reduced from the general thickness of the flange 94. The fastener area 100 is adapted to receive, or be pierced by, fasteners such as galvanized nails. A longitudinally elongated, transversely extending receptor flange 102 of the receptor 12 extends along the front or outer side of the flange 94. The flanges 94, 102 are joined by a riser portion 104, which is longitudinally elongated and extends in the perpendicular direction. At a joined end 106, the receptor flange 102 has a longitudinally elongated, flexible, reduced thickness biasing portion 108. The receptor flange 102 has a longitudinally elongated, transversely extending contact surface 110 facing the flange 94 from the biased portion 108 to the free end 112. The biased portion 108 biases the contact area 110 to a distance from the front surface 114 of the flange 94 substantially equal to and not greater than the thickness of the expanders 78, 82, 84. The flange 94, riser portion 104 and flange 102 form a expander receiving zone such as the expander receiving recess 116. The free end 112 of the flange 102 is nearer the riser portion 104 than the fastener receiving area 100, and thus the area 100 is accessible from the front of the receptor 12. A longitudinally elongated leg portion 118 is formed adjacent the riser portion 104, and extends in the perpendicular direction opposite the riser 104. A reduced thickness, weakened zone 120 is formed where the riser 104 meets the leg portion 118. The flange 12 is substanially uniform along its length.
As exemplified in FIG. 4, the expanders 78, 82, 84, 90 are also substantially uniform along their lengths. Each includes a generally planar cladding portion 122. The cladding portions 122 of the expanders 78, 82, 84 extend transversely (vertically in FIG. 4) from a receptor received end 130 to a backbend portion 132.
As shown in FIG. 5, the cladding portion 122 of the expander 90 is abbreviated, and extends to a backbend portion 132; the expander 90 has no receptor receiving end 130. The backbend portions 132 of the expanders 78, 82, 84 90 have a transverse dimension substantially equal to the width of the molding groove 76 (FIGS. 6, 7, 8) and a perpendicular dimension substantially equal to the depth of the molding groove 76. A back surface 134 of the cladding portion 122 is substantially planar, for overlying a frame member of the window 18, while a front surface 136 provides a display to the environment. The surface 136 may be finished, e.g., painted, as desired.
Referring to FIGS. 2 and 6, the sill nose cover 92 conforms generally to the shape of the sill 30. I.e., the sill nose cover 92 is longitudinally elongated, with elongated, substantially planar upper, outer edge and bottom surfaces 93, 95, 97 and closed ends 99, 101. The bottom surface 97 is substantially perpendicular to the edge surface 95. The upper surface 93 slopes upward, or away from the bottom surface 97, as it extends away from the edge surface 95.
The preferred method is begun by matching and fastening the sill nose cover 92 to the sill 30, after the sash 56 is installed. As necessary, the sill 30 is shimmed in thickness and length to provide firm support for the cover 92. Notches 103, 105 (FIG. 2) are then made in the upper surface 92 adjacent the ends 99, 101, to accommodate the jamb frame members 82, 84 and such other components of the frame 18 as necessary. The cover is then placed on the sill 30 and fastened along the upper edge 107 of the surface 94 to the sill 30 (FIG. 9). Fasteners such as exemplary fastener 109 are preferably aluminum nails.
The preferred method is continued by matching and fastening the receptors 12, 86, 88 to the frame members 22, 26 and 28. As in FIGS. 2 and 9, the receptor 88 is matched in length to the frame members 22, 28 so that the receptor 88 extends from the upper surface of the sill 30 to the uppermost corner of the head frame member 22. The receptor 88 is inwardly mitered at the upper end thereof. The receptor 12 is matched in size to the head frame member 22 so that the receptor 12 extends the full length of the member 22. The receptor 12 is inwardly mitered at both ends. The receptor 86 is matched to the frame member 28 as the receptor 88 is matched to the frame member 28. As in FIG. 9, the receptors 12, 88 are fastened to the window frame 18 along the outer edges of the frame members 22, 26, 28. The back surfaces 126 and the inner surfaces 128 of the flange 94 and the leg 118, respectively, are placed in abutment with the window frame 18 (FIG. 7). Fasteners such as exemplary fastener 124 are driven through the fastener receiving areas 100 to fasten the receptors 12, 88 to the window frame 18. The receptor 86 is similarly fastened to the jamb frame member 26, as in FIG. 10. A continuous bead of sealant (not shown) is applied along the edges 98 of the receptors 12, 86, 88, between the edges and the window frame 18.
Upon completion of fastening the receptors 12, 86, 88, the sill frame expander 90 is matched and mounted on the molding member 74, as in FIGS. 6 and 10. The backbend portion 132 is removed at the ends 127, 129 (FIG. 2) to accommodate the jamb frame members 26, 28. The expander 90 is trimmed in length to abut the receptors 86, 88, and in width to abut the sill nose cover 92. A continuous bead of sealant (not shown) is applied to the adjacent corner portions of the molding grooves 76 of the molding members 68, 70, 74, and along the backbend portion 132 of the expander 90 between the portion 132 and the back surface 134 thereof. The portion 132 is then driven into the groove 76 of the molding member 74, with the cladding portion 130 extending below the portion 132.
Upon completion of mounting the expander 90, the jamb frame expanders 82, 84 are mounted on the receptors 86, 88. As in FIGS. 7 and 10, the expander 84 is first mounted on the receptor 88 and the molding 70. Initially, the backbend portion 132 is removed at the upper and lower ends of the expander 84 to accommodate the sill frame expander 90 and the head frame member 22. A continuous bead of sealant (not shown) is applied between the portion 132 and the back surface 134. The receptor received end 130 of the expander 84 is slid or otherwise moved into the receptor receiving recess 116. The backbend portion 132 of the jamb frame expander 84 is then pressed into the expander receiving groove 76 of the molding 70. So placed, the jamb frame expander 84 overlies the jamb frame member 28, the fastener area 100 of the flange 94 of the jamb frame expander receptor 88 and the fasteners 124 therein. The receptor flange 102 of the receptor 88 overlies the outer edge of the expander 84. The receptor 88 firmly retains the outer edge of the expander 84 and the molding groove 76 firmly retains the backbend area 132. As shown in FIG. 11, the other jamb frame expander 82 is similarly placed on the jamb frame expander receptor 86.
As further shown in FIG. 11, the expander 78 is mounted on the receptor 12 in substantially the same way the expanders 82, 84 are mounted. In advance of mounting, however, the expander 78 is inwardly mitered at the ends to a length along the backbend portion 132 equal to the length of the expander receiving groove 76 in the molding 72. The tapered ends of the expander 78 overlie the upper ends of the expanders 82, 84, to provide the pleasing, jointed wood appearance of FIG. 1 and prevent rainfall from entering above the expanders 82, 84.
Besides providing pleasing appearance, the expanders 12, 82, 84, 90 and the receptors 12, 86, 88 provide a substantially moisture proof or watertight seal between the frame 18, the fasteners 124 and the environment. Upwardly directed openings are eliminated, and the receptor flange 102 of the head frame expander receptor 12 acts as a drip cap for the window 16. As seen by comparing FIGS. 6 and 8, the receptor 12 (and the receptors 86, 88) are adapted to be utilized where possible with the leg portion 118 overlapping a portion of the window frame 18, although where necessary, the leg portion 118 may be removed along the weakened zone 120.
As preferred, the assembly 14 is formed of extruded aluminum, plastic or other material. Also as preferred, the expanders 78, 82, 84 are formed in ranges of widths for selection by a customer to suit a particular application.
To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification. It is to be understood that claims directed to a window frame expander receptor do not include the frame expander or the frame, and that claims directed to an apparatus for cladding a window frame do not include the frame. | An improved method and assembly for cladding an existing, exterior window frame. Frame expander receptors are fastened to the window frame head and jamb members. Frame expanders are retained in receiving recesses of the receptors. Cladding portions of the expanders clad the frame members and cover the fasteners for pleasing appearance. Moisture barriers separate the fasteners and the frame from the environment. A sill nose cover clads the sill. |
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BACKGROUND
This invention relates to apparatus for controlling the direction of vehicular traffic flow so as to inhibit wrong way traffic or motor vehicles at designated locations.
The control of traffic flow in particular areas is necessary to ensure continuous traffic movement and to prevent unauthorized use of certain rights of way. At present, it is common to use a visual warning coupled with a road-mounted barrier that is routinely deflected by the wheels of a motor vehicle when the vehicle is traveling in the permitted direction. Typically, this is brought about by the use of rotationally mounted levers extending upwardly from beneath the road surface. When a vehicle tire contacts one or more of the levers, they are readily moved to a position below the road surface so as to permit authorized traffic flow.
In the case of traffic flow in the unauthorized direction, the device customarily contains tire damaging means which are preferably actuated by the vehicle tire rather than being motor driven. The tire damage leaves a lasting impression, not only on the driver of the vehicle moving in the non-permitted direction, but also on passengers, onlookers and the community at large. Thus, observation of effective operation and word of mouth play major roles in the device's effectiveness. The efficacy of devices of this type rely on the piercing of or shredding of a vehicle tire that has entered the designated area and then attempts to move through or across it contrary to the warning signs. The vehicle tire contacts the lever causing a normally retracted or hidden damage mechanism to appear and produce its designed-for effect. To the extent that vehicular traffic can be carried out in the non-permitted direction without causing damage, the device not only fails on this particular occasion, but also fails to provide the desired notice to the community that undesirable consequences will occur if the signage and other traffic flow indicators are not obeyed.
One traffic flow regulating device is disclosed in U.S. Pat. No. 4,158,514 wherein each upwardly extending lever is made integral with a barrier blade. The blade assumes a normally retracted position below the surface. When the tire of a vehicle traveling in the non-permitted direction engages the free end of an upwardly extending lever arm, it is expected that the lever will be depressed in the direction of the traffic flow and urge the associated blade up against the tire so as to produce a shredding effect. In the permitted direction, the levers are contacted by the tire and the blades are rotated in the opposing direction so that they never appear above surface and do not constitute a hazard during normal use. The device is preferably constructed so that the axis of the lever and that of the associated blade form an angle of the order of 90 degrees that the blade does not emerge accidentally during traffic movement in the permitted direction.
While this device may be effective in the case of solid vehicle tires or highly pressurized tires, the present day passenger vehicle is usually provided with relatively low pressure tires characterized by a wide tread. Consequently, it has been found that many tires in general use tend to frictionally engage and envelop the free end of the lever. As a result, the tire surrounds the adjacent portion of the lever and urges it backward in the direction of rotation of the tire. This direction is contrary to the direction of movement of the vehicle and corresponds to the permitted direction of traffic flow across the apparatus. The frequent result is that the device does not operate as intended and no damage to the vehicle tire takes place.
Accordingly, the present invention is directed to the provision of a vehicular traffic controller wherein the tendency of the vehicle tire to frictionally engage or envelop the lever arms is substantially eliminated. The ability to inhibit this envelopment results in increased operating reliability in that the spike associated with each lever arm is able to emerge from its retracted position and engage the tire. Thus, the present invention is constructed to produce the desired result of tire damage when the device is traversed by a vehicle moving in the non-permitted direction.
SUMMARY OF THE INVENTION
This invention relates to an improved traffic controller for allowing vehicular traffic flow in a permitted direction while inhibiting flow in an opposing direction. The apparatus includes a planar member which supports motor vehicles traveling thereacross. The planar member is provided with a plurality of openings spaced thereacross, each opening positioned in general alignment with the expected direction of traffic flow.
A plurality of actuating levers extend upwardly through the corresponding openings in the planar member and are positioned to contact a vehicle tire when it passes across the planar member. Beneath the planar member is located coupling means for rotationally mounting the levers to permit movement thereof in alignment with the expected traffic pattern. The levers are rotated to a position beneath the planar member when contacted by the vehicle tire traversing the planar member. A low friction contact member is affixed to the free end of each of the levers. The members contact the vehicle tire, reduce the frictional engagement therewith and move along the surface of the tire thereby avoiding rotation of the lever in the wrong direction. Removable piercing members are operatively connected to each of the actuating levers and are positioned beneath the planar member during periods of non-use.
In operation, the vehicle tire moves against the contacting members which are rotationally mounted on the lever ends and these members move along the adjacent surface of the tire in the direction of the vehicle movement, not in the direction of rotation of the tire. As a result, a piercing member rotates with its corresponding lever to engage the tire when the vehicle is moving in the non-permitted direction. When the vehicle is moving in the permitted direction, the vehicle tire moves against the contact members and thereby urges the end of the lever to a position beneath the planar member. The corresponding piercing member does not emerge from beneath the planar member in this circumstance.
Since the free end of each lever arm is provided with a rotationally mounted means for contacting the adjacent surface of the tire, the ability of a tire to envelop the lever arm and urge it to rotate therewith is essentially eliminated. In effect, the vehicle tire does not surround and fictionally engage the free end of the lever, but pushes it in the direction opposite to the direction of rotation of the vehicle tire. The piercing member then is free to emerge and damage the tire. Consequently, the device functions in its designed-for manner and the reliability of operation causes the warnings and signage at the location to be taken seriously.
Further features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial view in perspective of one embodiment of the invention.
FIG. 2 is a top view of a portion of the embodiment shown in FIG. 1.
FIG. 3 is an enlarged sectional view of one lever arm and its coupling means.
FIG. 4 is a view taken as indicated by line 4--4 of FIG. 3.
FIG. 5 is a view similar to FIG. 4 with a vehicle travelling in the non-permitted direction as shown by the arrow.
FIG. 6 is a view similar to FIG.4 showing the movement of the lever arm and associated spike for vehicle movement in the permitted direction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, planar plate 12 is shown emplaced in road surface 11. A grass verge 18 is shown bordering the road surface. A generally rectangular container is shown beneath the plate 12 by dashed lines to illustrate that clearance is needed between the portion of the invention residing beneath the plate 12 and the surrounding materials. The actual shape or dimensions of any container used may vary as needed.
The plate 12 is shown containing a plurality of openings spaced transversely across the plate so as to cover that portion of the roadway upon which the vehicular traffic is to be controlled. The objective of the invention is to permit unimpeded traffic flow in a single direction and to reliably inhibit flow in an opposing direction by use of a plurality of lever arms 14 extending upwardly from the top surface of plate 12. The openings are shown in the form of slots having opposing terminal portions of expanded width. When a vehicle travels in either direction, its tires first contact the disks 16 mounted on the exposed ends of lever arms 14 and urge the levers beneath the top surface of plate 12. Consequently, expanded area terminal portions of slots 15 are shown so as to accommodate the disks on the lever arms so they move beneath the plate 12.
In FIG. 2, a partial top view of the assembly of FIG. 1 shows the three end lever arms 14 and that portion of the mechanism visable from the top surface of plate 12. In particular, a piercing member or spike 23 is shown beneath the plate and positioned to contact a vehicle tire when the lever arm is moved in the non-permitted direction. When the vehicle is moving in the permitted direction, the lever is urged by the tire to rotate so as to move to a position beneath the surface of plate 12. The piercing member 23 is operatively connected thereto so as to rotate away from the plate and thus not contact the tire. The top section of the lever arm 14 is shown having a tapered edge portion 46 on either side of the central section 45. Disks 16 are mounted on either side of the free end of the lever arm 14. The disks are mounted on the opposing ends of axle 20 which extends through the corresponding end of a lever arm so as to permit rotation of the disks.
When a vehicle tire engages the free end of the lever arm and the disks mounted thereon, the disks are free to rotate and travel along the surface of the tire while still bearing a portion of the weight of the vehicle. Thus, the rotating disks decrease the frictional forces between the tire and free end of the lever arm thereby avoiding the enveloping of the end of the lever arm by the wide relatively low pressure tires used by present day vehicles. The central section 45 of each lever arm does contact the surface of the vehicle tire and also shares in supporting the weight thereof. However, the tapering of the sides and top edge portions of the lever arm serves to further reduce the tendency of the tire to grab the end of the lever arm and rotate it in a direction opposite to that of the vehicle movement. In the embodiment shown, the upper most end of the lever arm is shown extended to the outer peripheral portion of the disks 16. However, the lever arm can be made slightly shorter if the lever arm is sufficiently strong so as to support the weight of the vehicle on the disks 16 and axle 20 alone. In addition, the disks can be increased in width to assume more of the applied force.
The manner of rotation of the lever arms 14 is more readily understood from FIGS. 3 and 4, wherein shaft 24 is shown extending transversely beneath plate 12. A plurality of bearing blocks 41 are spaced therebeneath to provide support for the shaft 40 and are held in position by bolts 56 accessible from the top surface of plate 12. The second or opposing end 32 of the lever arms is provided with an opening through which shaft 40 extends. As noted in FIG. 3, the end of the shaft is provided with a retaining clip 42 and a retention washer 43 to limit lateral movement of the lever arm on the shaft. Each lever arm is provided with a double wound spring member 30 which urges the lever to return to an upright position regardless of which direction that a vehicle has crossed the plate 12. The spring has a first end 51 which is received in a groove 31 and wrapped about the shaft. It also extends in a generally U-shaped central section 52 to the opposite side of the lever arm and is then wrapped about the shaft on the other side of the lever. The second end 53 of the spring extends upwardly and resides against the bottom surface of plate 12. The two spring sections wrapped about the shaft 40 on either side of central section 52 are in opposing directions so that the lever is continually returned to its upright position as shown in FIG. 1.
The position of the spring 30 in its normal operating position is shown in FIG. 4 wherein the lever arm 14 extends vertically through the opening in plate 12. The disks 16 mounted for rotation on axle 20 are then positioned to contact a vehicle tire. The tapered edge portion of the lever arm shown as region 21 is an extension of the tapered top edge 46 and extends along the length of the lever until terminating just beneath the plate 12. As mentioned previously, the taper extends across the top of the lever arm so that the vehicle tire encountering a particular lever arm contacts primarily the rotatable disks 16. The second end of the lever arm is mounted on shaft 24 for rotation with the spring central portion 52 and second end 53 resting against the underside of the plate 12. The spike or piercing member 23 is held by retaining pin 25 in a receiving socket 28. This permits the retaining pin 25 to be driven out and the spike to be removed from the socket and replaced if it is broken off during use. Transverse pin 44 preferably does not engage the adjacent second end 53 of spring 30 so that a degree of movement is permitted in the lever arm in the upright position as shown. This pin extends through the central portion of the lever arm as shown in FIG. 3. Pin 44 serves to engage the adjacent portion of the spring member when the lever arm is moved by a vehicle travelling in the non-permitted direction.
The non-permitted direction of vehicle travel is shown by the arrow in FIG. 5. For vehicle movement in this direction the resultant movement of the lever arm is to a position beneath the top surface of plate 12. The emergence of the piercing member 23 from beneath the plate to a position where it engages and harms the vehicle tire is shown. As the lever arm 14 is urged in the direction shown by the arrow, the pin 44 engages the second end 53 of the spring and is urged thereagainst deflecting this end of the spring in the manner shown. The rotational mounting of the disks on the ends of each lever arm enable the disks to rotate along the surface of the tire as it moves in the direction of the arrow. The envelopment of the exposed end of the lever arm by the vehicle tire, which is characteristic of traffic controllers now in use, does not take place with the result that there is no significant force tending to drive the lever arm in the counterclockwise direction. In the prior art devices, the tire frictionally engages and grabs the lever arm moving it in the direction of travel of the vehicle tire. This reaction is contrary to the intended result. In such cases, the piercing member never emerges from beneath plate 12, no damage to the tire takes place and the general population begins to ignore the traffic controller. The present invention has been found to essentially eliminate this problem by reducing the frictional forces between the free end of the lever arm and the vehicle tire.
The operation of the device in the permitted direction is shown in FIG. 6 wherein the free end of the lever arm is contacted by the tire of the vehicle travelling in the direction of the arrow. In this circumstance, the vehicle is working against the central portion 52 of the spring and urges the lever down as shown with the piercing member safely moved out of the way. As noted previously, FIG. 6 shows the typical reaction to a vehicle moving in the non-permitted direction obtained with those previous devices utilizing a static or fixed lever arm end.
The present invention includes several features that are significant to the ease of assembly and costs of manufacture. In particular, the use of a single spring to provide the opposing restoring forces enables the assembly to be made in a remote location by spacing the parts along the shaft and loosely attaching the bolts 56 while maintaining the appropriate spacing of the spring members. The use of positioning clips 60, such as E-rings, on the shaft with corresponding receiving grooves on the shaft position the device on the shaft. The tightening of the bolts maintains the proper alignment of the springs in position against the underside of the plate 12. Furthermore, the provision of a receiving socket with a retaining pin enables a piercing member or spike to be removed and replaced without disassembling the entire apparatus. As shown in FIG. 5, each spike is provided with a notch 48 for receiving the retaining pin 25 which is accommodated in a suitable bored hole in the second end of each lever arm 14. In addition, the central portions of the openings 15 in plate 12 need not be expanded to permit movement of the lever arm through the plate since the region of expanded thickness is located at the very end of the lever arm. Thus, no significant hazard is presented to members of the public wishing to tamper with the apparatus when installed.
While the above description has referred to a specific embodiment of the invention, it is to be noted that many modifications and variations may be made therein without departing from the spirit and scope of the invention as claimed. | Apparatus for controlling the direction of traffic flow wherein a plurality of rotationally mounted levers have a free end extending upwardly from the road surface. The levers are provided with removable spikes which rotate therewith to damage tires when the levers are rotated in one direction. The free end of each lever is provided with a rotationally mounted low friction contact member which contacts the adjacent surface of the tire and moves along the surface thereof. Envelopment of the free end of the lever by the tire and the coerced rotation thereof in the wrong direction do not occur. As a result, the failure of the corresponding spike to damage a tire when the vehicle is moving in the wrong direction is thereby avoided. |
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BACKGROUND
In the downhole drilling and completion industry, there is often need to contain fluid within a formation during various operations. Conventionally, a mechanical barrier is put in the system that can be closed to contain the formation fluid when necessary. One example of a system known in the art will use a valve in operable communication with an Electric Submersible Pump (ESP) so that if/when the ESP is pulled from the downhole environment, formation fluids will be contained by the valve. While such systems are successfully used and have been for decades, in an age of increasing oversight and fail safe/failure tolerant requirements, additional systems will be well received by the art.
SUMMARY
Disclosed herein is a multi-barrier system including a first valve in fluid communication with a lower completion, and a second valve in fluid communication with the lower completion. The first valve and the second valve are positioned proximate an uphole extent of the lower completion, and a packer located proximate the first valve and the second valve is closable in response to retrieving an upper completion.
Also disclosed herein is a method of redundantly closing a wellbore nonpermanently upon retrieval of an upper completion, including disengaging an upper completion from a lower completion, closing a first valve in response to the disengaging, closing a second valve in response to the disengaging, reengaging an upper completion with the lower completion, opening the first valve, and opening the second valve.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a schematic view of a stackable multi-barrier system;
FIG. 2 is a schematic view of the system of FIG. 1 in partial withdrawal from the borehole;
FIG. 3 is a schematic view of a new stackable multi-barrier system engaged with the remains of the system illustrated in FIG. 1 ; and
FIG. 4 depicts a quarter cross sectional view of a portion of a hydraulically actuated valve employed in the stackable multi-barrier system of FIGS. 1-3 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a stackable multi-barrier system 10 is illustrated. Illustrated is a portion of a lower completion 12 , a packer 14 and a portion of an upper completion 16 . One of ordinary skill in the art will be familiar with the lower completion 12 and the packer 14 and the concept of an upper completion 16 in operable communication therewith. In the illustrated embodiment an electric submersible pump (ESP) 18 is included in the upper completion 16 , which is a device well known to the art. Between the illustrated ESP 18 and the lower completion 12 however, one of ordinary skill in the art will be surprised to see a number of mechanical barriers 20 , 22 (sometimes referred to herein as “valves”) that is greater than one. As illustrated in the figures hereof there are two but nothing in this disclosure should be construed as limiting the number of mechanical barriers to two. Rather more could also be added, if desired.
In one embodiment the more downhole valve 20 is a hydraulically actuated valve such as an ORBIT™ valve available commercially from Baker Hughes Incorporated, Houston Tex. and the more uphole valve 22 is a mechanically actuated valve such as a HALO™ valve available from the same source. It will be appreciated that these particular valves are merely exemplary and may be substituted for by other valves without departing from the invention.
Control lines 24 are provided to the valve 20 for hydraulic operation thereof. In the illustrated embodiment the lines also have a releasable control line device 28 in line therewith to allow for retrieval of the upper completion 16 apart from the lower completion 12 . Also included in this embodiment of the system 10 is a stroker 30 that may be a hydraulic stroker in some iterations.
The components described function together to manage flow between the lower completion 12 and the upper completion 16 . This is accomplished in that the valve 20 is settable to an open or closed position (and may be variable in some iterations) based upon hydraulic fluid pressure in the control line 24 . The valve 22 is opened or closed based upon mechanical input generated by movement of the upper completion 16 , or in the case of the illustration in FIG. 1 , based upon mechanical movement caused by the stroker 30 that is itself powered by hydraulic fluid pressure. Of course, the stroker 30 could be electrically driven or otherwise in other embodiments. In any condition, the valve 22 is configured to close upon withdrawal of the upper completion 16 . In normal production, both of the valves 20 and 22 will remain open unless there is a reason to close them. Such a reason occurs, for example, when it is required to retrieve the upper completion 16 for some reason. One such reason is to replace the ESP 18 . Regardless of the reason for closure, employment of the system 10 in a completion string provides more than one mechanical barrier 20 , 22 at an uphole extent of the lower completion 12 . The barriers when closed prevent fluid flow after the upper completion is retrieved.
Attention is directed to releasable control line devices 28 and FIG. 2 . During a withdrawal of the upper completion 16 , the control lines 24 are subjected to a tensile load. The releasable control line devices will release at a threshold tensile load and seal the portion of the control lines 24 that will remain in the downhole environment as a part of the lower completion string 12 . The valve 20 , if not already closed, is configured to close in response to this release of the control lines 24 . This will complete the separation of the upper completion 16 from the lower completion 12 and allow retrieval of the upper completion 16 to the surface. With more than one mechanical barrier 20 , 22 in place at the uphole extent of the lower completion 12 , there is improved confidence that fluids will not escape from the lower completion 12 . Important to note here briefly is that the system 10 also includes provision 44 for allowing the reopening of the valve 20 using tubing pressure after the upper completion 16 is reinstalled. This will be addressed further hereunder.
In order to restore production, another system 110 is attached at a downhole end of upper completion 16 and run in the hole. This is illustrated in FIG. 3 . The original system 10 has components such as packer 14 , valves 20 and 22 and control lines 24 are seen at the bottom of the drawing and a new system 110 stackable on the last is shown. The new system 110 includes a packer 114 valve 120 , valve 122 , lines 124 , stroker 13 , ESP 118 and releasable hydraulic line device 128 . In essence each of the components of system 10 is duplicated in system 110 . Moreover, it should be understood that the process of pulling out and stabbing in with new systems can go on ad infinitum (or at least until practicality dictates otherwise).
Since the valves 20 and 22 will be in the closed position, having been intentionally closed upon preparing to retrieve the upper completion 16 , they will need to be opened upon installation of the new system 110 . This is accomplished by stabbing a mechanical shiftdown 142 into valve 22 and setting packer 114 . The mechanical shiftdown 142 mechanically shifts the valve 22 to the open position. It should be pointed out that, in this embodiment, the mechanical shiftdown 142 does not seal to the valve 22 and as such the inside of the upper completion 16 is in fluidic communication with annular space 146 defined between the packers 14 and 114 . Applying pressure to the tubing at this point will result in a pressure buildup that will act on the valve 20 through the string uphole thereof since all valves thereabove, 22 , 120 and 122 are in the open position. Referring to FIG. 4 , a view of valve 20 illustrates the provision 44 that includes a port 52 in operable communication with an optional shifter 50 . The shifter 50 is configured to open the port 52 in response to retrieval of the upper completion 16 . As illustrated the shifter 50 in this embodiment is a sleeve that is automatically actuated upon retrieval of the upper completion 16 . More specifically, when upper completion 16 begins to move uphole, the provision 44 is shifted to the open position. When the provision 44 is in the open position tubular fluid pressure is in communication with the port 52 . The port 52 includes an openable member 54 such as a burst disk or similar that when opened provides fluid access to an atmospheric chamber 56 . The member 54 opens upon increased tubing pressure and allows fluid to fill the atmospheric chamber 56 . Fluid in the atmospheric chamber causes one or more pistons 58 to urge the valve 20 to the open position. In one embodiment, ratcheting devices (not shown) may be provided in operable communication with the one or more pistons 58 to prevent the pistons from moving in a direction to allow the valve to close by serendipity at some later time. It may also be that the valve 20 itself is configured to be locked permanently open by other means if the atmospheric chamber floods.
The foregoing apparatus and method for its use allows for the retrieval and replacement of an upper completion without the need for a wet connection.
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 multi-barrier system includes a first valve in fluid communication with a lower completion, and a second valve in fluid communication with the lower completion. The first valve and the second valve are positioned proximate an uphole extent of the lower completion, and a packer located proximate the first valve and the second valve is closable in response to retrieving an upper completion. |
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CROSS-REFERENCE TO RELATED PATENTS
For reference and understanding of Insulated Concrete Forms (ICF), U.S. Pat. No. 5,896,714 to Cymbala, et al, issued Apr. 27, 1999, describes an exemplary insulated concrete forming system and is hereby incorporated by reference.
FIELD
This invention relates to bucks used for forming an opening in a wall and more particularly to a buck system for forming an opening in a poured concrete wall in which the concrete is held by Insulated Concrete Forms.
BACKGROUND
Most windows and other openings in buildings include frames (e.g. window frames) and inserts (e.g. window glass panels, doors, etc.). For framed construction, rough framing is constructed before the frames (window frame, door frame) are installed and the rough framing is constructed sufficiently to support structures above the opening by extra studs and headers, etc.
For poured concrete installations, generally the frame is not strong enough to withstand the weight of the poured concrete. Furthermore, the typical frame does not provide sufficient rigidity for the openings after the building is completed, the walls are formed around the window opening, and the concrete dries.
To solve this problem, a rigidifying box or outer-frame called a “buck” is typically formed or built to provide a receptacle or opening into which the frames can be mounted after the concrete is poured.
In Modern construction techniques, the walls of portions or of the entire building are formed by pouring concrete into forms or molds. This method has long been done in the fabrication of basement walls, either created on-site or off-site in which an entire wall is pre-fabricated then positioned into a vertical position and installed on-site.
Bucks for use with poured concrete walls have been disclosed in the prior art. For example, U.S. Pat. No. 5,996,293 to Anderson, et al, describes a buck system made by extruding vinyl. Bucks of any useful dimension that are made according to this disclosure are not sturdy enough to withstand the force of wet, poured concrete and, therefore, require many braces to prevent sagging and/or collapse after the concrete is poured. Furthermore, the described buck system does not adequately accommodate Insulated Concrete Forms (ICF), which have become very popular in the construction industry.
In another example, U.S. Pat. No. 6,070,375 to Anderson, et al, describes a buck system made by extruding vinyl. Again, Bucks of any useful dimension that are made according to disclosure are not sturdy enough to withstand the force of wet, poured concrete and, therefore, require many braces to prevent sagging and/or collapse after the concrete is poured.
In another example, U.S. Pat. No. 6,530,185 to Scott, et al, describes a buck system for Insulated Concrete Forms that is made of plastic. Again, Bucks of any useful dimension that are made according to the disclosed system are not sturdy enough to withstand the force of wet, poured concrete and, therefore, require many braces to prevent sagging and/or collapse after the concrete is poured.
In all of the above examples, the overall construction, materials and design does not provide added structure to the ICF and, for all useful sizes of frames, requires substantial bracing and squaring (corner angles).
What is needed is a buck system that will support the force and weight of concrete with no or minimal bracing and will provide a sturdy base for frames.
SUMMARY
In one embodiment, a buck system for forming and framing an opening in a poured concrete foundation is disclosed. The foundation being poured between two insulated concrete foundation walls. The buck system includes a plurality of buck sections matching the desired dimension of the opening. Each of the buck sections is affixed to an adjacent buck section forming a closed geometric shape. Each buck section has an inner surface defining an inside dimension of the opening and each of the buck sections has a first channel and a second channel. The first channel snuggly accepts an edge of a first insulated concrete foundation wall of the insulated concrete foundation walls and the second channel snuggly accepts an edge of a second insulated concrete foundation wall of the insulated concrete foundation walls.
In another embodiment, a method of making a framed opening in a poured concrete foundation is disclosed. The foundation being poured between two insulated concrete foundation walls. The method including forming a plurality of buck sections to match the desired dimension of the opening and affixing each of the plurality of buck sections to an adjacent buck section of the plurality of buck sections forming a closed geometric shape. Each buck section has an inner surface defining an inside dimension of the opening and each of the buck sections has a first channel and a second channel. The method continues with positioning edges of a first insulated concrete foundation wall of the insulated concrete foundation walls into the first channel and positioning edges of a second insulated concrete foundation wall of the insulated concrete foundation walls into the second channel then pouring concrete between the first insulated concrete wall and the second insulated concrete wall.
In another embodiment, a buck system for forming and framing an opening in a poured concrete foundation is disclosed. The foundation being poured between two insulated concrete foundation walls. The buck system includes a plurality of buck sections matching the desired dimension of the opening. Each of the buck sections is affixed to an adjacent buck section forming a closed geometric shape. Each buck section has an inner surface defining an inside dimension of the opening and each of the buck sections has a first channel and a second channel. The first channel snuggly accepts an edge of a first insulated concrete foundation wall of the insulated concrete foundation walls and the second channel snuggly accepts an edge of a second insulated concrete foundation wall of the insulated concrete foundation walls. Each of the plurality of buck sections comprises an outer U-shaped member, an inner U-shaped member, and a hat. The inner surface is formed by an outer surface of the hat, the first channel is formed between a first inner surface of the outer U-shaped member and a first outer surface of the inner U-shaped member, and the second channel is formed between a second inner surface of the outer U-shaped member and a second outer surface of the inner U-shaped member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1A illustrates a cross-sectional view of a first example of a section of the buck system.
FIG. 1B illustrates a perspective view of the first example of the buck system installed as a window rough frame in an insulated concrete foundation.
FIG. 2A illustrates a cross-sectional view of a second example of a section of the buck system.
FIG. 2B illustrates a perspective view of the second example of the buck system installed as a window rough frame in an insulated concrete foundation.
FIG. 3A illustrates a cross-sectional view of a third example of a section of the buck system.
FIG. 3B illustrates a perspective view of the third example of the buck system installed as a window rough frame in an insulated concrete foundation.
DETAILED DESCRIPTION
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Throughout the description, the terms “insulated concrete foundation” and “insulated concrete foundation wall” refer the well-known system of fabrication of concrete walls, not necessarily limited to foundation walls, but to any concrete wall of a structure, including interior walls and higher story walls, etc.
The disclosed buck system provides an anchoring base for windows and doors that will provide extreme resistance to fenestration failures with wind damage situations such as hurricanes. The disclosed buck system provides the proper pull out strength required in the various wind/hurricane zone areas often required by building and life safety codes.
Referring to FIGS. 1A and 1B , a cross-sectional view of a first example of the buck section 6 is shown. The buck section 6 is shown installed in an insulated concrete foundation 4 / 5 in FIG. 1B . The buck section 6 in this example includes three components: an outer U-shaped member 1 , an inner U-shaped member 2 with bent edges 2 a and a hat member 3 .
The space between the inside of the side edges of the outer U-shaped member 1 and the outside of the side edges of the inner U-shaped member 2 form channels for receiving the edges of the insulated concrete foundation walls. The insulated concrete foundation walls 4 / 5 fit between snuggly in these channels between the inside of the side edges of the outer U-shaped member 1 and the outside of the side edges of the inner U-shaped member 2 .
The hat is part of and/or affixed to the outside of the base of the outer u-shaped member 1 . The components 1 / 2 / 3 of the buck section 6 are made of a sturdy material including, but not limited to, steel, iron, polyvinylchloride (PVC), etc., although steel is preferred. It is preferred to use a structurally strong material such as steel to eliminate and/or greatly reduce the need for bracing while concrete is poured into the gap between the insulated concrete foundation walls 4 / 5 . In this, the buck sections 6 receive fluid pressure from the concrete (until the concrete sets) as well as pressure from the weight of the concrete. The buck section 6 is self-supporting for openings of up to approximately 3.5 feet when the components 1 / 2 / 3 are made of, for example, 20 gauge steel. For wider spans, it is anticipated that the components 1 / 2 / 3 are made from a heavier gauge steel such as 16 gauge steel and/or minimal bracing is provided during pouring of the concrete and until the concrete sets.
The components 1 / 2 / 3 are formed as one piece or held together such as with fasteners 30 (screws are shown). When screws are used as fasteners 30 , it is anticipated that the screws are spaced at 8″ distances, though any spacing is anticipated.
To create the desired rough frame, a number of sections of the buck section 6 are provided/cut to the desired dimensions and the sections are then fastened to each other by, for example, clips. The example shown in FIG. 1B has four sections of the buck system 6 and four clips (not shown) holding the corners of the sections of the buck system 6 together. Note that, although a rectangular rough frame is shown in FIG. 1B , any shape rough frame is anticipated (e.g., hexagonal, octagonal, etc).
The hat member 3 typically interfaces with the window frame, door frame, etc. When the frame is installed into the rough frame constructed from multiple sections of the buck section 6 , fasteners are typically set through the frame and into the buck section 6 , in particular, the hat 3 of the buck section 6 .
In some embodiments, some or the entire gap between the inner sides of the hat 3 and the outer side surface of the outer u-shaped member 1 is filled with a soft material 9 such as Styrofoam® (closed-cell extruded polystyrene foam). This serves at least two purposes. The soft material 9 reduces flow of concrete into this gap and provides some amount of insulation. It is desired to prevent/reduce flow of concrete into this gap so that, after the concrete is poured and sets, fasteners (e.g. nails, screws, etc. not shown) are not blocked 20 by hardened concrete (e.g. when the frame is installed into the rough frame).
In some embodiments, the base of the inner u-shaped member 2 is lined with a section of a soft material 8 such as Styrofoam® (closed-cell extruded polystyrene foam), again providing some amount of insulation between the concrete and the buck section 6 , but also preventing/reducing flow of concrete into this gap so that, after the concrete is poured 5 and sets, fasteners (e.g. nails, screws, etc.) are not blocked by hardened concrete.
Referring to FIGS. 2A and 2B , a cross-sectional view of a second example of the buck section 10 is shown. The buck section 10 is shown installed in an insulated concrete foundation 4 / 5 in FIG. 2B . The buck section 10 in this example includes three components: two outer Z-shaped members 15 and an inner U-shaped member 12 with bent edges 12 a.
The space between the inside of the side edges 13 of the Z-shaped member 15 and the outside of the side edges of the inner U-shaped member 12 form channels for receiving the edges of the insulated concrete foundation walls. The insulated concrete foundation wall edges 4 / 5 fit between snuggly within these channels between the inside of the side edges 13 of the Z-shaped member 15 and the outside of the side edges of the inner U-shaped member 12 .
Each of the Z-shaped members are part of and/or affixed to outer surfaces of the side edges of the inner U-shaped member, for example using screws. The components 12 / 15 of the buck section 10 are made of a sturdy material including, but not limited to, steel, iron, polyvinylchloride (PVC), etc., although steel is preferred. It is preferred to use a structurally strong material such as steel to eliminate and/or greatly reduce the need for bracing while concrete is poured into the gap between the insulated concrete foundation walls 4 / 5 . In this, the buck sections 10 receive fluid pressure from the concrete (until the concrete sets) as well as pressure from the weight of the concrete. The buck section 10 is self-supporting for openings of up to approximately 3.5 feet when the components 12 / 15 are made of, for example, 20 gauge steel. For wider spans, it is anticipated that the components 12 / 15 are made from a heavier gauge steel such as 16 gauge steel and/or minimal bracing is provided during pouring of the concrete and until the concrete sets.
The components 12 / 15 are formed as one piece or held together such as with fasteners 30 (screws are shown). When screws are used as fasteners 30 , it is anticipated that the screws are spaced at 8″ distances, though any spacing is anticipated.
To create the desired rough frame, a number of the buck section 10 are provided/cut to the desired dimensions and the sections are then fastened to each other by, for example, clips. The example shown in FIG. 2B has four buck sections 10 and four clips (not shown) holding the corners of the sections of the buck section 10 together. Note that, although a rectangular rough frame is shown in FIG. 2B , any shape rough frame is anticipated (e.g., hexagonal, octagonal, etc.).
The inner U-shaped member 12 typically interfaces with the window frame, door frame, etc. When the frame is installed into the rough frame constructed from multiple buck sections 10 , fasteners are typically set through the frame and into the buck section 10 , in particular, the fasteners are set into the outer surface of the base of the U-shaped member 12 of the buck section 10 .
In some embodiments, the base of the inner u-shaped member 12 is lined with a section of a soft material 8 such as Styrofoam® (closed-cell extruded polystyrene foam), providing some amount of insulation between the concrete and the buck section 10 , but also preventing/reducing flow of concrete into this area against the inner surface of the base of the U-shaped member 12 so that, after the concrete is poured and sets, fasteners (e.g. nails, screws, etc.) are not blocked by 20 hardened concrete.
Referring to FIGS. 3A and 3B , a cross-sectional view of a first example of the buck section 20 is shown. The buck section 20 is shown installed in an insulated concrete foundation 4 / 5 in FIG. 3B . The buck section 20 in this example includes two components: an outer U-shaped member 21 and an inner U-shaped member 22 with bent edges 22 a.
The space between the inside of the side edges of the outer U-shaped member 21 and the outside of the side edges of the inner U-shaped member 22 form channels for receiving the edges of the insulated concrete foundation walls. The edges of the insulated concrete foundation walls 4 / 5 fit snuggly in these channels between the inside of the side edges of the outer U-shaped member 21 and the outside of the side edges of the inner U-shaped member 22 .
The outer U-shaped member is part of and/or affixed to outer top surfaces of the inner U-shaped member 22 , for example using screws. The components 21 / 22 of the buck section 20 are made of a sturdy material including, but not limited to, steel, iron, polyvinylchloride (PVC), etc., although steel is preferred. It is preferred to use a structurally strong material such as steel to eliminate and/or greatly reduce the need for bracing while concrete is poured into the gap between the insulated concrete foundation walls 4 / 5 . In this, the buck sections 20 receive fluid pressure from the concrete (until the concrete sets) as well as pressure from the weight of the concrete above. The buck sections 20 are self-supporting for openings of up to approximately 3.5 feet when the components 21 / 22 are made of, for example, 20 gauge steel. For wider spans, it is anticipated that the components 21 / 22 are made from a heavier gauge steel such as 16 gauge steel and/or minimal bracing is provided during pouring of the concrete and until the concrete sets.
The components 21 / 22 are formed as one piece or held together such as with fasteners 30 (screws are shown). When screws are used as fasteners 30 , it is anticipated that the screws are spaced at 8″ distances, though any spacing is anticipated.
To create the desired rough frame, a number of buck sections 20 are provided/cut to the desired dimensions and the sections are then fastened to each other by, for example, clips. The example shown in FIG. 3B has four buck sections 20 and four clips (not shown) holding the corners of the buck sections 20 together. Note that, although a rectangular rough frame is shown in FIG. 3B , any shape rough frame is anticipated (e.g., hexagonal, octagonal, etc.).
The inner U-shaped member 22 typically interfaces with the window frame, door frame, etc. When the frame is installed into the rough frame constructed from multiple sections of the buck section 20 , fasteners are typically set through the frame in into the buck section 20 , in particular, the fasteners are set into the outer surface of the base of the U-shaped member 22 of the buck 20 .
In some embodiments, the base of the inner u-shaped member 22 is lined with a section of a soft material 8 such as Styrofoam® (closed-cell extruded polystyrene foam), providing some amount of insulation between the concrete and the buck section 20 , but also preventing/reducing flow of concrete into this area against the inner surface of the base of the U-shaped member 22 so that, after the concrete is poured and sets, fasteners (e.g. nails, screws, etc.) are not blocked by hardened concrete.
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | A buck system for forming and framing an opening in a poured concrete foundation includes a plurality of buck sections matching the desired dimension of an opening. Each of the buck sections is affixed to an adjacent buck section forming a closed geometric shape. Each buck section has an inner surface defining an inside dimension of the opening and each of the buck sections has a first channel and a second channel. The first channel snuggly accepts an edge of a first insulated concrete foundation wall of the insulated concrete foundation walls and the second channel snuggly accepts an edge of a second insulated concrete foundation wall of the insulated concrete foundation walls. |
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BACKGROUND OF THE INVENTION
The invention relates to a method of venting odors from a room, and particularly from the locations of odorous and infectious air such as: home bathrooms, hotels, restaurants, sport arenas, hospitals, nursing homes and other public bathrooms, incontinent patients, bed pans, special ring pans used in barium enema radiological procedure, diapers and baby cribs, baby changing tables, or any other infectious or odoriferous source. Because suction vents are typically not used it is difficult to remove the contaminating gases in hospital environments (especially in waiting rooms and fluoroscopic rooms where barium enema examinations are performed) in convalescent homes, and in big public bathrooms.
The prior art venting of bathrooms, in commercial establishments, typically use ceiling mounted fans or use deodorant sprays. Ceiling fans require the use of pipes or plastic ducts to carry the vented air outside the building. Mounting of the venting pipes and fans is manageable if installed during the construction of the building. Installation is very difficult in existing buildings. Access to an external ducts extending out of the building is often very difficult. In addition, many fan systems inherently require diffusion of the contaminating gas into substantially the entire room before any contaminating gas is removed. Stated another way, the location of the contaminating gas is often a substantial distance from the inlet to the fan or the inlet to the duct that is connected to the fan. Thus, there will be substantial diffusion throughout the room and into adjacent rooms. More specifically, in many cases, the source of the contaminating gas is a toilet bowl and in many such systems the inlet for the exhaust fan is located much too far from the toilet bowl.
In addition, the prior ad devices are often inefficient because they pull the air coming from a door or window, leaving the odors to float above the toilet area. Yet another inefficiency of the ceiling fan is that it squanders to much energy by venting out an excessive amount of air which was previously heated or cooled to provide a comfortable room temperature. The use of a pleasant smelling deodorant does not eliminate the foul air but instead adds more chemicals to the already contaminated air trapped inside the room. Some existing very, very expensive toilet bowls provide other utilities such as water heating and washing systems.
An object of this invention is to eliminate the embarrassment related to using a bathroom immediately after someone else had used it, to living in the same room with another patient that uses a bed pan, to being in a room when diapers of a baby or adult are changed, to being in the room when a barium enema examination is conducted in a fluoroscopic room as well as in other situations.
It is an object of the invention to provide a method of venting the bathroom by using ducting placed under the toilet seat, so that the odors are vented right from the toilet bowl before disseminating throughout the entire room.
It is another object of the invention to provide a method of saving energy by using a small fan, since a minimal draft is all that is required to remove and eliminate the air from the toilet area.
It is still another object of the invention to provide a method of venting odors from a bathroom at a low investment cost and eliminating a substantial construction project, such as making holes in the walls, floor, or ceiling, which is usually required when installing a ceiling fan.
Yet another object of the invention is to use the venting fan mounted onto the toilet to vent odors from a remote odor source through an extension hose that may be attached to a bed pan, barium enema inflated ring, the diapers of an incontinent patient in his bed, or a baby changing table.
Still another object of the invention is to provide a design of a venting fan that can be used on all types of toilet bowls regardless of the specific form or size thereof.
Another object of the invention is to provide apparatus Having various forms so that some forms may be installed on existing toilet bowls and other forms may be constructed as an integral part of new toilet bowls that include venting systems that are much easier to install.
SUMMARY OF THE INVENTION
It has now been found that these and other objects of the invention may be attained in either (1) a ventilating system apparatus for an associated toilet bowl having an associated toilet seat and an associated soil pipe or (2) a ventilating toilet system that includes an integral toilet and toilet seat having a collar disposed intermediate the toilet bowl and the associated soil pipe. The collar has an opening therein. The apparatus further includes a conduit having a first end and a second end, the first end is dimensioned and configured for insertion intermediate the associated toilet seat and the associated toilet bowl. The second end is dimensioned and configured for insertion into the opening. A fan is disposed in fluid communications with the conduit to urge gases from the first end to the second end.
In some forms of the invention a valve is disposed within the conduit and the valve has an open position allowing free flow of gases from the first end to the second end and a closed position that prevents free flow of gases from the first end to the second end. Some forms of the invention include a switch operatively connected to the fan and causing the fan to operate or not operate. Other forms of the invention include a mechanical linkage connected to the valve mechanism. The mechanical linkage permits manual movement of the valve mechanism from the open position to the closed position and from the closed position to the open position.
The valve mechanism may be a flapper valve and the switch and valve mechanism may be interconnected for simultaneous operation. The mechanical linkage may include a cable and may also include an arm dimensioned and configured for movement within a channel.
In some forms of the invention the cable is attached to the arm and the tension on the cable is varied as the arm is moved in the channel. In some forms of the invention the switch abuts a portion of the arm in at least one position of the arm.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by referring to the accompanying drawings in which:
FIG. 1 is a partially schematic vertical cross section of one form of the present invention in which a venting fan connects the interior of the toilet bowl to the soil pipe connected by a spacer to the outlet of the toilet bowl.
FIG. 2 is a top view of the spacer in accordance with one form of the invention that is placed intermediate the toilet bowl and the soil pipe.
FIG. 3 is a sectional view taken through the line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken through the line 4--4 of FIG. 2.
FIG. 5 is a sectional view taken through the line 5--5 of FIG. 2.
FIG. 6 is a schematic elevational view of an alternate embodiment in which a T-shaped fitting with a branch hose replaces an elbow on the suction side of the fan to facilitate removal of odors other than the odors emanating from the toilet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown a toilet bowl 10 which cooperates with the ventilating apparatus 12 in accordance with the present invention. It will be understood that the various forms of the present invention may include apparatus in which the ventilating apparatus 12 is installed on an existing toilet bowl 10 as well as new toilet bowl constructions in which the ventilating apparatus 12 is an integral part of a single assembly. FIG. 1 has been simplified and has some parts that are shortened or rotated from their usual position for clarity.
In the conventional manner the toilet bowl 10 includes a seat 14 that is ordinarily spaced with respect to the top surface 16 of the bowl 18. A flange 20 extends around the circumferential extent of the base of the toilet bowl 10. The flange 20 is customarily bolted to a soil pipe with an intervening wax ring 21 to provide positive sealing therebetween.
In the illustrated preferred embodiment of the invention a flattened duct 22 having a height sufficiently small to permit insertion between the seat 14 and the top 16 of the bowl 18 connects the ventilating apparatus 12 to the toilet bowl 10. In the preferred form the duct 22 has a width of about three inches. Although this dimension is satisfactory for many applications it will be understood that other embodiments will use other dimensions. For example the duct 22 might have an annular form that extends around substantially the entire extent of the seat 14. Coupled to the duct 22 is a first elbow 24 that communicates with the duct 22 so that the duct communicates with a funnel shaped. coupling 26 having a flange engaging a housing 27 and an outside covering 28. The housing 27 includes a passageway 27 extending axially within the axially elongated passageway 27, and a laterally extending wall 29 in which is disposed a valve seat 30. Cooperating with the valve seat 30 is a spring loaded flapper 31 dimensioned and configured for selective seating on the valve seat 30. The housing 27 is coupled to the entering side of the fan 33.
A fan 33 is coupled between the passageway 30 and a second funnel member 32. The funnel member 32 is coupled to a second elbow 34. The second elbow 34 is connected to a third elbow 36 which is connected to a fourth elbow 38 which is connected to a collar 42 that extends under the toilet bowl 10 where it is seated between the flange 20 of the toilet bowl 10 and the flange 40 of the soil like 41.
The specific construction of the collar 42 will be more apparent by reference to figures 2,3,4, and 5. The fourth elbow 38 has a flattened shape that is wider than it is high and which is dimensioned and configured for fitting into a channel 42a in a collar 42 that is disposed intermediate the flange 20 of the toilet bowl 10 and the flange 40 of the soil pipe 41. Those skilled in the art will recognize that when the toilet is flushed water and waste material will flow through the collar 42 and particularly the central opening therein that is within a truncated conical shaped lip 54. The lip extends around substantially the entire central opening as best seen an FIG. 2. The shape of the lip 54 is most apparent by reference to FIGS. 1 and 5. More particularly, it will be seen that gases flowing through the system including the fan 33 will flow into the soil pipe 41. Those skilled in the art will recognize that the soil pipe 41 stays vented to atmosphere and accordingly there is no fluid pressure within the soil pipe 41 and thus no impediment to the free flow of gases into the soil pipe 41.
The collar 42 has a opening 42a dimensioned and configured for mating engagement with the fourth elbow 38. Thus, the gases are directed into the arcuate channel 54a that is defined between the lip 54 and the main body 55 of the collar 42. A wax ring 21 will ordinarily being disposed intermediate the collar and the flange 20 of the toilet bowl 10. The wax ring 21 is conventional to provide a good seal without the need for tightening of bolts securing the toilet bowl flange 20 to the soil pipe flange 40 in a manner that would crush the ceramic toilet bowl flange 20. Ordinarily, only two bolts (not shown) extend respectively through the slot 42c and the elongated bore 42b to couple the flange 20 to the flange 40.
Referring again to FIG. 1, when the venting system is not in use the flapper 31 is horizontal and closed. The flapper 31 is spring loaded or biased to the closed position. The structure also includes a generally horizontal arm 50 that is supported for movement up and down in a guide channel 49. In other words, the arm 50 is dimensioned and configured for sliding movement between upper and lower positions as illustrated in FIG. 1. In the normally closed position of the flapper 31, the arm 50 is in the upper position (indicated by dashed lines) and there is no tension in the cable 52 that extends from the arm 50 to the part of the flapper that is most remote from the hinge on which the flapper 31 pivots. It is the upper position, Illustrated in dashed line, in which the tension in the cable 52 is relaxed and the spring loaded flapper 31 is free to move to the horizontal position Illustrated in dashed line.
The arm 50 will ordinarily be manually moved downwardly to the position shown in solid line in FIG. 1 when it is desired to exhaust foul air. When the arm 50 is moved to the lower position manually the tension in the cable 52 is increased and thus the flapper 31 is moved to the vertical position Illustrated in solid line in FIG. 1. In addition, the movement of the arm 50 to the lower position also contracts a button 58 that is part of the switch 56. This contact closes the switch 56 that abuts the arm 50 when the arm 50 is in the lower position. The switch 56 is a momentary switch in the preferred embodiment of the present invention. Thus, movement of the arm 50 to the lower position causes the switch 56 to momentarily supply electrical power to the fan 33 by means of wires, represented schematically by dashed line 56a. Electrical power to the fan 33 causes venting of foul gasses through the fan 33.
The switch 56 is provided with a finger 50a that extends from the side of the generally cylindrical switch 56 in the preferred embodiment of the invention. The arm 50 has a lip 50b that is dimensioned and configured for selective engagement with the finger 50a to hold the arm 50 in the down position and provide continuous power to the fan 33. As indicated by the double ended arrow 50c the arm 50 is of telescopic construction so that the operator may lock the lip 50b into engagement with the finger 50a to provide continuous power to the fan 33.
The spring bias on the flapper 31 will cause the flapper 31 to move to the closed position if the arm 50 is manually moved upwardly. In the preferred embodiment the spring bias on the flapper 31 is sufficient to move the flapper 31 to the closed position and also to cause the arm 50 to move upwardly in the guide channel 49. This will release the force on the button 58 which will stop electrical power flow to the fan 33.
One embodiment of the invention achieves the object of venting odors from a remote odor source through an extension hose that may be attached to a bed pan, barium enema inflated ring, the diapers of an incontinent patient in his bed, or a baby changing table by the apparatus shown in which a separate hose 24b (shown schematically in FIG. 6) extends from a tee fitting 24a that is used in place of the elbow 24 shown in FIG. 1.
In other variations of the invention, the switch 56 may be replaced with a switch that is actuated by mounting it in the toilet seat and thus, it will be turned on automatically when ever someone sits on the toilet. The switch can also be activated by using an electric sensor mat that completes a circuit whenever someone steps on it. Still another embodiment of the invention utilizes a photo cell that closes a circuit upon detecting motion. In some embodiments the valve can is opened by using an electromagnet that will open it when the switch is activated.
The invention has been described with reference to the illustrated preferred embodiments. Persons skilled in the art of such devices may upon exposure to the teachings herein, conceive other variations. Such variations are deemed to be encompassed by the disclosure, the invention being delimited only by the following claims. | Apparatus for venting odors from the toilet bowl by using a fan installed on one side of the toilet bowl. The odors are discharged under the toilet in the drain pipe through an appropriate extension ring designed to allow transit of discharged air. Easy installation of the mechanism requires only unbolting the toilet from the floor, placing the extension ring, base extension board and a new wax ring on the drainage flange, rebolting the toilet in place and making the connection to the fan. |
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BACKGROUND OF THE INVENTION
[0001] Hunting stands are well known for the allowing hunters to hunt comfortably from an elevated position for an extended period of time. There are three basic types of hunting stands: hang-on stands, climbing stands, and ladder stands. All three types of stands have the two basic components: a platform portion for supporting the hunter in a standing position and a seat portion for supporting the hunter in a seated position. Key differences between the types of stands are the based on how a user installs the stand in an elevated position, how a user enters the stand once it is installed, and the portability of the stand.
[0002] Conventional hang-on stands are installed in an elevated position on a tree by using a separate conventional climbing device and are installed by being strapped to a tree and having the platform engage the tree. A user enters a hang-on stand by using a conventional ladder or a separate tree climbing aid, such as “climbing sticks.” A stand alone conventional hang-on stand offers significant portability as it does not include a ladder or climbing equipment. However, hang-on stands do require a ladder or climbing aid for use. U.S. Pat. No. 5,060,756 discloses a conventional hang-on stand.
[0003] Conventional climbing stands are configured to allow a user to climb a tree using climbing straps attached to the platform and seat portions. When using a conventional climbing stand a user uses the climbing straps to climb to a desired elevated position on a tree. Once the user reaches the desired elevated position, the user installs the stand by securing straps around the tree. Climbing stands also offer significant portability as they do not require a ladder or separate climbing aid for installation or use. U.S. Pat. No. 6,622,823 discloses a conventional climbing stand.
[0004] Conventional ladder stands include a ladder section which is used to support the platform and seat. Ladder stands are installed by attaching the platform and seat to the ladder section and simply leaning the ladder section against the tree and securing the ladder stand. Once a ladder stand is installed a user can freely enter or exit the stand by climbing the ladder section. Aside from ease which ladder stands can be entered or exited, ladder stands offer several other significant advantages over hang-on and climbing stands, such as the ability to support larger platforms and seats which can allow for multiple hunters to be able to use the stand simultaneously. U.S. Pat. No. 4,742,888 disclosed a conventional ladder stand.
[0005] Because conventional ladder stands include a ladder section, they typically lack the portability of hang-on and climbing stands. Prior art ladder stands, such as the ladder stands disclosed in U.S. Pat. Nos. 4,742,888 and 6,334,508 have attempted to increase portability by offering having a ladder section composed of a number of fixed ladder segments. Ladder segments of conventional ladder stands are typically constructed by welding rungs composed of steel tubing to rails composed of steel tubing. Ladder segments in prior art ladder stands are typically connected to one another by pins which traverse the respective connecting rails. Although having a ladder section composed of a number of fixed ladder segments increases the portability versus a ladder section composed of one large segment, the portability is limited by the width of each of the fixed ladder sections. Further, in conventional fixed ladder segments the connection points or joints between the rails of two ladders segments are in-line. Having ladder joints in-line does not provide for maximum stability. Further, conventional fixed ladder segment designs do not provide a method of easily adjusting the height of a platform.
[0006] U.S. Pat. Nos. 4,463,829 and 5,339,920 disclose prior art stand-alone fixed length ladders where the distance between the rails can be varied where the ladders rungs are located within channels of ladder rails. The stand-alone ladders disclosed U.S. Pat. Nos. 4,463,829 and 5,339,920 as well as other prior art stand-alone ladders do not provide predictable results for the design of a hunting stand ladder section, as stand-alone ladders are not designed to support the weight of a hunter or a platform. In particular, foldable ladders with rungs places within channels of the respective rails, as disclosed U.S. Pat. Nos. 4,463,829 and 5,339,920, do not account for potential ladder twist which may occur. Further, stand-alone ladders are not designed to operate as a ladder segment that must engage another ladder segment.
BRIEF SUMMARY OF THE INVENTION
[0007] The present disclosure is directed to an elevated hunting stand with a platform assembly and a collapsible ladder. The collapsible ladder includes a plurality of telescopically separating sections. The ladder sections are secured together by locking pins. The ladder rails and rungs are pivotally attached and operated as a parallelogram linkage system, so the ladder sections can be reduced in size to a compressed configuration by rotating the rungs relative to the rails. A plurality of stabilizing members are provided to hold the ladder sections in an expanded position during use.
[0008] The ladder rails are optionally staggered so that joints of adjacent ladder segments are staggered to increase stability. The present segmented ladder and various stabilizing members permit the ladder height to be easily adjusted.
[0009] In one embodiment, the collapsible includes a plurality of telescopically engaging ladder segments each have a first ladder rail, a second ladder rail, and a plurality of rung member pivotally attached to each of the first and second ladder rails in a parallelogram linkage. The separation between the first and second ladder rails is adjustable between a collapsed position to an expanded position. At least one stabilizing member is attached to the ladder segments to maintain the first and second ladder rails in the expanded position during use.
[0010] In one embodiment, the stabilizing member includes a least one rung member rigidly attached to a pair of rail sections. The rail sections telescopically engage with the first and second rails of the ladder section. A plurality of spring lock pins are used to retain the stabilizing member in telescopic engagement with the first and second ladder rails. One of the ladder segments preferably telescopically engages with the elevated hunting platform so the elevated hunting platform maintains the first and second ladder rails in the expanded position.
[0011] The first and second ladder rails can be the same or different lengths. In some embodiments, adjacent ends of the first and second rails are staggered when in the expanded position. The rung members are preferably attached to exterior surfaces of the first and second ladder rails.
[0012] In one embodiment, the first and second ladder rails are approximately the same length, but the rung members are pivotally attached to the first and second ladder rails at different respective points along the lengths thereof so adjacent ends of the first and second rails are staggered. In this embodiment, the rail sections on the stabilizing member are preferably different lengths. In one embodiment, the rail segments are releasably attachable to a rail section of the stabilizing member.
[0013] The present disclosure is also directed to an elevated hunting stand having a platform assembly and a ladder assembly having a first ladder rail, a second ladder rail, and a plurality of rung member pivotally attached to each of the first and second ladder rails in a parallelogram linkage. The separation between the first and second ladder rails is adjustable between a collapsed position to an expanded position. The platform assembly attaches to adjacent ends of the ladder assembly to maintain the first and second ladder rails in the expanded position.
[0014] The present disclosure is also directed to a method of assembling an elevated hunting stand. A first ladder assembly is converted from a collapsed position to an expanded position by separating first and second ladder rails connected by a plurality of pivotally attached rung members in a parallelogram linkage. Adjacent ends of the first and second rails are then attached to the platform assembly to maintain the first and second ladder rails in the expanded position.
[0015] The method may also include converting a second ladder assembly from a collapsed position to an expanded position, and telescopically engaging the second ladder assembly to the first ladder assembly. A stabilizing member is optionally attached to the second ladder assembly for additional stability.
[0016] Additional advantages and novel features of the disclosure are set forth in part in the description which follows, 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 disclosure. The advantages of the disclosure 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 DRAWING
[0017] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate an exemplary embodiment of the present disclosure and, together with the description, serve to explain the principles of the disclosure. In the drawings:
[0018] FIG. 1 is a perspective view of an exemplary hunting stand with a collapsible ladder assembly in accordance with an embodiment of the present disclosure.
[0019] FIG. 2 is an exploded view of the collapsible ladder assembly shown in FIG. 1 .
[0020] FIG. 3 illustrates an enlarged perspective view of an exemplary pivotally attached rail and rung in accordance with an embodiment of the present disclosure.
[0021] FIG. 4 is a cross sectional perspective view of the pivotally attached rail and rung of FIG. 3 .
[0022] FIG. 5A illustrates an exemplary collapsible ladder section in a collapsed position in accordance with an embodiment of the present disclosure.
[0023] FIG. 5B illustrates an exemplary collapsible ladder section in a partially expanded position in accordance with an embodiment of the present disclosure.
[0024] FIG. 6 illustrates an exemplary stabilizing section in accordance with an embodiment of the present disclosure.
[0025] FIG. 7 illustrates an alternative exemplary stabilizing section in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 illustrates an exemplary hunting stand 100 installed on a support post P wherein hunting stand 100 includes a platform assembly 102 , and a collapsible ladder assembly 104 . Hunting stand 100 can be constructed of any suitable materials capable of bearing weight and withstanding the weather elements, such as for example, powder-coated all-weather steel, aluminum, fiber reinforced thermoset resins, natural or engineered wood products, carbon fiber, composite materials, and/or combinations thereof. Hunting stand 100 can optionally be camouflaged and/or covered by a blind to conceal a hunter's presence. Hunting stand 100 materials can be camouflaged using a powder coating technique, water emersion printing, thin film coating, color fusion, or another suitable technique.
[0027] Platform assembly 102 includes a seat portion 106 and a platform portion 108 . Seat portion 106 is generally rectangular in shape and adapted to allow a hunter to sit comfortable for an extended period of time. Seat portion 106 can be sized to support one or more hunters. Seat portion 106 can be constructed of a rigid material, such as a steel or aluminum mesh, and include a support cushion constructed of a suitable foam material to provide comfort and insulation. Seat portion 106 can also be constructed of a weight bearing fabric, such a canvas or a synthetic weaved mesh fabric, spanning the platform assembly 102 .
[0028] Seat portion 106 optionally includes a back support, arm rests, and a shooting rail, such as disclosed in U.S. Patent Publication No. 2008/0128204 (Engstrom), which is hereby incorporated by reference. Platform portion 108 is preferably constructed of a rigid material adapted to support the weight of one or more hunters, such as steel or aluminum mesh welded on top of steel or aluminum tubing. Platform portion 108 can also be constructed out of cast metals or alloys, such as cast aluminum. Platform portion 108 provides a shooting platform for a hunter in a standing position and a foot rest for a hunter in a seated position.
[0029] FIG. 2 is an exploded view of the collapsible ladder assembly 104 including ladder sections 110 A, 110 B and 110 C (collectively “ 110 ”), ladder stabilizing assembly 112 , and rail extension 114 . The ladder assembly 104 is preferably constructed out of rigid material, such as steel or aluminum tubing.
[0030] Each ladder section includes a pair of rails 202 A, 202 B, 202 C (“ 202 ”) and 204 A, 204 B, 204 C (“ 204 ”) and a plurality of pivotally attached rungs 208 A, 208 B, 208 C (“ 208 ”). The rung 208 can be constructed from any of the materials disclosed herein, but are preferably constructed out of steel or aluminum tubing. More or less than three ladder sections 110 can be used with the present hunting stand 100 . In the exemplary embodiment, rail 202 , 204 are approximately the same length, as are the rungs 208 . Alternatively, the rails 202 , 204 and the rungs 208 could be different lengths.
[0031] As illustrated in FIGS. 3 and 4 , the rungs 208 are pivotally attached to rail 202 , 204 by rivet 302 . Alternatively, rungs 208 can be fastened to rails 202 , 204 using a nut and bolt combination. Nylon washers 304 allow for smooth and quiet pivotal movement of the rungs 208 relative to the rails 202 , 204 . Rungs 208 are preferably separated from the rails 202 , 204 by nylon washers 304 .
[0032] The pivotal attachment of the rungs 208 to the rails 202 , 204 allows ladder sections 110 to operate similar to a parallelogram linkage system, as illustrated in FIGS. 5A and 5B . In particular, the rails 202 , 204 move toward each other as the rungs 208 rotate relative to the rails 202 , 204 . FIG. 5B illustrates a partially collapsed position, while FIG. 5A illustrates the fully collapsed position. In the collapsed position, as shown in FIG. 5A , the rail 202 , 204 are a minimal distance apart. In the collapsed position the ladder sections 110 are more easily carried and transported.
[0033] Turning back to FIGS. 1 and 2 , the ladder section 110 A includes rails 202 A, 204 A, spring lock pins 206 A, 206 B, 206 C, and one or more rungs 208 A. The ladder section 110 A is moved to the expanded position, with the rungs 208 A generally perpendicular to the rails 202 A, 204 A.
[0034] Adjacent ends 216 A, 218 A of the rails 202 A, 204 A are staggered. The rail 202 A telescopically engages with rail extension 114 to compensate for the staggered rails 202 A, 204 A. Spring lock pin 206 B secures the rail extension 114 to the rail 202 A. The rail extension 114 is telescopically engaged with the platform assembly 102 , which are secured together by spring lock pin 206 A. The rail 204 A telescopically engages with the platform assembly 102 , which are secured together by spring lock pin 206 C. The platform assembly 102 serves to retain the ladder sections 110 in the expanded position.
[0035] Rails 202 B, 204 B of ladder section 110 B telescopically engage with corresponding rails 202 A, 204 A, respectively. Spring locking pins 206 D, 206 E secure the ladder section 110 A to the ladder section 110 B. Similarly, rails 202 C, 204 C of ladder section 110 C telescopically engage with corresponding rails 202 B, 204 B, respectively. Spring locking pins 206 F, 206 G secure the ladder section 110 B to the ladder section 110 C.
[0036] Adjacent ends 220 C, 222 C of the ladder rails 202 C, 204 C, respectively are staggered or vertically offset. Extension piece 116 is telescopically engaged with the rail 204 C in order to compensate for that vertical offset. In order to help retain the ladder sections 110 in the expanded position, ladder stabilizing assembly 112 telescopically engages with the ladder section 110 C. Rigid ground extension piece 118 includes rigidly attached rail sections 120 C, 122 C that telescopically engage with the ladder rail 202 C and the extension piece 116 . Spring locking pins 206 H, 206 I, and 206 J retain the ladder stabilizing assembly 112 to the ladder section 11 C.
[0037] FIG. 6 illustrates alternative exemplary ladder stabilizing assembly 402 , which is a single component. FIG. 7 illustrates alternative exemplary ladder stabilizing assembly 502 , with an extra ladder rung 504 to adjust the height of the ladder 104 .
[0038] In another embodiment, a ladder stabilizing assembly 112 , 402 , 502 is located between each ladder section 110 for increased stability.
[0039] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. The upper and lower limits of these smaller ranges which may independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either both of those included limits are also included in the disclosure.
[0040] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belong. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the disclosure, the preferred methods and materials are now described. All patents and publications mentioned herein, including those cited in the Background of the application, are hereby incorporated by reference to disclose and described the methods and/or materials in connection with which the publications are cited.
[0041] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present disclosure are not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
[0042] Other embodiments of the present disclosure are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the disclosure, but as merely providing illustrations of some of the presently preferred embodiments of this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of this disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form various embodiments. Thus, it is intended that the scope of at least some of the present disclosure should not be limited by the particular disclosed embodiments described above.
[0043] Thus the scope of this disclosure should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present disclosure fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present disclosure, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.
[0044] The foregoing description of various preferred embodiments of the disclosure have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise embodiments, and obviously many modifications and variations are possible in light of the above teaching. The example embodiments, as described above, were chosen and described in order to best explain the principles of the disclosure and its practical application to thereby enable others skilled in the art to best utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the claims appended hereto. | An elevated hunting stand with a platform assembly and a collapsible ladder. The collapsible ladder includes a plurality of telescopically separating sections. The ladder sections are secured together by locking pins. The ladder rails and rungs are pivotally attached and operated as a parallelogram linkage system, so the ladder sections can be reduced in size to a compressed configuration by rotating the rungs relative to the rails. A plurality of stabilizing members are provided to hold the ladder sections in an expanded position. The platform assembly can serve as one of the stabilizing members. |
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FIELD OF THE INVENTION
The disclosed inventions relate to a tool for securely cradling a subsea pipeline. More specifically, the disclosed inventions relate to a tool for securely cradling a subsea pipeline which land on one side of the pipeline and embed into the sea floor near the pipeline.
BACKGROUND
Subsea pipelines need to be elevated with respect to the sea floor proximate the pipeline on occasion for numerous reasons. It is often advantageous for such a tool to be capable of securely cradling the pipeline.
DRAWINGS
The various drawings supplied herein describe and are representative of exemplary embodiments of the invention and are described as follows:
FIG. 1 is a view in partial perspective of an exemplary embodiment of the device, and FIG. 1A is a view in partial perspective of a detail of the device;
FIG. 2 is a view in partial perspective of an exemplary embodiment of the roller arm assembly, and FIGS. 2A-2B are views in partial perspective of details of the exemplary embodiment of the roller arm assembly;
FIG. 3 is a top-down view in partial perspective of an exemplary embodiment of the roller assembly;
FIG. 4 is a top-down view in partial perspective of an exemplary embodiment of the roller assembly, and FIGS. 4A-4F are views in partial perspective of details of the exemplary embodiment of the roller assembly;
FIG. 5 is a view in partial perspective of an exemplary embodiment of the jacking assembly, and FIGS. 5A-5G are views in partial perspective of details of the exemplary embodiment of the device;
FIG. 6 is a view in partial perspective of an installed deployment of an exemplary embodiment of the device;
FIG. 7 is a view in partial perspective of a device embedded in the sea floor with the roller arm assembly extended underneath a pipeline in an exemplary embodiment of the device;
FIG. 8 is a view in partial perspective of a device embedded in the sea floor with the roller arm assembly extended underneath a pipeline and the cylinder extended in an exemplary embodiment of the device;
FIG. 9 is a view in partial perspective of a device embedded in the sea floor with the roller arm assembly engaged with and supporting the pipeline in an exemplary embodiment of the device; and
FIG. 10 is a view in partial perspective of a device embedded in the sea floor with the cylinder and lead screw assemblies removed in an exemplary embodiment of the device.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring generally to FIGS. 1 and 6 , in general, in various embodiments device 1 is a tool that lands on one side of a pipeline, e.g. pipeline 100 ( FIG. 6 ), and embeds into the sea floor, usually using gravity. Device 1 comprises components that reach under pipeline 100 in order to position a cradling component of device 1 . Device 1 provides a length of vertical adjustability for pipeline 100 and supports a load applied by the weight of pipeline 100 . The cradle must provide sufficient surface area to avoid excessive stress concentration on pipeline 100 . In preferred embodiments, the main structure of device 1 is fabricated out of 16″ OD, 1″ wall thickness riser pipe. In various embodiments, device 1 is capable of being sent overboard from a vessel in a horizontal position and deployed subsea in a vertical position.
In general, device 1 comprises three major subassemblies: pile tower 10 , roller carriage assembly 30 , and jacking assembly 70 .
Pile tower 10 is the main structural component of device 1 . In typical configurations it comprises three equally spaced legs 15 . In an embodiment, legs 15 are 16″ OD riser pipes around 57 feet in length. Preferably, legs 15 comprise API X70 steel with the ends, other than I-beams 111 ( FIG. 2A ) and cylinder mounting slots 112 ( FIG. 5A ), made of ASTM A36 steel. I-beams 111 , rails 3 ( FIG. 5E ), and cylinder mounting slots 112 are typically made from grade 70 steel.
The top of pile tower 10 is typically tied together with three gussets which are themselves tied to a short section of middle pipe which is raised above the level of legs 15 . A three inch thick pad-eye may protrude from the middle pipe and allow for a vertical deployment of pile tower 10 .
Skirt 20 comprises one or more skirts 22 connected to the bottom of legs 15 . Skirt 20 also provides a bearing surface for embedment into seabed 110 ( FIG. 6 ). In a preferred embodiment, skirt 20 comprises three skirts 22 , each of which measures around 1″ thick by around 55″ wide by around 300″ tall. Skirts 22 each have one or more holes to vent seawater during embedment, typically two holes having around a 12″ diameter. Scale 11 may be present to measure a level of embedment, e.g. starting at 5 feet above a mud line. In typical embodiments, skirts 22 are stitch welded to legs 15 .
In some embodiments, a small mud mat 21 provides surface area for resistance during embedment. Mud mat 21 typically sits above skirt 20 and extends out past legs 15 . Mud mat 21 has vent holes and, in certain embodiments, provides around at least 4250 square inches of surface area. In certain embodiments, one or more anodes are welded to the top of mud mat 21 to provide cathodic protection, e.g. ten twenty-nine pound anodes 27 .
One or more rails 14 , which in a preferred embodiment comprise gear tooth rails, are disposed along the outside of at least two legs 15 of pile tower 10 to provide one part of a ratcheting mechanism. Rails 14 are typically around two-inches wide and extend from mud mat 21 up to the top of pile tower 10 . One of legs 15 may comprise scale 11 which may be painted on an outer surface of leg 15 . Scale 11 may vary according to the desired height of pile tower 10 and usually measures an elevation above mud mat 21 .
The top of pile tower 10 , e.g. landing funnel 80 , may be angled toward the center to provide a landing “funnel” for a weighted follower.
Lifting bail 2 ( FIG. 1A ) may also be present, attached to the bottom of pile tower 10 , to facilitate horizontal lifting and overboarding operations.
In some embodiments, pile tower 10 is coated in three coat epoxy, except for a portion of pile tower 10 below a certain foot mark on 21 , which is left uncoated.
Roller carriage assembly 30 is the component that physically contacts pipeline 100 ( FIG. 6 ). Roller carriage assembly 30 comprises three major subassemblies: carriage weldment 40 , lead screw drive assembly 60 , and roller arm assembly 50 .
Carriage weldment 40 is a load-bearing part and typically comprises three or more plates 31 , which are preferably 18″ ID rolled plates, which are tied together with top plate 34 and bottom plate 35 . Two rolled plates 31 comprise slots and channels 36 on their respective sides to allow rails 14 to pass through rolled plates 31 . Rails 3 ( FIG. 5E ) mounted to bottom plate 35 secure a sliding roller frame 54 to carriage weldment 40 .
Latch mount plates 4 ( FIG. 5A ) on top of each channel 36 act as mounting points for latches 33 . A smaller hole 113 ( FIG. 5 b ) on each of latch mount plates 4 allows for a lockout pin (not shown in the figures) to be installed which overrides the ratcheting mechanism.
Two slotted cylinder plates 112 ( FIG. 5A ) are mounted on top of carriage weldment 40 . Cylinder 114 ( FIG. 5 ) slides into slots 115 ( FIG. 5D ) in slotted cylinder plates 112 .
Lead screw drive assembly 60 typically comprises a hydraulically powered unit, e.g. motor 63 , that drives roller arm assembly 50 back and forth along an axis defined by roller frame 54 . In preferred embodiments, lead screw drive assembly 60 is able to be removed subsea to extend its life. Motor 63 is preferably a 240 cc hydraulic motor which is coupled to lead screw 61 which can vary in length as needed, e.g. from around 1.5 inches to around 5 inches, with a typical travel of around 59 inches.
Motor mounting frame 6 ( FIG. 4B ) houses a docking probe receptacle, 17H dual port manifold 7 ( FIG. 5G ), and motor 63 . The docking probe receptacle interfaces with the docking probe on the carriage. Lead screw 61 nut is flanged and is attached to a drive plate. The drive plate interfaces with slots on the roller frame in order to drive it back and forth. Two stainless rods running the length of the screw prevent the drive plate from rotating while the screw is rotating. The 17H manifold provides an ROV interface for driving roller arm assembly 50 .
Roller arm assembly 50 slides in and out of carriage weldment 40 on roller frame 54 . Lead screw drive assembly 60 is removable and interfaces with carriage weldment 40 and roller arm assembly 50 in order to drive roller arm assembly 50 forward and backward with respect an axis defined by carriage weldment 40 . Latches on the sides of carriage weldment 40 interface with the gear rack in order to perform a one-way ratcheting function. Two ROV operable pins on top of carriage weldment 40 allow for the cylinder to be removed subsea. One 725 pound anode is welded to the top of carriage weldment 40 and provides cathodic protection for the carriage, as well as pile tower 10 . UHMW strips line the inside of each of the three rolled plates of the carriage. This reduces friction and eliminates the possibility of carriage weldment 40 binding up while being lifted under load.
A set of rollers 52 is mounted to roller frame 54 , which typically comprises a set of cantilevered I-beams, and roller frame 54 is typically mounted to carriage weldment 40 to support pipeline 100 . A hydraulic motor and lead screw are used to drive the I-Beams back and forth. Latch pawls interface with the gear teeth on pile tower 10 to perform a one-way ratcheting action.
Roller box assembly 50 defines a pipeline interface and allows for free axial movement of pipeline 100 ( FIG. 6 ) due to expansion via three rollers 52 , 53 . Roller arm assembly 50 comprises roller frame 54 , typically a set of matching I-beams, slotted drive mount 9 ( FIG. 4C ), and roller box assembly 59 .
In embodiments, roller frame uses a set of I-beams that ride along rails 3 ( FIG. 5E ) in carriage assembly 40 .
Drive mount 9 is typically bolted to the back of roller frame 54 and accepts drive plate 116 ( FIG. 4A ) on lead screw drive assembly 60 . Machined plate 117 ( FIG. 4D ) rides on top of roller frame 54 and houses the bearing and hub for roller box assembly 59 .
Roller box assembly 59 contains typically contains two or more rollers 52 , 53 , preferably three rollers 52 , 53 as well as mounting plates 118 ( FIG. 4D ), hub 119 ( FIG. 4E ) (which can be a pivoting base), and bearings 120 ( FIG. 4F ). Two outside rollers 52 match the radius of pipeline 100 ( FIG. 6 ) and extend up to three inches below the centerline of pipeline 100 . Middle roller 53 matches the radius of pipeline 100 but does not extend up the side of pipeline 100 . Rollers 52 , 53 are typically disposed about stainless steel axles (not specifically shown in the figures). Rollers 52 , 53 are held together with two mount plates 118 ( FIG. 4D ), which preferably comprise bronze bushings for bearings.
A pivoting base 119 ( FIG. 4E ) of roller box assembly 50 allows rollers 52 to dynamically conform (pitch) to the actual pipeline 100 position, thus ensuring an equal distribution of weight on all three rollers 52 , 53 at all times.
The hub weldment supports the rollers 52 and has a bronze bearing cup around it to reduce friction. Roller box assembly can usually pivot up and down, as well as yaw side-to-side, but cannot roll side-to-side.
The roller shafts and hub typically comprise 316 stainless steel. The surfaces of rollers 52 , 53 typically comprise 90 durometer polyurethane.
Jacking assembly 70 comprises jacking frame 77 , latches 72 , two ROV operable pins 74 , and two anodes 121 ( FIG. 5F ) and is used to raise roller carriage assembly 30 . Its “inchworm” hydraulic lifting mechanism is typically completely removable and comprises a hydraulic lifting mechanism and lateral adjustment hydraulic motor-driven screw-drive mechanism which allows for removal for ease of repairs and preservation/storage for future deployment/adjustments as required.
Jacking frame 77 comprises two rolled plates 71 , which act as interfaces for rails 14 , connected by I-beam 78 . Rolled plates 71 slide up and down along rails 14 . Channels 79 in the sides of rolled plates 71 allow clearance for rails 14 on pile tower 10 . Holes 79 a in each channel 79 allow for lockout pins (not shown in the figures) to be installed in order to set the location of jacking frame 77 relative to legs 15 .
Mounting plates (not shown in the figures) may be used for mounting one-way latches 72 . The mounting plates may also comprise a smaller secondary hole (not shown in the figures) which can be used to unlock and override the one-way ratcheting feature.
Two slotted plates 112 ( FIG. 5A ) on the bottom side of I-beam 79 provide a mounting location for cylinder 114 ( FIG. 5 ).
Jacking frame 77 also comprises two threaded bosses on the front in order for a continuity pin (not shown in the figures) to be installed.
Two 725 pound anodes 121 ( FIG. 5F ) are attached to the back of jacking frame 77 to provide cathodic protection for jacking frame 77 and pile tower 10 .
Jacking frame 77 typically uses the same one-way latch pawls 72 as does roller carriage assembly 30 .
Cylinder assembly 121 ( FIG. 5F ) is used to alternately raise jacking frame 77 and roller carriage assembly 30 . ROV operable pins allow for removal of cylinder 114 ( FIG. 5 ). Cylinder assembly 122 ( FIG. 5G ) consists of cylinder 114 and hydraulic control panel 123 ( FIG. 5G ). Cylinder 114 typically has a bore of around 5 inches and with 2 feet of total stroke. In preferred embodiments, cylinder 114 is rated for up to 55,000 pounds of force when extending and 45,000 pounds when retracting.
Cylinder 114 ( FIG. 5 ) is typically fitted with trunion nuts 124 ( FIG. 5G ) to allow it to be installed and removed from slotted plates 112 ( FIG. 5A ) on carriage weldment 40 and jacking frames 77 . Hydraulic control panel houses a 17H dual port manifold, as well as a 5000 psi pressure gauge. The gauge can be used to roughly estimate the weight of the load being lifted. The 17H manifold allows for ROV control of the cylinder.
In preferred embodiments, rotating components comprise 45 ksi nickel aluminum bronze; pins, rotating shafts, or areas where corrosion resistance is important comprise 316 stainless steel; and rolled plates which ride up and down legs 15 comprise ultra high molecular weight polyethylene (“UHMW”).
In the operation of various embodiments, referring additionally to FIGS. 6-9 , after device 1 is embedded into sea floor 110 , an ROV will actuate motor 63 which will turn lead screw 61 , thus extending roller box assembly 59 until rollers 52 , 53 are directly under pipeline 100 . The ROV will then swivel roller box assembly 59 until roller box assembly 59 is axially aligned with pipeline 100 . The ROV will then actuate cylinder 114 ( FIG. 5 ) in order to extend it and thereby extend cylinder 114 . One-way latches 33 on carriage weldment 40 will keep carriage weldment 40 from moving down, while one-way latches 72 on jacking frame 77 allow jacking frame 77 to move upward. Once the cylinder is fully extended, the ROV will then retract the cylinder. The cylinder will retract. The one-way latches will keep jacking frame 77 from moving down, while the one-way latches on carriage weldment 40 will allow carriage weldment 40 to be pulled up by the cylinder. This process is repeated until pipeline 100 is at the desired height. The ROV will then install pins in carriage weldment 40 and jacking frame 77 to fix its position. The ROV will install continuity pins in the 5 threaded bosses on carriage weldment 40 and jacking frame 77 . The ROV will then remove cylinder assembly 122 ( FIG. 5G ) as well as lead screw drive assembly 60 .
During lifting operations, pile tower 10 will be lifted by a two-part sling via a padeye at the top of pile tower 10 , and a lifting bail at the bottom of pile tower 10 . A 60° sling angle will be used when lifting. This will result in roughly 35,000 pounds of force on each lifting eye. During transport, pile tower 10 will be laid on deck horizontally. Device 1 will lay with its pipeline-facing side facing down on the deck. Timbers or other blocks will be laid under pile tower 10 to raise the structure slightly off of the deck. The 60,000 pound weight of device 1 will rest on these timbers.
It will be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated above in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as recited in the appended claims. | A system and method for securely cradling a subsea pipeline is claimed that lands on one side of the pipeline, is embedded into the sea floor, reaches under the pipeline, positions the cradling structure, and then lifts the pipeline. The system typically comprises a gravity driven pile based device, comprising a pile tower, a roller carriage assembly, and a jacking assembly that engages the roller carriage assembly and pile tower rails. |
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FIELD OF THE INVENTION
This invention relates to an apparatus that allows a user to move or be displaced in from one location to another along a track having a channel.
BACKGROUND OF THE INVENTION
Challenge courses are structures that allow a person or team to challenge themselves by participating in various events such as walking along swinging ropes or planks, at elevated heights. These courses are also used to train military personnel. These courses are also used at recreational parks or other such centers that have go-carts and miniature golf.
Zip lines are generally ropes or cables that are connected at both ends to fixed members of varying heights. In other words, one end is higher than the other. A participant then, by use of a pulley that rotatably engages with the rope or cable, glides from the higher end to the lower end.
The present invention is a track that has a channel configured to slow or stop a moveable member as it reaches a certain area of the track. The user then has to move a puck from its current position, so it can then slide with respect to the track, until, if, another stopping means is encountered. This prevents someone from falling downwardly into the person adjacent to them. This also prevents someone from sliding down the track.
This differs from the prior art in that it there is no way to prevent the puck from sliding down the track from top to bottom uninhibited.
There exists a need for a means to prevent a puck from sliding uninhibited downwardly in the track.
There also exists the need to prevent someone to fall into the person adjacent to them.
Multiple embodiments of the system are disclosed herein. It will be understood that other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings.
REFERENCE NUMERALS LIST
10 challenge course
20 element track
30 track with stopping means
40 stairs
50 channel
60 stopping means
70 first side
80 second side
90 first side first angle
100 second side first angle
110 first side second angle
120 second side second angle
140 second side third angle
150 rightwardly angled stopping means
160 leftwardly angled stopping means
170 puck
180 puck member
190 user
200 harness
210 track inside
220 interface
230 downward direction
SUMMARY OF THE INVENTION
One aspect of the present invention is a track with stopping means 30 , comprising: the track with stopping means 30 having a first side 70 , and an opposed second side 80 to define a channel 50 ; said first side 70 connected to a first side first angle 90 that extends rightwardly about 24 degrees for about 2.46 inches and connect to a first side second angle 110 that is substantially parallel to said first side 70 ; said second side 80 connected to a second side first angle 100 that extends rightwardly about 12.5 degrees for about 2.3 inches to a second side second angle 120 that is substantially perpendicular to said second side 80 ; said second side second angle 120 extends about ½ inch to a second side third angle 140 that is substantially parallel to said second side; an interface 220 where said second side first angle 100 connects to said second side second angle 120 .
Another aspect of the present invention is a track with stopping means 30 , comprising: the track with stopping means 30 having a first side 70 , and an opposed second side 80 to define a channel 50 ; said first side 70 connected to a first side first angle 90 that extends leftwardly about 24 degrees for about 2.46 inches and connect to a first side second angle 110 that is substantially parallel to said first side 70 ; said second side 80 connected to a second side first angle 100 that extends leftwardly about 12.5 degrees for about 2.3 inches to a second side second angle 120 that is substantially perpendicular to said second side 80 ; said second side second angle 120 extends about ½ inch to a second side third angle 140 that is substantially parallel to said second side; an interface 220 where said second side first angle 100 connects to said second side second angle 120 .
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of one embodiment of the present invention used with a challenge course;
FIG. 2 is a pictorial view of one embodiment of the present invention used above a stairway;
FIG. 3 is another pictorial view of one embodiment of the present used above a stairway;
FIG. 4 is a pictorial view of a puck member stopped by the stopping means;
FIG. 5 is a pictorial view of an embodiment of the channel, stopping means, rightwardly angled stopping means, and leftwardly angled stopping means;
FIG. 6 is a cross sectional view of FIG. 5 ;
FIG. 7 is a sectional view of the line B-B of FIG. 5 ;
FIG. 8 is a sectional view of the line A-A of FIG. 5 ;
FIG. 9 is a pictorial showing two users ascending a stairway using the track with stopping means;
FIG. 10 is a pictorial showing two users descending a stairway using the track with stopping means; and
FIG. 11 is a pictorial showing two users ascending a stairway using the track with stopping means.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly,” “downwardly,” “rightwardly,” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the system and designated parts. Said terminology will include the words specifically mentioned, derivatives, and similar words. Also, “connected to,” “secured to,” or similar language includes the definitions “indirectly connected to,” “directly connected to,” “indirectly secured to,” and “directly secured to.”
FIG. 1 illustrates a challenge course 10 that can utilize the present inventions, titled track with stopping means 30 . The track with stopping means 30 may have a differently configured channel 50 than a typical element track 20 .
FIG. 2 illustrates an embodiment of the track with stopping means 30 secured above a stairway 40 . When above a stairway, if the user 190 falls or slips, then a puck member 180 that may descend until it encounters a stopping means 60 , at which point it would stop, preventing the user from further falling.
FIG. 3 illustrates a one embodiment of track with stopping means 30 and a stopping means 60 .
FIG. 4 illustrates an embodiment of the stopping means 60 . The puck 170 may be movably disposed within the track with stopping means 30 . In one embodiment the puck 170 may have a puck member 180 descending therefrom, downwardly to be connected, directly, or indirectly to a harness worn by the user 190 . In FIG. 4 , the puck member 180 is stopped by the stopping means 60 .
FIG. 5 illustrates an embodiment of a track with stopping means 30 . Three stopping means 60 are shown in FIG. 5 .
FIG. 6 illustrates a cross section of FIG. 5 . The puck 170 may be movably displaced in the track with stopping means 30 upwardly from the channel 50 . A puck member 180 may extend downwardly through the channel 50 to a harness 200 that may be connected to a user 190 .
FIG. 7 illustrates the stopping means 60 . The stopping means 60 may be integral with a standard channel having a first side 70 and a second side 80 . The first side 70 may extend to a first side first angle 90 about 24 degrees to the right at a distance of about 2.46 inches. The first side first angle 90 may then extend to a first side second angle 110 that is substantially parallel to the first side 70 .
The second side 80 may extend to a second side first angle 100 about 12.5 degrees to the right at a distance of about 2.3 inches. The second side first angle 100 may extend toward the first side first angle 90 to a second side second angle 120 that is substantially perpendicular to the second side 80 for a distance of about ½ of an inch. The junction of the second side first angle 100 with the second side second angle 120 may have a radius of about ⅛ of an inch.
The second side second angle 120 may extend to a second side third angle 140 that may be substantially parallel to the second side 80 .
Generally, there the space between the second side 80 and the first side 70 defines the channel 50 , and the width of the channel may be about ¾ of an inch.
The present invention 30 may have a stopping means 60 disposed about 2 feet away from an adjacent stopping means 60 . The stopping means 60 may be configured as a mirror image of any adjacent stopping means 60 .
For example, the stopping means 60 adjacent to the above described stopping means 60 may have a first side 70 and a second side 80 . The first side 70 may extend to a first side first angle 90 about 24 degrees to the left at a distance of about 2.46 inches. The first side first angle 90 may then extend to a first side second angle 110 that is substantially parallel to the first side 70 .
The second side 80 may extend to a second side first angle 100 about 12.5 degrees to the left at a distance of about 2.3 inches. The second side first angle 100 may extend inwardly to a second side second angle 120 that is substantially perpendicular to the second side 80 for a distance of about ½ of an inch. The junction of the second side first angle 100 with the second side second angle 120 may have a radius of about ⅛ of an inch.
The second side second angle 120 may extend to a second side third angle 140 that may be substantially parallel to the second side 80 .
The adjacent or downstream stopping means 60 may be arranged in alternating mirror image fashion, but do not have to be.
If a user 190 starts to fall or if the puck member 180 is displaced in the downward direction 230 , then the user puck 170 may slide down the track inside 210 until the puck member 180 contacts the second side second angle 120 , which stops the puck member 180 . The user 190 may then move the puck member 180 off of the second side second angle 120 or away from the second side first angle 100 to allow the puck member 180 to move between the first side 70 and the second side 80 , or move within the channel 50 .
If a user 190 and puck member 180 is moving in the direction opposite of the downward direction 230 then the puck member 180 would contact the first side first angle 90 and continue to move within the channel 50 without stopping because the puck member 180 would not contact the second side second angle 120 , which causes to stop the puck member 180 .
In one embodiment, the puck member 180 may have a diameter of about 0.575 inches. In another embodiment the puck member 180 may have a diameter of about 0.580 inches.
FIG. 8 illustrates a sectional view of the track with stopping means 30 .
FIG. 9 illustrates an example of two users 190 walking upwardly on a staircase or stairs 40 , if the second user falls, the stopping means 60 will prevent him from descending all the way down to the bottom of the stairs 40 .
FIG. 10 illustrates an example of two users 190 descending a stairway 40 with one user 190 falling, as the stopping means 60 prevents them from sliding down to the bottom of the stairs 40 . If the user would slide to the bottom of the stairs 40 , the user 190 may have reached a speed that would result in a greater force to stop the user 190 , and thus greater force for the user 190 to endure.
FIG. 11 illustrates two users 190 ascending stairs 40 , with the first user 190 falling, and not falling into the lower user 190 because the stopping means 60 stops the puck member 180 at the junction or interface between the first side first angle 110 and the second side second angle 120 .
The track with stopping means 30 may be connected to a challenge course or an element track 20 , so the puck 170 may move from the track with stopping means 30 to a challenge course track, or an element track 20 , or a zip line.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A track having a stopping means that can stop a puck member from descending an undesired distance. After stopping of the puck member, the user can relocate the puck member within a channel for continued downward movement within the channel. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 14/331,841, filed Jul. 15, 2014 (issuing as U.S. Pat. No. 9,567,805 on Feb. 14, 2017), which is a continuation of U.S. patent application Ser. No. 14/022,384, filed Sep. 10, 2013 (now as U.S. Pat. No. 8,776,875 on Jul. 15, 2014), which was a continuation of U.S. patent application Ser. No. 13/663,609, filed Oct. 30, 2012 (now as U.S. Pat. No. 8,528,631 on Sep. 10, 2013), which was a continuation of U.S. patent application Ser. No. 13/438,053, filed Apr. 3, 2012, (now as U.S. Pat. No. 8,297,348 on Oct. 30, 2012), which was a continuation of U.S. patent application Ser. No. 13/074,327, filed Mar. 29, 2011 (now as U.S. Pat. No. 8,146,663 on Apr. 3, 2012), which was a continuation of U.S. patent application Ser. No. 12/724,846, filed Mar. 16, 2010, (now as U.S. Pat. No. 7,913,760 on Mar. 29, 2011), which application was a continuation of U.S. patent application Ser. No. 11/778,956, filed Jul. 17, 2007 (now as U.S. Pat. No. 7,681,646 on Mar. 23, 2010) which was a continuation-in-part of U.S. patent application Ser. No. 11/751,740, filed May 22, 2007 (now as U.S. Pat. No. 7,533,720 on May 19, 2009) which was a non-provisional of US Provisional Patent Application Ser. No. 60/829,990, filed Oct. 18, 2006 and U.S. Provisional Patent Application Ser. No. 60/803,055, filed May 24, 2006. Each of these applications are incorporated herein by reference. Priority of each of these applications is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND
[0004] In top drive rigs, the use of a top drive unit, or top drive power unit is employed to rotate drill pipe, or well string in a well bore. Top drive rigs can include spaced guide rails and a drive frame movable along the guide rails and guiding the top drive power unit. The traveling block supports the drive frame through a hook and swivel, and the driving block is used to lower or raise the drive frame along the guide rails. For rotating the drill or well string, the top drive power unit includes a motor connected by gear means with a rotatable member both of which are supported by the drive frame.
[0005] During drilling operations, when it is desired to “trip” the drill pipe or well string into or out of the well bore, the drive frame can be lowered or raised. Additionally, during servicing operations, the drill string can be moved longitudinally into or out of the well bore.
[0006] The stem of the swivel communicates with the upper end of the rotatable member of the power unit in a manner well known to those skilled in the art for supplying fluid, such as a drilling fluid or mud, through the top drive unit and into the drill or work string. The swivel allows drilling fluid to pass through and be supplied to the drill or well string connected to the lower end of the rotatable member of the top drive power unit as the drill string is rotated and/or moved up and down.
[0007] Top drive rigs also can include elevators are secured to and suspended from the frame, the elevators being employed when it is desired to lower joints of drill string into the well bore, or remove such joints from the well bore.
[0008] At various times top drive operations, beyond drilling fluid, require various substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as the top drive unit is rotating and/or moving the drill or well string up and/or down, but bypassing the top drive's power unit so that the substances do not damage/impair the unit. Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movement by the top drive unit of the drill or well string.
[0009] A need exists for a device facilitating insertion of various substances downhole through the drill or well string, bypassing the top drive unit, while at the same time allowing the top drive unit to rotate and/or move the drill or well string.
[0010] One example includes cementing a string of well bore casing. In some casing operations it is considered good practice to rotate the string of casing when it is being cemented in the wellbore. Such rotation is believed to facilitate better cement distribution and spread inside the annular space between the casing's exterior and interior of the well bore. In such operations the top drive unit can be used to both support and continuously rotate/intermittently reciprocate the string of casing while cement is pumped down the string's interior. During this time it is desirable to by-pass the top drive unit to avoid possible damage to any of its portions or components.
[0011] The following U.S. patents are incorporated herein by reference: U.S. Pat. Nos. 4,722,389 and 7,007,753.
[0012] While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
[0013] The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. One embodiment relates to an assembly having a top drive arrangement for rotating and longitudinally moving a drill or well string. In one embodiment is provided a swivel apparatus, the swivel generally comprising a mandrel and a sleeve with a packing configuration, the swivel being especially useful for top drive rigs.
[0014] In one embodiment the sleeve can be rotatably and sealably connected to the mandrel. The swivel can be incorporated into a drill or well string, enabling string sections both above and below the sleeve to be rotated in relation to the sleeve. Additionally, the swivel provides a flow path between the exterior of the sleeve and interior of the mandrel while the drill string is being rotated and/or being moved in a longitudinal direction (up or down). The interior of the mandrel can be fluidly connected to the longitudinal bore of the casing or drill string thereby providing a flow path from the exterior of the sleeve to the interior of the casing/drill string.
[0015] In one embodiment is provided a method and apparatus for servicing a well wherein a swivel is connected to a top drive unit for conveying pumpable substances from an external supply through the swivel for discharge into the well string and bypassing the top drive unit.
[0016] In another embodiment is provided a method of conducting servicing operations in a well bore, such as cementing, comprising the steps of moving a top drive unit rotationally and/or longitudinally to provide longitudinal movement and/or rotation in the well bore of a well string suspended from the top drive unit, rotating the drill or well string and supplying a pumpable substance to the well bore in which the drill or well string is manipulated by introducing the pumpable substance at a point below the top drive power unit and into the well string.
[0017] In other embodiments are provided a swivel placed below the top drive unit can be used to perform jobs such as spotting pills, squeeze work, open formation integrity work, kill jobs, fishing tool operations with high pressure pumps, sub-sea stack testing, rotation of casing during side tracking, and gravel pack or frack jobs. In still other embodiments a top drive swivel can be used in a method of pumping loss circulation material (LCM) into a well to plug/seal areas of downhole fluid loss to the formation and in high speed milling jobs using cutting tools to address down hole obstructions. In other embodiments the top drive swivel can be used with free point indicators and shot string or cord to free stuck pipe where pumpable substances are pumped downhole at the same time the downhole string/pipe/free point indicator is being rotated and/or reciprocated. In still other embodiments the top drive swivel can be used for setting hook wall packers and washing sand.
[0018] In still other embodiments the top drive swivel can be used for pumping pumpable substances downhole when repairs/servicing is being done to the top drive unit and rotation of the downhole drill string is being accomplished by the rotary table. Such use for rotation and pumping can prevent sticking/seizing of the drill string downhole. In this application safety valves, such as TIW valves, can be placed above and below the top drive swivel to enable routing of fluid flow and to ensure well control.
[0019] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0021] FIGS. 1A and 1B are a schematic views showing a top drive rig with one embodiment of a top drive swivel incorporated in the drill string;
[0022] FIG. 2 is a perspective view of one embodiment of a top drive swivel;
[0023] FIG. 3 is a sectional view of a mandrel which can be incorporated in the swivel of FIG. 2 ;
[0024] FIG. 4 is a perspective view of a sleeve, clamp, and torque arm which can be incorporated into the swivel of FIG. 2 ;
[0025] FIG. 5 is an exploded view of the sleeve, clamp, and torque arm of FIG. 4 ;
[0026] FIG. 6 is a cutaway perspective view of the swivel of FIG. 2 ;
[0027] FIGS. 7A and 7B include a sectional view of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
[0028] FIG. 8 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 2 ;
[0029] FIG. 9 is a perspective view of a spacer;
[0030] FIG. 10 is a top view of the spacer of FIG. 9 ;
[0031] FIG. 11A is a sectional side view of the spacer of FIG. 9 ;
[0032] FIG. 11B is an enlarged sectional side view of the spacer of FIG. 9 ;
[0033] FIG. 12 is a perspective view of a female backup ring;
[0034] FIG. 13 is a top view of the female backup ring of FIG. 12 ;
[0035] FIG. 14A is a sectional side view of the female backup ring of FIG. 12 ;
[0036] FIG. 14B is an enlarged sectional side view of the female backup ring of FIG. 12 ;
[0037] FIG. 15 is a perspective view of a seal ring;
[0038] FIG. 16 is a top view of the seal ring of FIG. 15 ;
[0039] FIG. 17A is a sectional side view of the seal ring of FIG. 15 ;
[0040] FIG. 17B is an enlarged sectional side view of the seal ring of FIG. 15 ;
[0041] FIG. 18 is a perspective view of a rope seal;
[0042] FIG. 19 is a top view of the rope seal of FIG. 18 ;
[0043] FIG. 20A is a sectional side view of the rope seal of FIG. 18 ;
[0044] FIG. 20B is an enlarged sectional side view of the rope seal of FIG. 18 ;
[0045] FIG. 21 is a perspective view of a seal ring;
[0046] FIG. 22 is a top view of the seal ring of FIG. 21 ;
[0047] FIG. 23A is a sectional side view of the seal ring of FIG. 21 ;
[0048] FIG. 23B is an enlarged sectional side view of the seal ring of FIG. 21 ;
[0049] FIG. 24 is a perspective view of a seal ring;
[0050] FIG. 25 is a top view of the seal ring of FIG. 24 ;
[0051] FIG. 26A is a sectional side view of the seal ring of FIG. 24 ;
[0052] FIG. 26B is an enlarged sectional side view of the seal ring of FIG. 24 ;
[0053] FIG. 27 is a perspective view of a male backup ring;
[0054] FIG. 28 is a top view of the male backup ring of FIG. 27 ;
[0055] FIG. 29A is a sectional side view of the male backup ring of FIG. 27 ;
[0056] FIG. 29B is an enlarged sectional side view of the male backup ring of FIG. 27 ;
[0057] FIGS. 30A and 30B include a sectional view of another embodiment of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
[0058] FIG. 31 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 30A ;
[0059] FIG. 32 is a perspective view of a spacer;
[0060] FIG. 33 is a top view of the spacer of FIG. 32 ;
[0061] FIG. 34A is a sectional side view of the spacer of FIG. 32 ;
[0062] FIG. 34B is an enlarged sectional side view of the spacer of FIG. 32 ;
[0063] FIG. 35 is a perspective view of a female backup ring;
[0064] FIG. 36 is a top view of the female backup ring of FIG. 35 ;
[0065] FIG. 37A is a sectional side view of the female backup ring of FIG. 35 ;
[0066] FIG. 37B is an enlarged sectional side view of the female backup ring of FIG. 35 ;
[0067] FIG. 38 is a perspective view of a seal ring;
[0068] FIG. 39 is a top view of the seal ring of FIG. 38 ;
[0069] FIG. 40A is a sectional side view of the seal ring of FIG. 38 ;
[0070] FIG. 40B is an enlarged sectional side view of the seal ring of FIG. 38 ;
[0071] FIG. 41 is a perspective view of a rope seal;
[0072] FIG. 42 is a top view of the rope seal of FIG. 41 ;
[0073] FIG. 43A is a sectional side view of the rope seal of FIG. 41 ;
[0074] FIG. 43B is an enlarged sectional side view of the rope seal of FIG. 41 ;
[0075] FIG. 44 is a perspective view of a seal ring;
[0076] FIG. 45 is a top view of the seal ring of FIG. 44 ;
[0077] FIG. 46A is a sectional side view of the seal ring of FIG. 44 ;
[0078] FIG. 46B is an enlarged sectional side view of the seal ring of FIG. 44 ;
[0079] FIG. 47 is a perspective view of a seal ring;
[0080] FIG. 48 is a top view of the seal ring of FIG. 47 ;
[0081] FIG. 49A is a sectional side view of the seal ring of FIG. 47 ;
[0082] FIG. 49B is an enlarged sectional side view of the seal ring of FIG. 47 ;
[0083] FIG. 50 is a perspective view of a male backup ring;
[0084] FIG. 51 is a top view of the male backup ring of FIG. 50 ;
[0085] FIG. 52A is a sectional side view of the male backup ring of FIG. 50 ;
[0086] FIG. 52B is an enlarged sectional side view of the male backup ring of FIG. 50 .
DETAILED DESCRIPTION
[0087] Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
[0088] FIGS. 1A and 1B are schematic views showing a top drive rig 1 with one embodiment of a top drive swivel 30 incorporated into drill string 20 . FIG. 1A shows a rig 1 having a top drive unit 10 . Rig 1 comprises supports 16 , 17 ; crown block 2 ; traveling block 4 ; and hook 5 . Draw works 11 uses cable 12 to move up and down traveling block 4 , top drive unit 10 , and drill string 20 . Traveling block 4 supports top drive unit 10 . Top drive unit 10 supports drill string 20 .
[0089] During drilling operations, top drive unit 10 can be used to rotate drill string 20 which enters wellbore 14 . Top drive unit 10 can ride along guide rails 15 as unit 10 is moved up and down. Guide rails 15 prevent top drive unit 10 itself from rotating as top drive unit 10 rotates drill string 20 . During drilling operations drilling fluid can be supplied downhole through drilling fluid line 8 and gooseneck 6 .
[0090] As shown in FIG. 1B , during operations swivel 30 can be connected to rig 1 through clamp 600 and torque arm 630 . Torque are 630 can be pivotally connected to swivel 30 and can resist rotational movement of swivel sleeve 150 relative to rig 1 . Torque arm 630 can be slidably connected to rig 1 to allow a certain amount of longitudinal movement of swivel 30 with drill string 20 .
[0091] At various times top drive operations, beyond drilling fluid, require substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as top drive unit 10 is rotating and/or moving drill or well string 20 up and/or down and bypassing top drive unit 10 so that the substances do not damage/impair top drive unit 10 . Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movements of drill or well string 20 being moved/rotated by top drive unit 10 . This can be accomplished by using top drive swivel 30 .
[0092] Top drive swivel 30 can be installed between top drive unit 10 and drill string 20 . One or more joints of drill pipe 18 can be placed between top drive unit 10 and swivel 30 . Additionally, a valve can be placed between top drive swivel 30 and top drive unit 10 . Pumpable substances can be pumped through hose 31 , swivel 30 , and into the interior of drill string 20 thereby bypassing top drive unit 10 . Top drive swivel 30 is preferably sized to be connected to drill string 20 such as 4½ inch (11.43 centimeter) IF API drill pipe or the size of the drill pipe to which swivel 30 is connected to. However, cross-over subs can also be used between top drive swivel 30 and connections to drill string 20 . Two sizes for swivel 30 will be addressed in this application—a 4½ inch (11.43 centimeter) version and a 6⅝ inch (16.83 centimeter) version.
[0093] FIG. 2 is a perspective view of one embodiment of a swivel 30 . Swivel 30 can be comprised of mandrel 40 and sleeve 150 . Sleeve 150 can be rotatably and sealably connected to mandrel 40 . Accordingly, when mandrel 40 is rotated, sleeve 150 can remain stationary to an observer insofar as rotation is concerned. As will be discussed later inlet 200 of sleeve 150 is and remains fluidly connected to a the central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 .
[0094] FIG. 3 is a sectional view of mandrel 40 which can be incorporated in swivel 30 . Mandrel 40 can be comprised of upper end 50 and lower end 60 . Central longitudinal passage 90 can extend from upper end 50 through lower end 60 . Lower end 60 can include a pin connection 80 or any other conventional connection. Upper end 50 can include box connection 70 or any other conventional connection. Mandrel 40 can in effect become a part of drill string 20 . Sleeve 150 can fit over mandrel 40 and become rotatably and sealably connected to mandrel 40 . Mandrel 40 can include shoulder 100 to support sleeve 150 . Mandrel 40 can include one or more radial inlet ports 140 fluidly connecting central longitudinal passage 90 to recessed area 130 . Recessed area 130 preferably forms a circumferential recess along the perimeter of mandrel 40 and between packing support areas 131 , 132 . In such manner recessed area 130 will remain fluidly connected with radial passage 190 and inlet 200 of sleeve 150 (see FIGS. 6 and 7A ).
[0095] Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 52 and 5/16 inches (132.87 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. NC50 is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Such tool joint designation is equivalent to and interchangeable with 4½ inch (11.43 centimeter) IF (Internally Flush), 5 inch (12.7 centimeter) XH (Extra Hole) and 5½ inch (13.97 centimeter) DSL (Double Stream Line) connections. Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7 G for new rotary shouldered tool joint connections having 6⅝ inch (16.83 centimeters) outer diameter and a 2¾ inch (6.99 centimeter) inner diameter. The Strength and Design Formulas of API 7 G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 1,477,000 pounds (6,570 kilo newtons) tensile load at the minimum yield stress; (b) 62,000 foot-pounds (84 kilo newton meters) torsional load at the minimum torsional yield stress; and (c) 37,200 foot-pounds (50.44 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
[0096] In another embodiment, Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 67 and 13/16 inches (172.24 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. 6⅝ inch (16.83 centimeters) FH is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7 G for new rotary shouldered tool joint connections having 8½ inch (21.59 centimeter) outer diameter and a 4¼ inch (10.8 centimeter) inner diameter. The Strength and Design Formulas of API 7 G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 2,094,661 pounds (9,318 kilo newtons) tensile load at the minimum yield stress; (b) 109,255 foot-pounds (148.1 kilo newton meters) torsion load at the minimum torsional yield stress; and (c) 65,012 foot-pounds (88.14 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
[0097] To reduce friction between mandrel 40 and packing units 305 , 405 and increase the life expectancy of packing units 305 , 405 , packing support areas 131 , 132 can be coated and/or sprayed welded with a materials of various compositions, such as hard chrome, nickel/chrome or nickel/aluminum (95 percent nickel and 5 percent aluminum) A material which can be used for coating by spray welding is the chrome alloy TAFA 95MX Ultrahard Wire (Armacor M) manufactured by TAFA Technologies, Inc., 146 Pembroke Road, Concord N.H. TAFA 95 MX is an alloy of the following composition: Chromium 30 percent; Boron 6 percent; Manganese 3 percent; Silicon 3 percent; and Iron balance. The TAFA 95 MX can be combined with a chrome steel. Another material which can be used for coating by spray welding is TAFA BONDARC WIRE—75B manufactured by TAFA Technologies, Inc. TAFA BONDARC WIRE—75B is an alloy containing the following elements: Nickel 94 percent; Aluminum 4.6 percent; Titanium 0.6 percent; Iron 0.4 percent; Manganese 0.3 percent; Cobalt 0.2 percent; Molybdenum 0.1 percent; Copper 0.1 percent; and Chromium 0.1 percent. Another material which can be used for coating by spray welding is the nickel chrome alloy TAFALOY NICKEL-CHROME-MOLY WIRE-71T manufactured by TAFA Technologies, Inc. TAFALOY NICKEL-CHROME-MOLY WIRE-71T is an alloy containing the following elements: Nickel 61.2 percent; Chromium 22 percent; Iron 3 percent; Molybdenum 9 percent; Tantalum 3 percent; and Cobalt 1 percent. Various combinations of the above alloys can also be used for the coating/spray welding. Packing support areas 131 , 132 can also be coated by a plating method, such as electroplating. The surface of support areas 131 , 132 can be ground/polished/finished to a desired finish to reduce friction and wear between support areas 131 , 132 and packing units 305 , 415 .
[0098] FIG. 4 is a perspective view of a sleeve 150 , clamp 600 , and torque arm 630 which can be incorporated into swivel 30 . FIG. 5 is an exploded view of the components shown in FIG. 4 . FIG. 6 is a cutaway perspective view of swivel 30 . FIG. 7A is a sectional view of swivel 30 taken along the line 7 A- 7 A of FIG. 6 .
[0099] FIG. 6 is an overall perspective view (and partial sectional view) of top drive swivel 30 . Sleeve 150 is shown rotatably connected to mandrel 40 . Bearings 145 , 146 allow sleeve 150 to rotate in relation to mandrel 40 . Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Retaining nut 800 retains sleeve 150 on mandrel 40 . Inlet 200 of sleeve 150 is fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 ; passing through radial passage 190 ; passing through recessed area 130 ; passing through one of the plurality of radial inlet ports 40 ; passing through central longitudinal passage 90 ; and exiting mandrel 40 through central longitudinal passage 90 at lower end 60 and pin connection 80 .
[0100] Sleeve 150 can include central longitudinal passage 180 extending from upper end 160 through lower end 170 . Sleeve 150 can also include radial passage 190 and inlet 200 . Inlet 200 can be attached by welding or any other conventional type method of fastening such as a threaded connection. If welded the connection is preferably heat treated to remove residual stresses created by the welding procedure. Lubrication port 210 (not shown) can be included to provide lubrication for interior bearings. Packing ports 220 , 230 can also be included to provide the option of injecting packing material into the packing units 305 , 405 . A protective cover 240 can be placed around packing port 230 to protect packing injector 235 . Optionally, a second protective cover can be placed around packing port 220 . Sleeve 150 can include a groove 691 for insertion of a key 700 . FIG. 7A illustrates how central longitudinal passage 90 is fluidly connected to inlet 200 through radial passage 190 .
[0101] Sleeve 150 slides over mandrel 40 . Bearings 145 , 146 rotatably connect sleeve 150 to mandrel 40 . Bearings 145 , 146 are preferably thrust bearings although many conventionally available bearing will adequately function, including conical and ball bearings. Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Inlet 200 of sleeve 150 is and remains fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 (arrow 201 ); passing through radial passage 190 (arrow 202 ); passing through recessed area 130 (arrow 202 ); passing through one of the plurality of radial inlet ports 140 (arrow 202 ), passing through central longitudinal passage 90 (arrow 203 ); and exiting mandrel 40 via lower end 60 at pin connection 80 (arrows 204 , 205 ).
[0102] Sleeve 150 is preferably fabricated from 4140 heat treated round mechanical tubing having the following properties: (120,000 psi (827,400 kilo pascal) minimum tensile strength, 100,000 psi (689,500 kilo pascal) minimum yield strength, and 285/311 Brinell Hardness Range). In one embodiment the external diameter of sleeve 150 is preferably about 11 inches (27.94 centimeters). Sleeve 150 preferably resists high internal pressures of fluid passing through inlet 200 . Preferably top drive swivel 30 with sleeve 150 will withstand a hydrostatic pressure test of 12,500 psi (86,200 kilo pascal). At this pressure the stress induced in sleeve 150 is preferably only about 24.8 percent of its material's yield strength. At a preferable working pressure of 7,500 psi (51,700 kilo pascal), there is preferably a 6.7:1 structural safety factor for sleeve 150 .
[0103] To minimize flow restrictions through top drive swivel 30 , large open areas 140 are preferred. Preferably each area of interest throughout top drive swivel 30 is larger than the inlet service port area 200 . Inlet 200 is preferably 3 inches having a flow area of 4.19 square inches (27.03 square centimeters). In one embodiment the flow area of the annular space between sleeve 150 and mandrel 40 is preferably 20.81 square inches (134.22 square centimeters). The flow area through the plurality of radial inlet ports 140 is preferably 7.36 square inches (47.47 square centimeters). The flow area through central longitudinal bore 90 is preferably 5.94 square inches 38.31 square centimeters).
[0104] Retainer nut 800 can be used to maintain sleeve 150 on mandrel 40 . Retainer nut 800 can threadably engage mandrel 40 at threaded area 801 . Set screw 890 can be used to lock in place retainer nut 800 and prevent nut 800 from loosening during operation. A set screw 890 (not shown for clarity) can threadably engages retainer nut 800 through bore 900 (not shown for clarity) and sets in one of a plurality of receiving portions 910 formed in mandrel 40 . Retaining nut 800 can also include grease injection fitting 880 for lubricating bearing 145 . A wiper ring 271 (not shown for clarity) can be set in area 270 protects against dirt and other items from entering between the sleeve 150 and mandrel 40 . A grease ring 291 (not shown for clarity) can be set in area 290 for holding lubricant for bearing 145 .
[0105] Bearing 146 can be lubricated through a grease injection fitting 211 and lubrication port 210 (not shown for clarity).
[0106] FIGS. 4 and 5 best show clamp 600 which can be incorporated into top drive swivel 30 . FIG. 5 is an exploded view of clamp 600 . Clamp 600 can comprises first portion 610 , second portion 620 , and third portion 625 . First, second, and third portions 610 , 620 , 625 can be removably attached by plurality of fasteners 670 , 680 . Key 700 can be inserted in keyway 690 of clamp 600 . A corresponding keyway 691 is included in sleeve 150 of top drive swivel 30 . Keyways 690 , 691 and key 700 prevent clamp 600 from rotating relative to sleeve 150 . A second key 720 can be installed in keyways 710 , 711 . Third, fourth, and additional keys/keyways can be used as desired.
[0107] Shackles can be attached to clamp 600 to facilitate handing top drive swivel 30 when clamp 600 is attached. Torque arm 630 can be pivotally attached to clamp 600 and allow attachment of clamp 600 (and sleeve 150 ) to a stationary part of top drive rig 1 preventing sleeve 150 from rotating while drill string 20 is being rotated by top drive 10 (and top drive swivel 30 is installed in drill string 20 ). Torque arm 630 can be provided with holes for attaching restraining shackles. Restrained torque arm 630 prevents sleeve 150 from rotating while mandrel 40 is being spun. Otherwise, frictional forces between packing units 305 , 405 and packing support areas 131 , 135 of rotating mandrel 40 would tend to also rotate sleeve 150 . Clamp 600 is preferably fabricated from 4140 heat treated steel being machined to fit around sleeve 150 .
[0108] FIG. 8 shows a blown up schematic view of packing unit 305 . FIG. 7B shows a sectional view through packing area 305 . Packing unit 305 can comprise female packing end 330 ; packing ring 340 , packing lubrication ring 350 , packing ring 360 , packing ring 370 , and packing end 380 . Packing unit 305 sealing connects mandrel 40 and sleeve 150 . Packing unit 305 can be encased by packing retainer nut 310 , spacer 320 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 305 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . Packing unit 405 (shown in FIG. 7A ) can be constructed substantially similar to packing unit 305 . The materials for packing unit 305 and packing unit 405 can be similar.
[0109] Spacer 320 can comprise, first end 322 , second end 324 , internal surface 326 , and external surface 328 . Spacer 320 can be sized based on the amount of squeezed to be applied to packing unit 305 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
[0110] Packing end 330 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 330 can comprise tip 332 with concave portion 331 . Concave portion 331 can have an angle of about 130 degrees at its center. Tip 332 can include side 333 , recessed area 334 , peripheral groove 337 and inner diameter 335 . Recessed area 334 and inner diameter 335 can be configured to minimize contact of female packing ring or end 330 with mandrel 40 . Instead, contact will be made between packing ring 340 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 330 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 340 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi (20,700 kilo pascals or 27,600 kilo pascals)). It is also believed that packing rings 370 and/or 360 perform the majority of sealing against lower pressure fluids. Female packing ring 330 can include a plurality of radial ports 336 fluidly connecting peripheral groove 337 with interior groove 338 to allow packing injected to evenly distribute around ring and into the actual sealing rings.
[0111] Packing ring 340 can comprise tip 342 , base 344 , internal surface 346 , and external surface 348 . Tip 342 can have an angle of about 120 degrees to have an non-interference fit with tip 332 of female packing end 330 which is at about 130 degrees Base 344 can have an angle of about 120 degrees. Packing ring 340 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 342 of packing ring 340 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 334 of the female packing ring or end 330 which would cause side 333 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 344 being at about 120 degrees is believed to assist in causing packing ring 340 to bear against mandrel 40 , and not side 333 of female packing ring 330 .
[0112] Packing lubrication ring 350 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 350 is shown after be shaped by packing rings 340 and 360 .
[0113] Packing ring 360 can comprise tip 362 , base 364 , internal surface 366 , and external surface 368 . Tip 362 can have an angle of about 90 degrees. Base 364 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 360 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
[0114] Packing rings 360 , 370 can have substantially the same geometric construction. Packing ring 370 can comprise tip 372 , base 374 , internal surface 376 , and external surface 378 . Tip 372 can have an angle of about 90 degrees. Base 374 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 370 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0115] In an alternative embodiment both packing rings 360 and 370 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
[0116] In another alternative embodiment packing ring 370 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 360 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0117] Male packing end or ring 380 can comprise tip 382 , base 384 , internal surface 386 , and external surface 388 . Tip 382 can have an angle of about 90 degrees. Packing end 380 is preferably an aluminum bronze male packing ring.
[0118] Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
[0119] Using the above packing configuration it has been surprisingly found that packing life in a displacement job at high pressure can be extended from about 45 minutes to about 10 hours, at rotation speeds of about 30, about 40, about 50, and about 60 revolutions per minute.
[0120] In installing packing units 305 , 405 , it has been found that the packing units should first be compressed in a longitudinal direction between sleeve 150 and a dummy cylinder (the dummy cylinder serving as mandrel 40 ) before sleeve 150 is installed on mandrel 40 . This is because a certain amount of longitudinal compression of packing units 305 , 405 will occur when fluid pressure is first exerted on these packing units. This longitudinal compression will be taken up by the respective packing retainer nuts 310 . However, using a dummy cylinder allows the individual packing retainer nuts 310 to cause pre-fluid pressure longitudinal compression on packing units 305 , 405 , but still allow the seals to maintain an internal diameter consistent with the external diameter of mandrel 40 . Such a procedure can avoid the requirement of resetting the individual packing retainer nuts 310 after fluid pressure is applied to the packing units causing longitudinal compression.
[0121] Female packing ring or end 330 can include a packing injection option. Injection fitting 225 can be used to inject additional packing material such as teflon into packing unit 305 . Head 226 for injection fitting 225 can be removed and packing material can then be inserted into fitting 225 . Head 226 can then be screwed back into injection fitting 225 which would push packing material through fitting 225 and into packing port 220 . The material would then be pushed into packing ring or end 330 . Packing ring or end 330 can comprise a plurality of radial ports 336 , outer peripheral groove 337 , and inner peripheral groove 338 . The material would proceed through outer groove 337 , through the plurality of radial ports 336 , and through inner peripheral groove 338 causing a sealing effect. The interaction between injection fitting 235 and packing unit 405 can be substantially similar to the interaction between injection fitting 225 and packing unit 305 . A conventionally available material which can be used for packing injection fittings 225 , 235 is DESCO™ 625 Pak part number 6242-12 in the form of a 1 inch by ⅜ inch (2.54 centimeter by 0.95 centimeter) stick and distributed by Chemola Division of South Coast Products, Inc., Houston, Tex.
[0122] Injection fittings 225 , 235 have a dual purpose: (a) provide an operator a visual indication whether there has been any leakage past either packing units 305 , 405 and (b) allow the operator to easily inject additional packing material and stop seal leakage without removing top drive swivel 30 from drill string 20 .
[0123] FIGS. 30A through 50 show an alternative packing arrangement for packing units 305 , 405 . In this alternative arrangement spacer 420 can include a plurality of radial ports for injecting packing filler material.
[0124] FIG. 31 shows a blown up schematic view of packing unit 405 . FIG. 30B shows a sectional view through packing unit 405 . Packing unit 405 can comprise female packing end 430 ; packing ring 440 , packing lubrication ring 450 , packing ring 460 , packing ring 470 , and packing end 480 . Packing unit 405 sealing connects mandrel 40 and sleeve 150 . Packing unit 405 can be encased by packing retainer nut 310 , spacer 420 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 405 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . An upper packing unit can be constructed substantially similar to packing unit 405 . The materials for packing unit 405 and upper packing unit can be similar.
[0125] Spacer 420 can comprise, first end 421 , second end 422 , internal surface 423 , and external surface 424 . Spacer 420 can be sized based on the amount of squeezed to be applied to packing unit 405 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
[0126] Packing end 430 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 430 can comprise tip 432 with concave portion 431 . Concave portion 431 can have an angle of about 130 degrees at its center. Tip 442 can include side 433 , recessed area 44 , peripheral groove 47 and inner diameter 445 . Recessed area 434 and inner diameter 435 can be configured to minimize contact of female packing ring or end 430 with mandrel 40 . Instead, contact will be made between packing ring 440 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 430 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 440 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi)(20,700 kilo pascals or 27,600 kilo pascals). It is also believed that packing rings 470 and/or 460 perform the majority of sealing against lower pressure fluids.
[0127] Packing ring 440 can comprise tip 442 , base 444 , internal surface 446 , and external surface 448 . Tip 442 can have an angle of about 120 degrees to have an non-interference fit with tip 432 of female packing end 430 which is at about 130 degrees Base 444 can have an angle of about 120 degrees. Packing ring 440 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 442 of packing ring 440 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 434 of the female packing ring or end 430 which would cause side 433 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 444 being at about 120 degrees is believed to assist in causing packing ring 440 to bear against mandrel 40 , and not side 433 of female packing ring 430 .
[0128] Packing lubrication ring 450 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 450 is shown after being shaped by packing rings 440 and 460 .
[0129] Packing ring 460 can comprise tip 462 , base 464 , internal surface 466 , and external surface 468 . Tip 462 can have an angle of about 90 degrees. Base 464 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 460 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
[0130] Packing rings 460 , 470 can have substantially the same geometric construction. Packing ring 470 can comprise tip 472 , base 474 , internal surface 476 , and external surface 478 . Tip 472 can have an angle of about 90 degrees. Base 474 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 470 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0131] In an alternative embodiment both packing rings 460 and 470 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
[0132] In another alternative embodiment packing ring 470 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 460 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0133] Male packing end or ring 480 can comprise tip 482 , base 484 , internal surface 486 , and external surface 488 . Tip 482 can have an angle of about 90 degrees. Packing end 480 is preferably an aluminum bronze male packing ring.
[0134] Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
[0135] The following is a list of reference numerals:
[0000]
LIST FOR REFERENCE NUMERALS
(Part No.)
(Description)
Reference Numeral
Description
1
rig
2
crown block
3
cable means
4
travelling block
5
hook
6
gooseneck
7
swivel
8
drilling fluid line
10
top drive unit
11
draw works
12
cable
13
rotary table
14
well bore
15
guide rail
16
support
17
support
18
drill pipe
19
drill string
20
drill string or work string
30
swivel
31
hose
40
swivel mandrel
50
upper end
60
lower end
70
box connection
80
pin connection
90
central longitudinal passage
100
shoulder
110
interior surface
120
external surface (mandrel)
130
recessed area
131
packing support area
132
packing support area
140
radial inlet ports (a plurality)
145
bearing
146
bearing
150
swivel sleeve
155
protruding section
156
shoulder
157
shoulder
158
packing support area
159
packing support area
160
upper end
170
lower end
180
central longitudinal passage
190
radial passage
200
inlet
201
arrow
202
arrow
203
arrow
204
arrow
205
arrow
210
lubrication port
211
grease injection fitting
220
packing port
225
injection fitting
226
head
230
packing port
235
injection fitting
240
cover
250
upper shoulder
260
lower shoulder
270
area for wiper ring
271
wiper ring (preferably Parker part number
959-65)
280
area for wiper ring
281
wiper ring (preferably Parker part number
959-65)
290
area for grease ring
291
grease ring (preferably Parker part number
2501000 Standard Polypak)
300
area for grease ring
301
grease ring (preferably Parker part number
2501000 Standard Polypak)
305
packing unit
310
packing retainer nut
314
bore for set screw
315
set screw for packing retainer nut
316
threaded area
317
set screw for receiving area
320
spacer
322
first end
324
second end
326
internal surface
328
external surface
330
female packing end and packing injection
ring
331
concave portion
332
tip
333
side
334
recessed area
335
inner diameter
336
radial port
337
peripheral groove
338
interior groove
340
packing ring
342
tip
344
base
346
internal surface
348
external surface
350
packing ring
360
packing ring
362
tip
364
base
366
internal surface
368
external surface
370
packing ring
372
tip
374
base
376
internal surface
378
external surface
380
packing end
382
tip
384
base
386
internal surface
388
external surface
405
packing unit
410
packing retainer nut
414
bore for set screw
415
set screw for packing retainer nut
416
threaded area
417
set screw for receiving area
420
spacer and packing injection ring
421
first end
422
second end
423
internal surface
424
external surface
437
radial port
438
peripheral groove
439
interior groove
430
female packing end
431
concave portion
432
tip
433
side
434
recessed area
435
inner diameter
436
external diameter
440
packing ring
442
tip
444
base
446
internal surface
448
external surface
450
packing ring
460
packing ring
462
tip
464
base
466
internal surface
468
external surface
470
packing ring
472
tip
474
base
476
internal surface
478
external surface
480
packing end
482
tip
484
base
486
internal surface
488
external surface
600
clamp
605
groove
610
first portion
620
second portion
625
third portion
630
torque arm
650
shackle
660
shackle
670
plurality of fasteners
680
plurality of fasteners
690
keyway
691
keyway
700
key
710
keyway
711
keyway
720
key
[0136] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0137] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | For use with a top drive power unit supported for connection with a well string in a well bore to selectively impart longitudinal and/or rotational movement to the well string, a feeder for supplying a pumpable substance such as cement and the like from an external supply source to the interior of the well string in the well bore without first discharging it through the top drive power unit including a mandrel extending through a sleeve which is sealably and rotatably supported thereon for relative rotation between the sleeve and mandrel. The mandrel and sleeve have flow passages for communicating the pumpable substance from an external source to discharge through the sleeve and mandrel and into the interior of the well string below the top drive power unit. The unit can include a packing injection system and novel seal configuration. |
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CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OF PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION—FIELD OF INVENTION
This invention relates to acquiring rock data in oil and gas wells, specifically to the mechanics of running the measuring instruments past sidewall obstructions to the bottom of the well during the logging operation.
BACKGROUND OF THE INVENTION—SUMMARY OF THE PROBLEM TO BE SOLVED BY THE PRESENT INVENTION
The measurement, or logging, of rock properties in wells drilled for hydrocarbons has become an increasingly essential part of petroleum exploration since the first downhole wireline electrical log was invented by Schlumberger in 1939. Paper data strips (or digital data displays), referred to as well logs, now constitute the main record of the rock formations penetrated by oil and gas wells. But throughout the 65-year history of electrical logging, obstructions on the borehole sidewall have caused difficulties in running logging sondes down the hole. Logging sondes comprise various sets of instruments that can be lowered into the borehole on an electrical cable, with the data thereby recorded at the surface. A problem that has never been completely solved is that of reliably getting the sonde to run in all the way to the bottom of the well.
As modem boreholes become deviated farther and farther from vertical, this problem is exacerbated. Instead of dropping freely down the center of the borehole, the logging sonde then tends to slide along the lower sidewall of the borehole. In this position, the sonde is slowed by friction or stopped by minor sidewall obstructions. Once the considerable down-hole momentum of the sonde has been lessened or lost, it becomes difficult to urge the sonde to pass even minor obstructions or sidewall roughness.
Despite the use of the many previous inventions for urging the logging sonde past borehole obstructions, it often happens that the borehole must be repeatedly reconditioned with the drilling bit, a time-consuming and costly remedy. In the worst cases, the logging sonde never reaches the lower part of the borehole, and that part of the hole does not get logged. In petroleum exploration and production drilling, it is usually the bottom part of the hole that is most important, as that is where the potential petroleum producing zones often lie. Failure to log these potentially producing zones may lead to inaccurate assessment of the potential producing zones or even the premature abandonment of an expensive borehole that might have become a profitable oil or gas well. In addition to the financial loss is the potential loss of valuable resources.
BACKGROUND OF THE INVENTION—PRIOR ART
In the petroleum drilling industry, determining the characteristics of the rock formations that have been drilled has been of critical importance since the birth of the industry over a hundred years ago. Since the 1940s, increasingly sophisticated rock measurements have been made by lowering logging sondes into the borehole or producing well. The logging sondes are suspended from the surface by an electrical cable that normally allows the recording of the information at the surface.
Prior Art
Since the inception of the well logging industry, various devices have been employed to ease the running in hole of the logging sondes. These devices have been partly successful, but as wells become deeper and the well angles become farther from the vertical, the difficulty of logging has increased apace. Consequently, sondes still frequently fail to reach bottom. However, none of the prior art bears much resemblance to the present invention and therefore they will be discussed mainly to highlight the differences.
One attempt to a solution that is still used is a tractor device, wherein a tiny tracked vehicle with an electric motor is attached to the sonde and is employed to pull the sonde along. However, the tractor can only be used when the sonde has come to a stop or nearly so. A related solution to the problem of running in hole involves small wheels, pressed against the sidewall and powered by motors in the sonde. These approaches have been patented, but they are unrelated to my invention and so will not be discussed further.
Pushing the sonde down the borehole with the drill pipe is another method currently in use, especially in boreholes with high deviation. This method has the disadvantages of being very slow, as running drill pipe in the borehole is an inherently slow process, and of potentially damaging or destroying the sonde and the logging cable. Damaging the logging equipment leads to long delays in the logging operation for repairs. Often the specific logging operation must be abandoned for lack of available replacement tools. Destruction of the logging sonde may leave junk in the borehole, leading to lost time in the retrieval of the junk or drilling past the junk in a parallel borehole.
An increasingly popular solution is to incorporate the logging sensors into the drilling assembly, wherein information is relayed to the surface acoustically via pulses in the drilling mud. The process is called measurement-while-drilling, or MWD. This is at best an imperfect solution and is limited to certain kinds of logs. However, the technology is utilized in some of the prior art discussed below.
Previous Patents
Several auger-like tools were found among prior patents, mainly war machines and hole-digging tools. None closely resemble the current invention beyond the novel use of an augering tool, itself an ancient device. They are described briefly below to demonstrate the evolution of auger tool patents:
(1) Auger. Perhaps it should be mentioned that my invention, in common with several of the patented inventions described below, makes some use of the auger, an ancient tool. The auger is fundamentally a coiled version of an inclined plane, or a screw. The auger dates at least as far back as the ancient Greek Empire, and probably much earlier. It was employed by Archimedes some 2200 years ago as the water-pumping device now known by his name, the Archimedes Screw. However, my invention introduces a new and unanticipated use of this basic tool. (2) Push screw driver. The present invention employs a helical gear in somewhat the same manner as the old push screw driver, in which the rotation of the blade is activated by pushing the handle. (3) U.S. Pat. No. 1,276,706—Issued August, 1918 to Mr. Gurdy L. Aydelotte. Land Torpedo. This ground torpedo appears to be a clever war machine developed to burrow in mud, soil or soft alluvium. It is powered by an electric motor energized by a trailing electric cable that is connected to a power source at the ground surface or possibly a trench. It is designed to carry a bomb that can be detonated by the operator.
Aydelotte's patented device has little in common with the current invention. Aydelotte's land torpedo is electrically powered, whereas my passive logging sonde auger derives its energy from the momentum of the logging sonde. Aydelotte's land torpedo is designed to progress by boring its way continuously through the soil in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate occasionally in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Aydelotte's land torpedo, and these two features are the main mechanical innovations of my invention.
(4) U.S. Pat. No. 1,303,764—Issued May, 1919, to Mr. Prentice C. Broadway. Armored War Apparatus. This war apparatus is an innovative battle tank that uses an auger device on both the front and back ends to aid the tank in penetrating forests and walls. (An application not specifically mentioned, and apparently never used, might have been to aid the tanks in penetrating dense hedges such as those encountered in the Normandy invasion during World War II.)
Broadway's patented armored war apparatus has little in common with the current invention. Broadway's war apparatus is designed to be actively powered, whereas my passive logging sonde auger derives its energy only from the momentum of the logging sonde to which it is attached. Broadway's war apparatus is designed for use above ground in a generally horizontal direction to penetrate obstacles, whereas my passive logging sonde auger is designed to operate in an open borehole in a generally downward direction and to bypass obstacles. Most importantly, Broadway's war apparatus anticipates neither the passive nature nor the spring return of my passive logging sonde auger, and these two features are the main mechanical innovations of my invention.
(5) U.S. Pat. No. 1,372,318—Issued Mar. 22, 1921, to Mr. Alois B. Saliger and assigned to Saliger Ship Salvage Corporation. Burrowing Machine. Like Aydelotte's land torpedo (U.S. Pat. No. 1,276,706), Saliger's burrowing machine is a device for burrowing semi-horizontally through soft material, in this case mud. It was invented to draw a line under a sunken ship to aid in its salvage. Also like the land torpedo, Saliger's burrowing machine employs auger-like attachments for this purpose, termed propellers in the patent description. The burrowing machine is to be powered by an included fluid hydraulic motor, either gas or liquid, with a pump at the surface. An electric motor is suggested as an alternative power source.
Saliger's patented device has little in common with the current invention. Saliger's burrowing machine requires a hydraulic or electrical power source, whereas my passive logging sonde auger derives its energy from the momentum of the logging sonde. Saliger's burrowing machine is designed to progress by boring its way continuously through the mud in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate only as needed in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Saliger's burrowing machine, and these two features are the main mechanical innovations of my invention.
(6) U.S. Pat. No. 1,388,545—Issued Aug. 23, 1921, to William J. Bohan. Self-intrenching Subsurface Land-Torpedo. This ground torpedo appears to be a sophisticated version of Aydelotte's land torpedo (U.S. Pat. No. 1,276,706). It is also powered by an electric motor and energized by a trailing electric cable that is connected to a power source at the ground surface, in this case a personnel trench. Like Aydelotte's land torpedo, it is designed to carry a bomb that can be detonated by the operator by means of an electrical signal transmitted along the trailing electrical cable.
Bohan's patented device has little in common with the current invention. Bohan's self-intrenching land torpedo is electrically powered, whereas my passive logging sonde auger derives its energy from the inertia of the logging sonde. Bohan's land torpedo is designed to progress by boring its way continuously through the soil in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate only as needed in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Aydelotte's land torpedo, and these two features are the main mechanical innovations of my invention.
(7) U.S. Pat. No. 2,216,656—Issued Oct. 1, 1940, to Roy Smythe and partly assigned to Angelo J. Giannone. Toy. Smythe's invention is basically a clever toy version of the war machines described above, employing a windup motor as a power source. Aside from the novel power source, Smythe's toy contributes nothing to the technology of augering tools. Like the inventions upon which it is based, it in no way anticipates my passive logging sonde auger. (8) U.S. Pat. No. 3,375,885—Issued Apr. 2, 1968, to R. F. Scott, et al. Burrowing Mechanism. Scott's invention is basically an industrial version of the clever toy of Smythe (U.S. Pat. No. 2,216,656). Like other inventions described above, it uses an electrical motor as a power source. Each of the basic elements were covered in the patents described above, and Scott's burrowing machine contributes nothing to the technology of augering tools. Like the inventions upon which it is based, it in no way anticipates my passive logging sonde auger. (9) U.S. Pat. No. 3,710,877—Issued Jan. 16, 1973, to Harry Michasiw. Auger Device. This patent describes one of what must be many augering devices designed for digging holes, particularly for posts. The device combines an auger, a shaft, and a power source. The power source in the generic digging auger may be manual, hydraulic, or machine. (10) U.S. Pat. No. 6,691,871—Issued Jan. 24, 2004, to Arthur E. Drumm and Thomas B. Mash. Auger tool for boring. Drumm's auger patent illustrates 31 years of progress in digging auger design since the issuing of the Auger Device patent to Harry Michasiw, above. Neither Drumm's patent, his prior art patent documents (U.S. Pat. Nos. 1,993,365, 2,221,680, 3,710,877, 5,487,432, 5,782,310, 6,089,334), nor patents referenced in the prior art (U.S. Pat. Nos. 6,161,631, 6,168,350, 6,283,321, 6,308,789, 6,675,916) provide material that anticipates my passive logging sonde auger.
The augering devices described above have little in common with my invention. Each is externally powered, whether by hand or by machine, whereas my passive logging sonde auger derives its energy from the inertia of a logging sonde. Neither the passive nature nor the automatic re-extension of my passive logging sonde auger is anticipated in the augers designed for digging holes. These two features are the main mechanical innovations of my invention.
The following items of patented prior art all relate specifically to drilling devices or measurement devices used in the oil and gas drilling industry:
(11) U.S. Pat. No. 4,270,620—Issued Jun. 2, 1981, to Mr. James D. Lawrence. Constant Bottom Contact Tool. Lawrence's invention pertains to maintaining constant bottom contact with a borehole bit during drilling operations, especially those conducted at sea. This field of invention is unrelated to my invention, which pertains to the lowering of a measuring sonde into a well bore.
In Lawrence's Constant Bottom Contact Tool, a spring and helical gear within the bottom hole drilling assembly function as a shock absorber, both for unavoidable vertical motion of the drilling assembly and for sudden changes in torque on the drill bit. The intent is to reduce vertical and torsional loads on the drill string without substantially interfering with normal drilling operations. In doing so, the entire drill pipe and drilling assembly suffers less stress that might otherwise cause it to break.
In contrast, my invention employs a helical gear and spring assembly in a measuring sonde to convert some on the kinetic energy of the sonde to rotational energy in the auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus even though Lawrence's and my inventions utilize similar mechanical elements, my invention uses these elements in a totally different manner so as to achieve a different and unrelated result.
(12) U.S. Pat. No. 4,422,043—Issued Dec. 20, 1983 to Mr. Richard A. Meador. Electromagnetic Wave Logging Dipmeter. Meador's invention pertains to an improvement in the dipmeter measuring sonde. My invention pertains to lowering measuring sondes into boreholes and is therefore unrelated in purpose.
In Meador's invention, a longitudinal spring is employed to provide force to extend measuring pads laterally to contact the sidewalls of the borehole. This is a common use of longitudinal springs in many modern logging devices. My invention uses a longitudinal spring in a contrasting manner as a means of resistance and to re-extend an augering tool to its initial position after pulling the attached sonde past an obstruction. Thus the use of a longitudinal spring in my invention bears no similarity the use in Meador's invention or to similar patented measuring sondes with pad-mounted sensors.
(13) U.S. Pat. No. 4,912,415—Issued to Kurt I. Sorensen on Mar. 27, 1990. Sonde of Electrodes on an Earth Drill for Measuring the Electric Formation Resistivity in Earth Strata. The field of Sorensen's invention pertains to measuring instruments that are incorporated into a drilling assembly, for logging during the drilling operation. It is an attempt to improve on the relatively new MWD (measurement while drilling) technology that is now in wide use in high-angle wells. My invention pertains to lowering measuring sondes into boreholes and is therefore unrelated in operational function.
Sorensen's invention makes use of a spiral winding to aid in the removal of drill cuttings from the vicinity of the MWD sonde. The spiral winding does not engage any other part of the mechanism and therefore does not function as a gear. The tool's function as an auger is limited to moving material up the borehole; it plays no part in the drilling operation or in the running-in-hole of the drilling and MWD assembly. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some of the kinetic energy of the sonde to rotational energy in the auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spiral winding in Sorensen's invention is used in an entirely different manner than the helical gear and auger in my invention, in order to achieve a totally different end.
(14) U.S. Pat. No. 4,676,310—Issued to Mr. Serge A. Scherbatskoy and Mr. Jacob Neufeld on Jun. 30, 1987. Apparatus for Transporting measuring and/or Logging Equipment in a Borehole. Scherbatskoy and Neufeld's invention utilizes a motor-driven helix mounted on a logging sonde that can be expanded to the sidewalls, fitting then snugly in the entire diameter of the borehole. The helix is then rotated by a motor within the logging sonde, causing it to rotate in screw fashion and pull the logging sonde along. Although the helix of Scherbatskoy and Neufeld's invention can be compared to the auger of my invention, the inventions themselves are very different, in that:
(a) The auger of my invention is powered by the momentum of a rapidly moving logging sonde, whereas the helix of Scherbatskoy and Neufeld's invention is powered by a motor in a stationary or near-stationary logging sonde. (b) The auger of my invention is designed to be an extension of the logging sonde and of similar diameter, whereas the helix of Scherbatskoy and Neufeld's invention is designed to be mechanically forced into the entire diameter of the sidewall, (c) The purpose of my invention is to keep the logging sonde moving down the borehole and maintain its momentum, whereas Scherbatskoy and Neufeld's invention has the purpose of pulling a logging sonde that has already become stuck or has otherwise lost its downward momentum.
(15) U.S. Pat. No. 4,771,830—Issued to Mr. William R. Peate on Sep. 20, 1988, and assigned to Schlumberger Technology Corp. Apparatus for Positioning Well Tools in Deviated Well Bores. Like my invention, Peate's invention employs an external augering tool on a logging sonde. However, they are not mounted on the nose of the logging sonde for the running in hole operation, but on the sides of the logging sonde to aid in tool orientation during the unrelated logging out operation. Peate's drawings show that the nose of the logging sonde has been left squared off, so that the projecting ribs of his invention could not have aided in the running-in-hole operation of the logging sonde. (16) U.S. Pat. No. 5,259,467—Issued to Mr. William N. Schoeffler on Nov. 9, 1993. Directional Drilling Tool. Schoeffler's invention pertains to the directional drilling of boreholes, more specifically to the operation of a hydraulic down-hole motor. This field of invention is unrelated to that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
Schoeffler's Directional Drilling Tool employs an internal longitudinally mounted spring to apply an upward force to a wash pipe and piston within the tool, as part of the operation of the hydraulic down-hole motor. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some on the kinetic energy of a measuring sonde to rotational energy in an auger, causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spring in Schoeffler's invention is used in an entirely different manner than the spring in my invention, in order to achieve a totally different end.
(17) U.S. Pat. No. 5,396,966—Issued to Mr. Albert E. Roos, Jr., Steven W. Drews, and William J. McDonald on Mar. 14, 1995. Roos, Drews, and McDonald's patent pertains to the downhole steering sub assembly for the drilling of horizontal wells for various purposes. This field of invention is unrelated that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
Roos, Drews, and McDonald's patent uses a longitudinally mounted compression spring only to provide pressure to expand bow springs that are mounted laterally on the side of the steering sub. There is no similarity to my invention in the purpose or function of the longitudinally mounted spring.
(18) patent application Publication 2004/0129457 A1—Application by Mr. Keith McNeilly dated Jul. 8, 2004. Torque Absorber for Downhole Drill Motor. The field of McNeilly's invention pertains to hydraulic down-hole motors used in the drilling of boreholes. This field of invention is unrelated to that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
McNeilly's invention uses a longitudinally mounted spring element to automatically adjust the weight on the drill bit, so as to prevent stalling of the downhole hydraulic motor due to resistance to bit rotation. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some on the kinetic energy of a measuring sonde to rotational energy in an auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spring in McNeilly's invention is used in an entirely different manner than the spring in my invention, in order to achieve a totally different end.
BACKGROUND OF INVENTION—OBJECTIVES AND ADVANTAGES
The present invention introduces a unique solution to the age-old problems related to running in and logging out of oil and gas wells with logging sondes. (running in hole is the literal term used in the petroleum industry for lowering either a logging sonde or a string of drillpipe into a well. Similarly, pulling out of hole is used for the reverse operation; logging out applies to pulling the logging sonde out of the well during the logging operation with the sensors and recorders turned on. The term hole is in common use to mean either a well or a borehole. These terms are integral parts of drilling jargon and as such are incorporated in many terms.) Several objectives and advantages of the present invention are:
(a) to facilitate the running-in-hole of logging sondes, (b) to provide a means for logging sondes to bypass sidewall obstructions in boreholes, particularly washouts, boulders, ledges, keyseat grooves, and cave-ins, as illustrated in the drawings, (c) to increase the likelihood that the logging sonde will reach the bottom of the hole where the critical oil and gas reservoir data may be recorded, (d) to thereby reduce the need for repeatedly cleaning out and reconditioning the borehole with expensive and time-consuming bit runs, (e) to reduce the chances of losing the hole because of delays in the logging operation, and (f) generally, to make the borehole logging process more efficient, complete, and cost effective.
BACKGROUND OF THE INVENTION—SUMMARY
The present invention is a passive auger device that is attached to the downhole end of a borehole logging sonde in the oil and gas drilling industry. The auger device is integrated with a spring means and a spiral gear means. When, during running in a borehole, a sidewall obstruction impedes the progress of the logging sonde, downward momentum will compress the auger against the spring, and at the same time the spiral gear will cause the auger to rotate. In rotating, the auger both deflects the sonde away from the sidewall obstruction with its rotary motion and pulls it through the area of the obstruction with its auger. When the obstruction has been thus bypassed, the spring extends the auger to its initial extended position where it is then in place to encounter subsequent obstructions.
DRAWINGS
Sidewall obstructions that are commonly encountered and can be passed more easily with the benefit of the passive logging sonde auger include ledges, projecting boulders, eroded washouts, caved out zones, key seat grooves, and general sidewall roughness or rugosity. These terms are well understood in the drilling industry and are illustrated by the sketches in FIGS. 1 a through 1 f in order to augment understanding of the utility of the invention. When the sonde assembly is pulled out or logged out of the borehole, the passive logging sonde auger trails the sonde and is inactive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified diagram of a borehole in which a wireline logging operation is being conducted.
FIG. 2 a shows a longitudinal cross section of the downhole portion of a deviated borehole in which a wireline logging operation is being conducted. It illustrates somewhat diagrammatically various sidewall obstacles to the running-in-hole of a logging sonde, that the present invention is designed to bypass. Details of the individual obstructions are discussed below with the transverse cross sections.
FIG. 2 b is a lateral cross section of an in-gauge borehole, approximately the same diameter as the nominal drill bit size. The bit size used may vary, but is commonly between 10 cm and 50 cm in diameter in the deeper and more important part of the hole that is usually most difficult to log. In contrast, most logging sondes are around 10 cm in diameter.
FIG. 2 c is a lateral cross section of an enlarged section of the borehole. These are common occurrences in softer rock formations. A common cause is erosion by the rotating drill pipe and the flow of drilling fluid. Enlarged sections can be very long, wide, and highly irregular.
FIG. 2 d is a lateral cross section of a sidewall cave-in, sometimes found in faulted rock formations. They can partly block the well bore, making it difficult for logging sondes to pass, especially if they occur on the part of the sidewall along which the sonde is running.
FIG. 2 e is a lateral cross section of boulder projecting into an enlarged section. Large boulders may also become dislodged and re-oriented so that they partly block the borehole.
FIG. 2 f is a lateral cross section of a keyseat groove. These are usually formed because of erosion by the drill pipe in cases where it continuously lies along one side of the hole. As the drill pipe and logging sonde are of similar diameter, the sonde can enter the keyseat groove and become stuck.
FIG. 2 g is a lateral cross section of a rock ledge in a washed out zone, a very common sidewall obstruction. Such ledges are normally composed of very hard rock. They can extend all around the hole and obstruct the sonde in any position.
FIG. 2 h is a lateral cross section of a rough sidewall, normally found in rock formations of rapidly varying strength and resistance to erosion. Rough patches in the sidewall can slow the progress of the sonde as it runs in the hole, robbing it of important downhole velocity and kinetic energy.
FIG. 3 a is an exterior view of the present invention in its initial extended position, attached to the lower end of a logging sonde.
FIG. 3 b is a cut-away view of the present invention in which the spiral gear and extended and the relaxed return spring can be seen.
FIG. 4 a shows an exterior view of the present invention in its collapsed position, attached to the lower end of a logging sonde.
FIG. 4 b shows a cut-away view of the present invention in its collapsed position, attached to the lower end of a logging sonde. The spiral gear and compressed spring are shown.
FIGS. 5 a – 5 f show some of the many auger designs suggested as alternate embodiments of the present invention. The normal diameter of the logging sonde and the body of the present invention is normally around four inches; the length of the augers can be short, as shown these illustrations, or much longer.
FIG. 5 a is a thick and rounded auger used in the preferred embodiment, emphasizing rounded nose and spirals.
FIG. 5 b adds a sharp ridge on the spirals.
FIG. 5 c is similar to the preferred embodiment of FIG. 5 a but with a nose similar in diameter to the logging sonde.
FIG. 5 d is a rounded, spade-shaped auger somewhat larger than the logging sonde.
FIG. 5 e shows a thick, rounded auger with a steep pitch.
FIG. 5 f is a more conventional auger with a deeply incised trough, commonly used in boring operations.
FIG. 6 a is a cut-away view of an embodiment of the present invention in which a pneumatic device replaces the spring as the compression resistance.
FIG. 6 b is a cut-away view of an embodiment of the present invention in which only gravity is employed to keep the auger in extended position.
FIG. 7 shows the borehole sketch of FIG. 1 a , in which the lower end of a logging sonde to which the present invention has been attached is shown striking two separate obstructions with the augering action set to commence.
DRAWINGS—REFERENCE NUMERALS
10 Earth borehole
12 Drilling fluid filling borehole
14 Sidewall of borehole
16 Oil and gas reservoir
18 Drilling rig
20 Logging sonde
22 Bull nose of logging sonde
24 Logging unit
26 Pulley
28 Logging cable
30 Surface of ground
32 Sidewall of in-gauge borehole
34 Nominal hole size, or bit diameter
36 Enlarged borehole due to erosion
38 Sidewall cave-in
40 Projecting boulder in sidewall
42 Keyseat groove
44 Ledge of hard rock
46 Rough, irregular sidewall
50 Apparatus of the present invention
52 Auger tool
54 Lower tool casing that also constitutes the exterior part of a spiral gear
55 Outside teeth of a spiral gear
56 Upper tool shaft that extends as the inside part of a spiral gear
58 Means of connection to logging sonde
60 Spring
62 Chamber
64 Inside shaft of a spiral gear
66 Mud ports
68 Safety stop
70 Logging sonde combined with the present invention as a unit
72 Cylinder portion of pneumatic device
74 Piston portion of pneumatic device
80 Sharp ridge on auger tool
82 Blunt nose on auger tool
84 Broad shoulder on auger tool
86 Steep pitch on auger tool
88 Deeply incised trough on auger tool
90 Sonde with auger tool striking a sidewall obstruction in the form of a cave-in
92 Sonde with auger tool striking a sidewall obstruction in the form of a ledge
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A general view of a logging operation in which the present invention is intended to be used is shown in FIG. 1 . The borehole (also referred to as the hole or well), 10 is normally in the range of 10–50 cm in diameter. Boreholes commonly decrease in diameter with depth as sections are sequentially protected behind pipe. A 30 cm diameter well is common. It is filled with viscous drilling fluid 12 during drilling operations. The wall of the open part of the hole is called the sidewall 14 , and it is on the sidewall that obstructions normally are found that impede the running-in-hole of logging operations. At the surface, the drilling rig 18 and associated equipment controls virtually all of the operations in the well.
Oil and gas reservoirs 16 are normally located near the bottom of the well, which may be anywhere from 200 meters to more than 10,000 meters in depth. The fluid content of these reservoirs is assessed with wireline logs obtained in a logging operation. Based on this assessment, the borehole may be completed as a producing oil or gas well or abandoned as a dry hole.
A basic logging operation is also illustrated in FIG. 1 . A logging sonde 20 with a rounded “bull nose” 22 is lowered into the borehole on a conductive logging cable 28 . The logging sonde may range from 3 m to 10 m in length and may weigh as much as 100 kg. The logging cable 28 extends to the surface, where it threads through the drilling rig 18 via a pulley 26 to the logging unit 24 located on the ground surface 30 or on the deck of an offshore drilling platform or ship. This unit contains the computers, recording equipment, and human operators and is the nerve center of the logging operation. Rock formation measurements of the entire borehole are made by instruments in the logging sonde 20 . The actual sensors may be centrally located in the logging sonde 20 or extended against the sidewall 14 .
The present invention deals with the problem of getting the logging sonde all the way to the bottom of the borehole to log the potentially producing formations. The running-in-hole operation may be especially difficult in a deviated well, as sidewall friction is increased and the down-hole component of gravity is decreased. In such wells, the logging sonde 20 slides dwonward along the low side of the borehole where it may encounter various sidewall obstructions and irregularities that have the potential of slowing or stopping its downward progress. As the logging sonde 20 is normally around 10 cm in diameter, the center of the bull nose 22 is therefore only 5 cm from the sidewall. Consequently, its progress can be impeded by relatively small sidewall irregularities.
FIG. 2 shows some examples of sidewall irregularities, among them enlarged sections or washouts 36 , cave-ins 38 , boulders 40 , keyseat grooves 42 , ledges 44 , and general sidewall roughness 46 . Any of these features can cause the logging sonde to hang up, thus slowing or stopping its progress down the hole. Once the downward momentum of the logging sonde 20 has been lost, it becomes difficult or impossible to urge it to proceed. Sidewall friction prevents easily restarting the logging sonde and the original momentum cannot be regained.
The preferred embodiment of my invention replaces the standard rounded nose (“bull nose”) of the logging sonde assembly 70 with a blunt-nosed augering device 50 powered by the momentum of the logging sonde. The augering device 50 comprises only a few main parts, shown and labeled in FIGS. 3A and 3B in the initial unstressed, extended position. These parts are:
(a) an auger tool 52 , (b) an external tool casing 54 that is connected to the auger tool, which functions also as the external tube component of a spiral gear assembly, (c) a plurality of mud ports 66 connecting an open chamber 62 inside of the tool casing and the borehole, to allow free circulation of drilling fluid in the tool to prevent pressure buildup during compression, (d) an internal shaft component of a spiral gear assembly 64 , that meshes with the external spiral gear component 55 and continues upward as a non-geared shaft 56 to a means of connection 58 with the main logging sonde 20 , (e) a spring resistance mechanism 60 contained within the open chamber 62 within the lower part of the apparatus that permits the lower tool component 54 to be compressed against the spiral gear assembly 64 of the upper tool component.
The spring resistance mechanism 60 is attached at one end to the top of the auger nose 52 and on the other end to the lower end of the internal shaft of the spiral gear 64 , so as to prevent the tool pulling apart. A conventional safety stop means 68 may also be placed within the spiral gear mechanism to supplement this same end.
OPERATION OF THE PREFERRED EMBODIMENT
During the making up of the logging sonde assembly in the drilling rig 18 , either at the surface of the ground 30 or on a drilling vessel, the augering tool of the present invention 50 is attached at the downhole end, in place of the conventional bull nose. The logging sonde thus modified 70 is then lowered into the borehole 10 in the conventional manner, suspended by the logging cable 28 . During this running-in-hole operation, the modified logging sonde 70 may strike an obstruction on the sidewall, such as a ledge cave-in 38 or a ledge 44 as illustrated in FIG. 7 . When this happens, the momentum of the heavy measuring sonde 20 then forces the auger nose assembly of the present invention 52 to compress rearward against the spring 60 , FIGS. 4A and 4B , so that the auger tool 52 is urged to rotate by the spiral gear 64 . The augering action thereby produced allows the auger tool 52 to pull the entire sonde assembly 90 past the cave-in, ledge, or any of the other sidewall obstructions displayed in FIG. 2 . In this way, sidewall obstructions that would have slowed or stopped logging sondes of older design can be bypassed with ease. Once the obstruction has been bypassed, the compressed spring resistance mechanism 60 urges the auger nose 52 to return to its original extended position FIG. 2 , whereupon it is ready to encounter and bypass the next sidewall obstacle by the same process.
Although the present claims broadly cover multiple design options, they work in general as the specific example described herein.
It will be appreciated by the reader that the example described herein represents but one of many tool designs which may be constructed and which will accomplish the result claimed in this patent application in basically the same way—that being to rotate an auger using the kinetic energy of the sonde, and that the patent should be broadly construed to include any tool design that produces that specific result in the same basic manner and using the same basic energy transfer. For example, there are many designs of spiral or helical gears that might be used. Instead of a spring 60 in the upper portion, a fluid-filled pneumatic device 72 or other form of resistance might be employed. The auger nose 26 might be given any of multiple pitches and shapes as shown in FIG. 5 ; or the upper or lower casing and mud ports might be given different design or eliminated altogether.
ALTERNATE EMBODIMENTS
While only a single embodiment of the present invention has been illustrated and described herein, it is apparent that various modifications and changes may be made without departing from the principles of this invention in its broader aspects, and, therefore the aim in the appended claims is to cover such modifications and changes as fall within the spirit and scope of this invention.
FIG. 5 illustrates a few of the many possible designs of the auger nose 25 of the present invention. Each may have its best use in specific situations, and this patent should not be construed as limited by auger design. In FIG. 4 a , the spring resistance device 27 in the augering tool is replaced by a pneumatic resistance device comprising a cylinder 40 and piston 41 , which could be constructed in numerous designs other than the one illustrated. The resistance devices depicted are standard mechanical products and are not claimed in this patent, but their function of storing kinetic energy as potential energy in the present invention is regarded as a new application that is claimed below. FIG. 4 b shows the simplest design of the present invention, in which the force of gravity is utilized to return the auger to initial extended position. This technique may be effective in a vertical hole. | The auger is attached to a spiral gear and a spring, the apparatus then being connected to the downhole, leading end of the logging sonde. When the auger nose of the modified sonde assembly strikes any of various obstructions on the sidewall that cause it to lose momentum, such as a rock ledge, the momentum of the heavy sonde causes the auger nose assembly to compress, forcing the auger to rotate on the spiral gear. The rotational action thus produced allows the auger to pull the sonde to pass the obstruction. After the obstruction has been passed, the potential energy stored in the spring induces the auger to return to its original extended position, whereupon it is ready to encounter and pass another obstacle. |
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to a hysteretic energy absorber.
There are circumstances in which it is desired to decrease the application of energy to a body or structure. In some circumstances this may be done by springs, but only when the elastic restoration of the energy can be dealt with. Various devices such as shock absorbers or viscous dampers are used when for some reason the energy must not be restored.
A particularly troublesome situation arises in preventing the cyclic forces imposed by earthquakes from damaging buildings and their contents. The present invention arose in the first place as a means of providing a damper to be connected between the base of a structure and the foundations below the structure. The structure was to be supported by a system, interposed between its base and its foundations, which allowed substantially free horizontal motion of the base. A combination of a flexible base-support system and a set of large-capacity energy absorbers of suitable characteristics would provide, for most structures, a substantial measure of protection from severe earthquake forces, while at the same time preventing frequent troublesome motions.
Common types of energy absorber are not satisfactory. In the first place, those which would absorb enough energy to protect a building in a severe earthquake would be so big as to be unusable. Velocity dampers are unsatisfactory, since they would do nothing to prevent the slow movement of the building. Hydraulic dampers might be made big enough, but they would allow drift from, for instance, wind loads, they would be expensive, and their upkeep would demand frequent attention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an energy absorber that will go some way to meet the requirements stated above, and to avoid the difficulties of existing types of energy absorber, or will at least provide the public with a useful choice.
A property of low-carbon mild steel when stressed beyond the elastic into the plastic regime provides the basis for a new type of energy absorber. If during stressing of a piece of steel displacement is plotted against load, the line which is at low stresses straight becomes curved when the stress is high. The line followed during the relief of stress is quite distinct from that during stressing, and if a cyclic stress into the plastic region is applied, a closed curve is followed. This is known as a hysteresis curve, and the type of energy absorber which uses this property of steel (the same applies to many other solid materials, but low-carbon steel is especially favourable) is known as a hysteretic energy absorber. The name applies only when the energy to be absorbed is cyclic.
An absorber of this type has already been described and claimed in United States Letters Patent to Skinner, No. 3,831,924 issued August 27, 1974, "Torsional Energy Absorber". It uses the hysteretic property of steel when stressed mainly in torsion, and has two limitations. In conformation it is essentially 3-dimensional, so that it may be relatively bulky and cannot, for instance, be fitted within a sandwich wall, and it will deal with forces applied along only one line. The hysteretic energy absorber to be described later has two general embodiments. In both, the device extends principally in two dimensions and can be fitted within a sandwich wall if required, and in one forces applies in any direction in a plane can be dealt with.
To protect a building, a hysteretic energy absorber capable of operating for motion in any horizontal direction would be particularly effective. There are other applications for which an absorber acting along a single line is appropriate; for example, the two ends of a bridge deck may themselves be designed to allow motion along only the deck's length. Earthquake resistance of the bridge structure might be increased by connecting a hysteretic energy absorber for longitudinal operation between one end of the bridge deck and the abutment.
A further application of energy absorbers is the protection of equipment within buildings such as apparatus racks (which might be 10' high and be relatively heavily loaded) or shelves and the like, from being overturned or wrenched from their foundations, or fractured by earthquakes. Such structures can be anchored to the floor. They can also be anchored to walls by tie rods but it is always possible that the walls will not move in phase with the floor, so that the tie rods might themselves impose forces on articles they were intended to protect. Protection would be possible if a plastic energy absorber could be incorporated in the tie rods, or between the tie rods and the supported equipment.
Accordingly the invention may be said to consist of a cyclic energy absorber designed to be interposed between first and second members of a structure which are caused by in-coming energy to move relative to each other, said energy absorber comprising in combination:
an anchor adapted to be connected rigidly to a first member of the structure;
a main beam rigidly connected at one peripheral plane to said anchor;
loading means connecting a second member of the structure to the main beam at a point remote from the connection to said anchor so that relative to-and-fro motion between said first and second member of the structure causes said main beam to form cyclically in flexure into the plastic range.
The invention consists in the foregoing and also envisages constructions of which the following gives examples only.
BRIEF DESCRIPTION OF THE DRAWING
One preferred form of the invention will now be described with reference to the attached drawings, in which:
FIG. 1 shows a hysteresis loop determined experimentally for a low-carbon mild steel,
FIG. 2 shows partly in cross-section a schematic representation of a multi-directional, cantilever, flexural, hysteretic energy absorber as it might be fitted between the base and foundation of a building after subjecting to a major earthquake,
FIG. 3 shows schematically a single-cantilever hysteretic energy absorber for action along one line in the condition it would have before severe deformation,
FIG. 4 shows partly in cross-section the same device as in FIG. 3 after heavy cyclic forces have been applied to it,
FIG. 5 shows schematically a development of the device of FIG. 2; a beam intended as a multi-directional, hysteretic energy absorber is equipped with two moment-resisting anchors, one attached to the base of the building and the other to a foundation,
FIG. 6 shows a development of the device of FIG. 3, having one anchor about which two of the devices of FIG. 3 are symmetrically located,
FIG. 7 bears the same relation to FIG. 2 that FIG. 6 bears to FIG. 4, showing a multi-directional double cantilever, flexural, hysteretic energy absorber with an anchor at its middle and a force connection at each end,
FIG. 8 is a schematic arrangement of the inverse of FIG. 7; a beam has anchors at each end and a force-applying means at its middle,
FIG. 9 shows a possible means of applying flexural, hysteretic energy absorbers for action along one line within the structure of a building, for instance in a diagonal brace; pairs of units of the type shown in FIG. 3 are joined by free ends of their main beams so forming the analogue of FIG. 5 for action along one line; a diagonal brace is divided and the two divided parts are joined by one or more of the double absorbers.
FIG. 10 shows a variant of FIG. 3 or FIG. 2 in which deformable materials are used to carry out the function of guide bars, and
FIG. 11 shows a simplification of FIGS. 2 and 3 in which the rigidity of the anchor carries out the function of guide bars.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a basic property of low-carbon mild steel. Other materials have a similar property, but low-carbon mild steel is convenient to use. When a sample of such steel is subjected to a number of cycles of alternating stress, it is possible to plot load against the displacement of some point on the specimen. In the beginning, the steel is at the point A and as the load is applied there is elastic displacement to point B. At this point there is yield and as the load is increased the displacement per unit of additional load is much greater until the point D is reached, at which the stress is slowly reduced. The curve then followed is D-E and not D-B-A. When the stress is reversed the point I is finally reached. If now the stress is once more reduced and reversed, the curve I-G-H is followed. Subsequent cycles of alternating load will follow the closed curve H-E-I-G-H with variations such as are shown at G-F. The area within the closed curve is the energy absorbed per cycle and for low-carbon mild steel the energy absorbed per cycle per pound weight is high.
In a preferred form of the invention, the basic component of the energy absorber is an energy absorbing beam which is attached to a rigid support by a moment-resistant anchor. Energy is absorbed in the fashion disclosed in FIG. 1 when the beam is deformed by a transverse load applied to its free end. The beam can be either single or composite, and may not be all of the same material.
The anchor includes guide beams which are fixed in place against but are not attached to faces of the main beam. This moment-resisting anchor increases substantially the energy absorbing capacity of the beam during deformation.
The first embodiment of the invention is shown in FIG. 2. The dished plate 1 is a moment-resisting anchor. Its precise form is unimportant. It is rigidly connected to a body which in this case is a foundation 2. An energy absorbing beam 3 (here shown deflected) is rigidly attached to the anchor 1. Around its base are guide beams 4. These also are rigidly attached to the anchor and are arranged to have their long axes parallel to the axis of 3; before heavy stressing they are in contact with the beam 3. Beam 3 may be cylindrical or prismatic with any number of sides, from 3 upwards. For any prismatic form of the beam, the cross-section should be as symmetric as possible, in order to present substantially the same resistance to bending for all loading directions perpendicular to the beam axis. If the beam 3 has flat sides it is to be expected that there will be a guide bar 4 for each side. When the beam 3 is cylindrical guide bars 4 may be rods, flat strips, a cylinder or segments of a cylinder replacing the strips shown at 4 in FIG. 4. Guide bars of various lengths have been tested and it is believed that the optimum length is approximately one-third of the length of the main beam between its anchorage and the point at which force is applied. There should be as little circumferential spaced unused between the guide bars as possible. Their optimum thickness is 0.5 to 1.0 times the thickness of the main beam.
At the head of the main beam 3 is the means by which a cyclic load is imposed on it. In FIG. 2,5 is a head whose perimeter is a great circle zone of a sphere; 6 is a squat cylinder attached to the base 7 of the building. The clearance between 5 and 6 is small so that as soon as the building moves, cylinder 6 causes a load to be imposed on the flexural beam 3. The maximum end rotation to be expected of beam 3 is in the neighbourhood of 15°. The depth of cylinder 6 should correspond with this, with a suitable allowance.
When an earthquake moves the foundation, 5 and 6 make contact and beam 3 will bend elastically. It must be understood that the movement between the building 7 and the foundation 2 is purely relative. If the relative movement embodies a great enough force, the beam 3 will be deflected out of its elastic range into its plastic range and it will move the guide beams 4 in front of it. When a heavy alternating force is applied, the main beam suffers alternating elastic deformation, together with alternating plastic deformations. The guide beams suffer alternating elastic deformation and unidirectional plastic deformations. That is to say, after the first large excursion the guide beam will be left in the curved state shown in FIG. 2.
The guide beams contribute several features to the moment-resisting anchor.
1. They increase the volume throughout which plastic deformations occur in the main deformable beam.
2. They prevent the concentration of large plastic strains by increasing the radius of curvature of the main beam when deformed.
3. They apply a rolling action to the surface of the main beam, so long as they have a width at least as great as that of the main beam. This induces a compressive stress in the superficial layers of the deforming beam. It has been shown in a number of scientific papers (see for instance Moore H.L. (1947) and A.S.T.M. (1941) that such compressive stress leads to a reduction in tensile stress in the vulnerable surface layer, and hence to an improvement in the fatigue strength of the specimen.
4. They absorb energy.
With the main beam 3 at 3 inches in length and 1/4 inch in thickness and with guide beams 4 projecting 1 inch from the anchor, it has been found that after a number of excursions into the plastic region, further excursions cause contact between the beam 3 and guide beam 4 over a 1/2 inch length. As the beam 3, after many cycles of stress, approaches failure it is found that cracks are distributed over this 1/2 inch length. When there are no guide beams the same energy is available for forming cracks confined to the immediate neighbourhood of the anchor, so that the useful life of the beam 3 is much shortened. The guide beams increase substantially the number of cycles of deformation for any given amplitude of deformation which can be applied to the beam before failure, so that the beam has an increased capacity for absorbing energy.
FIG. 3 shows a variant of the absorber of FIG. 2 and in addition shows a varied method of mounting that could also be applied to the device for FIG. 2. This method of mounting will be discussed later.
The numbering of FIG. 3 corresponds with the numbering of FIG. 2. 1 is an anchor and the body to which it is attached is not shown and 3 is again the deformable beam and in this embodiment it is transformed into a body of lower symmetry, a strip. As a result, it is suitable for dealing with forces only in the directions shown by the arrows -- it has a single line of action as an absorber. Guide bars 4 are fitted only on the two main faces. The linkage for applying the force to the end of bar 3 is not shown. It may be an analogue of parts 5 and 6 of FIG. 2, but because of the use to which this form can be applied, it may also be a conventional linkage.
Clearly, the anchor 1 of FIG. 3 is different from the anchor of FIG. 2. It consists of a rectangular tube that is slotted on both faces to take both guide bars and main beam. The guide bars are welded to both faces of the tube. The main beam is welded to the guide bars only on the face remote from the applied load.
Guide bars provide a region of decreasing fixity between the anchor and the main beam 3 of both FIGS. 2 and 3, the region extending from the face of the anchor 1 to the part of the main beam which is clear of the guide bars where the main beam is subjected to severe bending deformations. It is believed that the arrangement of FIG. 3 provides a second region of decreasing fixity for the main beam between its welds to the guide bars on the reverse face and the front face 8 of the tubular anchor.
FIG. 4 shows the conformation of an absorber according to the pattern of FIG. 3 after it has been subjected to severe stressing. Guide bars 4 are permanently bent. When main beam 3 is again moved to make contact wiht the guide bars in their new position they can be deflected still further elastically about their present position. If they are stressed still more heavily they can be plastically moved to a new position which is still more deflected.
Since in the embodiment of FIG. 3 the axis of the main beam and of the guide bars and the line of action of the loads will all be in the same plane, these absorbers can be designed to take up only a small transverse space and can be put within a wall panel. The absorbers of FIG. 2 could also be used in this way but they are less suitable.
It is obvious that the embodiment of FIG. 3 can be considered as an extension of the embodiment of FIG. 2 in which a number of square beams lie side by side. This process may be extended by installing absorbers in multiple.
As an alternative, absorbers may be duplicated by joining two end-to-end. In FIG. 5 is shown an absorber which is effectively two of the embodiments of FIG. 2 joined by their free ends. The force-transfer means 5 and 6 are no longer needed. There are two anchors 1 and 11, a single main beam 3, and two sets of guide bars 4 and 14. The two anchors are rigidly fixed. One could be fixed to the foundation 2 and the other to the base 7 of a building. In FIG. 5 is shown also a development which is required in some circumstances, i.e. when a tall building on a small base is subjected to earthquake forces it may suffer uplift. The extensions 13 and 23 on the main beam 3 are continuous with main beam 3 and form a tensile member. Extension 13 is rigidly fixed within the building and extension 23 is rigidly fixed to the foundation. A number of units corresponding with FIG. 5, installed around the edge of a building, can be a safeguard against uplift.
FIG. 6 shows a doubling of the pattern of FIG. 3. The anchor 1 is now the mid-point of a main beam 3/13 and rigidly fixed to it are guide bars 4 and 14. Force is applied at the two free ends of the main beam. It would be normal to arrange that the two ends were so connected that the forces applied were in phase and this reduces moments on the anchor 1. FIG. 7 shows a doubling of the pattern of FIG. 2, corresponding in general with the doubling of FIG. 3 which is shown in FIG. 6. The absorber is extended by a reflection about its base. At the middle of the main beam 3/13 is a connection 7 to one of the two members which move relative to each other and fitted to it are guide bars 4 and 14. 5/6 and 15/16 are symmetrical means for moving the main bar in phase at its two ends.
In FIG. 8, the pattern of FIG. 2 is duplicated by reflection about its free end. The anchor now comprises a bracket 20, similar to that which holds an upper force applying means 15/16 in FIG. 7. It now holds an upper anchor 11. The short cylinder 6 is replaced by a hole in a force applying bar 7. Guide bars are advantageous at the ends of the beam, and there should be some provision for axial motion of a beam end.
An energy absorber which contains one or more of the basic components may be designed for an endurance which lies in the range from a few tens of cycles to a few hundreds. It may be designed for an force from a few tens of Newtons to a few Mega-Newtons.
FIG. 10 shows a variation of FIG. 3 which is also applicable to FIG. 2. Guide bars 4 in both these Figures have been assumed to be of mild steel. FIG. 10 shows a pattern that has been found effective if a more readily deformable material such as lead is used. Bars 24 are of lead. Bars 25 may be of lead, or of steel if greater stiffness is wanted. It has been found that if both 24 and 25 are of lead, a region of decreasing strain is induced in that part of the main beam 3 adjacent to anchor 1.
FIG. 11 shows a simplification that may be applied to the pattern of either FIG. 2 or FIG. 3. These Figures show a system of guide bars that involves rather expensive welding. In FIG. 11, increase of rigidity in the anchor (by thickening in the Figure, but other methods are possible) is, in a sense, a replacement for guide bars. It will be noted that beam 3 is welded only on the side of anchor 1 which is remote from the applied force. When a force is applied, the effect of the stiffness of the anchor is to increase the volume in which plastic strain occurs in beam 1, and decrease the concentration of strain in it.
The energy absorbers have so far been discussed principally in relation to the absorption between a foundation and a structure above. A number of other applications have been envisaged and one of them is one of the two matters shown in FIG. 9. The first matter is a further extension of the device of FIG. 3. Two of these devices were taken and were joined at their free ends. They would be absorbers in relation to forces applied relatively at the two anchors. FIG. 9 shows a possible application for one or more of the double ended version of FIG. 3 to absorbing the energy with absorbers mounted in a diagonal brace in a framed structure.
Absorbers according to FIGS. 2 and 3 have a still further field of application. They can provide a component which is rigid when subjected to moderate loads, but is flexible when subjected to severe loads. They could in other words provide a cheap, compact but very stiff spring. The shape of response against applied force could be controlled by the relative proportions of the deformation beam and the guide bars.
In this description, the axes of a deformation beam and of guide bars are referred to as being perpendicular to the anchor so that they are fixed at a peripheral plane of the beam and guide bars, i.e. a plane perpendicular to the axis. This arrangement is not essential. The axes of the anchor and of the beam may be inclined to each other.
The forms of anchor so far described are somewhat particular. Other forms than those referred to may be used, so long as they hold the foot of the main deformable beam and the feet of the guide beams with what is effectively complete rigidity. The invention may in fact be considered to be a means of providing a beam adapted to bend under load, especially under cyclic load, and to be of such a composite form that at its anchor it is held with effectively absolute rigidity, and at a short distance away from its anchor it is so constrained by parts additional to the main beam and not attached to it that the stiffness of the additional parts, equal to the substantial part of the stiffness of the main beam, is added to that of the main beam. As a result, the maximum radius of curvature of the main beam is decreased and stress concentration is reduced. At the same time, relative motion between the main and subsidiary beams causes, by imposing surface compressive stresses, an increase in the fatigue strength of the main beam. It is considered that any conformation which will lead to the attainment of these objectives will lie within the present invention.
REFERENCES
1. surface Stressing of Metals. Moore, Murray, Alman, Horger and Kosting. American Society for Metals, Cleveland, U.S.A. 1947 (p. 40-43).
2. Proceedings of the 44th Annual Meeting, June 1941 of the American Society for Testing Materials. American Society for Testing Materials, Vol. 41, 1941 (p. 672). | A cyclic absorber of energy in massive quantities. It is suitable for installation between two parts of a structure that would be caused to move relative to each other by earthquakes or heavy winds. Energy is absorbed by the cyclic, flexural deformation into the plastic range of a main beam which may be a single or double cantilever. Strain of the main beam may be distributed and the capacity of the device increased, by short auxiliary cantilevers initially in contact with the main beam. |
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FIELD OF THE INVENTION
[0001] The present invention relates to column placement and more particularly to a template for fixing the placement of a column.
BACKGROUND OF THE INVENTION
[0002] Column placement involves the physical disposition of a column-typically concrete-in or proximate to the ground for supporting associated structure. Columns often support bridges, roadways, platforms and walls, to name but a few associated structures. Given the massive weight of many associated structures supported by columns, precision in the placement of the columns can be critical to ensure the integrity of the associated structures. Moreover, given the sheer manpower required to place columns and associated structure, misplacement of a column can result in substantial cost overruns. In the modern world of razor-slim margins in civil works project management, cost overruns can be intolerable and can form the difference between a loss on a project and profitability.
[0003] Conventional column placement generally involves the lifting of a pre-cast column by a crane to a position above a drill hole. Several workers can subsequently guide the hovering column down and into the hole where the column can be secured by temporary scaffolding. Recognizing the imprecise nature of this exercise, many skilled artisans prefer the use of a template in placing the column. A template generally includes a scaffold-like arrangement of wooden or metal bars configured to support the placement of a column in or above a hole. Ordinarily, the template can be placed such that an opening in the template can align with a hole in the ground, A column can be lowered by crane and guided through the hole into the ground. Still, given the mass of a typical column, many works are required to position and support the column in the hole.
[0004] FIG. 1 illustrates a typical template arrangement, such as a “Hubbard” arrangement. A typical template arrangement includes a template body 120 supported over a hole 130 in the ground 140 by one or more template feet 160 . A column 110 can be lowered through the template body 120 into the hole 130 and secured in place by one or more adjustable straps 150 such as “come-alongs” as is known in the art. Notably, the adjustable straps 150 can be coupled to the template body 120 and tightened individually so as to cause the column 110 to stand as close to vertical as possible without unduly leaning to any one side.
[0005] It will be apparent to the skilled artisan, however, that controlling the vertical placement of the column 110 through the use of multiple individually adjustable straps 150 can be resource intensive and quite difficult given the number of control points dictating the vertical placement of the column and the distance between each control point. Moreover, the mass of the column 110 often can cause shifting in the placement of the template body 120 in respect to the hole given the free-floating nature of the template feet 160 . Accordingly, substantial imprecision can result.
[0006] The skilled artisan further will recognize several other deficiencies associated with the conventional column placement template. Most notably, only a single column can be placed at any one time. Also, once a column has been placed and has been secured in the hole in the ground, placing the next column may require alignment with the previously set column. Preserving the accuracy of placement of a new column relative to an existing column can introduce an entirely new set of difficulties. Additionally, the process of auger-cast drilling a hole prior to the placement of a column through the template, and the subsequent dismantling of the template once the column has set in order to remove the template can result in substantial time and manpower consumption. Thus, a more efficient template for placing columns would be desirable.
SUMMARY OF THE INVENTION
[0007] The present invention advantageously provides a column placement template which overcomes the limitations of the prior art and provides a novel and non-obvious template system and column placement method which facilitates the placement of a column resulting in enhanced placement efficiencies for large scale column construction projects. In a preferred aspect of the present invention, a template for column placement can include a frame, at least one pivotal column engagement scaffold coupled to the frame and at least one docking collar extending from the pivotal column engagement scaffold and configured to secure a column to the pivotal column engagement scaffold. A base further can be provided for supporting the frame, and optionally, the frame can be adjustably mounted to the base.
[0008] Notably, the base can include at least one engageable stabilizing pin. Moreover, either or both of the base and the frame can include leveling feet. In this regard, a hand crank further can be provided for operating the leveling feet. Also, the pivotal column engagement scaffold preferably can include a counterweight disposed at a bottom portion of the scaffold opposite an axis of rotation of the scaffold. Also, the docking collar can include a removable face plate. The template yet further can include a multiplicity of shims configured for insertion between a column secured by the docking collar and an interior portion of the docking collar.
[0009] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
[0011] FIG. 1 is a side elevation illustrating a template arranged for the placement of a column in a hole as is known in the art;
[0012] FIG. 2 is a side elevation illustrating a template arranged for the placement of columns in holes in accordance with the present invention;
[0013] FIG. 3 is a perspective view of the docking collar of a pivotal column engagement scaffold of the template of FIG. 2 ;
[0014] FIG. 4 is a perspective view of an base corner of the adjustable base of the template of FIG. 2 ; and,
[0015] FIG. 5 is a template side view illustrating the operation of the template of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention is a column placement template configured for the efficient installation of one or more columns in one or more corresponding holes. In accordance with the present invention, the column placement template can include pivotal column engagement scaffolding coupled to a template frame. The template frame can be supported by a template base which can include leveling feet such that the template base can be adjusted vertically to achieve a level foundation for the template. The template base further can include engageable stabilizing pins which when activated can engage the ground so as to prevent the lateral and rotational movement of the template base. Preferably, at least two pivotal column engagement scaffolds can be disposed at opposite ends of the template base. Additionally, the pivotal column engagement scaffolds can include counterweights opposite an access of rotation for the pivotal column scaffolding to facilitate the manual rotation of the scaffolds.
[0017] In a preferred aspect of the invention, at least one docking collar and preferably at least two docking collars can be incorporated in each pivotal column engagement scaffold. Each docking collar can be configured with a removable face plate so as to permit the engagement of column in the docking collar. In this regard, when secured to the docking collar, the removable face can enclose and secure a column inside the docking collar. To provide for a snug fit, one or more shims can be disposed between the docking collar and an enclosed portion of a column. Optionally, the function of the shims can be performed by mechanically engageable clamps which can be activated to engage the column on different sides of the column.
[0018] In more particular illustration of a preferred arrangement, FIG. 2 is a side elevation illustrating a template configured for the placement of columns in holes in the ground in accordance with the present invention. The template 250 can include frame 290 and one or more pivotal column engagement scaffolds 295 . The frame 290 can be unitary in design, or the frame 290 can be telescopically adjustable by securing separate ends of the base 290 into a sleeve 225 . The frame 290 can be mounted to a base 260 . In particular, the bottom portion of the frame 290 can be secured to the top portion of the base 260 using bolts which can extend from the frame 290 to the base 260 through a hole or channel formed in the base 260 . In this way, the frame 290 can be adjustably mounted to the base 260 by sliding the frame 290 along the channel of the base 260 until a desired position is reached. Subsequently, the frame 290 can be “tightened down” to the base 260 .
[0019] Importantly, the base 260 can be of substantial mass to support the operation of the pivotal column engagement scaffolds 295 when the pivotal column engagement scaffolds 295 secure one or more columns 210 in one or more corresponding holes 230 in the ground 240 . Moreover, an adjustable ballast 255 can be affixed to the base 260 , for instance by bolting the ballast 255 to the bottom surface of the base 260 . Consequently, the ballast 255 can be used to shift the center of gravity of the base 260 to accommodate non-level sites such as canal embankments in the like.
[0020] In a preferred aspect of the invention, one or more engageable stabilizing pins 275 can be affixed to the base 260 so that when activated, the engageable stabilizing pins 275 can inhibit the lateral or translational movement of the base 260 relative to the ground 240 and the columns 210 . For instance, referring to FIG. 4 , each engageable stabilizing pin 420 can be coupled to the frame 410 of the base of the template. Moreover, leveling feet 430 can be coupled to the frame 410 so as to provide for vertical leveling of the base of the template. In this regard, an adjustable crank and shaft 440 can be configured to vertically adjust the leveling feet 430 so as to provide a control point for leveling the frame 410 .
[0021] Referring again to FIG. 2 , to support the engagement of the columns 210 , each of the pivotal column engagement scaffolds 295 include scaffolding supports 265 and a docking collar 280 . The docking collar 280 can be configured to engage and enclose a column 210 when the column is placed over a hole, spread footing, or other such target 230 in the ground 240 . In this regard, referring to FIG. 3 , the docking collar 280 can include vertical supports 350 , and fixed arms 320 protruding from a fixed backing 360 (which can be substituted for a specifically configured backing plate). The fixed arms 320 further can be structurally reinforced through the coupling of the inclined struts 340 to the vertical supports 350 . As it will be apparent from the illustration, multiple sets of fixed arms 320 can protrude from the frame of the docking collar to provide additional support. In the exemplary embodiment, two sets of fixed arms 320 are utilized in each docking collar 280 although a single set can suffice as can several.
[0022] Notably, to permit the docking of a column in the arms 320 of the docking collar 280 , a confinement element 330 further can be included so that when secured to the arms 320 of the docking collar 280 (or to the fixed backing 360 ) utilizing a bolt, an enclosed column can be limited in its lateral and translational movement. Notwithstanding the foregoing, the structural configuration of the docking collar 280 is not limited to the embodiment shown in FIG. 3 and other configurations are contemplated to fall within the scope of the invention including any configuration in which a column can be engaged within the docking collar 280 and secured through the operation of a sealing mechanism which can be adjusted to permit the entry of a column into the interior portion of the docking collar 280 , for example where the docking collar 280 is a friction collar. To that end, a cylindrical docking collar or a docking collar 280 having an elliptical cross-section also can suffice for the intended purpose of the docking collar 280 .
[0023] Referring once again to FIG. 2 , a counter weight 270 can be coupled to or incorporated with each the pivotal column engagement scaffold 295 opposite an axis of rotation of the pivotal column engagement scaffold 295 so as to facilitate the inward and outward rotation of the pivotal column engagement scaffold 295 . In this way, the pivotal column engagement scaffold 295 can be removed from the immediate vicinity of the hole 230 as the hole is drilled or otherwise formed (presumably through the operation of a drill), and also from the immediate vicinity of a column 210 as the column 210 is lowered into place (presumably through the operation of a lifting device such as a crane) over the hole 230 . Once the column 210 has been lowered into the hole 230 , the pivotal column engagement scaffold 295 can be rotated outward towards the column 210 and secured to the column.
[0024] To provide a snug fit and to inhibit the movement of the column 210 from its true vertical position, one or more shims 285 can be applied to the space between the docking collar 280 and the column 210 . The shims 285 can include wedge type structures which when set between the column 210 and the collar 280 , force a snug fit. In an alternative embodiment, however, in substitute for wedges, the shims can include mechanically activated screw clamps 215 as shown in FIG. 2 . Specifically, in the alternative embodiment, the docking collar interior service can include indentation 205 at select locations in which a clamp 215 can retract when activated by a wrench or other activating tool. In this way, the process of securing a column 210 to the collar 280 can include the mere activation of each clamp 215 by mechanical or manual means.
[0025] In more particular illustration, FIG. 5 is a template side view illustrating the operation of the template 250 of FIG. 2 when drilling holes 230 and placing columns 210 therein in a process of placing columns (for instance, in the construction of sound barrier walls in highway construction). As in the case of the template 250 of FIG. 2 , in the template 550 of FIG. 5 , the template 550 can include a template base 560 coupled to a ballast 525 , the base 560 supporting a template frame 590 and one or more pivotal column engagement scaffolds 595 disposed at opposite ends of the template frame 590 . The template 550 can be positioned over the target site of one or more holes 530 to be formed to support the placement of corresponding columns 510 , albeit the invention is not limited to the placement of columns over holes and spread footings and other such column supporting structure can suffice. Once positioned over the target site, the base 560 can be secured from movement through the operation of the engageable stabilizing pins 575 . Optionally, the base 560 further can be leveled through the operation of leveling feet (not shown for the simplicity of illustration).
[0026] To form the hole 530 , a proximate pivotal column engagement scaffold 595 positioned over the hole 530 can be rotated inwardly as shown in FIG. 5 . In this way, a drill 520 can be positioned over the target area and the hole 530 can be formed. Notably, the skilled artisan will recognize many techniques for drilling holes including that which is disclosed in U.S. Pat. Nos. 5,429,455 and 5,234,288 to Bone entitled INTEGRATED COLUMN AND PILE issued on Jul. 4, 1995. Once the hole 530 has been formed, the column 510 can be secured to the hole 530 either by direct placement in the hole 530 or by attaching the column 510 to a foundational structure established within the hole 530 .
[0027] Once the column 510 can been secured to the hole 530 , the pivotal column engagement scaffold 595 can be rotated outwardly towards the column 510 so that the arms of the docking collar 580 engages the column 510 as shown in FIG. 5 . Optionally, additional docking collars (not shown) can engage the column 510 so as to further secure the column in place. In this regard, the use of the docking collar 580 can also secure the column 510 at a desired vertical position as well as a desired horizontal position. In any case, preferably, a docking collar can be placed at or near the bottom portion of the pivotal column engagement scaffold 595 . In any case, once the docking collar 580 has engaged the column 510 , the column 510 can be secured within the docking collar 580 by attaching the confinement element 565 to the docking collar 580 . Furthermore, additional confinement elements 565 can be attached to other docking collars included as part of the pivotal column engagement scaffolds 595 (or optionally as part of the template frame 590 . When the column 510 has been secured within the docking collar 580 , the column 580 can be leveled vertically and stabilized through the insertion of shims 585 . The insertion of the shims 585 can provide for a snug fit for the column 510 in the docking collar 580 . As an alternatively, mechanically engageable clamps can be applied to the column 510 so as to provide a snug fit for the column 510 in the docking collar 580 .
[0028] Several advantages of the template of the present invention will be apparent to the skilled artisan. First and foremost, by including two pivotal column engagement scaffolds in a single template, two columns can be placed at once resulting in a half-time reduction in the placement of a series of columns. Second, by utilizing the pivotal column engagement scaffolds, the template placement can be coordinated with the drilling of the hole and once the column has been fixed in the hole, the template need not be completely dismantled to remove the template. Rather, the pivotal column engagement scaffolds can be rotated away from the columns and the template simply can be removed from the vicinity of the columns.
[0029] The rigid nature of the docking collars obviate the use of straps or come-alongs in positing the column vertically over the hole. Moreover, the shims provide a snug fit of the column in the docking collar. Importantly, all control points for adjusting the lateral and translational position of the columns in the hole are located within arms reach about the docking collar. Finally, the base can be secured firmly to the ground through the operation of the engageable stabilizing pins so as to prevent the movement of the base, and the base can be precisely leveled through the operation of the leveling feet. As a result, inaccuracies associated with conventional templates can be eliminated and columns can be most efficiently placed in holes at a minimum of cost.
[0030] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention, which is limited only by the following claims. | A template system and column placement method which facilitates the placement of a column resulting in enhanced placement efficiencies for large scale column construction projects. In a preferred aspect of the present invention, a template for column placement can include a frame, at least one pivotal column engagement scaffold coupled to the frame and at least one docking collar extending from the pivotal column engagement scaffold and configured to secure a column to the pivotal column engagement scaffold. Additionally, a base can be provided in order to support the frame. |
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a mounting strip with carpet gripping means for relocatable partition walls.
(2) Description of the Prior Art
Movable partition walls are often installed over fully carpeted areas to eliminate any carpet patching when the movable partitions are relocated. Power driven fasteners, which are typically used in this type of installation, are driven through the floor runner, carpet, and into the floor. Upon removal of these penetrating fasteners, damage to the floor and carpeting may occur. If the floor is concrete, when the penetrating fasteners are removed, the concrete surface crumbles into mounds, thereby causing visible bulges in the carpeting. Damage also may occur as a result of the partition weight crushing carpet fibers.
With the desirability of relocating partition walls in carpeted areas, such as in offices, schools and residential recreational areas, it would be desirable to allow such versatility without damage to flooring and carpeting. It would also be very useful to provide a mounting strip which may be relocated and reusable at other locations for movable partition wall systems.
(3) Objects of the Invention
It is accordingly a primary object of the invention to provide a mounting strip for mounting relocatable partition walls over carpeted flooring without damage to carpet fibers or flooring.
It is also a goal of the invention to provide a mounting strip which can accommodate floor runners disposed between spaced apart rows of partition walls.
It is an allied object of the invention to provide a mounting strip which provides support shelves for mounting wall panels thereon and avoids damage to carpeting.
It is additionally a goal of the invention to provide a mounting strip which is easily affixed to carpeted flooring and may be readily removed without damage to the carpet or the floor below.
It is a concomitant goal of the invention to provide a mounting strip that is capable of gripping a carpet and adapted to support wall panels thereon, which resists lateral movement of the floor runner and eliminates normally required floor fasteners.
SUMMARY OF THE INVENTION
In satisfying all the aims, objects and goals of the invention as set forth, a mounting strip with carpet gripping means for relocatable partition walls is provided. The mounting strip comprises a central portion having a generally rectangular configuration, support shelves integral with said central portion and extending outwardly from marginal edges thereof, a multiplicity of barbs extending downwardly from said mounting strip, and locating tabs extending upwardly from said central portion along said marginal edges defining an accommodating path for floor runners therebetween. Said mounting strip being capable of gripping a carpet at said barbs and adapted to support wall panels along said support shelves while accommodating floor runners between said locating tabs. Whereby said mounting strip is movable without harmfully affecting a carpet to permit relocation of a movable partition wall construction mounted thereon.
Further aims and objects of the invention are attained by the provision of a movable partition wall constructed over a carpeted floor. Said partition wall comprises two spaced-apart rows of panels with studs supporting said panels at wall panel joints and floor runners extending between said rows of panels in supportive engagement with said panels. The movable partition wall further includes a mounting strip for accommodating said floor runners and supporting said wall panels. The mounting strip comprises a central portion, integral support shelves extending outwardly from marginal side edges of central portion, a multiplicity of carpet gripping barbs extending downwardly from said mounting strip, and locating tabs extending upwardly from said central portion and being spaced apart a sufficient distance to accommodate said floor runners therebetween. The wall panels of said movable partition wall being supported along the support shelves and said floor runners disposed between said locating tabs. The movable partition wall constructed over a carpeted floor further includes a floor with covering comprising carpeting wherein said carpeting is gripped by the barbs of the mounting strip and supporting said mounting strip thereon. Wherein said partition wall construction is demountable and said mounting strip is disengageable from said carpeting without harmfully affecting said carpet and floor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view partially broken away showing the mounting strip of this invention in its preferred embodiment for use with a conventional partition wall.
FIG. 2 is an end view of the inventive mounting strip of this invention shown in an exploded alignment with a conventional partition wall as shown in FIG. 1.
FIG. 3 is a top view of the mounting strip as shown in FIG. 2.
FIG. 4 is a side view of the mounting strip as shown in FIG. 2.
FIG. 5 is an end view of the mounting strip, alone, similar to FIG. 2.
FIG. 6 is an alternate preferred embodiment for the mounting strip as installed with a conventional partition wall in a partially exposed perspective view.
FIG. 7 is another alternate preferred embodiment for the mounting strip of this invention shown in a perspective view for use with a conventional partition wall.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the use of this invention with a conventional partition wall 10. Conventional partition wall 10 is easily removable in a fashion widely known to the industry and as such the ability to mount it over carpeted flooring is desirable. Conventional partition wall 10 comprises spaced apart wall panels 11 meeting at joints and interengaged by studs 12, which have a general H-shape. Other widely used removable studs configurations are equally suitable for use with this invention as would be well understood. Disposed between, and supportive thereof, wall panels 11 is floor runner 13. Floor runner 13 comprises a conventional channel-shape suitable for affixation of wall panels 11 by means of screw fasteners 14. Screw fasteners 14 are conventionally known dry wall screws for such purposes. Along lower portions of wall panels 11, covering screw fasteners 14 and providing a decorative appearance, is base trim 15. Base trim 15 is shown partially removed for better illustration. Conventional partition wall 10 is supported atop floor 16 having a covering comprising carpet 17. In order to provide for such removability, it is very desirable to allow conventional partition wall 10 to be removed without damage to the fibers of carpet 17 or to floor 16. In satisfaction thereof, mounting strip 18 is provided for utilization with conventional partition wall 10 to attain these goals.
To more fully describe the utilization of mounting strip 18, joint reference is now made to FIGS. 1 and 2. In its preferred form, mounting strip 18 comprises a central portion 19 having opposite ends 20 and opposite marginal edges 21. Central portion 19 thus has a generally rectangular-shape. Extending adjacent central portion 19 are support shelves 22 integrally connected at opposite marginal edges 21 of central portion 19. In its preferred form, support shelves 22 and central portion 19 are co-planar. Support shelves 22 are thus envisioned as being continuing planar adjacent surfaces for support of wall panels 11 thereon. In order to facilitate ease of installation, support shelves 22 terminate at downwardly angled lip portions 23. Thus, wall panels 11 may be positioned atop support shelves 22 in a facile manner. Mounting strip 18 accommodates floor runner 13 by means of locating tabs 26. Locating tabs 26 are struck out from mounting strip 18 generally along opposite marginal edges 21 of central portion 19. In the preferred form, locating tabs 26 are struck out adjacent opposite ends 20. In this formation, a mounting strip 18 is provided at stud 12 locations at joints between wall panels. Thereby, each wall panel will be supported at its opposite edges by a mounting strip 18 at stud 12 locations. In order to accommodate sufficient supportive engagement for conventional partition wall 10, mounting strip 18 is provided in a preferred length of from about 4" to about 12" . To afford resistance to lateral forces and to securely maintain conventional partition wall 10 in place, barbs 27 are provided. Barbs 27 are struck downward from mounting strip 18 for engagement with carpet 17. Preferably, barbs 27 are struck out downwardly from both central portion 19 and support shelves 22. Barbs 27 are provided both in longitudinal and transverse alignments for proper securement as shown in FIG. 2 more clearly. It is however within the scope of the invention, that barbs 27 may only be struck out from central portion 19 or from support shelves 22. This is envisioned within the range of construction for mounting strip 18.
Continuing further with FIGS. 1 and 2, mounting strip 18 is shown to be an easily positioned means for support of conventional partition wall 10 while yet affording proper support for wall panels 11. By supporting wall panels 11 atop support shelves 22, crushing of carpet fibers of carpet 17 is minimized. Moreover, in previous carpet mounting designs, mechanical fasteners would be driven into floor 16 through carpet 17. Such fasteners may be nails, screws, or other driven mechanical fasteners. One of the problems which the invention solves is the elimination of damage to both carpet and flooring incidental to such fastening techniques. When these previously used fasteners are removed in order to relocate or completely remove a conventional partition wall, damage to the floor may be evident by mounds of material which are left as the fasteners are removed. Plus, carpet fibers may be torn or shreaded at such engagement points. Thus mounting strip 18 alleviates these problems while yet affording excellent supportive engagement for conventional partition wall 10.
With more specific regard to mounting strip 18, reference is now made to FIGS. 3, 4 and 5. FIG. 3 shows mounting strip 18 from a top view. As can be seen, central portion 19 is generally provided as existing between locating tabs 26 wherein opposite marginal edges 21 are the imaginary parallel lines extending longitudinal of mounting strip 18 generally in line with locating tabs 26. Support shelves 22 extend adjacent central portion 19 along opposite marginal edges 21 and are integral therewith. Support shelves 22 are provided to accommodate the particular width of wall panels 11 used. Such widths are of a conventional dimension of from about 3/8" to about 1". The width of central portion 19 is provided to accommodate floor runner 13 between locating tabs 26. Accordingly, the width of central portion 19 can vary with the particular dimension of floor runner 13 used. Such dimension may be in the range of from about 1" to about 4" depending on the wall construction. Mounting stip 18 is preferrably comprised of steel and may be manufactured by conventional equipment. A preferrable thickness is 26 gauge (0.0217") and comprises hot dipped galvanized steel. The range of gauges for mounting strip 18 is not critical but it is envisioned that such thickness would be most suitably found in the ranges of from between 18 gauge to 30 gauge. The lip portions 23 generally incline downwardly at a preferred angle of about 30° for positioning wall panels 11 thereon. Such downward angle is again not critical and may be provided in a range of from about 0° to about 45°. Additionally, the length of mounting strip 18, in the preferred form, is about 8" with about twenty five barbs 27 struck downwardly from both central portion 19 and support shelves 22, as previously described. In order to facilitate resistance to both lateral forces and longitudinal forces, approximately half of barbs 27 will be oriented longitudinal of mounting strip 18 with the remainder transverse. It is additionally envisioned that barbs 27 do not extend downwardly from that part of central portion 19 between locating tabs 26, but may, however, be alternately provided at these locations within the scope of the invention. Lip portions 23 may alternately be deleted and mounting strip 18 would simply afford support shelves 22 for positioning of wall panels 11 thereon. Base trim 15, which would be lastly installed, covers screw fasteners 14 and covers lip portions 23, if provided.
Turning now to FIG. 6, an alternate preferred embodiment for the invention is shown as mounting strip 18a. Similar reference numerals in FIG. 6 correspond to reference numerals previously mentioned with regard to FIGS. 1-5. Whereby, conventional partition wall 10a is shown with wall panels 11a spaced apart in parallel relationship. 13a is shown for affixation of wall panels 11a by means of screw fasteners 14a passing therethrough. In this embodiment base trim 15a is again provided for decorative covering of screw fasteners 14a. Conventional partition wall 10a is supported atop floor 16a covered by carpeting 17a. Conventional partition wall 10a has wall panels 11a supported along mounting strip 18a with all panels 11a resting upon support shelves 22a. Mounting strip 18a has central portion 19a with opposite ends 20a and opposite marginal edges 21a. Central portion 19a has an elongate rectangular configuration. In this embodiment, mounting strip 18a is provided for the full extent of wall panels 11a and thus bottom surfaces of wall panels 11a rest for their full length atop support shelves 22a as shown. In this Figure support shelves 20a do not include lip portions but lip portions could be provided as previously discussed. For accommodation and positioning of floor runners 13a, locating tab 26a are struck upwardly from mounting strip 18a generally along opposite marginal edges 21a of central portion 19a. Support shelves 22a are integral with, and adjacent to, central portion 19a and a co-planar relationship is thereby provided. In the embodiment of FIG. 6 mounting strip 18a has locating tabs 26a at spaced-apart intervals along opposite marginal edges 21a intermediate opposite ends 20a, rather than adjacent opposite ends 20a. It is preferable that locating tabs 26a be provided in opposing pairs at these spaced-apart intervals. Thus, a symmetric relationship is disclosed for ease of manufacture and installation. However, locating tabs 26a may be staggered along either side as would be well understood. Mounting strip 18a may be provided in varying lengths. A single mounting strip 18a could be provided for the full extent of a wall panel 11a, wherein a conventional wall panel 11a width would be from about 24" to about 48". Longer lengths could be manufactured for extension beneath all or most of a wall construction. Lengths could also be provided equal to, or less than, the widths of panels and as such a series of mounting strips 18a could be abutted end-to-end. Barbs 27a are shown struck downwardly from mounting strip 18a both along central portion 19a and support shelves 22a. However, within the scope of this invention, and within the ambit of the alternate preferred embodiment from mounting strip 18a, barbs 27a may be struck downwardly only from central portion 19a, or only from support shelves 22a. Barbs 27a, similar to barbs 27 of the embodiment for mounting strip 18, are desirably provided both longitudinal and transverse of mounting strip 18a to afford resistance to both lateral and longitudinal forces in supportive engagement with carpet 17a. However, all, or a majority, of barbs could be provided parallel of mounting strip when longitudinal forces are not anticipated. The distance between locating tabs 26a across central portion 19a corresponds to the particular dimension for the particular floor runner 13a width utilized. Such dimension is typically in the range up from about 1" to about 4".
With reference now taken to FIG. 7, another alternate embodiment for the mounting strip of this invention is shown as mounting strip 18b. Mounting strip 18b is shown supporting wall panels 11b of conventional partition wall 10b. Conventional partition wall 10b utilizes wall panels 11b in a spaced-apart relationship meeting at joints. Floor runner 13b is disposed for affixation of screw fasteners 14b for supportive engagement of wall panels 11b thereto. Mounting strip 18b provides central portion 19b having opposite ends 20b and opposite marginal edges 21b. Support shelves 22b extend adjacent and integrally from central portion 19b along marginal edges 21b. Similarly, support shelves 22b and central portion 19b extend in the same plane. Support shelves 22b are provided in widths to accommodate the particular wall panel 11b widths involved. In the alternate preferred embodiment shown in FIG. 7, mounting strip 18b is characterized by the provision wherein support shelves 22b, rather than terminating in lip portions, terminate in upwardly extending flanges 24b, which in turn terminate at upper portions in outwardly angled lip portions 25b. Thus, wall panels 11b are disposed between locating tabs 26b and upwardly extending flanges 24b. The outwardly angled lip portions 25b facilitate positioning of wall panels 11b upon support shelves 22b. In this embodiment, a base trim 15b is provided in a slotted configuration for nesting atop upwardly extending flanges 24b as shown. Thereby base trim 15b decoratively covers screw fasteners 14b to provide an esthetically pleasing base portion. Locating tabs 26b are again preferably provided in opposing pairs at spaced apart intervals along opposite marginal edges 21b of central portion 19b. Mounting strip 18b, similar to alternate preferred embodiment 18a, could be provided for continuous support of wall panels 11b along support shelves 22b, or may also be provided in shorter lengths for location at joints similar to the preferred embodiment for mounting strip 18. One length, or a multiplicity of strips, may be provided. When more than one length is used, mounting strips 18b could abut end-to-end to provide said continuous support, as would be well understood. In the preferred embodiment, wall panels 11b rest completely atop support shelves 22b over carpeting 17b. Damage to floor 16b and carpet 17b is minimized allowing removability of conventional partition wall 10b therefrom. The thickness of mounting strip 18b, as well as 18a, corresponds to the dimensions previously discussed, for mounting strip 18.
In the embodiments of conventional partition walls 10, 10a, and 10b, channel-shaped floor runners and H-shape studs are envisioned. However, other demountable partition assemblies utilizing other configurations can be accommodated within the scope of this invention. The accommodation of floor runners 13, 13a and 13b between locating tabs 26, 26a and 26b affords positive installation. It is also to be noted that the upwardly extending flanges 24b of mounting strip 18b may extend upwardly and angle inwardly from support shelves 22b, as shown in FIG. 7, and are not limited to a right angle intersection thereto. Barbs 27b of mounting strip 18b, as shown in FIG. 7, may be struck downward from both central portion 19b and support shelves 22b, or from either of those portions, sufficient to resist lateral and longitudinal forces affecting conventional partition wall 10b.
Thus it is seen that a mounting strip has been provided for utilization with conventional partition wall construction permitting demountability from a carpeted floor surface without damage to the flooring or the carpeting. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be readily apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | A mounting strip with carpet gripping means for relocatable partition walls is disclosed. Said mounting strip comprises a central portion having a generally rectangular configuration, support shelves integral with said central portion and extending outwardly from marginal edges thereof, a multiplicity of barbs extending downwardly from said mounting strip, locating tabs extending upwardly from said central portion along said marginal edges defining an accommodating path for floor runners therebetween. Said mounting strip is capable of gripping a carpet at said barbs and adapted to support wall panels along said support shelves and accommodate floor runners between said locating tabs. Said mounting strip is removable without harmfully affecting a carpet to permit relocation of a movable partition wall construction mountable thereon. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national phase application of international application no. PCT/NO2008/000283, filed on Aug. 6, 2008, which claims the benefit of and priority to Norwegian application no. 20074140, filed on Aug. 9, 2007. The disclosures of the above-referenced applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates to an actuator. More particularly, it relates to an actuator for moving a tool within a borehole in the ground, the actuator being positioned between a coiled tubing and a tool, and the actuator being arranged to move the tool at a substantially constant axial speed. The actuator includes an actuator housing with an internal cylinder jacket and an end wall, there being arranged at the end wall a releasable nut which engages, in its active position, a threaded, axially bored-through mandrel, the mandrel projecting, axially movable, through an opening in the end wall. A motor is arranged to rotate the mandrel about its longitudinal axis via a non-circular, axially bored-through shaft. A locking piston, which is movable within the cylinder jacket, surrounds the mandrel, the locking piston being arranged to lock, when it is in its end position nearest to the end wall, the nut in its active position. An inner through opening in the wall of the shaft communicates with a first space in the actuator housing upstream relative to the locking piston when the mandrel is in its retracted position within the actuator housing, whereas an outer through opening in the wall of the mandrel communicates with a second space between the locking piston and the end wall when the mandrel is in its extended end position.
BACKGROUND
[0003] During work in a borehole, for example, the cleaning of a pipe, which is in the borehole, by means of a pressure-fluid tool which is on the end portion of a coiled tubing, it is well known that the feeding rate of the tool into the borehole may be irregular even though the coiled tubing is fed into the borehole at a regular rate.
[0004] The reason for this irregular rate of conveyance may be friction between the coiled tubing and borehole wall, obstructions in the borehole or curved boreholes, in which the coiled tubing changes the radius of curvature as it is being fed in. These conditions may result in a so-called “stick slip” effect, in which the tool stops, only to be moved, next, at a relatively high speed.
SUMMARY OF THE INVENTION
[0005] The invention has for its object to remedy or reduce at least one of the drawbacks of the prior art.
[0006] The object is achieved in accordance with the invention through the features which are specified in the description below and in the claims that follow.
[0007] An actuator in accordance with the invention for moving a tool within a borehole in the ground, the actuator being positioned between a coiled tubing and a tool, and the actuator being arranged to move the tool at a substantially constant axial speed, is characterized by the actuator including an actuator housing with an internal cylinder jacket and an end wall, a releasable nut being arranged at the end wall, engaging, in its active position, a threaded, axially bored-through mandrel, the mandrel projecting, axially movable, through an opening in the end wall, and a motor being arranged to rotate the mandrel about its longitudinal axis via a non-circular, axially bored-through shaft, and a locking piston, movable in the cylinder jacket, surrounding the mandrel, the locking piston being arranged to lock, when it is in its end position nearest to the end wall, the nut in its active position, and an inner through opening in the wall of the shaft communicating with a first space in the actuator housing upstream relative to the locking piston when the mandrel is in its retracted position within the actuator housing, and an outer through opening in the wall of the mandrel communicating with a second space between the locking piston and the end wall when the mandrel is in its extended end position.
[0008] In its initial position the mandrel is in its retracted position, the locking piston is in an intermediate position between the piston and the nut, whereas the motor rotates the mandrel and thereby the tool about the longitudinal axis of the mandrel. Pressurized fluid flows through the axial bores of the shaft and mandrel.
[0009] Pressurized fluid flows via the inner opening into the first space, moving the locking piston up to the nut, where the locking piston causes the nut to be moved from its inactive position into its active position, engaging the threads of the mandrel.
[0010] The motor thereby feeds the mandrel out of its retracted position, whereby the liquid flow via the inner opening is shut off.
[0011] As the mandrel takes its projecting end position, the outer opening is uncovered, whereby pressurized fluid may flow into the second space. The locking piston is moved away from the nut which is thereby moved back into its inactive position.
[0012] With advantage, the mandrel is provided with a piston which is sealingly movable within the cylinder jacket. The fluid pressure moves the locking piston and the piston together with the mandrel in the direction of their initial positions. The further movement of the mandrel into its initial position may take place by means of, for example, a force directed at the actuator from the tool.
[0013] In an alternative embodiment the mandrel may be connected to a spring or gas spring which is arranged to move the mandrel in an inward direction within the actuator housing.
[0014] In a further embodiment the mandrel is moved inwards within the actuator housing by means of an external displacing force.
[0015] With advantage, the locking piston is provided with releasable locking dogs fitting complementarily into a locking groove in the cylinder jacket, the piston being provided with a releaser which is arranged to release the locking dogs when the piston is near the locking piston.
[0016] The motor is typically driven by means of pressurized fluid, but electric operation may also be applicable under certain conditions. It is advantageous that the motor is in the actuator housing, but the motor may also project, at least partially, from the actuator housing.
[0017] By the motor feeding the mandrel in a direction out of the actuator housing by means of a thread-nut-connection, a steady feeding rate is achieved, even if the axial force on the mandrel should vary somewhat. The device according to the invention provides a relatively simple actuator, in which the mandrel is moved automatically outwards at a constant rate, subsequently returning at a relatively high speed before the feeding out of the mandrel is repeated again.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In what follows, is described an example of a preferred embodiment which is visualized in the accompanying drawings, in which:
[0019] FIG. 1 shows, partially in section, an actuator in accordance with the invention which is connected between a coiled tubing and a tool coupling;
[0020] FIG. 2 shows, on a somewhat larger scale, the actuator in its initial position;
[0021] FIG. 3 shows the same as FIG. 2 , but here a locking piston is moving within the actuator;
[0022] FIG. 4 shows the actuator after the locking piston has moved the nut of the actuator into its active position;
[0023] FIG. 5 shows the mandrel of the actuator as it is being fed out;
[0024] FIG. 6 shows the actuator as the mandrel is in its projecting position;
[0025] FIG. 7 shows the actuator after the locking piston has been moved from its locking position relative to the nut; and
[0026] FIG. 8 shows a section III-III of FIG. 3 .
DESCRIPTION OF THE INVENTION
[0027] In the drawings the reference numeral 1 indicates an actuator which is fitted between a coiled tubing 2 and a tool, not shown, by means of a tool holder 4 .
[0028] The actuator 1 includes an actuator housing 6 which is provided with an internal cylinder jacket 8 and an end wall 10 at its end portion facing away from the coiled tubing 2 . The end wall 10 is formed with a centric through opening 12 . A pressure-fluid-operated motor 14 with a through centre opening 16 is connected to the actuator housing 6 and the coiled tubing 2 by means of an adapter 18 .
[0029] Just inside the end wall 10 is arranged a nut housing 20 including a number of nut segments 22 pivotal in the nut housing 20 . Each nut segment 22 is pivotal about a nut axle 24 between a passive position, see FIG. 2 , and an active position, see FIG. 4 . The nut segments 22 are held in their passive positions by an annular spring 26 . Together the nut segments 22 constitute a nut 28 .
[0030] In its active position the nut 28 is in engagement with a threaded, axially bored-through mandrel 30 . The mandrel 30 projects, axially movable, through the opening 12 in the end wall 10 , the mandrel 30 being connected to the tool holder 4 .
[0031] At its opposite end portion, extending inwards, the mandrel 30 is provided with a piston 32 which is sealingly movable within the cylinder jacket 8 . A through opening 34 of the mandrel 30 , see FIG. 2 , is along a portion of the opening 34 given a hexagonal shape, see FIG. 8 , complementarily matching an axially bored-through shaft 36 .
[0032] The shaft 36 is rotated about its longitudinal axis by the motor 14 . An inner opening 40 through the wall of the shaft 36 corresponds with a bore 42 in the piston 32 when the mandrel 30 is in its retracted position, see FIG. 2 . The mouth of the bore 42 is on the side of the piston 32 facing the nut 28 .
[0033] A valve sleeve 44 is moved sealingly in over the inner opening 40 by means of a spring 46 as the mandrel 30 is moved away from its retracted position, see FIG. 5 .
[0034] A locking piston 48 which is movable within the cylinder jacket 8 surrounds the mandrel 30 . On its side facing the nut 28 , the locking piston 48 is provided with an externally conical sleeve projection 50 which is arranged to be moved in under the portions 51 of the nut segments 22 facing the locking piston 48 , the locking piston 48 thereby being arranged, when it is in its end position nearest to the end wall 10 , to lock the nut 28 in its active position, in which the nut 28 is in engagement with the mandrel 30 , see FIG. 4 .
[0035] When the mandrel is in its projecting position, an outer opening 52 in the wall of the mandrel 30 is uncovered, the outer opening 52 then having its mouth between the end wall 10 and the locking piston 48 .
[0036] In this preferred embodiment, the locking piston 48 is provided with a number of locking dogs 54 which are arranged to engage a locking groove 56 in the cylinder jacket 8 , see FIG. 4 . The piston 32 is provided with an axially movable, spring-biased release sleeve 58 which is biased in the direction of the end wall 10 by a spring 60 . The release sleeve 58 is arranged to move the locking dogs 54 out of their respective engagements in the locking groove 56 when the piston 32 is at the locking piston 48 , see FIG. 6 .
[0037] In its initial position the mandrel 30 is in its retracted position, the locking piston 48 is in its intermediate position between the piston 32 and the nut 28 . The motor 14 rotates the shaft 36 , the mandrel 30 and thereby the tool, not shown, about the longitudinal axis 62 of the mandrel 30 . Pressurized fluid from the coiled tubing 2 flows via the adapter 18 , centre bore 16 of the motor 14 , shaft 36 and mandrel 30 to the tool holder 4 . At the same time, pressurized fluid is flowing via the inner opening 40 and the bore 42 of the piston 32 into a first space 64 between the piston 32 and the locking piston 48 .
[0038] The locking piston 48 is moved in the direction of the nut 28 by the fluid pressure, see FIG. 3 , until the locking piston 48 hits the nut 28 , the sleeve projection 50 of the locking piston 48 being underneath the projecting portions 51 of the nut segments 22 , whereby the nut segments 22 have been moved into their respective active positions, in which they are in engagement with the mandrel 30 , see FIG. 4 . At the same time, the locking dogs 54 engage the locking groove 56 , thereby preventing the nut 28 from being movable inwards within the actuator housing 6 .
[0039] The rotating mandrel 30 , which is rotated by the motor 14 , is screwed outwards within the actuator housing 16 by means of the nut 28 , see FIG. 5 . The spring 46 in the shaft 36 thereby moves the valve sleeve 44 closingly in over the second opening 40 . Fluid from the first space 64 is evacuated via the bore 42 in the piston 32 . Moreover, the actuator housing 6 can be replenished with fluid from the outside of the actuator 1 via an opening 66 in the actuator housing 6 .
[0040] When the motor 14 has fed the mandrel 30 out into its projecting end position, see FIG. 6 , the release sleeve 58 is underneath the locking dogs 54 , whereby the locking dogs 54 have been pivoted out of their engagement with the locking groove 56 . At the same time, the outer opening 52 communicates with a second space 68 located between the end wall 10 and the locking piston 48 . In this preferred embodiment the nut 28 has been fed out of engagement from the mandrel 30 as well.
[0041] The pressure from the pressurized fluid flowing into the second space 68 works against the locking piston 48 and the force overcomes the force from the spring 60 , whereby the release sleeve 50 is moved sufficiently far back relative to the piston 32 for the sleeve projection 50 of the locking piston 48 to be disengaged from the nut segments 22 , see FIG. 7 . The annular spring 26 moves the nut segments 22 into their respective inactive positions, whereby the mandrel 30 can be moved back into its retracted initial position.
[0042] In the figures are shown a number of seals which have generally been assigned the reference numeral 70 . The purpose and operation of the seals 70 are well known and not described any further. Because of the relatively great flow rate of pressurized fluid prevailing, no great demands are made on the seals 70 . For example, it has turned out to be unnecessary to place a seal between the end wall 10 and the mandrel 30 . | An actuator device for moving a tool within a borehole in the ground, the actuator being positioned between a coiled tubing and a tool, and the actuator being arranged to move the tool at a substantially constant axial speed and the actuator including a motor-operated mandrel which is moved outwards in the actuator by means of a releasable nut, the nut being locked in its active position by means of a hydraulically operated locking piston. |
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BACKGROUND OF THE INVENTION
This invention relates to the installation of wells. During well installation, the securing of well tubing or pipe in a borehole while the borehole is backfilled with sand and cement is often hampered by the upward buoyant force of groundwater located in the borehole. A need exists for a device for securing a well pipe in a borehole in the presence of a buoyant force due to groundwater.
SUMMARY OF THE INVENTION
According to the present invention, a spider is provided which, in a flexed condition, allows a desired vertical movement of a well pipe relative to an auger to occur, and in an unflexed condition, may be used to secure the well pipe in circumdisposed relationship to the lower end of the auger. The spider includes a circular planar base which is frictionally circumferentially mounted on a well pipe section. The spider also includes a plurality of resilient arms which are integral to the base and which normally extend radially outwardly therefrom. The resilient arms are of sufficient length such that in their unflexed position, they overlap the rim of the lower end of the auger, holding the well pipe against the auger while sand or other material is backfilled over the arms. The resilient arms of the spider may also be flexed upwardly relative to the base. The diameter of the spider in the flexed condition is less than the inner diameter of the auger. Thus, the well pipe with the spider mounted may be lowered vertically through the auger when the spider is in the flexed condition.
The above and other features of the invention including various novel details of construction will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular spider embodying the invention is shown by way of illustration only and not as a limitation of the invention. The principles and features of this invention may be employed in varied and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of the spider of the present invention.
FIG. 1B is a sectional side view of the spider of the present invention taken along line I--I.
FIG. 2 is a cross-sectional elevation view of the spider 8 when the well pipe W is disposed between the inner walls 20 of the auger.
FIG. 3 is an elevation view, partly in cross-section, of the spider mounted on a well pipe positioned within an auger when the well pipe is being moved vertically relative to the auger.
FIG. 4 is a view similar to FIG. 3 but showing the spider arms in the unflexed position when the well pipe is moved below the lower end of the auger.
FIG. 5 is a view similar to FIG. 4 showing sand backfill added to hold the well pipe in position.
FIG. 6 is a bottom plan view, partly in cross-section, taken on the line VI--VI of FIG. 4, showing the spider in the unflexed position when the well pipe is moved below the lower end of the auger.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIGS. 1-6 which illustrate the preferred embodiment of the present invention. A flexible spider 8 has an inner circular planar base portion 10 and an outer peripheral portion in the form of flexible extension arms 12 which are integral to the base portion 10 (FIG. 1). The base portion 10 provides a lateral opening 11 for receiving a well pipe section 18. Although the spider 8 as presently illustrated optionally has eight extension arms, equally spaced from each other, a greater or lesser number of arms may be used. While the resilient spider arms 12 are optionally shown as being triangular in shape, other shapes, such as rectangular or oblong may also be used. The spider 8 is preferably made from a resilient plastic material such as polyethylene, of approximately 1/8 inch thickness, and is of molded construction. Each spider arm 12 terminates in an actuating portion 13.
The lateral opening 11 of the base portion 10 is adapted to fit snugly about a well pipe section 18 (FIG. 2) of a cylindrical well pipe W having an outer diameter W OD . A well cap 19 is formed at the lower end of the well pipe section to prevent sand from entering into the well. When the spider 8 is being used, a cylindrical auger A is circumdisposed about the well pipe section 18 in substantially concentric relationship thereto. In a flexed condition, the spider arms 12 are flexed upwardly so that the well pipe W can move vertically through the auger A. In an unflexed condition, the spider 8 may be used to secure the well pipe W in circumdisposed relationship to the lower end of the auger A such that the unflexed spider arms 12 overlap a rim 16 of the auger A, holding the well pipe W against the auger while sand or other material is backfilled over the arms.
The present invention is particularly suited for the installation of monitoring wells. While the well pipe W may typically have an outer diameter W OD of about 21/2 inches, the cylindrical auger A may typically have an inner diameter A ID of about six inches and an outer diameter A OD of about ten inches.
The operation of the spider 8 will now be described in detail. In a well installation, the auger A having a bit B is used to form a borehole H in stratum E (FIG. 3). The well pipe W with the spider 8 attached is placed into the upper end of the auger and pushed downward through the auger. FIGS. 2 and 3 illustrate the spider in the flexed condition as the well pipe W is passed through the inner walls 20 of the auger. The actuating portion 13 of each resilient spider arm 12 frictionally contacts the inner walls 20 of the auger A, and the vertical movement of the well pipe causes the spider arms 12 to flex upwardly. The diameter of the spider in the flexed condition is less than the inner diameter A ID of the auger. The frictional contact of the resilient spider arms 12 with the auger walls 20 opposes an upward buoyant force F due to groundwater located in the borehole.
When the well pipe W is pushed to a point where the spider 8 is positioned below the lower end of the auger A, the resilient arms 12 return to their unflexed condition (FIG. 4). The resilient arms 12 are of sufficient length such that in their unflexed condition, they overlap the auger rim 16 as shown in the sectional view of FIG. 6. With the spider 8 positioned below the lower end of the auger A, the buoyant force F of the groundwater causes the unflexed spider arms 12 to contact the auger rim 16, thereby securing the well pipe W in circumdisposition thereto. With the spider 8 securing the well pipe in circumdisposed relationship to the auger, and after the auger is retracted slightly, sand backfill may be introduced into the hollow auger so as to rest upon the upper horizontal surface of the spider arms 12, thereby further securing the well pipe W in the borehole (FIG. 5).
EQUIVALENTS
Those skilled in the art will know, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. These and all other equivalents are intended to be encompassed by the following claims. | A resilient spider is circumferentially mounted on a well section and has extension arms which, in a flexed condition, allow a desired vertical movement of the well relative to an auger in a borehole, and in an unflexed condition, may be used to secure the well in circumdisposed relationship to the lower end of the auger. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to utility structures and, more specifically, to an Inflatable Shelter
[0003] 2. Description of Related Art
[0004] A myriad of temporary structures are available for a variety of specialty and general purposes. Many times these structures are lightweight tent-type structures that provide protection from the sun and weather as well as providing some measure of privacy. These structures are generally collapsible in order to make them easy to transport from location to location. The problem with tent structures is that their frames are many times fairly heavy and/or difficult to handle in cases where above-average durability or stability is required. Furthermore, the frame members are generally constructed from metal (again, for durability), which can corrode over time. None of these tent-type structures provides a lightweight, durable and easily-erected protective structure.
[0005] One specialty application area for temporary outdoor structures that has exploded in recent years is that of the play toy known as the “bounce house.” FIG. 1 is a perspective view of a conventional inflatable “bounce house.” The conventional bounce house is a completely collapsible structure that can be erected in minutes by a single person. As shown in the FIG. 1 example, the house 10 consists of two or more inflatable frame members 16 interconnected by wall skins 20 and a roof skin 18 . As is indicated by their name, the bounce house 10 has an inflatable floor pad 12 upon which children can bounce to their hearts' content without harm.
[0006] The houses 10 are generally transported to and from the locations of use in a tote bag (albeit a fairly large bag); upon arrival at the site, an electric (or gas-powered) blower 22 is first connected to the house 10 with an air fill tube 24 , and then turned on. Subject to the sizing of the blower 22 and house 10 , the typical inflation of the house 10 will take less than an hour. Furthermore, the transport, inflation and deflation of the house 10 can typically be accomplished by a single person. If we turn to FIG. 2, we can examine how the conventional bounce house is constructed.
[0007] [0007]FIG. 2 is a cutaway perspective view of the bounce house 10 of FIG. 1. As can be seen, the roof and wall skins 18 and 20 , respectively, are stretched between the inflated frame members 16 . The frame members 16 themselves are essentially long tubes made from rubber-impregnated canvas (much like an inflatable boat) and defined by a hollow frame chamber 32 into which air from the blower (see FIG. 1) is blown.
[0008] Similarly, the floor pad 12 consists of a floor chamber 30 enclosed between a floor pad bottom surface 28 (resting against the ground), and a floor pad top surface 26 (upon which the children bounce). The frame chambers 32 and floor chamber 30 are in fluid communication with one another such that when one is inflated (or deflated), the others are inflated or deflated as well. Because of the durability of the material used for the frame members 16 and floor pad 12 , the house 10 can be inflated to a fairly high pressure where exceptional structural integrity is necessary—this does not really add to the structural weight of the house 10 (at least when compared to the tent-type structures previously described).
[0009] Bounce houses 10 are constructed in a variety of shapes and sizes, including forms simulating animals, famous buildings, or even sinking cruise ships (the “Titanic”), with the intent being to provide the most entertainment for the children bouncing around inside of them. Common to all of these various shapes and sizes are the inflatable frame members 16 and inflatable floor pad 12 .
[0010] While the design for the bounce house 10 is interesting, it does not really provide the utility necessary for it to serve as a utility structure for temporary utilitarian use rather than as a child's play area. What is needed is an inflatable utility structure that provides the benefits of the bounce house 10 plus additional usefulness.
SUMMARY OF THE INVENTION
[0011] In light of the aforementioned problems associated with the prior devices, it is an object of the present invention to provide an Inflatable Shelter. The shelter should include a plurality of arched tubes designed to rest directly upon the ground or other surface. In order to provide cooling to occupants of the shelter, the shelter may include an attachable misting mesh for dispensing a fine mist of water or other fluid from the top of the shelter. It is a further object that the misting mesh may also be incorporated within the inflatable tubes of the shelter. It is another object that the shelter be attachable to an inflation air source as well as a liquid source for pressurizing the misting mesh. It is a still further object that the structure include tie-down loops extending from the feet of the arched tubes; these tubes being provided to accept stakes therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:
[0013] [0013]FIG. 1 is a perspective view of a conventional inflatable “bounce house;”
[0014] [0014]FIG. 2 is a cutaway perspective view of the bounce house of FIG. 1;
[0015] [0015]FIG. 3 is a perspective view of a preferred embodiment of an inflatable shelter of the present invention;
[0016] [0016]FIG. 4 is a cutaway perspective view of a preferred embodiment of a rafter tube of the shelter of FIG. 3;
[0017] [0017]FIG. 5 is a cutaway perspective view of an alternate embodiment of a rafter tube of the shelter of FIG. 3;
[0018] [0018]FIG. 6 is a perspective view of a preferred misting mesh used with the shelter of FIG. 3;
[0019] [0019]FIG. 7 is a perspective view of an alternate embodiment of the shelter of the present invention; and
[0020] [0020]FIG. 8 is a perspective view of an assembly including an alternate embodiment of a water source for use with the shelters of FIG. 3 or 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide an Inflatable Shelter.
[0022] The present invention can best be understood by initial consideration of FIG. 3. FIG. 3 is a perspective view of a preferred embodiment of an inflatable shelter 40 A of the present invention. Unlike the conventional bounce house described above, the shelter of the present invention eliminates the floor pad; this is for at least two reasons: (1) the floor pad provides unwanted cushioning, and (2) any floor covering (i.e. over the ground) in a utility environment will invariably become soiled, will wear out, and perhaps may be a safety hazard.
[0023] The structure 40 A comprises a plurality of hollow, inflatable arched tubes 42 interconnected by hollow rafter tubes 44 . The arched tubes 42 and rafter tubes 44 are in fluid communication with one another such that when one is inflated or deflated, all others are inflated or deflated as well. Of course, in larger or specialty designs, the tubes 42 and 44 may be grouped together so that they might be inflated separately (e.g. from separate blowers 22 ).
[0024] In this embodiment, the arched tubes 42 comprise a pair of vertical portions 46 A each terminating at the ground in feet 52 . At the opposite ends of the vertical portions 46 A are sloped portions 48 A; these then transition into a horizontal portion 50 (which interconnects the two sides).
[0025] As depicted, the vertical portions 46 A each terminate in a foot 52 at their ends. In close proximity to, or actually extending from each foot 52 are tie-down loops 54 or flaps for securing the shelter 40 A to the ground. The shelter 40 A is preferably secured to the ground with stakes 56 or the like pounded through one or more of the tie-down loops.
[0026] Similar to the bounce house discussed previously, the shelter 40 A is erected by inflating with a blower 22 forcing air through an air fill hose 24 . The hose 24 may be connected to any suitable connection point provided on any of the members of the shelter 40 A—here it is shown connected to the bottom of one of the vertical portions 46 A of the third arched tube 42 C.
[0027] In this embodiment, five arched tubes, 42 A- 42 D, respectively, are employed, however in other embodiments either more or fewer tubes 42 may be used, depending upon the desired length of the shelter 40 A.
[0028] In addition to those novel aspects previously discussed, one notable aspect of the shelter 40 A is that it can be configured to dispense a water mist downwardly in order to cool off persons that are under the shelter 40 A. The misting system obtains its water for misting from a water source 60 A, such as the outdoor hose bib shown. Water dispensed by the source 60 A is carried to the shelter 40 A by a water supply hose 62 , which then connects to the shelter at a water supply port 58 . Misting can be turned on or off either at the source 60 A or some other internal system valve. Examples of the entire misting system will be discussed below in connection with other drawing figures.
[0029] Also shown is a display panel 64 extending across the top section of the first arched tube 42 A. This panel 64 may be used to advertise or to otherwise display indicia thereon. The panel 64 is preferably made from the same flexible material as the tubes 42 and 44 .
[0030] Although not depicted here, it should be understood that the shelter may be configured with rollable or removable wall or roof panels for providing privacy, environmental protection, or even insect protection (such as by screens). One embodiment may comprise a permanently-attached solid vinyl sheet covering over the top portion of the shelter 40 A, and one or more vinyl sheets removably attached in between the vertical portions 46 , such as by hook-and-loop fasteners. Now turning to FIG. 4, we can examine the invention in more detail.
[0031] [0031]FIG. 4 is a cutaway perspective view of a preferred embodiment of a rafter tube 44 of the shelter of FIG. 3. In this embodiment, the rafter tube 44 includes an internal water distribution hose 70 A running through the rafter tube chamber 72 for distributing water from the supply system (see FIG. 3) and out to the individual misting nozzles 66 A. Under normal household pressure, the misting nozzles 66 A will provide a fine water mist 68 which serves to evaporatively cool the air in the general vicinity of the nozzles (i.e. inside the shelter). In this embodiments, the misting nozzles 66 A protrude through the tube wall 45 from the internal water distribution hose 70 A. If we turn to FIG. 5, we can review another embodiment of the nozzle arrangement.
[0032] [0032]FIG. 5 is a cutaway perspective view of an alternate embodiment of a rafter tube 44 of the shelter of FIG. 3. In this embodiment, there are one or more hose clips 74 attached to (or molded into) the outside of the tube wall 45 . The hose clips 74 are configured to securely grasp the external water distribution hose 70 B therein. The benefits of this externally-mounted version is that the rafter tube 44 air-tight integrity is not jeopardized by the through-penetration of the nozzles, and furthermore, there is greater flexibility and control by the user of the positioning of the misting nozzles 66 B—in fact, the nozzles 66 B might be re-positionable from location to location on the shelter. It should further be understood that while FIGS. 4 and 5 depict the nozzles 66 extending from the rafter tube 44 , they may also be positioned in other locations (e.g. from the arched tubes). Now turning to FIG. 6, we can examine how the individual misting nozzles are interrelated.
[0033] [0033]FIG. 6 is a perspective view of a preferred misting mesh 76 used with the shelter of FIG. 3. In this embodiment, the misting mesh 76 refers to a matrix of interconnected piping or tubes 78 that distribute water from the water supply port 58 and out to the individual misting nozzles 66 . As discussed above, the tubes 78 may be retained within the inflated structural tubes, or they may be attached to the outer surfaces of the structural tubes, or the may the positioned in a way that is a combination of the two. Furthermore, although not depicted here, a shutoff valve and/or pressure regulator may be included in the first branch tube 78 A; provided to control the water pressure and flow. The material used for the tubes 78 is extremely flexible and durable in order to permit the structure to be collapsed and packed into a single bag without damage to either the shelter or the mesh 76 . Similarly, the nozzles 66 are constructed in a way to prevent their cutting into any of the other portions of the shelter (i.e. from plastic with no sharp edges). Having completed the review of a first embodiment of the shelter of the present invention, we will now turn to FIG. 7.
[0034] [0034]FIG. 7 is a perspective view of an alternate embodiment of the shelter 40 B of the present invention. In this embodiment 40 B, alternate arched tubes 43 are employed. These alternate arched tubes 43 comprise vertical portions 46 B and long sloped portions 48 B, with the sloped portions 48 B meeting at the peak 80 of the shelter 40 B. This design provides more headroom than the previously-described embodiment, while retaining the benefits of light weight and ease of erection and packing. Although only three rows of rafter tubes 44 are shown here, it should be understood that additional rows may be added in alternate embodiments. Another optional element in this present invention is the second row of rafter tubes 47 ; these second rafter tubes 47 , if included, are essentially the same construction as those previously discussed (tubes 44 ).
[0035] Similar to the previous shelter embodiment, another embodiment of the instant shelter 40 B may comprise a permanently-attached solid vinyl sheet covering over the top portion (i.e. over the sloped portions 48 and peaks 80 ) of the shelter 40 A, and one or more vinyl sheets removably attached in between the vertical portions 46 , such as by hook-and-loop fasteners. Finally turning to FIG. 8, we can evaluate yet another alternate embodiment of a component of the present invention.
[0036] [0036]FIG. 8 is a perspective view of an assembly including an alternate embodiment of a water source 60 B for use with the shelters of FIG. 3 or 7 . In some remote locations, for example construction sites or remote holes on golf courses, there may not be a permanent water supply available; there may, however be electrical power available (e.g. from generators or inverters). In such cases, an alternate water source 60 B may be utilized. This alternate source includes a water pump 82 and a portable water reservoir 84 (although a lake or pond may be used, if it is clean enough). In this example, the water pump 82 and blower 22 are both being run from the same motor 88 . In other embodiments, the pump 82 and blower might be separate. Furthermore, it should be appreciated that the portable water reservoir 84 shown here is simply an theoretical example to demonstrate functional relations between the components; it is not intended to restrict the potential form of the reservoir 84 in any way.
[0037] Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit, of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | An Inflatable Shelter is disclosed. The shelter includes a plurality of arched tubes designed to rest directly upon the ground or other surface. In order to provide cooling to occupants of the shelter, the shelter may include an attachable misting mesh for dispensing a fine mist of water or other fluid from the top of the shelter. The misting mesh may also be incorporated within the inflatable tubes of the shelter. Furthermore, the shelter may be attachable to an inflation air source as well as a liquid source for pressurizing the misting mesh. Still further, the structure may include tie-down loops extending from the feet of the arched tubes; these tubes being provided to accept stakes therethrough. |
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FIELD OF THE INVENTION
This invention relates to a novel, rapid assembly secure burglar and fire resistant building construction. More particularly, this invention pertains to a unique and inexpensive prefabricated fire retardant, burglar resistant building which is constructed of unique wall panels, floor and roof truss systems, secure locking doors and secure locking windows.
BACKGROUND OF THE INVENTION
Construction costs for buildings, both residential and commercial, in the industrialized world, have risen dramatically over the past quarter century. At one time, labour costs comprised one-third of the total building costs, while residential materials costs represented two-thirds of the total building cost. In the past quarter century or so, costs have become reversed so that labour costs now comprise two-thirds of the total building cost. There is a strong need for a solid building construction which requires minimum labour input for assembly.
Break and entry frequencies and vandalism have also increased over the past quarter century or so. Many residential homes in existence today, as well as many commercial buildings, are not particularly secure, that is, they are not break and enter proof. In recent times, bars on windows and doors, improved door and window locking systems, security alarm systems and other expensive accessories have been added to increase the security of the typical residential home in the western industrialized world. There is therefore a strong need for a low labour construction content, high security building that is inexpensive and easy to assemble.
Conventional wood frame buildings are prone to ignition and destruction by fire due to carelessness of the occupants, or malfunctioning heating systems such as furnaces. A strong need exists, therefore, for a building which is fire resistant. Fire and break and entry insurance rates would be reduced.
To reduce labour input, various types of prefabricated buildings have been designed. Some of these include modular construction techniques.
British Patent No. 2,135,363 discloses a panel which comprises a primary skin pressed or otherwise formed into a section with alternate longitudinal troughs and peaks for longitudinal stiffness, some or all of the peaks being flat-topped. A secondary skin formed by one or more rigid members bridges adjacent peaks to form a box section and increase lateral, longitudinal and torsional stiffness.
The skins are preferably of plastic and are welded together. The secondary skin may be formed by spaced strips applied to both sides of the primary skin, or may consist of continuous facing sheets. The spaces between the skins may be filled with concrete for increased stiffness and strength. The troughs and peaks are preferably of equal width and equidistant, and each trough has outwardly diverging inclined sides to form open trapezoidal channels. This panel has the advantage of increased stiffness and can be insulated to suit the application.
Patent Cooperation Treaty patent application WO 93/11321, published Jun. 10, 1993, discloses a standardized panel used for constructing walls and floors of buildings. The panels are constructed of ribbed central steel members which are lined on one or both sides, and assembed on site. At the site, materials are applied to each side of the panels. The steel centres have perforations throughout and do not provide a seal. Foam or insulation is placed in only some of the troughs of the panels.
The applicants are aware of a steel truss or beam which is constructed of parallel back-to-back longitudinal concave channels. Flat top and bottom longitudinal steel plates are secured to the top and bottom of the longitudinal concave channels. This results in a beam construction which has roughly an hourglass cross-section.
SUMMARY OF THE INVENTION
The invention is directed to a rapid assembly, burglar and fire retardant building construction comprising: (a) a foundation; (b) a roof; and (c) a wall extending from the foundation to the roof, said wall being constructed of an interior corrugated metal sheet, insulation covering both sides of the metal sheet, a wall covering on an interior surface of the insulation and a wall covering on the exterior surface of the insulation.
The metal sheeting of the construction can be corrugated so that alternating interior and exterior grooves run vertically, the insulation can be urethane foam on interior and exterior surfaces of the corrugated metal sheeting, and a vertical connecting anchor rod can connect the base of the wall to the top of the foundation, the top end of the anchor rod connecting the top of the wall to the roof, and the bottom end of the anchor rod connecting the bottom of the wall to the foundation. The metal sheeting can have alternating grooves facing opposite sides of the sheeting, the walls of the grooves being disposed at a 45° angle, and the tops and bottoms of the grooves can be flat.
The invention also pertains to a building construction comprising: (a) a foundation; (b) a roof; (c) a wall extending from the foundation to the roof, said wall being constructed of an interior corrugated metal sheet, insulation covering both sides of the metal sheet, a wall covering on an interior surface of the insulation and a wall covering on the exterior surface of the insulation; and (d) a roof truss supporting the roof, the roof truss being constructed of intersecting members which have a "capped Y" cross-section shape.
The roof can be constructed of concrete shingles on corrugated metal sheeting, which can be supported by the top of the roof truss. The construction can include a window in the wall comprising a pair of sliding panels, said panels being secured to respective pairs of loop and pulley systems, so that the sliding panels can be withdrawn into respective pockets formed in the wall, and extended from the pockets towards one another to close the window opening. The construction can include a door mounted within a door opening in the wall, said door having in the interior thereof a concentric wheel door lock system.
The concentric wheel door lock system of the construction can comprise at least one locking rod which can extend from an edge of the door into the wall, or be withdrawn from the wall into the interior of the door; and a wheel rotationally mounted within the interior of the door, the wheel being connected by a linkage means to the locking rod, the wheel when being rotated to a first position, extending the rod from the edge of the door into the wall, and the wheel, when rotated to a second position, withdrawing the rod from the wall into the interior of the door. The door can have at least two locking rods, each hingedly secured to the concentric wheel.
In a further aspect, the invention relates to a building construction comprising: (a) a foundation; (b) a roof; (c) a wall extending from the foundation to the roof, said wall being constructed of an interior corrugated metal sheet, insulation covering both sides of the metal sheet, a wall covering on an interior surface of the insulation and a wall covering on the exterior surface of the insulation; and (d) a floor spanning the interior of the walls, said floor being supported by at least one joist, the joist having a cross-section comprising a first "capped Y", a second inverted "capped Y", the stems of the first and second "capped Y" intersecting with one another. The first and second "capped Y's" can have an internal reinforcing steel plate.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate specific embodiments of the invention, but which should not be construed as restricting the spirit or scope of the invention in any way:
FIG. 1 illustrates an isometric partially cutaway view of a building constructed according to the invention.
FIG. 2 illustrates a front elevation of a residential building constructed according to the invention.
FIG. 3 illustrates a rear elevation of a residential building constructed according to the invention.
FIG. 4 illustrates a left-side elevation of a residential building constructed according to the invention.
FIG. 5 illustrates a right-side elevation of a residential building constructed according to the invention.
FIG. 6 illustrates a floor plan of the main floor of a residential building constructed according to the invention.
FIG. 7 illustrates a plan of the foundation and unfinished basement of a residential building constructed according to the invention.
FIG. 8 illustrates a side elevation cross-section view taken along section A--A of FIG. 6 of a residential building constructed according to the invention.
FIG. 9 illustrates a plan view of a stair construction of a residential building constructed according to the invention.
FIG. 10 illustrates a side section view of the stair landing taken along section B--B of FIG. 9.
FIG. 11 illustrates a detail side view of the connection between a main floor and a top of the stair of a residential building constructed according to the invention.
FIG. 12 illustrates a detail side view of the connection between the base of the stairs and the stair landing of a residential building constructed according to the invention.
FIG. 13 illustrates a detail side view of the connection between the base stairs below the landing and the foundation floor of the basement of a residential building constructed according to the invention.
FIG. 14 illustrates a front elevation of the wall construction of a residential building constructed according to the invention.
FIG. 15 illustrates a section view taken along section C--C of FIG. 14.
FIG. 16 illustrates a section view taken along section D--D of FIG. 14.
FIG. 17 illustrates a detail plan of the end construction of a wall of a residential building constructed according to the invention.
FIG. 18 illustrates a detail plan of the joint in a wall construction of a residential building constructed according to the invention.
FIG. 19 illustrates a detail plan of a corner wall construction of a residential building constructed according to the invention.
FIG. 20 illustrates a detail plan of an interior and exterior wall connection of a residential building constructed according to the invention.
FIG. 21 illustrates a detail elevation of a connection between a wall base and a foundation of a residential building constructed according to the invention.
FIG. 22 illustrates a plan of a floor slab construction of a residential building constructed according to the invention.
FIG. 23 illustrates a section taken along section E of FIG. 22.
FIG. 24 illustrates an enlarged detail of the section view of FIG. 23.
FIG. 25 illustrates a section taken along section F of FIG. 22.
FIG. 26 illustrates a section taken along section G of FIG. 22.
FIGS. 27a, 27b and 27c illustrate in three successive side views the construction of a truss member of a residential building constructed according to the invention.
FIG. 28 illustrates a side view of a typical truss construction of a residential building constructed according to the invention.
FIG. 29 illustrates a detail side view of the crown construction of a roof truss of a residential building constructed according to the invention.
FIG. 30 illustrates a detail side view of a joint plate and intersecting truss members of a roof truss.
FIG. 31 illustrates a detail side view of an intersection between the upper end of a diagonal truss member and a roof truss member of a roof truss of a residential building according to the invention.
FIG. 32 illustrates a detail side view of a joint plate and intersecting truss members of a corner of a roof truss and roof construction according to the invention.
FIG. 33 illustrates a front view of a gusset plate of a crown of a roof truss.
FIG. 34 illustrates a front view of a joint plate for intersecting base truss members and diagonal truss members of a roof truss.
FIG. 35 illustrates a front view of a corner joint plate of intersecting base truss members and roof truss members.
FIG. 36 illustrates a front view of a joint plate for intersecting diagonal truss members and base truss members.
FIG. 37 illustrates a front elevation of a wall and window system with horizontal sliders of a residential building constructed according to the invention.
FIG. 38 illustrates a section taken along section line H--H of FIG. 37.
FIG. 39 illustrates a detail side view of a top connection between a slider and the top wall of a window of a building constructed according to the invention.
FIG. 40 illustrates a detail side view of a base connection between a slider and the bottom wall of a window of a building constructed according to the invention.
FIG. 41 illustrates a front elevation of an exterior door and wall of a residential building constructed according to the invention.
FIG. 42 illustrates a front cut-away view of the interior locking mechanism of an exterior door of a residential building constructed according to the invention.
FIG. 43 illustrates a section taken along section I--I of FIG. 42.
FIG. 44 illustrates a detail front view of a concentric locking rod linkage of the interior of an exterior door of a residential building constructed according to the invention.
FIG. 45 illustrates a detailed front view of a connection between a bottom locking rod and a foundation of an exterior door of a residential building according to the invention.
FIG. 46 illustrates a detail top view of the concentric linking rod assembly of a concentric locking system of an exterior door of a residential building according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an isometric partially cut-away view of a building constructed according to the invention. In particular, FIG. 1 illustrates a residential building 2 constructed with walls 4, roof 6, window 10 and foundation 12. The cut-away portion reveals the construction of the floor 16, hot water piping 54, floor joists 56, floor decking 58, and wire mesh 60. The roof trusses 14 and roof decking 88, as well as the corrugated steel backbone 36 of the wall panels, are also shown.
FIG. 2 illustrates a front elevation of a residential building constructed according to the invention. As seen in FIG. 2, the residential building 2 is constructed of a plurality of vertical walls 4, a roof 6, a door 8, and a number of windows 10. The building 2 rests on a basement foundation 12, shown in dotted lines.
FIG. 3 illustrates a rear elevation of a residential building constructed according to the invention. The walls 4 are constructed of a unique combination of prefabricated materials as will be discussed below. The roof 6 is typically constructed of tile or concrete shingles, available from various sources, such as Columbia Concrete, or combination concrete-wood shingles, such as those available from MacMillan Bloedel, Vancouver, British Columbia, under the trade-mark CEMWOOD. These shingles are constructed of a combination of concrete and wood, and are porous and lightweight. They have a life of fifty years or more, and have good insulating qualities.
FIG. 4 illustrates a left-side elevation of a residential building constructed according to the invention. FIG. 5 illustrates a right-side view of a residential building 2 constructed according to the invention. The building has porches, stairs and other conventional accessories.
FIG. 6 illustrates a floor plan of the main floor of a residential building constructed according to the invention. As seen in FIG. 6, the interior of the residential building constructed according to the invention is relatively conventional, comprising three bedrooms, two baths, a kitchen, a dining room and a living room. An adjoining garage houses a family automobile. All of the rooms can be constructed according to the invention utilizing the unique exterior and interior wall assemblies according to the invention, as will be explained in greater detail below.
FIG. 7 illustrates a plan of the foundation and unfinished basement of a residential building constructed according to the invention. As seen in FIG. 7, the basement includes a conventional hot water heater (HW), a furnace, and a main floor-basement connecting stairway which is constructed of steel as will be discussed in detail below. FIG. 7 also shows the foundation 12, upon which the building 2 rests, the foundation being constructed in conventional manner from poured concrete and reinforced steel. FIG. 7 further illustrates a series of windows around the exterior of the foundation. The garage rests upon concrete footings, rather than on an excavated foundation.
FIG. 8 illustrates a side elevation cross-section view taken along section A--A of FIG. 6 of a residential building constructed according to the invention. As seen in FIG. 8, the roof 6 is supported by a plurality of roof trusses 14, which span in parallel across the opposite walls 4 in conventional manner. The construction of the roof truss 14 will be explained in greater detail below.
The main floor 16 of the building is constructed of a unique combination of cooperating steel trusses, steel floor decking and other components, which also will be discussed in greater detail below. A steel staircase 18 is connected to the main floor 16, and enables users of the residence to descend to the basement area of the residential building. The walls 4 rest on poured reinforced concrete foundations 12. The exterior areas of the concrete foundation 12 include conventional storm drains, tile drains, drain rocks, and other conventional materials, to transport water away from the foundation 12.
FIG. 9 illustrates a plan of the stair construction. The staircase 18 is constructed of a pair of hand rails 19, upper steel grate treads 24, a steel grate landing 28 and lower steel grate treads 24.
FIG. 10 illustrates a side section view taken along section line B--B of FIG. 9. The landing 28 has upwardly extending vertical hand rail posts 20, which support the hand rails 19. A pair of lower steel grate treads 24 extending between two parallel matching stringers 26, lead from the landing 28 to the floor of the foundation 12.
FIG. 11 illustrates a detail side view of the connection between the upper end of the staircase 18 and the main floor 16. As seen in FIG. 11, the stair case 18 has an upwardly extending hand rail post 20, a clip angle 22, steel grate treads 24, and a steel channel stringer 26. A matching stringer 26 is on the opposite side. The clip angle 22 (one of a pair) enables the top of the staircase 18 to be welded to the adjoining edge of the main floor 16.
FIG. 12 illustrates a detail side elevation of the connection between the lower end of the main staircase 18 and the landing 28. As seen in FIG. 12, a vertical hand rail post 20 is welded to the base of each of the steel channel stringer 26. The pair of stringers 26 is welded to the steel grate landing 28 via a pair of clip angles 22. A right angle steel channel 30 is welded underneath the landing 28 and provides support for the lower portion of the staircase. A steel angle post 32 supports the landing 28 above the floor of the foundation 12.
FIG. 13 illustrates a detail elevation of the connection between the lower part of the staircase 18 and the basement foundation floor 12, as seen previously in FIG. 10. A vertical handrail post 20 extends vertically upward from the foundation floor 12. The steel channel stringer 26 supports a steel grate tread 24. The stringer 26 is secured by clip angle 22 to a concrete anchor bolt secured in the foundation floor 12. The various components of the stairway are welded together, as required.
FIG. 14 illustrates a detail front elevation of a wall 4 of a residential building according to the invention. The wall 4 is constructed of adjoining panels of angle-formed steel sheeting, with alternating parallel interior and exterior grooves extending vertically from the top to the bottom. The top of the wall 4 is capped by a steel top channel 37, while the bottom of the wall 4 is capped by a steel bottom channel 39. Adjacent steel panels are connected at their intersection with periodic panel connection bolts 50 to construct a complete wall. A wall anchor bolt 46 extends vertically behind the vertical series of connecting bolts 50.
Strength tests have been calculated for 14 gauge, 16 gauge, 18 gauge and 20 gauge 8 foot high corrugated metal sheet having 12 inch centres from one corrugation peak to the next, 45° angle walls, 4 inch depth and 2 inch flat areas at the peak of each corrugation. The 45° angle provides the greatest strength in all directions, for example, diagonal, longitudinal, vertical and lateral. Table 1 illustrates the results of these computations.
TABLE 1______________________________________ Wind Pressure 15 20 25 30 0 psf 5 psf 10 psf psf psf psf psf,Thickness Factored Compression Load per one foot of wallt(in.) (kip)______________________________________20 ga. 0.036 6.94 6.79 6.79 6.49 6.34 6.19 6.0418 ga. 0.048 11.37 11.20 11.04 10.88 10.71 10.55 10.3816 ga. 0.060 15.91 15.73 15.55 15.36 15.18 15.00 14.8214 ga. 0.075 22.30 22.09 21.89 21.68 21.47 21.27 21.06______________________________________ Conforms to CAN/CSAS136-M89 ColdFormed Steel Structural Members.
FIG. 15 illustrates a section taken along section C--C of FIG. 14. This section illustrates in particular the unique construction of the wall of the residential building according to the invention. The wall 4 is constructed of adjoining an angle-formed interior steel panels 36 which are coated on both sides thereof by sprayed foam insulation, or some other suitable insulating material. Typical sprayed foam insulation is sprayed polyurethane rigid foam. It will be understood, of course, that other suitable insulating materials can be used. It should be noted that the exterior flat edges 37 of the angles of the steel panels 36 are covered with foam so that they do not impinge on the interior and exterior walls 40 and 42. This increases insulating ability. Accordingly, there is no direct metal connection between the exterior wall 42 and the interior wall 40, whereby heat may be conducted along high heat conductivity metal and thereby reduce insulating value of the wall 4.
As seen in FIG. 15, the interior of the wall is constructed of conventional gypsum drywall 40. The exterior is clad with conventional vinyl siding 42. Vapour barrier film can also be incorporated into the wall, if required. Wall anchor bolt 46 extends vertically from the top to the bottom of the wall and secures the wall firmly to the foundation 12. The wall anchor bolt 46 at its upper end also secures the top of the wall 4 to the roof truss 14 and the roof of the residential building.
Each 3'-1" steel panel is crimped from 4'-0"×8'-0" steel sheets. However, other sizes are possible to suit specific requirements or building codes of different countries. For instance, Japan requires 7 foot panels. Some new constructions in Canada utilize 9 foot panels. Heavier gauge steel is used for panels and channels as required. Unless noted otherwise, all connections are welded. The side walls of the panels are crimped at 45°. Drywall is fastened through insulation and into the ribs of the panel with screws. All interior walls, without plumbing, are typically 51/8" thick.
FIG. 16 illustrates a section view taken along section D--D of FIG. 14. The foam coated steel panel interior 36 is clad on the interior by conventional drywall 40 and on the exterior by conventional vinyl siding 42. The base of the foam covered steel panel 36 is connected by a steel bottom channel 39, which bears on the top of concrete foundation 12, and is held securely in place by anchor bolts 44. One of the anchor bolts 44 is threaded at the top end, and receives a nut which securely connects the steel bottom channel 39 to the top of the concrete foundation 12. While not shown, the anchor bolts 46 in series also secure the wall 4 to the foundation 12.
FIG. 17 illustrates a detail of the left end of the wall 4 illustrated in FIG. 15. The end of the wall 4 is capped with an exterior channel 47. The corrugated 45° angle construction of the interior steel panel 36 is shown in detail in FIG. 17. Foam insulation 38 coats both sides of the steel panel backbone 36. FIG. 17 also shows clearly the interior drywall 40 and the exterior vinyl siding 42. The interface between the drywall 40 and the foam insulation 38 has a 6 mm polyethylene vapour barrier 41, to prevent or deter the transmission of vapour barrier from the interior to the exterior of the building, and vice versa.
FIG. 18 illustrates a detail of the anchor bolt 46 and connecting configuration between adjoining panels of the wall 4. The ends of adjacent panels 36 are connected with a vertical series of connecting bolts 50, as seen previously in FIG. 14. The drywall anchor bolt 46, as explained previously, extends from the top to the bottom of the wall panel 4. The foam insulation 38 extends throughout the interior and exterior side of the steel panels 36, including intersections and connecting bolts 50, and prevents a direct metal connection and transmission of heat between the exterior and interior of the wall 4.
FIG. 19 illustrates a detail of a corner wall construction of a residential building constructed according to the invention. As seen in FIG. 19, a simple secure connection is made between right angle corners of adjacent walls with no intersections that extend directly between the exterior and interior of the wall. The edge of one wall has steel end channel 52 which bears directly on a corresponding end channel 52 of the adjacent perpendicular panel wall. The interior corners are clad with intersecting conventional drywall 40. The exterior corners are also clad with intersecting conventional vinyl siding 42. The exterior and interior end channels 52 can house plumbing piping, electrical connections, and the like. The adjoining faces of the pair of end channels 52 are connected together by welding, or alternatively, bolts (not shown).
FIG. 20 illustrates a detail of an interior connection between an exterior wall and an interior wall as shown previously in FIG. 15. Steel end channel 52 bears directly against the interior side of the exterior wall. The corners of the interior wall are clad with conventional drywall 40 which intersects with drywall 40 of the inside of the exterior wall. The interior walls are held securely in place by anchor bolts 46, as shown previously in FIG. 14.
FIG. 21 illustrates a detail of the anchor bolt connection between the base of a wall and the top of a concrete foundation 12. Anchor bolts 44 are cast in place when the concrete foundation 12 is poured. One of the anchor bolts 44 is threaded at its top end so as to receive a nut 45 and washer 49 combination. This secures the steel bottom channel 39 firmly to the top of the concrete foundation 12. The interior drywall cladding 40 extends to an elevation below the intersection between the wall and the concrete foundation, in order to seal off the intersection between the wall and the foundation. The bottom end of exterior siding 42 bears directly on the top of the concrete foundation 12.
FIG. 22 illustrates a plan of the floor 16 of the residential building according to the invention. A hot water pipe 54 traverses back and forth in parallel passes throughout the area of the floor 16 and provides radiant floor heating for the building. The temperature of the main floor of the building can be regulated by regulating the temperature of the water passing through the interior of the network created by traversing hot water pipe 54. Standard hot water plumbing is used so no exceptional parts are required.
FIG. 23 illustrates a section taken along section E of FIG. 22. The edge of the floor 16 abuts the foundation 12, and is connected thereto by supporting joist 56, which extends into the foundation. Steel panel decking 58 rests directly on the series of parallel joists 56, only one being shown in FIG. 23. Hot water heating pipes 54, together with steel wire mesh 60 to reinforce poured concrete floor 59, extends throughout the floor area.
Heavier gauge wire mesh is used as required. Heavier gauge steel to be used for floor joists as required to support the weight of wet concrete (150 lbs./cu. ft.) (height of floor joists remains constant). Steel roof decking must also be able to support the weight of wet concrete across the width of joist separation. Each heating pipe in the slab will consist of a 1/2" I.D. copper tube inside a 1" I.D. PVC pipe, or black steel, or other suitable pipe. Other combinations of pipe materials are feasible. In the event of an emergency, the inside pipe can be disconnected under the access hatch plate 62 and slid out from PVC pipe at the garage/depression end of the floor slab 16.
It will be understood that the piping system can be used for both heating and cooling. In hot climates, cold water will be circulated through the system. In cold climates, hot water will be circulated.
FIG. 24 illustrates in enlarged view the detail of FIG. 23. The underside of the joist 56 is clad with conventional drywall 40, as is the interior wall of the concrete foundation 12. The steel decking 58 is corrugated to provide strength. The top surface of the floor can be covered with any conventional material such as linoleum, carpet, ceramic tile, and the like. Access hatch 62 can be opened and permits servicing of the external water pipe 54, and its internal copper pipe. Since the joist 56 extends into the foundation 12, a solid weight supporting connection is readily made between the joist 56 and the foundation 12.
FIG. 25 illustrates a section taken along section F of FIG. 22. FIG. 25 illustrates in particular the cross-sectional construction of the joist 56, as will be explained below in association with FIGS. 27a, 27b and 27c. As seen in FIG. 25, the concrete floor 59, and reinforcing wire mesh grid 60 are supported by the steel decking 58 and joist 56. While not shown, there are in fact a plurality of joists 56 arranged in parallel across the floor area, as is conventional.
FIG. 26 illustrates a section taken along section G of FIG. 22. Steel panel decking 58 is supported by the joists 56, one of which is shown. As seen in FIG. 26, the hot water heating pipe 54, with internal copper pipe, passes to the exterior of the foundation 12 into a light metal box 64. This metal box 64 extends along the entire length of the foundation and has a hinged access door along the vertical edge. The light metal box 64 enables the hot water pipe 54 to be easily serviced. The box 64 can also carry electrical wiring, and regular hot and cold water plumbing.
FIGS. 27a, 27b and 27c illustrate successive side views of the construction of a truss member of a residential building constructed according to the invention. As seen in FIG. 27a, the joist 56 is formed of a pair of opposing channel pieces 66, one of which is shown. Each channel piece 66, is folded as shown in FIG. 27b to provide the "capped Y" configuration illustrated in FIG. 27b. As used herein, and in the claims, the term "capped Y" refers to the configuration illustrated in FIG. 27c, and other drawings illustrating the truss construction. A pair of "capped Y" shaped pieces 66 are then fitted together at their stems, one piece inverted relative to the other, to form the cross-sectional configuration illustrated in FIG. 27c. The stems of the two pieces 66 are welded together by spot welds or continuous welds. If additional strength is required, a reinforcing steel plate 70 running the entire length of the joist can be included in the construction.
FIG. 28 illustrates a side view of a typical truss construction of a building constructed according to the invention. The truss 14 is constructed of a horizontal base member 15, diagonally upwardly extending load supporting truss members 72, and slanted upper roof truss members 74. The connecting points between the various members making up the truss 14 are connected by metal plates 82, 84 and 86 of various designs, as will be discussed in more detail below.
FIG. 28 also illustrates electrical wiring 76 which is passed through junction box 78, and then runs as wiring 80 downwardly through the interior of the walls 4. The wall wiring 80 can be connected to various conventional wall outlets, located in the various rooms of the residential building, according to conventional techniques.
FIG. 29 illustrates a side detail of the crown connection of the roof truss. The pair of diagonal truss support members 72 intersect at the crown with the pair of adjacent slanted roof truss supports 74. This crown intersection is secured by a crown gusset plate 82, which is welded to the four truss supports 72 and 74. The cross-sectional configuration of diagonal truss members 72 and roof truss members 74 is according to the "capped Y" configuration discussed previously. The cross-section is shown schematically in the breaks in the members 72 and 74 shown in FIG. 29.
The top surfaces of the roof support members 74 carry corrugated steel decking 88, which by reason of its corrugated design, provides lateral strength in a direction perpendicular to the support provided by the roof trusses. The top of the steel roof decking 88 is clad with concrete shingles 90, which are porous, have good insulating value, and a long life. A steel crown cap plate 92 covers and weatherproofs the top intersection between the adjacent shingles 90 running along the crown of the roof.
FIG. 30 illustrates a detail side view of a joint plate 84 which connects the diagonal truss supports 72 with the base truss supports 15. The joint plate 84 is welded to the respective truss members 72 and 15 at appropriate locations. The intersection between the diagonal supports 72 and the base supports 15 is secured in a direction perpendicular to the joint plate 84 by joint plate 104, which will be discussed in association with FIG. 34 below. It will be noted that the "capped Y" configuration of the base truss supports 15 is inverted to present a broad downward facing side for ready attachment of wallboard 40 to the base truss supports 15.
FIG. 31 illustrates a detail side view of the connection between a diagonal support 72 and a roof truss support 74. The roof decking 88 and overlying concrete shingles 90 are also illustrated in FIG. 31. The connection is made by conventional spot welding or continuous welding. The end of the diagonal support 72 is notched on the top in order to intersect with the base of the "capped Y" cross-sectional shape of the roof truss member 74. The intersection can be welded.
FIG. 32 illustrates an enlarged detail front view of the connection between the lateral end of the roof truss 14 and the wall 4 of the building. As seen in FIG. 32, the base truss member 15, and the roof truss member 74 intersect and are secured together by end joint plate 86, which can be welded to the respective truss members 15 and 74. The intersecting end of the truss is supported on the top of wall 4. The roof truss 74 carries the steel decking 88 and overlying concrete shingles 90. The exterior edge of the roof is finished in conventional manner by steel fascia 96, rain gutter 98 and underlying soffit 100. Wallboard 40 clads the underside of base truss member 15 and the interior of the wall 4.
FIG. 33 illustrates in detail front view the construction of the gusset plate 82, with vertical notch 102. Gusset plate 82, as explained in association with FIG. 29, connects the crown components of the roof truss 14. The notch 102 received supporting steel plate 94.
FIG. 34 illustrates a front view of joint plate 104, with inverted "Y" shaped notch 106 in the lower region thereof. The function of notch plate 104 was explained above in association with FIG. 30. Notch 106 intersects with the inverted stem and body of bottom roof truss 15.
FIG. 35 illustrates a front view of joint plate 86 which is used to connect the intersection between the roof truss member 74 and the base truss member 15, as illustrated previously in FIG. 32. The angles of plate 86 can be varied to accommodate different pitches of roof trusses.
FIG. 36 illustrates a front view of joint plate 84, which is used to connect diagonal truss member 72 with base truss member 15, as illustrated in FIG. 28, and also FIG. 30.
All connections between plates and truss members are welded unless noted otherwise. All joint plates are typically 1/8" thick steel. Different roof angles/pitch does not affect the overall truss design. All the joint plates are inserted into the various truss members and are welded. As seen in FIG. 28, an electrical main line from a circuit breaker is run along the truss members to appropriate junction boxes and then down appropriate walls or across the ceilings to conventional outlets. All electrical accessories follow standard practice, and no unique equipment is reqired.
FIG. 37 illustrates a front view of a window system with horizontal sliders in wall 4 of a residential building according to the invention. As seen in FIG. 37, the window is constructed of a pair of sliders 108 and 110, which can be slid away from one another laterally into receiving cavities (pockets) in the interior of the wall, as illustrated by arrows in FIG. 37. The pair of sliders 108 and 110 are welded at their bases to respective chains 116 (loops), which are mounted in pulley fashion on a respective pair of sprockets 118. The bases of the two sliders 108 and 110 fit into and slide upon respective lower slide guides 114. The upper edges of the pair of sliders 108 and 110 are received in and slide laterally within upper slide guides 112.
While not shown in FIG. 37, the window can include on the inside of sliders 108 and 110 a conventional single or double pane window system. Sliders 108 and 110 are typically formed of steel and when closed over the window opening, provide exterior security against breaking and entering into the building through the window.
FIG. 38 illustrates a section view taken along section H--H of FIG. 37. FIG. 38 illustrates in detail the construction of the window opening in wall 4, and the manner in which the upper and lower steel window channel members 122 extend around the circumference of the window opening and seal the window opening from the interior of the wall 4.
FIG. 39 illustrates an enlarged detail of the manner in which the upper end of slider 110 is received in upper slide guide 112, which is adjacent window channel 122. The slide guide fits behind vinyl siding 42. The channel 122 caps the lower end of wallboard siding 40.
Likewise, FIG. 40 illustrates in enlarged view the manner in which the lower end of slider 110 is received in lower slide guide 114, which is positioned adjacent channel 122 and inside vinyl siding 42. FIG. 40 also illustrates endless chain 116, to which the base of slider 110 is welded, and also sprocket 118, which enables the endless chain 116 to be moved back and forth in pulley fashion around the respective pair of sprockets 118 (see FIG. 37).
FIG. 41 illustrates a front view of a door 8 opening in a wall 4 of a residential building according to the invention. The periphery of the door 8 has a door channel 124 extending up each side and along the top opening, to seal the door opening from the interior of the wall 4.
FIG. 42 illustrates a front view of the interior construction of an exterior door 8, which fits within door opening illustrated in FIG. 41. The interior of the door 8 has a concentric four-way door locking system. In this way, the top, both sides and the bottom of the door can be locked securely within door channel 124, and concrete base 12, to prevent unwanted access into the interior of the residential building. The concentric locking system is easily operated as will be explained below. The concentric locking system is constructed to have four door locking rods 126, which move longitudinally and extend upwardly, laterally, and downwardly to the respective top, sides and bottom of the door 8. These locking rods slide longitudinally in the interiors of corresponding rod guide sleeves 130. The interior ends of the four respective locking rods 126 are connected by respective second hinged steel rods 132, to central concentric door lock wheel 128. By means of this linkage, the respective rods can be extended in four respective directions by rotating the wheel 128 in one direction (counter-clockwise in FIG. 42), and withdrawn by rotating the wheel 128 in the opposite direction clockwise in FIG. 42). While not shown in FIG. 42, the concentric wheel 128 is operated by a hand wheel 134, positioned on the interior of the exterior door 8. The door 8 can also be fitted with conventional locking hardware, such as latches and deadbolts, in addition to the concentric door locking system described above.
FIG. 43 illustrates a section view taken along section line I--I of FIG. 42. FIG. 43, in particular, shows the concentric locking wheel 128 and the hand wheel 134, as well as door locking rods 126, linking rods 132, and rod sleeves 130.
FIG. 44 illustrates a detail front view of the concentric locking rod linkage of the interior of an exterior door of a residential building constructed according to the invention. As seen in FIG. 44, the second steel linking rod 132 is hingedly connected to main steel rod 126, which slides longitudinally and horizontally within rod sleeve 130. The right end of second steel rod 132 is connected in pivotal manner to the interior (left) end of main steel rod 126, while the opposite end (the left end) is hingedly connected to concentric door lock wheel 128. This linkage system enables main steel rod 126 to be moved to the right to a locking position when the concentric door lock wheel 128 is moved in a counterclockwise manner and withdrawn from a locking position when the concentric door lock wheel 128 is moved in a clockwise manner. In the latter position, the connecting rod 132 assumes the position shown in dotted lines in FIG. 44.
FIG. 45 illustrates a detail front view of how the bottom downwardly extending locking rod 126, when in an extended locked position, extends downwardly into a corresponding receptacle (not shown) located in foundation 12. The rod slides upwardly or downwardly in sleeve 130.
FIG. 46 illustrates a detail plan view of the connections between main door locking rod 126, second linking steel rod 132, concentric door lock wheel 128, and hand wheel 134. The rods 126 and 132 are hingedly connected by a first connecting bolt 136, and the opposite end of second steel rod 132 is hingedly connected to the concentric door lock wheel 128 by a second connecting bolt 136. The locking rod 126 slides within sleeve 130.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims. | A novel, rapid assembly secure burglar resistant building construction. More particularly, this invention pertains to a unique and inexpensive prefabricated building which is constructed of unique wall panels, floor and roof truss systems, secure locking doors and secure locking windows. A building construction comprising: (a) a foundation; (b) a roof; and (c) a wall extending from the foundation to the roof, wall being constructed of an interior corrugated metal sheet, insulation covering both sides of the metal sheet, a wall covering on an interior surface of the insulation and a wall covering on the exterior surface of the insulation. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to methods of laying railroad track, apparatus therefor, and, in a preferred embodiment thereof, more particularly provides apparatus for continuous track laying utilizing dual blocks.
Railroad track is typically laid by placing individual rails atop wooden ties which are sequentially spaced orthogonal to the rails. The wooden ties are conventionally embedded atop ballast material intended to stabilize the earth over which the rails traverse. After the rails are placed on the wooden ties they are spaced apart according to the proper "gauge" (lateral spacing between the rails of a track), longitudinally joined to correspondingly spaced rails, and fastened to the wooden ties with spikes.
It is well known in the art to automate the railroad track laying procedure. U.S. Pat. No. 4,232,610 to Theurer discloses an apparatus which lays completed portions of track end to end while the apparatus propels itself on the previously laid track. The completed portions of track include the spaced apart rails fastened to wooden ties.
U.S. Pat. No. 3,713,396 to Colius discloses an apparatus for sequentially spacing and fastening wooden ties to continuous rails. A turntable mechanism is used to drop a tie longitudinally between the rails and then turn the tie so that it is orthogonal to the rails. The tie is then fastened to the spaced apart rails with spikes.
Additionally, it is well known in the art to renew old railroad track rails and/or wooden ties. U.S. Pat. No. 5,357,867 to Theurer et al. discloses an apparatus which renews old railroad track or, if properly configured, lays new track. In order for the new wooden ties to be placed on the ballast, the rails must be widely spaced apart so that the ties will fit transversely between the rails. The apparatus then places the wooden ties on the ballast, gauges the rails, and fastens the rails to the ties. A similar apparatus which includes ballast conditioning features is disclosed in U.S. Pat. No. 4,316,416 to Theurer et al.
For subway applications, a modern technique of laying railroad track utilizes a "dual block" system wherein there are no ties fastened to the spaced apart rails. Instead, the rails are supported on masonry blocks which have elastomeric pads attached to their bottom surfaces for noise and shock suppression. The rails are typically fastened to the blocks, "gauged", and supported up off of grade level so that concrete may be poured around and underneath the blocks, effectively encapsulating the bottoms of the blocks.
Subways are becoming more common as cities grow more congested, and the use of "dual blocks" for supporting rails is increasing as well. The benefits which accrue from the use of blocks instead of ties include reduced noise and shock, and minimal maintenance. The disadvantages of using blocks include increased installation costs.
The above-described process of laying track on blocks is tedious and time-consuming and a need exists for its automation. Unfortunately, none of the existing track laying or renewal apparatus or methods, which were designed for use with wooden ties in an open environment, are suited for laying rails on blocks, nor are they suited for use in the confines of a subway tunnel.
Lateral space is limited in a subway tunnel, so those apparatus which are adapted for spreading of the rails prior to placement of wooden ties therebetween, or picking up of previously spread rails, prior to placement of the rails on wooden ties are unusable therein. Vertical space is also limited in a subway tunnel, so those apparatus which are adapted for lifting track sections or rails over a large structure for placement in front of or behind the large structure are likewise unusable.
Additionally, virtually all of the apparatus adapted for laying track with wooden ties require the apparatus to travel supported, at least in part, on the newly installed track. This cannot be done in dual block installations, which cannot support travel thereupon until the blocks are encapsulated in concrete.
Furthermore, existing apparatus and methods do not take advantage of the unique features available in a modern subway tunnel. For example, electricity and/or compressed air are normally available as sources of power to propel a track laying apparatus. The tunnel, having already been constructed, defines the path the track will follow, and structures therein, such as wiring troughs, may be utilized to provide guidance for a track laying apparatus. In addition, other structures within a tunnel may be utilized for placement of track laying supplies which may be used by the track laying apparatus as it proceeds through the tunnel.
From the foregoing, it can be seen that it would be quite desirable to provide automated track laying apparatus and methods which are suited for the laying of track utilizing dual blocks. Furthermore, such apparatus and methods are needed which may operate in the confines of a subway tunnel. Still further, such apparatus and methods are needed which are adapted to take advantage of the features existing in a modern subway tunnel. It is accordingly an object of the present invention to provide such track laying apparatus and methods.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, track laying apparatus and methods are provided which facilitate the laying of rails on blocks and attachment thereto, and which are particularly suited for efficient operation in a subway tunnel.
In broad terms, track laying apparatus is provided which includes an articulated framework, a plurality of wheels operatively attached to and supporting the framework, means mounted to the framework for lifting the rails, means mounted to the framework for spacing the rails a predetermined lateral distance apart from each other, means for steering the framework on the roadbed, means for propelling the framework on the roadbed, first means mounted to the framework for transporting the blocks from a first position exterior to the framework to a second position interior to the framework, means at the second position for spacing the blocks a predetermined transverse and longitudinal distance apart from each other, and second means for transporting the blocks from the second position to a third position adjacent the rails.
A method of laying railroad track is also provided, the method comprising the steps of disposing the rails longitudinally on the roadbed, lifting the rails from the roadbed, spacing the rails apart from each other to a predetermined lateral distance, spacing the blocks apart from each other to the predetermined lateral distance and a predetermined longitudinal distance, positioning the blocks adjacent the rails, fastening the blocks to the rails, providing a spacer for maintaining the predetermined lateral distance between the rails, installing the spacer on the rails, and laying the rails and blocks onto the roadbed.
The use of the disclosed track laying apparatus and methods permits efficient installation of railroad track utilizing blocks instead of ties. Especially adapted for use in a subway tunnel, the present invention is operable therein and able to benefit from facilities available in the tunnel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of apparatus for laying track embodying principles of the present invention, the view illustrating the apparatus laying track in a subway tunnel;
FIG. 2 is a cross-sectional view through the apparatus, taken along line 2--2 of FIG. 1; and
FIG. 3 is a top plan view of a template for use in the apparatus of FIGS. 1 & 2.
DETAILED DESCRIPTION
Illustrated in FIGS. 1 and 2 is a track laying apparatus 10 which embodies principles of the present invention. The apparatus 10 is illustrated in a subway tunnel 12 having a roadbed 14 approximately in the center thereof and extending longitudinally therethrough. The roadbed 14 is the portion of the tunnel 12 onto which track is to be laid.
At one side of the roadbed 14 is a cableway 16 for enclosure of, for example, electrical cables. An upright wall 18 separates the cableway 16 from the roadbed 14. On the opposite side of the cableway 16 from the roadbed 14 is a walkway 20 which has a concrete surface.
A side-by-side pair of continuous rails 22 are initially placed on, parallel to, and approximately in the center of, the roadbed 14 as shown in the leftmost portion of FIG. 1. It is convenient in subway construction for the rails 22 to be in this initial placement so that, before the rails are mounted to blocks (described hereinbelow), vehicles may travel along the subway tunnel 12 on the roadbed 14 with their wheels straddling the rails.
Blocks 24 are initially distributed along the walkway 20 where they may be conveniently accessed by the apparatus 10. A small crane 26 of conventional construction extends laterally across the midsection of the apparatus 10 and over the walkway 20 sufficiently far so that it can lift and transport the blocks 24 from the walkway 20 to the apparatus 10. The crane 26 has a lifting fixture 28 of conventional construction for lifting a pair of blocks 24 at one time.
The blocks 24 are loaded by the crane 26 onto table 30 where they are placed in a template 32 having the proper spacing both laterally and longitudinally for the blocks. The template 32 accepts four blocks 24 and is configured for straight sections of track as representatively illustrated in FIG. 1. Another template for use with curved sections of track is described hereinbelow. It is to be understood that various numbers of blocks 24 and placements of the blocks may be accommodated by modifying the template without deviating from the principles of the present invention. The illustrated template 32 has indexing fixture 34 for maintaining accurate spacing between the blocks 24 already installed onto the rails 22 and the blocks loaded in the template.
The direction in which the representatively illustrated apparatus 10 travels is leftward as illustrated by the arrow 36 in FIG. 1. When the apparatus 10 has traveled sufficiently far that the indexing fixture 34 indicates the proper spacing has been achieved between the previously installed blocks 24 and the blocks loaded in the template 32, the apparatus is stopped. A table winch 38 pulls cable 39 (attached to the table 30) upwardly, thereby raising the table 30 by rotating it about a pivot 40, so that the blocks 24 are properly positioned beneath the rails 22 for fastening thereto. The blocks 24 are then fastened to the rails 22 and the table 30 lowered by the table winch 38.
The apparatus 10 is steered through the subway tunnel 12 by guide arm 42 which acts to maintain a predetermined distance between the apparatus and the cableway wall 18. A roller 44 is positioned to roll atop the cableway wall 18 and thus bias the guide arm 42 laterally when a correction is needed in the travel direction of apparatus 10. Where a structure extending parallel to the roadbed 14, such as the cableway wall 18 is not available, conventional means such as a guide wire system which is typically used for paving machines may be utilized without deviating from the principles of the present invention. On straight alignments, a laser beam guidance system could be utilized as well.
Front portion 46 of the apparatus 10, which is supported on front wheel 48 and intermediate wheels 50, is pivotably mounted to rear portion 52 at pivot 54 so that the apparatus 10 is steerable. Rear portion 52 is supported on two rear wheels 53.
Mounted atop the guide arm 42 are a pair of conventional guide rollers 56 each of which consists of three cylindrical rollers arranged in a "U" shape so that a rail 22 rests on the bottom roller of the "U" and is constrained laterally by the rollers on the sides of the "U". As the apparatus 10 progresses through the subway tunnel 12, the guide rollers 56 lift the rails 22 upwardly off of the roadbed 14.
In a position approximately over the intermediate wheels 50 are a pair of intermediate guide rollers 58, similar to the front pair of guide rollers 56 in that they each consist of three cylindrical rollers configured in a "U" shape. The intermediate guide rollers 58, however, perform an additional function in that they are positioned on the front portion 46 to spread the rails 22 apart to approximately the desired gauge.
A crossmember 60 extends laterally across the front portion 46 rearward from the intermediate guide rollers 58. Mounted to the underside of the crossmember 60 are a pair of rear guide rollers 62 (see FIG. 2) which are similar to the front and intermediate guide rollers 56,58. This pair of guide rollers 62 perform the final gauging of the rails 22 before the blocks 24 are attached and also bias the rails in a downward direction before they enter the rear portion 52 of the apparatus 10.
Various means may be utilized to propel the apparatus 10 through the subway tunnel 12, for example, a conventional bulldozer-type continuous tread drive, gasoline or diesel power, etc., in keeping with the principles of the present invention. The illustrated preferred embodiment apparatus 10 utilizes an electric winch 64 (shown in dashed outline in FIG. 1) mounted to the front portion 46 of the apparatus 10. The winch 64, when activated, pulls on a cable 66 which is secured to the roadbed 14 by a spike 68. Where the cable 66 passes over the guide arm 42 a roller 70 mounted atop the guide arm between guide rollers 56 acts to support the cable.
Referring now primarily to FIG. 2, a cross sectional view of the apparatus 10 in the subway tunnel 12 may be seen, illustrating the manner in which track is laid, only one of the rails 22 being visible in this view. The following description will trace the progress of the single rail 22 shown in FIG. 2 from its entry into the apparatus 10 at the lefthand side to its exit at the righthand side as representatively illustrated in FIG. 2.
The rail 22 is picked up off of the roadbed 14 by guide rollers 56 on the guide arm 42 as the winch 64 pulls on the cable 66 attached to the roadbed 14 with spike 68, thus propelling the apparatus 10 to the left as viewed in FIG. 2. When the rail 22 is initially threaded into the apparatus 10, it must be manually placed onto the guide rollers 56. Guide rollers 56 support and align the rail 22 as it enters the apparatus 10.
The rail 22 next passes through intermediate guide rollers 58. The intermediate guide rollers 58 support and space the rail 22 to approximately the proper gauge distance from the other rail 22 (not shown in FIG. 2).
The rail 22 next passes through rear guide rollers 62 mounted to crossmember 60. The rear guide rollers 62 limit the upward travel of the rail 22 and accurately gauge the rail 22.
The rail 22 next enters the rear portion 52 where the blocks 24 are to be attached. The rail 22 passes between the table 30 and the crane 26. Blocks 24 are loaded onto the table 30 and positioned with the aid of the template 32.
When the indexing fixture 34 indicates that the apparatus 10 has moved forward (in the direction of arrow 36) sufficiently far, the winch 64 is deactivated, and the apparatus stops. The blocks 24 are lifted upwardly to the rail 22 by means of the table winch 38 mounted to the crane 26. The table winch 38 pulls upward on cable 39, thereby raising table 30 (table 30 being rotated about pivot 40). The blocks 24 on the raised table 30 are fastened onto the rail 22 and the table is lowered by table winch 38.
The rail 22 next exits the apparatus 10 when the winch 64 is reactivated to pull the apparatus forward. A spacer 72 is attached to the pair of rails 22 after they exit the apparatus 10 in order to maintain the correct gauge distance between the rails. As more blocks 24 are fastened to the rail 22 and the apparatus 10 moves repeatedly forward, the rail eventually drops far enough downward for the blocks 24 to rest on the roadbed 14. According to conventional practice, the blocks 24 are then prepared for final cementing by, for example, adjusting their positions relative to the roadbed 14, and cement 74 is poured around the blocks.
Illustrated in FIG. 3 is a specially designed template 74 for use, in place of the previously described "straight" template 32, in laying track on curved sections of roadbed 14. The curvature indicated in FIG. 3 has been exaggerated for illustrative clarity. Template 74 is made of a flat sheet of material such as plywood or steel plate.
In laying track on blocks 24 on curved sections, it is important to maintain the proper longitudinal spacing between the blocks fastened to the outer rail 22 (that is, the rail having the larger radius in the curved section). Consequently, the longitudinal spacing between blocks 24 fastened to the inner rail 22 (the rail having the smaller radius) is reduced as compared to the longitudinal spacing in a straight section of track. The gauge distance between blocks 24 must be maintained in all sections of track.
Outer cutouts 76 in template 74 are for the blocks 24 to be fastened to the outer rail 22. Inner cutouts 78 are for the blocks 24 to be fastened to the inner rail 22. Note that the longitudinal spacing between the outer cutouts 76 is greater than the longitudinal spacing between the inner cutouts 78. Also note that the cutouts 76,78 are not orthogonal to the sides 80 of the template 74; this is because the cutouts are positioned to follow the curvature of the track and the sides of the template are configured to fit the outline of the table 30 in the apparatus 10.
On one side 80 of the template 74, an indexing fixture 82 is positioned so that the proper spacing may be maintained between blocks 24 in the template being fastened to the rails 22 and blocks previously fastened to the rails. For the blocks 24 being fastened to the outer rail, fixture 82 has a protrusion 84. For the blocks 24 being fastened to the inner rail 22, fixture 82 has an indentation 86. The indentation 86 is necessary due to the exaggerated curvature of the illustrated template 74. In actual practice, fixture 82 may have another protrusion in place of the indentation 86.
The template 74 may be used for curvatures in either direction by simply turning the template over on the table 30. When the track again enters a straight section, the straight template 32 may be reinstalled on the table 30.
Thus it can be clearly seen that various templates may be fashioned for different curvatures and block spacings without deviating from the principles of the present invention. Different indexing fixtures may also be utilized. For example, an indexing fixture having an upwardly facing "U" shape may be used to locate two sides of a block 24. As another example, an indexing fixture may be fitted with a limit switch which would stop the winch 64 automatically when the blocks 24 are properly spaced.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims. | Track laying apparatus and associated methods are provided for installing rails on blocks. In a preferred embodiment, a track laying apparatus has an installation portion for installing the blocks to the rails at predetermined lateral and longitudinal spacings, relative to the lengths of the rails, and a positioning portion for propelling and steering the apparatus and lifting and laterally spacing the rails. |
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RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 13/440,415 filed Apr. 5, 2012, said application being herewith expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Membrane roofs are roofs that are covered with a polymeric sheet or membrane. These polymeric sheets can be, for example, polyvinyl chloride (PVC), thermoplastic olefin (TPO), or ethylene propylene diene monomer rubber (EPDM), as well as many others. The polymeric sheet is positioned over a roof surface and held in place by fasteners, adhesive, or ballast. Adjacent sheets are bonded together along lap seams to form a unitary single sheet of the polymer covering the entire roof.
[0003] Generally, the roofing membrane is either white or black. Theoretically, the membranes could be basically any color.
[0004] One chooses a white membrane roof for either aesthetic purposes or to reduce energy costs by reflecting thermal energy. In either event, it is important that the white membrane roof sheeting be clean, i.e., white, subsequent to installation or it will not provide the aesthetic appearance desired nor have the same reflective properties.
[0005] Particularly, when replacing an existing roof, it is difficult to keep the new sheeting clean. In a re-roofing application, a section of the old roof covering is removed and new roof membrane is immediately installed in its place. This allows the roof to be fully covered each night. As subsequent sections of the old roof are removed, the roofers walk on the previously installed new membrane. This can scratch and mar the new membrane. Even when installing a new roof, it is difficult to keep the white membrane clean during installation.
SUMMARY OF THE INVENTION
[0006] The present invention is premised on the realization that during installation of a single-ply roofing membrane, the surface of the membrane can be protected from dirt, scratches and scrapes by providing a removable tinted or colored release liner adhered to the membrane. The release liner is left in place during installation of the white membrane roof sheeting and be removed after completion of the installation. The tinting or coloration on the release liner ensures that the release sheet is noticeable and not inadvertently left on the roof. Further, the release liner can be formed from an environmentally degradable polymer so that even if some portions of the release sheet remain on the roof, they will degrade quickly and basically wash off the roof.
[0007] The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings in which:
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a perspective view of the present invention;
[0009] FIG. 2 is a cross sectional view taken at lines 2 - 2 of FIG. 1 ;
[0010] FIG. 3 is a cross sectional view of an alternate embodiment of the present invention;
[0011] FIG. 4 is a perspective view of the present invention during installation;
[0012] FIG. 5 is a cross sectional view of an edge portion of the present invention during installation and prior to removal of the release sheet;
[0013] FIG. 6 is a perspective view of an alternate embodiment of the present invention;
[0014] FIG. 7 is a cross sectional view broken away taken at line 7 - 7 of FIG. 6 .
[0015] FIG. 8 is a cross sectional view partially broken away of a second alternate embodiment of the present invention; and
[0016] FIG. 9 is a perspective view of a third alternate embodiment of the present invention.
DETAILED DESCRIPTION
[0017] The present invention is a roof laminate 10 that includes a roof membrane 12 and a release sheet or protective sheet 14 . The roof membrane 10 includes a first surface 16 and a second surface 18 , and, likewise, the release sheet 14 includes a first surface 20 and a second surface 22 which rests on and covers the first surface 16 of membrane 12 .
[0018] Membrane 12 can be formed from any polymer typically used in roofing applications. These include polyvinyl chloride, thermoplastic olefin, ethylene propylene diene monomer rubber polyethylene polyolefin, as well as others. The membrane can have a bottom fibrous surface referred to as fleeceback, which improves bond strength in a fully adhered system. The membrane 12 is preferably white or slightly off-white. It can be any color. The present invention is most useful when the membrane is a lighter color, such as white or off-white, and is least advantageous when the membrane is black. Although theoretically one may want to incorporate a protective covering over a black sheeting for use in the present invention.
[0019] Membrane 12 can be any typical size. These can be as narrow as 5 feet and as wide as 40 feet. Length can be 50-100 feet or more. Membrane 12 has a thickness effective for use in a membrane roof system. Generally, these will be 20 to about 160 mils thick. Roofing membranes are water insoluble and designed to withstand environmental conditions for at least 15 to 20 years.
[0020] The protective sheet 14 is a thin polymeric sheet which can be formed from a variety of different polymers. Although the protective sheet can be clear, it is preferable that it be tinted with a color that is distinguishable from the color of the membrane 12 . Thus, if the membrane 12 is white, the protective sheet 14 is preferably any color other than clear or white, such as green, red blue or yellow.
[0021] Preferably, the protective sheet 14 is formed from an environmentally degradable polymer. Exemplary environmentally degradable polymers include polyhydroxyalkanoates such as those disclosed in U.S. Pat. No. 5,070,122, polylactic acid and copolymers of polylactic acid and ethylene carbonmonoxide copolymers as disclosed in U.S. Pat. No. 5,135,966. These polymers break down over a period of time, preferably less than a month when exposed to certain environmental conditions, such as sunlight, heat or moisture, or a combination of any of these. Preferably, these environmentally degradable membranes will break down in a matter of days.
[0022] The roofing laminate 10 is formed by separately forming the roofing membrane 12 and the protective sheet 14 , and laminating the two together. If the protective sheet 14 includes an adhesive layer, this can be formed by co-extruding a pressure sensitive adhesive along with the membrane, or subsequently coating the formed membrane with a pressure sensitive adhesive, in particular a thermoplastic pressure sensitive adhesive. The protective sheet can also be made naturally adherent to the membrane by incorporating tackifiers into the protective sheet and applying the protective sheet to the membrane in a slightly stretched condition which liberates tackifier. The exposed tackifier provides weak adhesion of the protective sheet to the membrane. Once the protective sheet 14 is laminated to the membrane, the laminate 10 is formed into a roll 24 .
[0023] Alternately, as shown in FIG. 3 , a thin layer of adhesive 25 may be applied between the first surface of the membrane 12 and second surface of the protective sheet 14 to adhere the two together. The adhesive should be clear and have a preferable adherence to the protective sheet 14 as opposed to the membrane 12 . A water soluble adhesive is preferred so that if any remains on the membrane 12 after removing the protective sheet it will wash away.
[0024] To apply the membrane 12 over a roof surface 30 , two adjacent sheets 32 and 34 of the roofing laminate 10 are laid down side by side over the roof surface 30 . The membrane 12 of laminate 32 is fixed to the roof, generally using adhesives (not shown). However, other methods such as mechanically fastening the membrane to the roof can be employed. Second sheet 34 of roofing laminate 10 is rolled out and adhered to the roof surface adjacent the first sheet 32 with edge 36 of the second sheet 34 overlapping edge 38 of the first sheet 32 . The overlapping edges 36 and 38 are adhered or welded to each other.
[0025] With the embodiment shown in FIG. 1 , the edge portion 40 of the protective sheet 14 on the first laminate 32 is pulled up enough to allow the edge 36 of the second membrane sheet to overlap the exposed edge 38 of the first membrane 32 . The two edges 36 and 38 are then bonded together by heat or adhesive. As shown in FIG. 5 , the edge portion 40 of the protective sheet from the first laminate sheet 32 is then folded back and rests over the overlapped portion 42 of the two membranes 12 , 12 .
[0026] As shown in FIG. 1 , the protective sheet 14 covers the entire membrane 12 from side to side. However, as shown in FIG. 8 , the protective sheet 14 may cover the entire membrane except for 4- to 12-inch portions on either edges 26 and 28 of the laminate 10 .
[0027] Alternately, as shown in FIG. 9 , the protective sheet 14 can include perforations 50 , 52 along side edges 26 and 28 , which allow strips 54 and 56 to be removed from the sheet leaving the field portion 56 of the protective sheet protecting the membrane. Either of these embodiments allow adjacent sheets of membrane to be bonded together while either the field portion, as in FIG. 9 , or the entire sheet, as in FIG. 8 , remain on the membrane 12 .
[0028] Once the roof is fully installed, all of the protective sheets are pulled away from the membrane leaving an exposed white or colored membrane surface free of scratches and dirt. In the event a protective sheet or a portion of a protective sheet is inadvertently left on the roof, sunlight and water will cause it to disintegrate and wash away.
[0029] An alternate embodiment of the present invention is shown in FIG. 6 wherein two protective sheets 20 A and 20 B protect the membrane 12 . Sheets 20 A and 20 B overlap in the central portion of the membrane. The overlapped portion 58 lies loose on the membrane 12 . The loose overlapped portions 58 can be easily pulled up, allowing one to remove both protective sheets 20 A and 20 B.
[0030] This has been a description of the present invention along with the preferred method of practicing the present invention. However, the invention itself should only be defined by the appended claims, WHEREIN WE CLAIM: | A roofing laminate includes a roofing membrane, preferably a white roofing membrane, which is covered with a protective sheet. The protective sheet is tinted so that it has a coloration distinguishable from the roofing. The roofing laminate is applied to a roof surface and the release liner protects the outer surface of the membrane from scrapes and dirt during installation. Once the roof is installed the protective sheets are removed from all of the membrane sheets, exposing a clean surface. |
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention is a device for eliminating unpleasant odors in bathrooms and the like. In particular it is a device for dispersing a fragrance or deodorant into the air of a bathroom when a conventional flush type toilet therein is flushed.
That efforts have been made for a number of years to try to find an effective system for eliminating unpleasing ordors in bathrooms is evidenced by the disclosure of U.S. Pat. No. 4,168,550 and the prior art patents described therein. It is believed the reason that devices and systems for eliminating odors in bathrooms are not in significant use today despite the number of different ones known in the prior art is because previously known systems and devices are too complex and/or expensive to be practical or have not worked effectively.
It is an object of the present invention to provide a bathroom deodorizing device that is practical, economical and effective.
The device of the present invention uses readily available conventional pressurized containers of deodorant or fragrance and is adapted to be connected to a conventional flush toilet mechanism without having to provide expensive special fixtures or having to modify the mechanism. The device makes economical use of the deodorant or fragrance by dispensing it only when the toilet is flushed, which is usually the time when it is most effective.
The device of this invention consists of a support for a conventional container of a deodorant or fragrance under pressure which has a valve that releases vaporized deodorant or fragrance when the valve is depressed. The support also carries a battery operated electrical means for rotating a lever arm in a direction to depress the container valve to release vapor. The electrical means may be any suitable means such as a d.c. electric motor connected through a gear train to rotate the lever arm, or, alternatively, a solenoid having its armature linked to rotate the lever arm.
The electrical means is actuated by a tilt switch that is mounted on the actuation arm of the toilet flushing mechanism in a position such that the switch closes a cicuit which connects the electrical means to batteries to actuate the electrical means and cause the container valve to be opened and dispense vapor when the actuation arm of the flushing mechanism moves from its usual `at rest` position when the toilet is flushed.
It will be appreciated that though this device is adapted primarily for use in combination with a conventional flush toilet in a bathroom, it has other useful applications. The essential feature of the device of this invention is that it releases a vapor when a movable element, such as the actuation arm of a toilet flushing mechanism, moves in a predetermined direction from a usual `at rest` position. Thus the device can be connected to dispense a deodorant or fragrance when a garbage can lid is raised, or to disperse vaporized insect repellant when a screen door is opened, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects, advantages and features of the invention will be apparent from the following more detailed description of preferred embodiments of the invention illustrated in the accompanying drawings in which:
FIG. 1 is a side elevation, partly in section, of a conventional toilet tank including a usual type of flushing mechanism and showing the manner in which the device of this invention is connected for use therewith,
FIG. 2 is a side elevation, in section, of the major portion of a device of this invention,
FIG. 3 is a side elevation of the tilt switch and switch mounting mechanism of the device,
FIG. 4 is a section along the line 4--4 of FIG. 2 looking in the direction of the arrows, and
FIG. 5 is a partial sectional view, generally similar to the top portion of the view of FIG. 2, but showing an alternative electrically operable means for rotating the lever arm which operates to open the container valve.
DETAILED DESCRIPTION
Referring to FIG. 1 of the drawings, a deodorant or fragrance dispensing device 10 of this invention is primarily adapted and intended for use with a conventional flush type toilet that has a water tank 11 in which the flushing mechanism is located. FIG. 1 illustrates a typical flushing mechanism. The particular structure and arrangement of various brands and types of flushing mechanisms vary to quite an extent, but substantially all include an actuation arm 12, or comparable element, which is raised or moved in some predetermined direction when a handle 13, outside the tank 11, is turned to actuate the flushing of the toilet (not shown). The flushing action is initiated by turning and releasing the handle 13.
When the handle 13 is turned an arm 14, which is fixed to the handle and which extends through the tank wall into the tank, has an offset, crank type end portion, as shown, that extends under and lifts up the actuation arm 12 as the handle 13 turns. The ctuation arm 12, pivoted at 12a, is connected by a chain or cable 15 to a ball valve 16 which is seated in the tank outlet 17. The tank outlet 17 leads to the toilet bowl (not shown). Lifting the actuation arm 12 thus lifts the ball valve 16 up from the outlet 17, opening the outlet and permitting water from the tank to rush out through the outlet to swirl through and flush out the toilet bowl. When the handle 13 is released the actuation arm 12 returns to its usual `at rest` position shown in FIG. 1. The momentary movement of the actuation arm 12 when the toilet is flushed is utilized to actuate the deodorant or fragrance dispensing device 10 of this invention in a manner subsequently described below.
As the water level drops from its usual level, indicated at 20, when the flushing action is initiated, and the water rushes out the outlet 17, the ball valve 16 floats above the outlet opening by its own buoyancy and by the action of the water rushing out under it. Then as the water level drops to about the level of the outlet 17 the ball valve 16 reseats in the outlet 17 and stops the outflow.
Also as the water level in the tank 11 drops from the level 20 a float 18 on the end of an arm 19 follows the level down so that the arm 19, pivoted at 21, swings; the end of arm 19 having the float 18 on it swings down and the opposite end swings up. The latter end is connected through a link 22 to a lower arm 23, which is pivoted at 24, and lifts the lower arm 23. The arm 23 has a vertical link 25 hanging from it and the lower end of the link 25 is attached to a gate element 26 of inlet valve mechanism 27. When the arm 23 is lifted, as above, it lifts the link 25 and gate element 26 from its usual closed position, shown in FIG. 1, and permits water from a water supply inlet pipe 28 to flow into the tank 11 through an inlet 29.
When the ball valve 16 recloses the outlet 17, as described above, water entering the tank through the inlet 29 raises the water level back up to its usual level 20.
Referring now to FIGS. 2 and 4, the device 10 of this invention includes a support 31 having a base 32 and a vertical, semi-cylindrical support portion 33 for supporting a conventional cylindrical container 34 of a deodorant or fragrance. The container 34 contains a deodorant or fragrance under pressure so that it disperses from the container as a vapor through an outlet 35 of the valve 36 at the top of the container (as viewed in FIG. 2) when the valve body 37 is pressed in toward the body of the container.
The container 34 and the elements of the device on the support 31 are enclosed by a housing 38 which fits down over the elements and seats on the base 32 of the support 31. A hole 39 (FIG. 1) is provided through the housing at a point in line with the valve outlet 35 of a container 34 on the support for vapor dispersed from the container valve outlet 35 to pass through.
When a container 34 is in position on the support 31 its valve 36 is opened to disperse a deodorant or fragrant vapor therefrom by means of a lever arm 40. The lever arm 40 is pivoted at 41 and has an end 42 adapted to engage and depress the valve body 37 when the lever arm 40 is rotated in the valve depressing direction by associated mechanism of the device.
In the embodiment illustrated in FIG. 2 the lever arm 40 is rotated to open the valve 36 by a small d.c. electric motor 43 which has an armature 44 with a gear 45 fixed on the end. When the motor is energized it turns its gear 45 which, by connection through a train of gears--gear 46, gear 46a coaxially attached to gear 46, and a gear 47--rotates a gear 47a that is coaxially attached to gear 47. The gear 47a meshes with a gear sector 48 on the end of the lever arm 40 opposite the end 42 of the lever arm, so that the gear 47a causes the lever arm 40 which is to rotate in the valve depressing direction when the motor 43 is energized.
In the conventional type of pressurized spray containers, as illustrated by the container 34 depicted in the drawings, the valve 36 is spring loaded to close when the pressure that was applied to depress and thereby open it is released. In the practice of the present invention it has been found satisfactory to rely upon this spring loading of the valve 36 to close the valve 36 and return the lever arm 40 back upward from its valve opening position after the motor 43 has been energized to open the valve 36. That is, a simple unidirectional d.c. motor is suitable for the effective practice of the invention. When the power to the motor 43 shuts off, the spring loading of the valve 36, and possibly also reverse pressure built up in the gears of the gear train, pushes and moves the end 42 of the lever arm 40 back up to let the valve close; the motor then being in an unenergized state its armature 44 is free to rotate in a reverse direction to permit the aforesaid reverse rotation of the lever arm 40.
Electric power to operate the motor 43 is supplied by two 11/2 volt dry cell batteries 49a and 49b which are positioned between positive and negative contacts 50 and 51, respectively.
The application of power from the batteries 49a, 49b to operate the motor 43 is controlled by a tilt switch 52 which is connected between the positive contact 50 and a positive terminal 53 of the motor 43.
As shown in FIGS. 1 and 3 the tilt switch 52 is mounted on the actuation arm 12 of the toilet flushing mechanism in a position to close, and thus energize the motor 43, when the right hand portion (as viewed in FIG. 1) of the actuation arm 12 is moved up from its usual, `at rest`, position when the toilet is flushed.
Referring to FIG. 3, the tilt switch 52 is attached by a screw 53 to the body portion 54 of a clamp 55 which is adapted to clamp onto the actuation arm 12. As shown the clamp 55 is suitably a C type clamp in which a screw 56 through one arm of the C bears against the portion of arm 12 which passes through the center of the C. The screw 56 captures the actuation arm portion between itself and a V-shaped seat 57 in the other arm of the C.
The tilt switch 52 may be any conventional type which is constructed to open an electric circuit in which it is included when the switch body is in one position and which closes, normally by gravity, when the switch body is moved in a predetermined direction from said one position. In the structure shown the position of the tilt switch 52 is adjustable relative to the position of the actuation arm 12 by adjusting the rotational position of the clamp 55 relative to the cross section of the actuation arm and then by adjusting the position of the tilt switch 52 relative to the clamp body 54. This latter is accomplished by loosening the screw 53, rotating the tilt switch around the screw 53 until the switch is in the desired position (open or closed) and then fixing the position by tightening the screw 53 again.
In this manner the tilt switch is adjusted for it to be open when the actuation arm 12 is in its usual `at rest` position shown in FIG. 1, and to close when it tilts up as the actuation arm 12 swings up when the handle 13 is turned to flush the toilet.
Referring to FIG. 2, the amount and duration of the vapor spray dispersing from the valve 36 of the container 34 is determined by the length of time and the amount the valve body is depressed for opening the valve 36.
In the structure shown the amount and length of time the valve body 37 is depressed to open position is determined by the distance the end 42 of the lever arm 40 must travel to engage and depress the valve body 37. The position of the lever arm 40 and the amount it rotates is not variable and the adjustment for the duration and amount of vapor spray to be dispersed is made by adjusting the vertical position of the container up or down on the support 31 relative to the end 42 of the lever arm 40. This is accomplished by a jackscrew mechanism 58 in the base 32 of the support. It consists of a screw 59 rotatably fixed through the base 32 with a cup-shaped member 60 threaded onto the upper end of the screw. The cup-shaped member is prevented from rotation relative to the screw 59 by vertical grooves 61a and 61b in the opposite sides of the member 60 which are engaged by vertical posts 62a and 62b projecting up from the support base 32.
The upper end of the cup-shaped member 60 bears against the bottom of the container 34 on the support 31. Turning the screw 59 thus moves the cup-shaped member 60 up or down between the posts 62a, 62b and moves the container 34 up or down relative to the end 42 of the lever arm 40.
FIG. 5 shows an alternative means for operating the container valve when the toilet is flushed. In this embodiment the motor 43 is replaced by a solenoid 63 which has an armature 64 linked to rotate a lever arm 40' about a pivot point 41' by a pin 65 extending from the side of the armature and projecting through a slot 66 in the lever arm 40'. The operation of this embodiment is the same as the operation of the embodiment described with reference to FIG. 2 except that in this embodiment when the toilet is flushed electric power from the batteries 49a, 49b actuates the solenoid 63 whose armature 64 thus moves upward (as viewed in FIG. 5). This causes the lever arm 40' to rotate in the direction in which the lever arm end 42' moves down to engage and depress the valve 36 so that the valve opens and a deodorant or a fragrant vapor is dispersed into the air from the valve outlet 35. | This is a device for dispersing a vapor, such as a deodorant or fragrant vapor, into the air when a movable element, such as the actuation arm of a flush toilet, is moved from a usual `at rest` position. A switch responsive to movement of the movable element from its `at rest` position closes a circuit which energizes an electrically actuated means, such as a motor or a solenoid operated lever, which when actuated opens the valve of a container from which a vapor of a deodorant or fragrance is dispersed under pressure. The device is particularly adapted for dispersing a deodorant into the air in a bathroom or lavatory when the toilet therein is flushed. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Patent Application Nos. 61/467,858, filed Mar. 25, 2011, and 61/490,138, filed May 26, 2011, which are incorporated by reference in their entireties herein. This patent application is also a continuation of co-pending U.S. patent application Ser. No. 13/428,625, filed Mar. 23, 2012, which is incorporated by reference in its entirety herein.
BACKGROUND
[0002] Sinks have drains for permitting water to drain from the sink into a plumbing system. During installation, drains are typically inserted into the interior of the sink basin and dropped into an opening at the base of the basin. The drain has a rim with a diameter exceeding the diameter of the opening such that the rim rests on the top surface of the base of the sink basin. Often, the portion of the base surrounding the opening has a countersink portion such that the rim of the drain is generally flush with the adjacent portion of the base of the sink. Nonetheless, a groove is present between the rim of the drain and the sink base that is difficult to clean and susceptible to bacterial growth. In addition, the presence of the groove is visible to a user and aesthetically unappealing.
BRIEF SUMMARY
[0003] Embodiments of sinks and drains for sinks are disclosed herein. The embodiments permit the attachment of a drain to a sink such that the drain is substantially disposed below the top surface of the sink basin, and such that there is no discernable separation between the base of the sink basin and the drain when viewed from above the sink. A method of making a sink is also disclosed wherein there is no discernable separation between the base of the sink basin and the drain when viewed from above the sink.
[0004] A sink is described comprising a sink basin, a drain entry portion, a flange plate, a strainer, a first seal, and a second seal. The sink basin can have a sidewall and a base. The base can have an opening. The drain entry portion can be disposed at the opening and attached to the base. The drain entry portion can extend away from the base. The drain entry portion can have a lip for receiving the first seal. The flange plate can have an inner edge portion and an outer edge portion. The outer edge portion can be in contact with the first seal. The first seal can be disposed between the lip and the outer edge portion. The strainer can be disposed near the inner edge portion. The second seal can be disposed between the strainer and the inner edge portion.
[0005] A drain is also disclosed comprising a first seal, a drain entry portion, a flange plate, a strainer, and a second seal. The drain entry portion can have a lip for receiving the first seal. The flange plate can have an inner edge portion and an outer edge portion. The outer edge portion can be in contact with the first seal. The first seal can be disposed between the lip and the outer edge portion. The strainer can be disposed near the inner edge portion. The second seal can be disposed between the strainer and the inner edge portion.
[0006] A method of making a sink is also described. The method comprises forming a sink basin having a sidewall and a base, providing a drain entry portion, welding the drain entry portion to the base at the opening, and grinding the weld at the opening such that the drain entry portion appears integrally formed with the base when viewing into the sink basin. The base can have an opening. The drain entry portion can be cylindrical.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a sink;
[0008] FIG. 2 is a sectional view of a drain for the sink of FIG. 1 ;
[0009] FIG. 3 is a sectional view of a second embodiment of a drain for the sink of FIG. 1 ;
[0010] FIG. 4 is a sectional view of a third embodiment of a drain for the sink of FIG. 1 ;
[0011] FIG. 5 is a perspective view of another embodiment of a sink;
[0012] FIG. 6 is a sectional view of an embodiment of a drain for the sink of FIG. 5 ;
[0013] FIG. 7 is a sectional view of an embodiment of a drain for a sink attached to a garbage disposer;
[0014] FIG. 8 is a fragmentary bottom perspective view showing the drain of FIG. 7 ;
[0015] FIG. 9 is a sectional view of a drain entry portion welded to a sink;
[0016] FIG. 10 is a sectional view of another embodiment of a drain entry portion welded to a sink; and
[0017] FIG. 11 is a sectional view of a further embodiment of a drain entry portion welded to a sink.
DETAILED DESCRIPTION
[0018] Referring to FIG. 1 , a sink 100 with the appearance of an edgeless drain is shown. The sink 100 can include one or more sink basins 102 and a rim 104 . The sink basin 102 can include one or more sidewalls 106 and a base 108 . The base 108 can include an opening 110 for a drain. The sidewalls 106 and base 108 can form an interior surface of the basin 102 to retain water and washable items. The rim 104 can be used to support the basin 102 in an above-mount arrangement or under-mount arrangement with respect to a counter. The sink 100 can be made of any suitable material, such as stainless steel.
[0019] Referring to FIG. 2 , a drain 101 is shown that can include a drain entry portion 112 , a flange plate 114 , a strainer 116 , a drain pipe 118 , and a cover 120 . The drain entry portion 112 can be cylindrical and can extend from the bottom of the sink basin at the opening for the drain 101 . The drain entry portion 112 can include a first end portion 122 and a second end portion 124 . In some embodiments, the drain entry portion 112 can be formed as part of the sink 100 . In other embodiments, the drain entry portion 112 can be a component separately manufactured from the sink 100 . The first end portion 122 of the drain entry portion 112 can be welded to the base of the sink to fix the drain entry portion 112 to the sink basin at the opening. In order to conceal the welded intersection between the drain entry portion 112 and the base, a grinding and polishing operation can be applied such that the intersection is hidden to a user looking into the sink basin. In addition, because the drain entry portion 112 can be mounted from below without the need for a drain rim to rest on the base, there is no groove between the drain 101 and the sink basin 102 . From a user's perspective, the drain opening leads directly into the drain 101 . The weld between the sink basin and the drain entry portion 112 can be accomplished in any suitable manner, such as with a shielding gas weld.
[0020] FIGS. 9-11 show examples of suitable embodiments of a drain entry portion welded to a base of a sink. It will be appreciated, however, that the drain entry portion can be coupled to the sink via any suitable manner.
[0021] Referring to FIG. 9 , the drain entry portion 612 can include a radially extending flange 680 . The flange 680 can be disposed against the underside of the sink base 108 . The drain entry portion 612 can have an interior diameter that is smaller than the opening 110 of the sink 100 such that there is a portion of the flange 680 extending inward from the opening 110 that can receive a solder material 682 for welding the drain entry portion 612 to the sink 100 . As discussed, after welding, a grinding and polishing operation can be applied to the weld such that the intersection between the drain entry portion 612 and the sink 100 is hidden to a user looking into the sink basin 102 .
[0022] Turning to FIG. 10 , the drain entry portion 712 can include a radially extending flange 780 . The flange 780 can be disposed within the opening 110 such that the flange abuts the portion of the sink base 108 forming the opening 110 . Thus, the perimeter of the flange 780 has a diameter that is smaller than the opening 110 of the sink 100 such that the flange 780 fits within the opening 110 . The thickness of the flange 780 can be smaller than the thickness of the sink base 108 such that a space is formed on the upper surface of the flange 780 for receiving a solder material 782 for welding the drain entry portion 712 to the sink 100 . As discussed, after welding, a grinding and polishing operation can be applied to the weld such that the intersection between the drain entry portion 612 and the sink 100 is hidden to a user looking into the sink basin 102 .
[0023] As shown in FIG. 11 , the drain entry portion 812 can include a radially extending flange 880 . The flange 880 can be disposed away from the edge 884 of the drain entry portion 812 on the first end portion 822 . The flange 880 can be disposed against the underside of the sink base 108 , and the edge 884 of the drain entry portion 812 can have an exterior diameter that is smaller than the opening 110 of the sink 100 . The flange 880 can be located on the drain entry portion 812 a sufficient distance from the edge such that the edge is disposed below the upper surface of the sink base 102 and such that the edge 884 can receive a solder material 882 for welding the drain entry portion 812 to the sink 100 . As discussed, after welding, a grinding and polishing operation can be applied to the weld such that the intersection between the drain entry portion 812 and the sink 100 is hidden to a user looking into the sink basin 102 .
[0024] Referring again to FIG. 2 , the second end portion 124 of the drain entry portion 112 can include a lip 126 for receiving a seal 128 . The flange plate 114 can have an outer edge portion 130 and an inner edge portion 132 . The outer edge portion 130 of the flange plate 114 can rest on the seal 128 such that the seal 128 prevents water inside the drain 101 from passing between the intersection of the drain entry portion 112 and the flange plate 114 . The inner edge portion 132 of the flange plate 114 can receive a lip 134 of the drain pipe 118 for supporting the drain pipe 118 .
[0025] The strainer 116 can be disposed above the lip 134 of the drain pipe 118 and the inner edge portion 132 of the flange plate 114 . The strainer 116 can include a seal 136 for contacting the lip 134 of the drain pipe 118 and preventing the passage of water in the drain 101 past the seal 136 . The strainer 116 can be press fit within the flange plate 114 . The strainer 116 can have one or more openings in the bottom of the strainer to permit water to flow past the strainer 116 and into the drain pipe 118 .
[0026] The drain 101 can include a cover 120 over the drain entry portion 112 , the flange plate 114 , and the strainer 116 . The cover 120 can be secured to the sink with a locking nut 138 . The drain pipe 118 can be threaded to receive the locking nut 138 , and the locking nut 138 can be tightened to enhance the seal force applied between the drain entry portion 112 and the flange plate 114 . A coupler 140 can be used to attach the drain pipe 118 to a pipe 142 leading to a trap.
[0027] A removeable strainer basket 144 can be disposed within the drain 101 . The strainer basket 144 can include a basket portion 146 for capturing solids and a stopper 148 that can be lowered into the strainer 114 to plug the drain 101 .
[0028] Turning to FIG. 3 , a second embodiment of a drain 201 is shown that can include a drain entry portion 212 , an attachment portion 250 , a strainer 216 , and a drain pipe 218 . The drain entry portion 212 can be cylindrical and can extend from the bottom of the sink basin at the opening for the drain 201 . The drain entry portion 212 can include a first end portion 222 and a threaded exterior surface 252 . The drain entry portion 212 can be a component separately manufactured from the sink. The first end portion 222 of the drain entry portion 212 can be welded to the base to fix the drain entry portion 212 to the sink basin at the opening. In order to conceal the welded intersection between the drain entry portion 212 and the base, a grinding and polishing operation can be applied such that the intersection is hidden to a user looking into the sink basin. In addition, because the drain entry portion 212 can be mounted from below without the need for a drain rim to rest on the base, there is no groove between the drain 201 and the sink basin. From a user's perspective, the drain opening leads directly into the drain 201 . The weld between the sink basin and the drain entry portion 212 can be accomplished in any suitable manner, such as with a shielding gas weld.
[0029] The attachment portion 250 can have a threaded surface 254 and an inner edge portion 232 . The attachment portion threaded surface 254 can be received and tightened to the threaded surface 252 of the drain entry portion 212 . The inner edge portion 232 of the attachment portion 250 can receive a lip 234 of the drain pipe 218 for supporting the drain pipe 218 .
[0030] The strainer 216 can be disposed above the lip 234 of the drain pipe 218 and the inner edge portion 232 of the attachment portion 250 . The strainer 216 can include a seal 236 for contacting the lip 234 of the drain pipe 218 and preventing the passage of water in the drain 201 past the seal 236 . The strainer 216 can be press fit within the attachment portion 250 . The strainer 216 can have one or more openings in the bottom of the strainer to permit water to flow past the strainer 216 and into the drain pipe 218 . The drain pipe 218 can be threaded to receive a coupler that can be used to attach the drain pipe to a pipe leading to a trap.
[0031] A removeable strainer basket 244 can be disposed within the drain 201 . The strainer basket 244 can include a basket portion 246 for capturing solids and a stopper 248 that can be lowered into the strainer 216 to plug the drain 201 .
[0032] Referring to FIG. 4 , a third embodiment of a drain 301 is shown that can include a drain entry portion 312 , an attachment portion 350 , a strainer 316 , and a drain pipe 318 . The drain entry portion 312 can be cylindrical and can extend from the bottom of the sink basin at the opening for the drain 301 . In this embodiment, the drain entry portion 312 can be formed from the sink basin during the drawing process to shape the sink. Thus, the drain entry portion 312 can be integrally formed to lead directly from the sink basin to the drain 301 . Threads 352 can be welded or otherwise attached to the drain entry portion 312 .
[0033] The attachment portion 350 can have a threaded surface 354 and an inner edge portion 332 . The attachment portion threaded surface 354 can be received and tightened to the threads 352 of the drain entry portion 312 . The inner edge portion 332 of the attachment portion 350 can receive a lip 334 of the drain pipe 318 for supporting the drain pipe 318 .
[0034] The strainer 316 can be disposed above the lip 334 of the drain pipe 318 and the inner edge portion 332 of the attachment portion 350 . The strainer 316 can include a seal 336 for contacting the lip 334 of the drain pipe 318 and preventing the passage of water in the drain 301 past the seal. The strainer 316 can be press fit within the attachment portion 350 . The strainer 316 can have one or more openings in the bottom of the strainer to permit water to flow past the strainer 316 and into the drain pipe 318 . The drain pipe 318 can be threaded to receive a coupler that can be used to attach the drain pipe to a pipe leading to a trap.
[0035] A removeable strainer basket 344 can be disposed within the drain 301 . The strainer basket 301 can include a basket portion 346 for capturing solids and a stopper 348 that can be lowered into the strainer 316 to plug the drain 301 .
[0036] FIGS. 5 and 6 show another embodiment of an edgeless drain 401 suitable for use with a non-metallic sink 400 , such as a sink made of granite or other suitable stone. The drain 401 can include a first drain entry portion 411 , a second drain entry portion 412 , a flange plate 414 , a strainer 416 , a drain pipe 418 , and a cover 420 . The first drain entry portion 411 can be cylindrical and can extend from the bottom of the sink basin at the opening for the drain 401 . Similar to the embodiment of FIG. 4 , the first drain entry portion 411 can be formed as part of the sink basin during the process of making the sink. Thus, the first drain entry portion 411 leads directly from the sink basin into the drain 401 .
[0037] The second drain entry portion 412 can include a first end portion 422 and a second end portion 424 . The second drain entry portion 412 can be a component separately manufactured from the sink. The first end portion 422 of the second drain entry portion 412 can include one or more apertures such that the drain entry portion 412 can be fastened to the bottom of the sink using suitable fasteners 456 disposed through the apertures, such as one or more screws.
[0038] The second end portion 424 of the second drain entry portion 412 can include a lip 426 for receiving a seal 428 . The flange plate 414 can have an outer edge portion 430 and an inner edge portion 432 . The outer edge portion 430 of the flange plate 414 can rest on the seal 428 such that the seal 428 prevents water inside the drain 401 from passing between the intersection of the second drain entry portion 412 and the flange plate 414 . The inner edge portion 432 of the flange plate 414 can receive a lip 434 of the drain pipe 418 for supporting the drain pipe 418 .
[0039] The strainer 416 can be disposed above the lip 434 of the drain pipe 418 and the inner edge portion 432 of the flange plate 414 . The strainer 416 can include a seal 436 for contacting the lip 434 of the drain pipe 418 and preventing the passage of water in the drain 401 past the seal 436 . The strainer 416 can be press fit within the flange plate 414 . The strainer 416 can have one or more openings in the bottom of the strainer to permit water to flow past the strainer 416 and into the drain pipe 418 .
[0040] The drain 401 can include a cover 420 over the second drain entry portion 412 , the flange plate 414 , and the strainer 416 . The cover 420 can be secured to the sink with a locking nut 438 . The drain pipe 418 can be threaded to receive the locking nut 438 , and the locking nut 438 can be tightened to enhance the seal force applied between the second drain entry portion 412 and the flange plate 414 . A coupler 440 can be used to attach the drain pipe 418 to a pipe 442 leading to a trap.
[0041] A removeable strainer basket 444 can be disposed within the drain 401 . The strainer basket 444 can include a basket portion 446 for capturing solids and a stopper 448 that can be lowered into the strainer 416 to plug the drain 401 .
[0042] It will be appreciated that the above-described sink and drain embodiments may be utilized with a garbage disposer. For example, FIGS. 7 and 8 show an embodiment of a drain 501 attached to a garbage disposer 560 . In this embodiment, the drain 501 can include a drain entry portion 512 , a disposer attachment ring 562 , a strainer 516 , and a disposer assembly 564 . The drain entry portion 512 can be cylindrical and can extend from the bottom of the sink basin at the opening for the drain 501 . The drain entry portion 512 can include a first end portion 522 and a threaded exterior surface 552 . The drain entry portion 512 can be a component separately manufactured from the sink. The first end portion 522 of the drain entry portion 512 can be welded to the base to fix the drain entry portion 512 to the sink basin at the opening. In order to conceal the welded intersection between the drain entry portion 512 and the base, a grinding and polishing operation can be applied such that the intersection is hidden to a user looking into the sink basin. In addition, because the drain entry portion 512 can be mounted from below without the need for a drain rim to rest on the base, there is no groove between the drain 501 and the sink basin. From a user's perspective, the drain opening leads directly into the drain 501 . The weld between the sink basin and the drain entry portion 512 can be accomplished in any suitable manner, such as with a shielding gas weld.
[0043] The disposer attachment ring 562 can have a threaded surface 566 and a lower portion 568 . The flange plate threaded surface 552 can be received and tightened to the threaded exterior surface 566 of the drain entry portion 512 . The lower portion 568 can have a detent 570 for receiving a snap ring 572 . The strainer 516 can be disposed above detent 570 . The strainer 516 can have one or more openings in the bottom of the strainer to permit water to flow past the strainer 516 and into the disposer 560 .
[0044] The disposer assembly 564 can include a backup flange 574 and a mounting ring 576 . The backup flange 574 can be generally triangular and the mounting ring 576 can have a plurality of tightening screws 578 for contacting the backup flange 574 near each vertex of the backup flange 574 . During tightening of the screws 578 , the mounting ring 576 can be retained to the disposer attachment ring 562 by the snap ring 572 . As is known to those of skill in the art, the disposer 560 can include a bracket for hanging the disposer from the mounting ring.
[0045] A removeable strainer basket 544 can be disposed within the drain 501 . The strainer basket 544 can include a basket portion 546 for capturing solids and a stopper 548 that can be lowered into the strainer 516 to plug the drain 501 .
[0046] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0047] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0048] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | Sinks and drains for sinks permitting the attachment of the drain to the sink such that the drain is substantially disposed below the top surface of the sink basin, and such that there is no discernable separation between the base of the sink basin and the drain when viewed from above the sink. A method of making a sink such that there is no discernable separation between the base of the sink basin and the drain when viewed from above the sink. |
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BACKGROUND
[0001] Sumps, also referred to as catch basins, have traditionally been utilized in chemical, petrochemical, metal finishing, industrial and municipal operations to capture the flow of hazardous materials. Due to the development and implementation of storm water runoff regulations, the use of sumps is now common in parking lots, salvage yards, scrap yards, and anywhere that rain can combine with oil, grease, fuel, or other hazardous materials. The sumps are typically located in holes dug out of the pavement so that only their upper surface is exposed, allowing run-off to collect directly into the sump. The concrete or asphalt surrounding a sump is generally sloped to the sump to provide for gravitational flow and capture.
[0002] In current constructions, sumps are commonly constructed from a layer of concrete with a protective coating of tile, brick, or FRP. Other solutions include molded single wall tanks, however these tanks have a tendency to lift or “float” out of their hole and become either damaged or unusable. Anchored sumps of these types are traditionally expensive because the materials necessary to create the anchored sump are costly and there is relatively significant fabrication labor.
SUMMARY OF THE INVENTION
[0003] The present invention overcomes the shortcomings of the prior art and comprises a seamless, rotationally molded double wall sump. The seamless, one piece double wall design is unique to the industry and has inherent advantages over previous designs. The dual wall design provides insurance against leakage, and the seamless design prevents seepage or leaks from penetrating the sump. The double wall design may be molded with a fabric faced grating seat as an integral part. The design results in a cost effective, high performance solution that can be produced in large quantities with relatively little labor costs compared with previous sump manufacturing concepts. The double walls form a gap that may be filled with a foam stiffener to further increase the rigidity and strength of the sump.
[0004] For both retrofit and new construction, the sump of the present invention is cast-in-place using standard concrete materials and methods. That is, the sump is placed into wet cement formed in a pit and allowed to harden around the sump. The adjoining ground level is set such that any liquids within the immediate area will flow to the sump for further disposition which can include outlet piping for gravity flow to a larger collection tank. Or, the sump can be equipped with a level control device and relays to activate a pump for “lifting” or transferring the liquids to another location for storage and/or treatment. The integral ribs of the secondary containment portion of the sump function to “lock” the sump into the surrounding concrete to prevent flotation of the sump in “high water table/empty sump” conditions. The integral fabric face, which can be a polyester or polypropylene sheet, is located on the vertical side and top of the grating seat to allow the thermoplastic sump to be effectively integrated with the chemically resistant flooring system being applied to the surrounding concrete floor. This feature provides for the isolation of the interface between the sump and concrete.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is top view of the sump of the present invention without the grate;
[0006] FIG. 2 is a cross sectional view of the sump of FIG. 1 ; and
[0007] FIG. 3 is a cross-sectional view of the sump in ground with a pump installed to purge collected waste.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] A sump 10 of the present invention is generally shown in FIGS. 1-3 , comprising a cylindrical body 12 having two integrally molded vessels that form a double walled container. The first vessel 14 is a primary containment vessel that forms the interior of the sump 10 and is used to collect the various materials that the sump is designed to capture. The outer or secondary vessel 16 is a redundancy guard against leakage and is molded with the primary vessel to form a seamless integral one-piece unit of double wall construction. Between the two walls is a gap that may be filled with a stiffening foam 18 or other stiffening agent that can be injected between the two walls of the sump 10 during the molding process. The rigidity of the sump 10 is most critical at the upper portion of the sump, since the sump 10 is typically buried in the ground 20 (See FIG. 3 ) and surrounded by concrete. If the upper portion of the sump is flexible, it can separate from the concrete and create gaps at the surface between the secondary vessel and the ground that can allow contaminants to seep between the cement and the sump, leading to contamination, corrosion, and other deleterious effects.
[0009] The outer surface of the secondary vessel 16 is formed with a plurality of ribs 22 that protrude radially outward, preferably in concentric circles, and serve as anchors for the sump 10 to prevent the sump from lifting or “floating” in the concrete. First the ground is excavated and then wet cement is poured into the hole to create the base for the sump 10 . Before the concrete sets, the double walled sump 10 is placed on the cement and additional cement poured around the walls to encase the sump 10 in wet cement until only the upper edge 24 of the sump 10 is visible in the concrete. The wet cement fills the gaps 26 between the ribs 22 , and as the cement hardens the ribs 22 and the interleaving cement ridges formed in the gaps 26 prevent the sump from rising upward.
[0010] The sump 10 may be formed with a first port 28 along the lower surface that can be used to drain the sump as it fills with materials. Piping (not shown) connecting the sump through the port 28 can be gravity fed, so that as material collects when it reaches the port it is carried away under the influence of gravity to a collection area. Alternatively, the port and connecting piping can be coupled to a pump 30 that extracts the material collected in the sump. The pump 30 can be manually actuated, timer actuated, or it may be actuated upon the signaling of a fluid level sensor (not shown) incorporated into the sump. The level sensor determines the level of the collected waste in the sump 10 , and sends a signal to the pump 30 when the level reaches a predetermined position or elevation in the sump to prevent overflow. Alternatively, the level sensor may send a signal to a processor (now shown) remote from the sump that can be used to actuate the pump 30 or other drainage measures.
[0011] The sump 10 may be configured with a leak detection sensor 32 to warn if the primary container 14 becomes compromised. If the primary container 14 forms a crack or loses integrity, waste will enter the area between the primary container 14 and the secondary container 16 , collecting at the bottom of the gap between the two walls. If sensor 32 is placed at the bottom of the gap, it can send a signal to a nearby microprocessor to send an alarm that the sump needs repair. The leak detector can be as standard detector that detects a change in resistance or capacitance when in contact with a liquid.
[0012] It is preferable to have the surround ground 20 area adjacent the sump contoured or sloped so that all run-off will collect into the sump via gravity. The sump may also have a second port 36 that leads other collection areas into the sump, such that the sump acts as a localized collection reservoir. The sump 10 may also preferably be formed with a circumferential upper lip 38 that retains a grate 40 , such as a fiberglass grate, so that the opening of the sump 10 is not a hazard that workers can fall into.
[0013] The foregoing description is intended solely to be exemplary and not limiting as to the scope of the invention. There are many alterations and modifications that would be understood by one of ordinary skill in the art, and the invention is intended to include all such modifications, particularly as to pertains to use, materials, shape, dimension, and the like. For example, the sump could take on a rectangular shape without departing from the spirit or scope of the invention, or could be made from other materials suitable for the particular application. Thus, the invention should be construed to cover all such modifications and alterations, consistent with the language of the claims herein construed using their ordinary and customary meanings without limitation to anything depicted in the drawings or any descriptions above unless expressly limited. | A seamless, double-walled sump is disclosed for collecting run-off materials and waste products. The sump includes a primary containment vessel and a secondary vessel, integrally molded into a single seamless unit. The sump includes a plurality of ribs that cooperate with surrounding concrete or other enclosing material to anchor the sump and prevent floating. The sump may also include a fabric outer layer that serves as an interface between the concrete and the sump to prevent corrosion. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U. S. patent application Ser. No. 10/916,773, filed Aug. 11, 2004, for “Releasable Mill”, which claims the benefit of U. S. Provisional Patent Application No. 60/495,021, filed Aug. 13, 2003, for “Releasable Bridge Plug Mill”.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention is in the field of apparatus used to mill out downhole equipment in a well, such as in an oil or gas well.
[0005] 2. Background Art
[0006] Some oil or gas wells are drilled into locations at which multiple oil or gas formations are found, at different depths. That is, one hydrocarbon formation may be above or below another, and there may be more than two such formations at different depths. It is common to produce hydrocarbons from only one selected formation at a time. One means used to assist in this type of production is a plug, which can be installed in the bore hole or casing, between two of the formations. Such a plug isolates one formation from another, while allowing access to the upper formation via the bore hole. It is also common to remove such a plug, in order to allow access to the lower formation, via the bore hole, for the purpose of producing hydrocarbons, or for other purposes.
[0007] When such a plug is removed, it is often removed by lowering a mill into the bore hole or casing, attached to a work string. The mill is usually provided with some type of cutting structure on its lower face, and this cutting structure is often dressed with some type of cutting material, such as inserts or abrasives. The mill is lowered into contact with the upper end of the plug; then, the work string is rotated, thereby rotating the mill. Alternatively, a downhole motor can be used on the work string, as is commonly known in the art, and the mill can be rotated by operating the downhole motor. In either case, as the mill is rotated, the cutting structure cuts the plug into small cuttings, which are returned to the surface entrained in the drilling fluid which is pumped downhole through the work string. This operation is continued until the entire plug is removed, or until a sufficient portion of the plug is removed to allow the remaining portion to fall farther into the borehole.
[0008] After this type of operation, it is necessary to remove the mill from the bore hole before access to the lower formation is available. This is because, although the mill may have passageways for drilling fluid, these fluid passageways are not sufficiently large to provide the desired degree of access to the lower formation. The mill body itself is typically a substantially solid, comparatively hard, metal body. Therefore, in order to complete the operation, the work string and the mill must be pulled from the bore hole to provide the desired access to the lower formation. As is well known, tripping a work string into or out of a well is a time consuming, expensive process. It is desirable to have a method and apparatus for removing such plugs, or other types of objects in a well bore, while eliminating the necessity for tripping the work string out of the bore hole, to remove the mill and provide access to the lower formation.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a mill assembly having a releasable milling head attached to a mill body with one or more shear pins, or another releasable fastening feature. The mill assembly can be lowered into a bore hole to mill out a plug, after which the milling head can be completely released from the work string, such as by shearing the shear pins, and allowed to drop into the bore hole. Separation of the milling head from the mill body leaves a substantially open bore into and through the work string. The mill body and the work string can be left in the bore hole while production from the lower formation takes place, through this open bore. The milling head is provided with a check valve in the fluid path, to allow the downhole flow of drilling fluid during milling, but to prevent the uphole flow of fluids during a kick or pressure excursion. A fishing neck can also be provided on the milling head, to assist in the later removal of the milling head where desired.
[0010] The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 is a longitudinal section view of a first embodiment of the apparatus of the present invention;
[0012] FIG. 2 is a lower end view of the milling head portion of the apparatus shown in FIG. 1 , and showing the location of the line along which the section in FIG. 1 is taken;
[0013] FIG. 3 is an upper end view of the milling head portion of the apparatus shown in FIG. 1 ;
[0014] FIG. 4 is a lower end view of the mill body portion of the apparatus shown in FIG. 1 ;
[0015] FIG. 5 is a longitudinal section view of the apparatus shown in FIG. 1 , after complete separation of the milling head from the mill body;
[0016] FIG. 6 is a longitudinal section view of a second embodiment of the milling head of the present invention, with a ball check valve;
[0017] FIG. 7 is an expanded longitudinal section view of a third embodiment of the apparatus of the present invention, with a flapper check valve and a fishing neck;
[0018] FIG. 8 is an assembled longitudinal section view of the apparatus shown in FIG. 7 ;
[0019] FIG. 9 is a longitudinal section view of a ball clutch and fishing neck for use in a fourth embodiment of the apparatus of the present invention;
[0020] FIG. 10 is a longitudinal section view of a collet for use in the fourth embodiment of the apparatus of the present invention, along with the ball clutch and fishing neck shown in FIG. 9 ; and
[0021] FIG. 11 is an assembled longitudinal section view of the fourth embodiment of the apparatus of the present invention, incorporating the ball clutch and fishing neck, and the collet, shown in FIGS. 9 and 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] As shown in FIG. 1 , the mill assembly apparatus 10 of the present invention principally includes a mill body 12 , to which a milling head 14 is releasably attached, such as by one or more shear screws or pins 16 . The mill body 12 is adapted to be mounted on a work string (not shown) as is commonly known in the art, such as by threading thereto. A plurality of cutting inserts 18 can be provided on the lower face 34 of the milling head 14 to form a cutting structure. Alternatively, the cutting structure can include milled teeth, crushed carbide, or abrasives, without departing from the spirit of the present invention.
[0023] One or more torque lugs 20 , better shown in FIG. 3 , can be provided on an upwardly facing annular shoulder 46 of the milling head 14 . These torque lugs 20 can extend into one or more torque notches 28 , better shown in FIG. 4 , formed on the lower end 48 of the mill body 12 . An axially oriented inner face or shoulder 42 in each torque notch 28 abuts an axially oriented outer face or shoulder 40 on each torque lug 20 . Rather than torque lugs and notches, mating shoulders could alternatively be used. When the milling head 14 is mounted to the mill body 12 , the upwardly facing annular shoulder 46 of the milling head 14 abuts the lower end 48 of the mill body 12 . Also, the upper end 36 of the milling head 14 can abut a downwardly facing annular shoulder 38 within the mill body 12 .
[0024] The section shown in FIG. 1 is taken along a broken section line as shown in FIG. 2 , to better illustrate a possible placement of the torque lugs 20 and torque notches 28 , and the shear pins 16 .
[0025] A fluid flow path can be provided through the mill body 12 and the milling head 14 , which can for example include the inner bore 44 in the mill body 12 , and a first conical surface 50 , a ball seat 30 , an inner bore 32 , a second conical surface 52 , an axial jet 24 , and a plurality of angled jets 26 on the milling head 14 . Drilling or milling fluid can be pumped down the work string (not shown) to flow through this fluid path in the mill body 12 and the milling head 14 , as indicated by the arrows. In addition to the mill assembly apparatus 10 , a pumpable ball or plug 22 can be provided for selectively restricting this fluid flow, as will be described below.
[0026] The mill assembly apparatus 10 , assembled as shown in FIG. 1 , is mounted to a work string (not shown) and lowered into a well bore, until the cutting structure on the lower face 34 of the milling head 14 contacts a plug or other item to be milled out of the bore hole. A rotatable work string or a downhole motor can be used, without departing from the spirit of the present invention. After contacting the plug to be milled, the mill body 12 is rotated in the clockwise direction, as viewed from the upper end, rotating the milling head 14 by virtue of the abutment of the axially oriented torque shoulders 40 and 42 , and causing the inserts 18 or other cutting structure to mill the plug away. Cuttings or fragments of the milled plug are removed from the bore hole entrained in the milling fluid which is pumped through the mill body 12 and the milling head 14 and returned up the annulus to the surface.
[0027] After the plug has been milled away, the pumpable plug or ball 22 can be pumped downhole through the work string to land in the ball seat 30 in the milling head 14 . Alternatively, the fluid flow rate can simply be increased through the apparatus 10 by increasing the speed of the fluid pumps. Either action results in an increased hydraulic pressure at a location in the fluid flow path as it passes through the milling head. If the pumpable ball 22 is used, the increased hydraulic pressure occurs primarily on the first conical surface 50 and across the top of the ball 22 . If the increased pump speed is used, the increased hydraulic pressure occurs in the fluid flow path 50 , 30 , 32 , 52 , 24 , 26 . This increased hydraulic pressure exerts an increased downward hydraulic force on the upwardly facing components of the surfaces of the milling head 14 which are exposed to the increased pressure. As this downward hydraulic force reaches a sufficient, predetermined, level, it causes the shear pins 16 to shear.
[0028] When the shear pins 16 shear, the milling head 14 is completely released from the mill body 12 and completely separates therefrom, as shown in FIG. 5 . This complete axial separation of the milling head 14 from the mill body 12 allows the milling head 14 to fall downhole, completely opening up the borehole at the previously plugged location. Since the torque shoulders 40 and 42 are axially oriented, they are adapted to separate from each other easily when the shear pins 16 shear, and they do not interfere with the shearing of the pins 16 or the complete axial separation of the milling head 14 from the mill body 12 .
[0029] After complete separation of the milling head 14 from the mill body 12 , the inner bore of the mill body 12 is completely open to allow for flow of hydrocarbon fluids upwardly through the mill body 12 as shown by the arrows in FIG. 5 . The separated mill body 12 thus performs thereafter as simply an extension of the work string, and the hydrocarbon fluid flow continues upwardly through the work string to the surface. Therefore, the complete separation of the milling head 14 from the mill body 12 allows for the efficient production of hydrocarbons from the bore hole, through the work string, without pulling and replacing the work string with a production tube.
[0030] A second embodiment of the milling head is shown in FIG. 6 . This embodiment of the milling head 140 can be fitted with a check valve comprising a ball seat 142 , a check ball 144 , and a spring 146 . It can be seen that, as milling fluid passes downhole through the fluid path in the milling head 140 , the check ball 144 can be lifted off its seat 142 , against the bias of the spring 146 , to allow flow out the lower end of the work string. A kick or pressure excursion sometimes occurs in the formation fluids, which could create an undesirable flow in the uphole direction through the work string. To prevent this, the spring 146 biases the check ball 144 toward engagement with its seat 142 . As pressure below the milling head 140 increases above the drilling fluid pressure, this causes the check ball 144 to seat more securely, thereby preventing flow in the uphole direction.
[0031] A third embodiment of the apparatus 210 of the present invention is shown in FIGS. 7 and 8 . In this embodiment, the mill body 212 is secured to the milling head 214 by shear pins 216 in shear pin bores 224 and 226 in the mill body 212 and the milling head 214 , respectively. Flow passages 228 are provided through the milling head 214 . However, in this embodiment, the check valve comprises a swing check type valve, with a check valve body 262 assembled in the milling head 214 , and with a flapper valve 264 , which is pivotably mounted to the check valve body 262 by a pivot pin 266 . The check valve body 262 can be retained in the milling head 214 by one or more snap rings or pins, as is known in the art. The flapper valve 264 is biased toward the closed position by a spring. Flow of fluid down through the apparatus can open the flapper valve 264 against the spring bias, but backflow through the check valve is prevented by shutting of the flapper valve 264 , which seats against the lower side of the check valve body 262 .
[0032] Also provided in this embodiment is a fishing neck 260 , which is retained in the milling head 214 , above the check valve body 262 , by one or more snap rings or pins, as is known in the art. A ball seat 230 is provided in the upper side of the check valve body 262 . When milling has been completed, and it is desired to release the milling head 214 from the mill body 212 , a ball 222 is pumped downhole through the work string, to seat in the ball seat 230 . Increasing pressure above the pumpable ball 222 then shears the shear pins 216 , releasing the milling head 214 from the mill body 212 , as in the first embodiment. If it is desired to subsequently remove the milling head 214 from the well bore, known fishing techniques can be used to attach to the fishing neck 260 and pull the milling head 214 .
[0033] A fourth embodiment of the apparatus 310 of the present invention is shown in FIGS. 9, 10 , and 11 . In this embodiment, a ball clutch mechanism 360 is provided, incorporating a fishing neck, and including one or more ball clutch bores 324 through the wall of the ball clutch 360 . One or more clutch balls 326 are positioned in the clutch bores 324 , when the ball clutch 360 is assembled to the mill body 312 . The clutch balls 326 are forced outwardly in an inner annular groove within the mill body 312 by a collet 370 which is positioned in the inner bore of the ball clutch 360 . The fingers on the upper end of the collet 370 are outwardly biased to seat in an inner shoulder of the fishing neck and ball clutch 360 . This positioning of the collet 370 releasably retains the ball clutch 360 to the mill body 312 . The ball clutch 360 is, in turn, secured to the milling head 314 by one or more snap rings or pins, as is known in the art. So, the ball clutch mechanism 360 releasably retains the milling head 314 to the mill body 312 .
[0034] Flow passages 328 are provided through the milling head 314 . This embodiment of the apparatus 310 can be fitted with a check valve comprising a ball seat 340 in the lower end of the ball clutch 260 , a check ball 344 , and a spring 346 . It can be seen that, as milling fluid passes downhole through the fluid path in the milling head 314 , the check ball 344 can be lifted off its seat 340 , against the bias of the spring 346 , to allow flow out the lower end of the work string. To prevent a kick or pressure excursion, the spring 346 biases the check ball 344 toward engagement with its seat 340 . As pressure below the milling head 314 increases above the drilling fluid pressure, this causes the check ball 344 to seat more securely, thereby preventing flow in the uphole direction.
[0035] A ball seat 330 is provided in the upper side of the collet 370 . When milling has been completed, and it is desired to release the milling head 314 from the mill body 312 , a ball 322 is pumped downhole through the work string, to seat in the ball seat 330 . Increasing pressure above the pumpable ball 322 then forces the collet fingers inwardly, releasing the collet 370 from the inner shoulder in the ball clutch 360 . After the collet 370 is released in this fashion, it is forced further downwardly by fluid pressure. This downward movement of the collet 370 allows the clutch balls 326 to be released from the inner groove in the mill body 312 , releasing the ball clutch 360 and the milling head 314 from the mill body 312 . If it is desired to subsequently remove the milling head 314 from the well bore, known fishing techniques can be used to attach to the fishing neck on the ball clutch 360 and pull the milling head 314 .
[0036] While the particular invention as herein disclosed is capable of obtaining the objects hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention. | A mill assembly having a milling head which is releasable from the mill body, such as by shearing a shear pin. The release mechanism can be released by dropping a pumpable plug through the work string to block fluid flow through the releasable milling head, or by increasing fluid flow through a constriction in the releasable milling head to increase the back pressure above the milling head. A check valve in the milling head can prevent uphole flow through the work string in the event of a pressure excursion. A fishing neck can be attached to the milling head. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/635,577, filed Apr. 19, 2012 and is incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] This invention relates to aisle containment systems and, more particularly, to scalable and adjustable ceiling supported cold aisle containment systems.
BACKGROUND
[0003] There is a need for cold aisle containment systems where the basic structure of the system is easily installed prior to the majority of cabinets being in place. It would also be beneficial to have a containment system that is adjustable to take into account the future installation of cabinets of varying sizes and where cabinets can be easily added or removed without major reconfiguration of the structure. It would also be beneficial if the cold aisle containment system could be secured to the structure of a typical drop ceiling to aid in the ease of installation.
SUMMARY
[0004] The present invention relates generally to a ceiling supported cold aisle containment system.
[0005] In one embodiment, a cold aisle containment system comprises a plurality of floor tracks secured to a raised floor grid and a plurality of wall beams positioned above the floor tracks and supported from the structure of a drop ceiling. Blanking panels are disposed side by side, extend between the floor tracks and the wall beams, and are secured to the floor tracks and wall beams. A ceiling tile support system extends between the wall beams and supports a plurality of ceiling tiles.
[0006] In another embodiment, the blanking panels of the cold aisle containment system comprises fixed blanking panels and adjustable blanking panels.
[0007] In another embodiment, the ceiling tile support system of the cold aisle containment system comprises a plurality of tee beams extending between and perpendicular to the wall beams and a plurality of center beams extending between and perpendicular to the tee beams.
[0008] In another embodiment, the cold aisle containment system further comprises a plurality of corner cabinets positioned at the ends of the containment system and end of row doors, which are supported by the corner cabinets and positioned at the ends of the containment system.
[0009] In another embodiment, the cold aisle containment system further comprises a plurality of above cabinet blanking panels. Each above cabinet blanking panel has an upper panel that is securable to the wall beams and a lower panel that is vertically adjustable to seal against a corresponding cabinet.
[0010] In another embodiment, a method of installing a cold aisle containment system comprises the steps of: securing a plurality of floor tracks to a raised floor tile grid; positioning a plurality of wall beams above the floor tracks and supporting the wall beams from the structure of a drop ceiling; securing a plurality of tee beams between the wall beams; positioning a plurality of center beams between the tee beams; positioning a plurality of ceiling tiles between the wall beams, tee beams, and center beams; and securing a plurality of blanking panels side by side between the floor tracks and the wall beams.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Certain embodiments of the present invention are illustrated by the accompanying figures. It should be understood that the figures are not necessarily to scale and that details that are not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
[0012] FIG. 1 is a front perspective view of an exemplary cold aisle containment system with corner cabinets and end of row doors;
[0013] FIG. 2 is a rear perspective view of an exemplary floor track of the cold aisle containment system;
[0014] FIG. 3 is a front perspective view of the floor track of FIG. 2 ;
[0015] FIG. 4 is a perspective view of a series of exemplary floor tracks installed on a raised floor tile grid;
[0016] FIG. 4A is an enlarged partial view of a floor track shown in FIG. 4 ;
[0017] FIG. 5 is a front perspective view of an exemplary wall beam of the cold aisle containment system;
[0018] FIG. 6 is a rear perspective view of the wall beam of FIG. 5 ;
[0019] FIG. 7 is a front perspective view of a series of floor tracks and wall beams installed with corner cabinets;
[0020] FIG. 8 is an enlarged exploded view of a series of exemplary wall beams and tee beams of the cold aisle containment system;
[0021] FIG. 8A is an enlarged partial view of a wall beam and tee beam of FIG. 8 ;
[0022] FIG. 9 is an enlarged exploded view of a series of exemplary wall beams, tee beams, and cross brackets of the cold aisle containment system;
[0023] FIG. 10 is a front view of an alternative ceiling tile retainer of the cold aisle containment system;
[0024] FIG. 11 is an exploded partial view of an alternative exemplary ceiling tile retainer and wall beam;
[0025] FIG. 12 is a front view of a ceiling tile being installed between a tee beam and wall beam of the cold aisle containment system;
[0026] FIG. 12A is an enlarged partial view of the tee beam with retention bracket of FIG. 12 ;
[0027] FIG. 12B is a front view of an L-shaped retention bracket;
[0028] FIG. 13 is a partial front perspective view of a series of ceiling tiles installed between wall beams of the cold aisle containment system;
[0029] FIG. 14 is a partial front perspective view of an exemplary adjustable blanking panel being installed between a floor track and wall beam of the cold aisle containment system;
[0030] FIG. 14A is an enlarged partial view of the bottom of the adjustable blanking panel in FIG. 14 ;
[0031] FIG. 14B is an enlarged partial view of the top of the adjustable blanking panel in FIG. 14 ;
[0032] FIG. 15 is partial exploded side perspective view of exemplary floor skirts of the cold aisle containment system;
[0033] FIG. 15A is an enlarged partial perspective view of a floor skirt of FIG. 15 ;
[0034] FIG. 16 is a side view of an exemplary floor skirt installed against an adjustable blanking panel;
[0035] FIG. 17 is a partial exploded side perspective view of an exemplary upper sealing bracket being installed between a wall beam and an adjustable blanking panel of the cold aisle containment system;
[0036] FIG. 18 is a partial side view of the exemplary upper sealing bracket as installed;
[0037] FIG. 19 is a front perspective view of an exemplary fixed blanking panel;
[0038] FIG. 20A is a front perspective view of an exemplary adjustable blanking panel in a retracted position;
[0039] FIG. 20B is a front perspective view of the adjustable blanking panel of FIG. 20A in an extended position;
[0040] FIG. 20C is an exploded front perspective view of the adjustable blanking panel of FIG. 20A ;
[0041] FIG. 20D is a partial rear view of the adjustable blanking panel of FIG. 20A in a fully retracted position;
[0042] FIG. 20E is a partial rear view of the adjustable blanking panel of FIG. 20A in a fully extended position;
[0043] FIG. 21 is a side perspective view of a fully installed cold aisle containment system;
[0044] FIG. 22 is a partial side perspective view of an additional cabinet being installed in the cold aisle containment system;
[0045] FIG. 23 is an exploded side perspective view of an exemplary above cabinet blanking panel;
[0046] FIG. 24 is a side perspective view of the above cabinet blanking panel of FIG. 23 ;
[0047] FIG. 25 is a side perspective view of the above cabinet blanking panel of FIG. 23 installed with a wall beam and cabinet;
[0048] FIG. 26 is a side perspective view of two different above cabinet blanking panels installed with a wall beam and different size cabinets; and
[0049] FIG. 27 is a side perspective view of an exemplary cold aisle containment system installed with a plurality of different size cabinets.
DETAILED DESCRIPTION
[0050] Referring to FIG. 1 , one embodiment of a cold aisle containment system 10 is shown installed on a raised floor tile grid 20 with four corner cabinets 30 and end of row doors 40 . The cold aisle containment system 10 allows the basic structure to be erected prior to the majority of the cabinets being in place, allows cabinets to be easily added or removed into the cold aisle containment system 10 without major reconfiguration of the structure, and accepts a wide variety of makes and sizes of cabinets, which is particularly advantageous for pre-configured systems that incorporate computer and storage cabinets of varying widths and heights. Although the embodiments shown and described herein are for a cold aisle containment system, the same structure and arrangement could also be used for a hot aisle containment system or any other type of aisle containment system desired.
[0051] The cold aisle containment system 10 shown in FIG. 1 generally comprises a series of wall beams 100 , a series of floor tracks 200 , a ceiling tile support system 300 , and a series of blanking panels 400 , 500 . Wall beams 100 attach to threaded rods 105 that hang from a data center's ceiling grid system and define the upper limit of the containment system 10 . The floor tracks 200 are positioned directly below the wall beams 100 and run the entire length of the containment system 10 . The blanking panels 400 , 500 are positioned between and secured to the wall beams 100 and floor tracks 200 , define the containment area, and seal off areas where future cabinets can be installed. At each corner of the containment system 10 are corner cabinets 30 , which are positioned to support end of row doors 40 .
[0052] Referring to FIGS. 2 and 3 , the floor tracks 200 are used to support and position the cabinet blanking panels 400 , 500 and any cabinets that are installed in the containment system 10 . FIG. 2 is a view looking at the back (cabinet side) of a floor track 200 and FIG. 3 is a view looking at the front (contained area side) of a floor track 200 . Each floor track 200 is formed from a metal sheet, or other appropriate material, and generally defines a base plate 210 , back wall 220 extending from the base plate 210 , front wall 230 , and connecting wall 240 extending between the back wall 220 and front wall 230 . A series of slots 212 are formed longitudinally along and through base plate 210 and are used to secure the base plate 210 to the raised floor tile grid 20 with screws or other fasteners. Slots 212 are formed along the entire length of base plate 210 , which allows the placement of the screws anywhere along the length of base plate 210 to allow easy positioning and alignment of floor track 200 .
[0053] Threaded holes 222 are formed along the length of back wall 220 and allow the blanking panels 400 , 500 to be fastened to the floor track 200 for better stability. Holes 232 are also foam in front wall 230 and allow a seal to be attached, which is discussed in more detail below. The profile shape of back wall 220 , front wall 230 , and connecting wall 240 mimics the bottom profile shape of base members 440 , 520 of the blanking panels 400 , 500 (see FIG. 16 ). This allows floor track 200 and blanking panels 400 , 500 to nest together in a secure fashion.
[0054] Referring to FIG. 4 , to install containment system 10 , multiple floor tracks 200 are positioned on a raised floor tile grid 20 , to form a base for the containment system 10 , and secured with screws (not shown) through slots 212 . Several floor tracks 200 are laid end to end, and a second set of floor tracks 200 are positioned parallel to the first, to define the containment system 10 width and define the edges of the containment perimeter. The length of each parallel track is determined by the desired size of containment system 10 being installed. As shown in FIG. 4A , in an exemplary installation, the front walls 230 of floor tracks 200 are positioned so that they run along the floor tile edges. This makes floor track 200 placement well defined and simple for an installer and also allows the individual floor tiles located within the containment system 10 to be removed if under floor access is needed.
[0055] Referring to FIGS. 5 and 6 , an exemplary wall beam 100 is shown having a generally L-shaped configuration formed by top wall 120 , front wall 130 , side walls 140 , upper back wall 150 , and lower back wall 160 . Wall beam 100 is connected to threaded rods 105 that drop from a data center's ceiling grid system and extend through slots 122 formed in top wall 120 . A first series of posts 124 A extend from and are positioned at predetermined intervals along top wall 120 and are used to align and connect cross aisle tee beams 320 of ceiling tile support system 300 to wall beams 100 , as is described in more detail below. A second series of posts 124 B also extend from and are positioned at predetermined intervals along top wall 120 and are used to align and connect ceiling tile retainers 170 to wall beams 100 . Ceiling tile retainers 170 have a generally L-shaped configuration formed by base plate 174 and vertical wall 172 and are used to prevent or limit the horizontal movement of an installed ceiling tile 50 . A pair of tabs 176 (see FIG. 8A ) extend from base plate 174 and have apertures therethrough that engage posts 124 B to align and secure ceiling tile retainers to wall beams 100 . A series of threaded holes 132 can also be formed through front wall 130 for use in securing alternative ceiling tile retainers 330 to wall beams 100 , as described in more detail below. A series of threaded holes 162 are also formed through lower back wall 160 and are used to connect blanking panels 400 , 500 to wall beams 100 . Threaded holes 162 are spaced at regular increments, preferably 50 mm, to allow blanking panels 400 , 500 to be installed as needed anywhere in the containment system 10 .
[0056] Wall beams 100 are modular and are sized to be handled by a single installer. As with floor tracks 200 , the size of the particular containment system 10 being installed dictates how many end to end wall beams 100 are needed. Adjacent wall beams 100 can be bolted together using nuts and bolts (not shown) through holes 110 to tie the system together. Wall beams 100 are installed at a predetermined height off of the raised floor tile grid 20 that corresponds to the height of blanking panels 400 , 500 that will be installed.
[0057] As with floor tracks 200 , the number of wall beams 100 required for a given containment system 10 is determined by the desired length of the containment system 10 being installed. Preferably, the length of each individual wall beam 100 is the same length as the corresponding floor track 200 and wall beams 100 are installed directly above floor tracks 200 . Therefore, an equal quantity of both would be needed to create the containment system 10 . Floor tracks 200 define the lower perimeter of the containment system 10 and wall beams 100 define the upper perimeter.
[0058] Referring to FIG. 7 , once floor tracks 200 and wall beams 100 are installed, corner cabinets 30 can be rolled into place at each end of each parallel track of floor tracks 200 . Alternatively, installation of corner cabinets 30 can be done at any time after floor tracks 200 have been installed. Corner cabinets 30 can be any type of network, server, or other type of cabinet, such as Panduit® Net-Access™ server or switch cabinets, and are used to mount end of row doors 40 . Preferably, all cabinets placed into the containment system 10 , including corner cabinets 30 , need to be on casters or raised onto leveling legs so that the cabinets can be positioned above floor tracks 200 . In FIG. 7 , a partially assembled containment system 10 is shown with two series of three floor tracks 200 secured to raised floor tile grid 20 , two series of three wall beams 100 connected to threaded rods 105 that drop from the ceiling grid system, and four corner cabinets 30 properly placed.
[0059] Once all wall beams 100 have been installed, ceiling tile support system 300 is installed between wall beams 100 . Ceiling tile support system 300 generally comprises cross aisle tee beams 320 , center beams 340 , ceiling tile retainers 170 , 330 , and retention brackets 350 , and is used to support ceiling tiles 50 in the containment system 10 .
[0060] Referring to FIGS. 8 and 8A , cross aisle tee beams 320 are first installed between wall beams 100 at intervals approximately equal to the length of a ceiling tile 50 . Each tee beam 320 has a generally inverted T-shaped construction comprising a generally vertical wall 326 and an intersecting general horizontal wall 328 , similar to a standard drop ceiling beam, and a tab 322 extending from each end of the horizontal wall 328 . Each tab 322 has a pair of holes 324 that are configured to engage the threaded posts 124 A in wall beam 100 . Once a tee beam 320 has been positioned between wall beams 100 , nuts can be threaded onto threaded posts 124 A to secure tee beam 320 to wall beams 100 . Each tee beam 320 also has a pair of apertures 327 through the vertical wall 326 , positioned on opposite sides of a midline of the tee beam 320 , that are used to secure center beams 340 to tee beams 320 . Similar to tee beams 320 , L-shaped end of row support beams 360 are installed between wall beams 100 at the ends of containment system 10 . End of row support beams 360 are also used to support ceiling tiles 50 and are only used at the adjacent end of row doors 40 .
[0061] Referring to FIGS. 9 and 12A , once tee beams 320 have been installed, a series of center beams 340 are installed between each tee beam 320 and between a tee beam 320 and end of row support beam 360 . Center beams 340 are positioned along the midline of the tee beams 320 and rest on horizontal walls 328 . Each center beam 340 has a pair of end walls 342 adjacent corresponding vertical walls 326 of tee beams 320 . End walls 342 each have a pair of apertures 344 that align with apertures 327 in vertical walls 326 and are used to secure center beams 340 to tee beams 320 . A horizontal wall 348 extends between end walls 342 and a pair of side walls 346 and has a hole 354 that can be used to install an appropriate fire suppression system or capped when not in use. A pair of support lips 352 extend outward from side walls 346 and are used as support ledges to support ceiling tiles 50 .
[0062] Once the tee beams 320 , end of row support beams 360 , and center beams 340 have been installed, ceiling tiles 50 can be placed into the openings. Referring to FIGS. 10-13 , generally L-shaped retention brackets 350 are secured to side walls 346 of center beams 340 with screws or other appropriate methods. A space is left between retention bracket 350 and support lip 352 of center beam 340 that is slightly larger than the depth of ceiling tile 50 . In the example shown, an alternative ceiling tile retainer 330 is secured to a second end of ceiling tile 50 , opposite the first end that is adjacent center beam 340 . As can be seen in FIGS. 10 and 11 , ceiling tile retainer 330 has a generally U-shaped body 332 that is configured to receive ceiling tile 50 and, once installed, prevents both horizontal and vertical movement of ceiling tiles 50 . Two threaded holes 336 are formed through the upper wall 334 of body 332 , which allows screws (not shown) to secure ceiling tile retainer 330 to ceiling tile 50 . This prevents ceiling tile retainer 330 from falling off ceiling tile 50 when an installer removes ceiling tile 50 from ceiling tile support system 300 . A pair of tabs 337 extend from a lower wall 338 of body 332 . Each tab 337 has a slot 339 that is configured to engage a screw 134 threaded into holes 132 in front wall 130 of wall beam 100 to secure retainer 330 to wall beam 100 . Slots 339 and screws 134 allow ceiling tile 50 and retainer 330 to be easily installed and removed by simply loosening screws 134 and lifting retainer 330 free of wall beam 100 . As shown in FIG. 11 , posts 124 B have been removed from the top of wall beam 100 and are not required when alternative ceiling tile retainer 330 is used. However, a standard wall beam 100 with posts 124 B could also be used, although posts 124 B will not be engaged.
[0063] As shown in FIGS. 12 and 12A , to install ceiling tile 50 a first end of ceiling tile is inserted between retention bracket 350 and support lip 352 of center beam 340 . In the example shown, ceiling tile retainer 330 is also mounted to ceiling tile 50 and locked into place with screws, as described above. Ceiling tile 50 is then pivoted until it is perpendicular to wall beam 100 and slots 339 in ceiling tile retainer 330 engage screws 134 in wall beam 100 . Ceiling tile 50 is the secured into place by tightening screws 134 .
[0064] To enclose the containment area until future cabinets are installed, blanking panels 400 , 500 are used. Blanking panels 400 , 500 rest on floor tracks 200 and extend to wall beams 100 to create a barrier to prevent escape of cool air from the containment area. To account for the wide variety of different cabinet widths that could potentially be installed, a flexible system is needed. This flexibility is accomplished with the combination of two types of exemplary blanking panels: an adjustable blanking panel 400 that is about a cabinet wide with adjustable side panels ( FIGS. 20A-E ); and a narrow fixed blanking panel 500 ( FIG. 19 ).
[0065] Referring to FIG. 19 , fixed blanking panel 500 has a main panel 505 and two side panels 510 that extend from opposite sides of main panel 505 . A set of slots 515 are formed along the top of main panel 505 and are configured to align with threaded holes 162 in lower back wall 160 of wall beam 100 . A generally V-shaped base member 520 , which is essentially the same as base member 440 of adjustable blanking panel 400 , is secured to the bottom of the panels 505 , 510 and is used to secure fixed blanking panel 500 to floor tracks 200 .
[0066] Referring to FIGS. 20A-E , adjustable blanking panel 400 has a main panel 405 and two adjustable side panels 420 . A first set of slots 410 are formed along the top of main panel 405 and are configured to align with threaded holes 162 in lower back wall 160 of wall beam 100 . A second set of slots 415 are formed along each side of main panel 405 and are configured to align with holes 425 in side panels 420 . Adjustable side panels 420 are secured to main panel 405 by threaded studs inserted through holes 425 in side panel 420 and slots 415 in main panel 405 . Side panels 420 can slide in slots 415 to expand or contract the overall size of adjustable blanking panel 400 . A generally V-shaped base member 440 is secured to the bottom of main panel 405 and is used to secure adjustable blanking panel 400 to floor tracks 200 . As can best be seen in FIG. 14A , base member 440 has the same profile as floor track 200 . A first wall 445 engages back wall 220 of floor track 200 and a second wall 450 engages connecting wall 240 so that base member 440 rests on floor track 200 . A series of slots 447 are formed in first wall 445 and generally align with threaded holes 222 in floor track 200 to secure adjustable blanking panel 400 to floor track 200 .
[0067] As can be seen in FIG. 14 , adjustable blanking panel 400 and fixed blanking panel 500 are both installed by placing the respective base member 440 , 520 on floor track 200 and rotating the panel into position until the main panel 405 , 505 contacts wall beam 100 . Screws are used to secure the base members 440 , 520 to floor tracks 200 through threaded holes 222 and main panels 405 , 505 to wall beams 100 through slots 410 , 515 and threaded holes 162 . Both blanking panels 400 , 500 can be positioned along wall beam 100 /floor track 200 in 50 mm increments for future reconfiguration needs.
[0068] As shown in FIGS. 15-16 , to seal the containment system 10 at the floor level, floor skirts 600 are added to floor tracks 200 . Floor skirts 600 have a rigid base member 605 that can be secured to floor track 200 by screws or other threaded members through threaded holes 232 in front wall 230 of floor track 200 . Flexible rubber seal 610 is secured to and extends from base member 605 and butts up against blanking panels 400 , 500 and/or installed cabinets to seal the containment system 10 at the bottom. The rigid base members 605 of the floor skirts 600 are fastened along the entire length of floor tracks 200 . FIG. 15 shows the first two floor skirts 600 not fully installed for clarity. FIG. 16 shows a side view detail of a floor skirt 600 sealing against an adjustable blanking panel 400 .
[0069] As shown in FIGS. 17 and 18 , to seal the containment system 10 at the top, an upper sealing bracket 700 is mounted to the underside of wall beam 100 . Upper sealing bracket 700 has a generally L-shaped bracket 705 and a continuous foam strip 710 mounted along bracket 705 . Foam strip 710 protrudes outward towards blanking panel 400 / 500 and compresses against main panel 405 , 505 to seal the units together.
[0070] During initial installation, adjustable blanking panels 400 and fixed blanking panels 500 are alternated as they are installed. FIG. 21 shows one side of containment system 10 fully filled with alternating adjustable blanking panels 400 and fixed blanking panels 500 . In the example shown, an adjustable blanking panel 400 in a fully retracted position is about 650 mm wide (see FIG. 20D ) and in a fully extended position is just less than 800 mm wide (see FIG. 20E ) and can be factory set at 700 mm wide. Adjustable blanking panels 400 also have foam type seals on the outer sides of side panels 420 to seal side to side with adjacent panels and/or cabinets. Therefore, the overall width of adjustable blanking panels 400 will be slightly larger than stated above. In the example shown, the fixed blanking panel 500 is 100 mm wide. The adjustable blanking panels 400 and fixed blanking panels 500 can both be moved along wall beams 100 /floor tracks 200 in 50 mm increments to allow course adjustments. Fine adjustments can then be made by moving side panels 420 on adjustable blanking panel 400 . Once containment system 10 has been fully installed, as future cabinets are installed, blanking panels 400 , 500 can be removed as needed.
[0071] Using the exemplary adjustable blanking panels 400 and fixed blanking panels 500 described above, an adjustable blanking panel 400 and fixed blanking panel 500 side by side measures approximately 800 mm wide. Therefore, if a cabinet 60 that is 800 mm wide will be installed, one of each blanking panel 400 , 500 will be removed. If a cabinet 60 that is 700 mm wide will be installed, only an adjustable blanking panel 400 will need to be removed. If a cabinet 60 that is 600 mm wide will be installed, one adjustable blanking panel 400 is removed and the adjacent fixed blanking panel 500 and adjustable blanking panel 400 are repositioned and adjusted. The fact that 24 inch (610 mm), 30 inch (762 mm), and other sized cabinets 60 (as well as different combinations of these sizes) may be placed into the containment system 10 requires this type of flexibility. Once the containment system 10 is nearly fully populated with cabinets of different sizes, the remaining area could easily be less than the width of an adjustable blanking panel 400 . At this point, fixed blanking panels 500 can be utilized to fill the remaining small area.
[0072] Once the desired cabinets 60 have been installed, the space above cabinets 60 must be sealed if cabinets 60 do not reach the full height of wall beams 100 . Referring to FIGS. 23-25 , an exemplary above cabinet blanking panel 800 is shown, which can be used to seal the space above under sized cabinets 60 . The overall height and width above cabinet blanking panel 800 depends on the height and width of a particular cabinet 60 being installed. An upper panel 805 of above cabinet blanking panel 800 has a set of horizontal slots 810 that are used to secure above cabinet blanking panel 800 to a wall beam 100 anywhere along the length of wall beam 100 . Screws (not shown) or other threaded members can be used secure above cabinet blanking panel 800 to a wall beam 100 by inserting the screws through horizontal slots 810 and threading the screws into threaded holes 162 in wall beam 100 . Lower panel 820 is secured to upper panel 805 via washers 835 and screws 830 that pass through vertical slots 815 in upper panel 805 and thread into threaded holes 825 in lower panel 820 . This allows lower panel 820 to be vertically adjusted to match the top of cabinet 60 .
[0073] FIG. 25 shows an exemplary above cabinet blanking panel 800 installed above a corresponding cabinet 60 . To create a seal, foam seals 840 are placed along the side and bottom edges of lower panel 820 to seal above cabinet blanking panel 800 to the top of cabinet 60 as well as to adjacent components (such as a blanking panel 400 , 500 , another above cabinet blanking panel 800 , or another cabinet 60 ). In the example shown, the vertical adjustment to lower panel 820 is made from the interior of containment system 10 (the cold aisle) for convenience. Lower panel 820 can be adjusted vertically to facilitate sealing against cabinet 60 .
[0074] FIG. 26 shows a corner cabinet 30 and a cabinet 60 side by side with corresponding above cabinet blanking panels 800 A, 800 B installed (foam seals 840 are removed for clarity) and highlights why certain above cabinet blanking panels 800 need to be cabinet specific based on a cabinet's particular height and width. Since above cabinet blanking panels 800 are vertically adjustable, they can be used with multiple types of cabinets that have the same width but only a small difference in height. However, different height and width above cabinet blanking panels 800 are required for cabinets having different widths or large differences in height. Above cabinet blanking panels 800 also have to be capable of being installed anywhere along wall beams 100 to match wherever a cabinet may be placed. This is accomplished by the horizontal slots 810 in upper panel 805 of above cabinet blanking panels 800 and threaded holes 162 in wall beams 100 , which are spaced at 50 mm increments along wall beam 100 .
[0075] Referring to FIG. 27 , a fully installed containment system 10 with a pair of different sized cabinets 60 A, 60 B installed is shown and illustrates how the containment system 10 can grow with the needs of a customer. It is adaptable enough to allow a wide variety of cabinets 60 to be installed at any time during the life of the containment system 10 .
[0076] While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modification, variations, and/or improvements, whether known or presently unforeseen, may become apparent. Accordingly, the exemplary embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. | An aisle containment system is provided. The aisle containment system includes a pair of wall beams suspended from a ceiling, a pair of floor tracks positioned beneath the wall beams and secured to a floor, and at least one blanking panel secured to one of the wall beams and one of the floor tracks. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional application Ser. No. 61/661,306, filed Jun. 18, 2012, and whose entire contents are hereby incorporated by reference.
BACKGROUND
As the demand for fresh water increases and the supplies of fresh water decrease, water conservation is becoming critically important in the United States, China and elsewhere in the world. Water shortages are more common, particularly in the Southwestern United States, due to a combination of rising temperatures, population growths, water waste and droughts, as well as a very large increase in water demand from commercial industries.
Personal showers are a major user of fresh water. An average shower lasts twelve minutes and uses 2.5 gallons of fresh water per minute. When that amount of water is multiplied by the number of people and the average number of showers per person per day, it is readily apparent that a tremendous quantity of fresh water is used every day for showering. Additionally, considerable energy is used in the pumping, heating and treatment of water in treatment facilities. Shortening the time spent showering dramatically reduces this energy. Thus, there is a continuing need to decrease the amount of shower water used, not only in personal households, but also in hotels, military bases, college campuses, apartment buildings, passenger ships and the like.
SUMMARY
Disclosed herein is a shower flow monitoring and display apparatus having a power unit (or a first unit, a recharging unit, a water flow path unit, or a water temperature sensing unit) and a display unit (or a second unit or a visual and audio display assembly unit). The apparatus can be operatively positioned between a water pipe and a shower head and thereby define a shower water flow path therebetween and through the power unit. The display unit can include a visual/audio display assembly; and the display unit can be connected to the power unit by a connection, such as a ball-and-joint connection, that allows a user to position the display assembly to a desired orientation relative to the power unit.
The power unit can include a thermistor which with the apparatus in place on and between a water pipe and a shower head and the shower water turned on, senses the temperature of the water in the water flow path. The thermistor can send temperature signals to a controller in the display unit. When the controller receives a temperature signal corresponding to a predetermined acceptable water shower temperature the controller can actuate a shower session of the display assembly by sending visual and/or audio signals alerting the user that the shower water is hot enough and that his timed shower session has begun.
The session can have a plurality of stages, each having a different audio and/or visual display from the display assembly and each following the previous one after the passage of a respective predetermined time period. The stages can include a shower stage, a rinse stage and a stop stage. And the stop stage can have a first part/phase followed by a second part/phase wherein the display of the second part/phase is more “urgent” than that of the first part/phase. The start of each stage or part can be signaled to the user by an audio and/or visual signal. And audio and/or visual signals corresponding to each stage or part can be displayed or sent to the user during each of the respective stages or parts, as he showers.
The display assembly (and the remote control) can be powered by a battery that is recharged by a hydroelectric power generator in the power unit and powered by water flowing in the flow path. Wires from the power generator can transmit the AC current to the display unit where it is converted by the controller to DC current, which recharges the battery. When the controller detects incoming electricity from the power generator it knows that the water to the power unit has been turned on and that, for example, it can start the shower session. Similarly, when the controller then detects no incoming electricity it knows that the water has been turned off and for example, it can end the shower session.
With reference to the hydroelectric power generator, a hydraulic turbine converts the energy of flowing water into mechanical energy and a hydroelectric generator converts this mechanical energy into electricity.
If the user tries to short cut the shower session by turning the water off early and then quickly turning it back on, the display assembly can send out an audio and/or visual alert. For example, if the user turns the water off before the stop stage of the shower session and then turns the water back on before a predetermined time period (e.g., three minutes) has passed, the display assembly emits an audio and/or visual alert. An example of this alert can be beeping sounds accompanied by blinking lights. Another example can be blinking lights accompanied by a voice message, such as “please exit the shower,” “allotted shower time has been exceeded; please exit” or something similar. In other words, the alert “session” discourages a user from obtaining a long shower time by avoiding the full shower session, that is by avoiding the annoying the audio/visual signals of the stop stage.
A mute button can be provided on the display unit to allow a user to turn off the audio portion of the display assembly if he finds it unnecessary, annoying or distracting.
As mentioned above, the display unit can be attached to the power unit such that the display assembly, which can include an LCD panel, can be repositioned by the user as desired. The user may choose to reposition it, for example, because of his height or where he likes to stand (or sit) in the spray of a shower or in the shower stall. Repositioning the display assembly can include repositioning the entire display unit relative to the power unit. And the repositioning can be about a pivot axis and/or a rotational axis.
One connection that provides for the above-mentioned repositioning is a ball-and-socket joint with the ball portion attached to or part of the display unit and the socket portion attached to or part of the power unit, or vice versa. As an example, the display unit can include a lower housing portion having a ball lower portion and an upper housing portion having a ball upper portion. And the power unit can have upper and lower housing portions each having a respective upper and lower socket portion. The upper and lower housing portions of the display unit together with the upper and lower ball portions are snapped, screwed or otherwise attached together. With the assembled ball positioned in one of the upper and lower socket portions, the upper and lower housing portions of the display unit together with the upper and lower socket portions can be snapped, screwed or otherwise attached together, such that the ball is within the assembled socket. The display unit can thereby be rotated and/or pivoted relative to the power unit, as desired by the user. The housing portions can be releasably attached together so that a user can subsequently disassemble them to repair or replace internal components as may be needed.
The apparatus can be sold or otherwise made available to the user with the predetermined temperature and the shower session fixed, and/or with the predetermined temperature and/or shower session customizable by the user. One way of customizing is using a remote control unit that operatively connects to the controller via an IR sensor. Another way is to plug one end of a cord into a USB port of the display unit and the other end connected to a computer. With the computer accessing a website of this disclosure and synched with the controller, the user chooses by clicking on the appropriate areas on the page on the computer monitor the desired water shower temperature, the lengths of the wash, rinse and stop (first phase) stages, the audio selections for each of the stages, and/of the blinking and/or beeping rates for the alert session.
More particularly, with the computer accessing the website and synched up to the apparatus and its internal controller, the user can re-program the factory settings of the controller. The apparatus can be synched up via the USB port. Thereby, the user can program the desired starting temperature, the duration of the shower stage, the duration of the rinse stage, and the duration of the stop “grace” period phase. Using the computer/device interface, the user can also select and re-program the factory set audio alerts, selecting from a list of sound effects and volumes. These sound effects and/or voice recordings can be used to alert the user that a) the shower temperature has been reached, b) the shower time is up, transition to the rinse stage, c) the rinse time is up, transition to the stop stage, and/or d) the grace period is over, turn the water off and exit the shower.
According to one definition of the present disclosure a shower flow monitoring and display apparatus having a first unit and a second unit extending out from it is disclosed. The apparatus can be positioned between a water pipe and a shower head with a flow path through the first unit. The second unit can be repositioned in rotational and/or pivotal directions by a user with the power unit in place and about a ball-and-socket joint. A hydroelectric power generator in the first unit recharges the battery of the second unit and also lets the controller in the first unit know when the water has been turned on and off. A thermistor in the first unit lets the controller know when the water has reached a predetermined temperature and the shower session thereby can begin. The session can include shower, rinse and stop part one and stop part two stages. Each of the stages includes corresponding visual and/or audio signals to the user from a display assembly of the display unit. If the user turns the water off before the stop part one stage and then turns it back on before a predetermined time period has lapsed, an alert stage/mode is started. Connecting the controller to a website of the disclosure allows a user to customize the visual and/or audio signals. Alternatively, customization can be done using a remote control unit.
1. Disclosed herein is a shower apparatus which comprises: a power unit which includes: a water supply inlet adapted to be positioned in fluid communication with a water pipe; a water supply outlet adapted to be positioned in fluid communication with a shower head; and a water path between the inlet and the outlet; and a display unit which: is connected to the power unit; extends out from the power unit; has a display assembly configured to convey to a user information concerning water flowing in the water path; and receives electricity from the power unit.
1a. The apparatus of 1 wherein the user is a user of water from the shower head, and the display assembly is configured to convey the information when water is flowing into the power unit from the water pipe.
1b. The apparatus of 1 wherein the shower head is orientation and spray adjustable by the user when attached to the water supply outlet.
1c. The apparatus of 1 wherein the shower head includes an elongate flexible hose and a shower nozzle at a distal end of the hose.
1d. The apparatus of 1 further comprising a connector connecting the display unit to the power unit and configured to allow the display unit to move in both rotational and pivotal directions relative to the power unit.
1e. The apparatus of 1d wherein the connector includes a ball-and-socket joint.
1f. The apparatus of 1e wherein the ball-and-socket joint includes a ball connected to a post extending out from a housing of the display unit and a socket extending out from a housing of the power unit and in which the ball is rotatably positioned.
1g. The apparatus of 1f wherein the socket includes first and second portions on opposite sides of the ball and fastened together.
1h. The apparatus of 1e wherein: the ball-and-socket joint includes a first socket portion which is part of a power unit first housing portion, a second socket portion which is part of a power unit second housing portion, a first ball portion which is part of a display unit first housing portion, and a second ball portion which is part of a display unit second housing portion; and wherein the power unit first and second housing portions are configured to be attached together with the first and second ball portions attached together and the attached ball portions positioned between the first and second socket portions.
1i. The apparatus of 1e wherein at least one wire passes from the power unit to the display unit and through the ball-and-socket joint.
1j. The apparatus of 1e wherein the at least one wire passes through the ball of the ball-and-socket joint.
1k. The apparatus of 1j wherein the power unit includes a water temperature sensor, the display unit includes a printed circuit board assembly and the at least one wire includes a wire operatively connecting the water temperature sensor to the printed circuit board assembly.
1l. The apparatus of 1k wherein the power unit includes a hydroelectric power generator, the display unit includes a microcontroller and the at least one wire includes a wire operatively connecting the generator to the microcontroller.
1m. The apparatus of 1k wherein the generator has a generally round shape and is generally two inches in diameter and generally 1.5 inches thick.
1n. The apparatus of 1 wherein the display assembly is configured to convey at least some of the information visually to the user.
1o. The apparatus of 1 wherein the display assembly is configured to convey at least some of the information audibly to the user.
1p. The apparatus of 1 wherein the display assembly includes a liquid crystal display that includes graphic and/or alphanumeric symbols.
1q. The apparatus of 1p wherein the symbols include at least one shower symbol which is illuminated during a shower stage of a shower session of the apparatus, at least one rinse symbol which is illuminated during a subsequent rinse stage of the shower session and at least one stop symbol which is illuminated during a subsequent stop stage of the shower session.
1r. The apparatus of 1q wherein the display assembly includes audio prompts that alert the user to a transition from the shower session to the rinse stage and from the rinse stage to the stop stage and to the start of the stop stage.
1s. The apparatus of 1r wherein the display assembly includes a series of audio prompts that are more extreme during a second phase of the stop stage than during a first phase of the stop stage.
1t. The apparatus of 1s wherein the more extreme includes more frequent and/or louder audible prompts.
1u. The apparatus of 1q wherein the stop stage has a first part and a subsequent second part after a predetermined time period, and the display assembly has a first visual and/or audio display during the first part and a different second visual and/or audio display during the second part.
1v. The apparatus of 1u wherein the second visual and/or audio display includes a continuous blinking of at least one light, and the predetermined time period is between thirty seconds and one hundred and twenty seconds.
1w. The apparatus of 1 wherein the display assembly has a plurality of stages during a shower session including a final stop stage, and the display assembly has a visual and/or audio alert display which commences in the event that the water to the apparatus is turned off before the start of the stop stage and turned back on before a predetermined time period has elapsed.
1x. The apparatus of 1w wherein a hydroelectric power generator in the power unit sends a first signal to the display unit when the water to the apparatus has been turned off and a second signal when the water has been turned on.
1y. The apparatus of 1 wherein the power unit includes: a housing; a back nipple at a back of the housing and configured to operatively connect to the water pipe; a front nipple at a front of the housing and configured to operatively connect to the shower head; and a hydroelectric power generator in the housing and powered by water passing along the water path.
1z. The apparatus of 1 wherein the power unit includes a temperature sensor positioned to sense the temperature of water in the water path and the display unit is configured to commence a shower session upon receipt of a temperature signal from the sensor indicating that the water in the water path has reached a predetermined shower temperature.
1aa. The apparatus of 1z wherein the display unit includes a printed circuit board assembly.
1bb. The apparatus of 1z wherein an audio and/or visual commencing signal from the display unit alerts the user that the shower session of the apparatus has started.
1 cc. The apparatus of 1z wherein the shower session includes: a shower stage with the display unit having a shower stage display; followed after a first predetermined time by a rinse stage and with the display unit having a rinse stage display; and followed after a second predetermined time by a stop stage with the display unit having a stop stage display.
1 dd. The apparatus of 1 cc wherein each of the displays includes a visual and/or audible display.
1ee. The apparatus of 1cc wherein the stop stage includes a preliminary stop visual and audio display for a predetermined time and then a second phase visual and audio display.
1ff. The apparatus of 1ee wherein the predetermined time is approximately one minute and the second phase visual and audio stop display includes a continuous beeping sound or repeating message.
1gg. The apparatus of 1 wherein the power unit includes a water temperature sensor and the display unit includes a microcontroller which is configured to cause the display assembly to start a display for a timed shower session upon receipt of an indication from the sensor that water in the water path has reached a predetermined temperature corresponding to an acceptable water shower temperature.
1hh. The apparatus of 1gg wherein the predetermined temperature is adjustable using a remote control and/or an electronic device which is connectable to the display unit, such as via an electrical cord.
1ii. The apparatus of 1hh wherein the electronic device is communicable to a website that provides for a user to adjust at least the predetermined temperature.
1jj. The apparatus of 1ii wherein the website provides for a user to adjust the lengths of stages of the shower session.
1kk. The apparatus of 1gg wherein the shower session includes a shower stage, a rinse stage and a stop stage.
1ll. The apparatus of 1kk wherein the shower stage lasts between five and seven minutes and the rinse stage lasts between forty-five seconds and ninety seconds.
1mm. The apparatus of 1kk wherein the only way to end the stop stage without disconnecting the apparatus is to stop the water flowing in the water flow path.
1nn. The apparatus of 1kk wherein turning the water off stops the shower session by sending a signal from a hydroelectric power generator to the controller.
1oo. The apparatus of 1kk wherein the display includes an audible signal at the start of the shower stage, an audible signal at the start of the rinse stage and audible stop signals during the stop stage.
1pp. The apparatus of 1oo wherein the audible stop signals continue until water flow to the water flow path is turned off.
1qq. The apparatus of 1kk wherein the display assembly includes: during the shower stage the word “shower,” a shower bubbles image and a smile symbol being illuminated; during the rinse stage a stop watch symbol, the word “rinse” and a rinse off symbol being illuminated; and during the stop stage a frown symbol, the word “stop,” and an open stop hand image being illuminated.
1rr. The apparatus of 1kk wherein the lengths of the shower and rinse stages are adjustable by a user.
1ss. The apparatus of 1kk wherein the audible signals of the display assembly are adjustable by a user.
1tt. The apparatus of 1 wherein the orientation of the display unit relative to the power unit is manually repositionable by a user in both rotational and pivotal directions with the power unit connected to the water pipe.
1uu. The apparatus of 1 wherein the display includes an LCD and a color bar, and the color bar includes a plurality of LEDs and embedded imagery.
1vv. The apparatus of 1 wherein the display unit includes a USB port via which a user can customize the display assembly.
1ww. The apparatus of 1 wherein the display assembly includes an audio temperature signal indicating that the water in the flow path has reached a predetermined acceptable shower water temperature and the shower session has started and the display assembly includes an audio time signal indicating that at least a predetermined shower time in the showering session in the shower session has past since the audio temperature signal commenced.
1xx. The apparatus of 1ww wherein the display assembly includes a visual temperature signal indicating that the water in the flow path has reached a predetermined acceptable shower water temperature and the display assembly includes a visual “stop” signal indicating that the predetermined shower time has elapsed since the visual temperature signal commenced.
1yy. The apparatus of 1ww wherein the display assembly includes an audio temperature signal indicating that the water in the flow path has reached a predetermined acceptable shower water temperature and the shower session has thereby started and the display assembly includes an audio “stop” signal indicating that a predetermined shower time of the shower session has elapsed.
1zz. The apparatus of 1 wherein the display unit includes an infrared sensor which is configured to receive signals from a remote control which allows a user to re-program the controller or printed circuit board assembly to change the volume, duration and/or sound of the audio signals, to change the times of at least one of the stages of a shower session of the apparatus and/or to change the water temperature setting of the start of the shower session.
1aaa. The apparatus of 1zz wherein the remote control has a first button for adjusting the volume of an audible display, a second button for adjusting the length of a shower stage of the session, a third button for adjusting the length of a rinse stage of the session, a fourth button for adjusting the length of a stop stage of the session, and a fifth button for a sound “off” mute.
1bbb. The apparatus of 1 wherein the power unit includes a housing, a back nipple at the inlet, a front inlet at the outlet, and a hydroelectric power generator in the housing and powered by water flowing in the flow path.
1ccc. The apparatus of 1bbb wherein the back nipple has internal threads and the front nipple has external threads.
1ddd. The apparatus of 1 wherein the display assembly includes pre-recorded audio messages sounding at predetermined time intervals during a shower session of the apparatus.
1eee. The apparatus of 1 wherein the display assembly includes an LCD that includes a color bar.
1fff. The apparatus of 1eee wherein the color bar includes three vertically arranged lights that include a green light at the top, a yellow light in the middle and a red light at the bottom.
1ggg. The apparatus of 1 wherein the display unit is configured to operatively connect to an external device through which the display assembly can be adjusted.
1hhh. The apparatus of 1ggg wherein the external device is a laptop or tablet computer.
1iii. The apparatus of 1ggg wherein the display assembly is configured to be modified through the device by creating a personalized audio message that the display unit sounds out at a predetermined time in a shower session.
1jjj. The apparatus of 1ggg wherein the external device is a remote control.
1kkk. The apparatus of 1ggg wherein the external device is a computer that can access a website via which the audio message can be created or changed.
1lll. The apparatus of 1 wherein the display unit includes a printed circuit board assembly and at least one user control, which includes a mute button that is operatively connected to the printed circuit board assembly.
1mmm. The apparatus of 1 wherein the power unit has a first rectangular prism shape with a first width, a first length and a first thickness, the display unit has a second rectangular prism shape with a second width, a second length and a second thickness, wherein the first thickness is greater than the second thickness, and the second length is greater than the first length.
1nnn. The apparatus of 1mmm wherein the first width and the second width are within generally 15% of each other.
1ooo. The apparatus of 1mmm wherein the power unit includes a first nipple extending out a rear face of the first rectangular prism shape and a second nipple extending our a front face of the second rectangular prism shape.
1ppp. The apparatus of 1mmm wherein the power unit has a ball extending out from a side of the first rectangular prism shape and the display unit has a socket extending out from an adjacent side of the second rectangular prism shape and fitting on to the ball to form a ball-and-socket joint.
1qqq. The apparatus of 1ppp wherein wires pass through the ball of the ball-and-socket joint between the power unit and the display unit.
1rrr. The apparatus of 1mmm wherein the power unit has a plurality of elastomeric plugs on a back side thereof and positioned on fasteners that hold two parts of the power unit housing together.
1sss. The apparatus of 1 further comprising a pivot/rotation joint connecting the display unit to the power unit.
1ttt. The apparatus of 1 wherein the display unit includes a printed circuit board assembly having the following components: a capacitor, a plurality of LEDs, a resister, an IR receive sensor, a DC-to-DC regulator, at least one battery charging control chip and a PIN slot connector.
1uuu. The apparatus of 1ttt wherein the printed circuit board assembly includes a circuit test button and/or an MUC.
1vvv. The apparatus of 1 wherein the display unit has a button positioned to be actuated by a user to turn off or mute the audible signals of the display assembly.
1www. The apparatus of 1 wherein the display unit includes a rechargeable 3.7 Volt lithium ion battery.
1xxx. The apparatus of 1 wherein the display unit includes a USB connector adapted to connect to a USB cable for customizing a display regimen.
1yyy. The apparatus of 1 wherein the display unit includes a printed circuit board assembly and the power unit includes a thermistor connected to the printed circuit board assembly by one or more wires.
1zzz. The apparatus of 1 further comprising wiring between the power unit and the display unit, and wherein: the power unit includes a hydroelectric power generator which is powered by water flowing along the path and which generates alternating current; the display unit includes a battery, the display assembly, and a printed circuit board assembly having a rectifier and a filter circuit; the wiring transmits the alternating current to the printed circuit board assembly which converts the alternating current to direct current and the direct current recharges the battery; and the battery provides electricity to the display assembly.
1aaaa. The apparatus of 1 wherein the power unit includes a thermistor that has different resistance values in different water temperatures, the display unit includes a microcontroller and the display assembly, and the different resistance values when actuated cause the microcontroller to instruct the display assembly to take different actions.
1bbbb. The apparatus of 1 wherein: the power unit includes: a hydroelectric power generator that is driven by water flowing in the water path; and a temperature sensor positioned for sensing temperature of water in the water path; the display unit includes: a controller that receives electricity from the generator and temperature signals from the temperature sensor and that controls the stages of a shower session; and the display assembly includes at least one differently colored light for each of the stages, and a speaker that emits an audible signal for each of the stages.
1 cccc. The apparatus of 1bbbb wherein the controller controls the operation of the display assembly.
1dddd. The apparatus of 1bbbb wherein the at least one colored light includes at least two LED lights.
1eeee. The apparatus of 1 wherein the display unit includes a battery, a battery charge control circuit and a bridge rectifier between the power unit and the battery charge control circuit, and the display assembly includes an audio circuit and an LED display circuit.
1ffff. The apparatus of 1 wherein the power unit includes a hydroelectric power generator that generates three-phase AC by water flowing in the water path and the display unit includes circuits that rectify, filter and stabilize the AC to 5V DC.
1gggg. The apparatus of 1 wherein the power unit includes a housing made of ABS plastic and the display unit includes a housing made of ABS plastic.
1hhhh. The apparatus of 1 wherein the power unit includes a hydroelectric power generator that includes an impeller and a dynamo.
2. Disclosed herein is a shower apparatus which comprises: a power portion including: a water supply inlet adapted to be positioned in fluid communication with a water pipe; a water supply outlet adapted to be positioned in fluid communication with a shower head; a water path between the inlet and the outlet; and a temperature sensor positioned to sense temperature of water in the water path; and a display portion including a controller and a display assembly; wherein the controller is configured to cause the display assembly to commence a shower session having a plurality of stages when the controller receives a signal from the sensor indicating that the water has reached a predetermined showering temperature, and is configured to cause the display assembly to send out at least one visual and/or audible signal to alert a user that the water has reached the acceptable temperature and that the shower session is thus commencing.
2a. The apparatus of 2 wherein: the power portion includes a power unit housing having a socket; the display portion includes a display unit housing having a display panel and a ball; and the ball is fitted in the socket to define a ball-and-socket joint that allows the pivotal and rotational movement of the display unit housing relative to the power unit housing to reposition the display panel relative to the user.
2b. The apparatus of 2a further comprising a thermistor wire operatively connecting the thermistor to the controller and passing through the ball.
2c. The apparatus of 2a wherein the power portion includes a hydroelectric power generator powered by water flowing in the water path, and further comprising a power wire passing from the generator, through the ball and to a circuit board for the display assembly.
2d. The apparatus of 2 wherein the temperature sensor is a thermistor.
2e. The apparatus of 2 wherein the shower session includes a delay of three or more minutes prior to commencement of a subsequent shower session.
3. Disclosed herein is a shower apparatus which comprises: a flow portion including: a water supply inlet adapted to be positioned in fluid communication with a water pipe; a water supply outlet adapted to be positioned in fluid communication with a shower head; and a water flow path between the inlet and the outlet; and a display portion attached to the flow portion and including a controller, a display assembly and a battery; wherein the controller is configured to cause the display assembly to start a shower session after shower water has been turned on; wherein the shower session has a plurality of stages including a final stop stage; and wherein the display assembly is configured to include an visual and/or audio alert display which commences in the event that water to the flow portion is turned off during the shower session and before the start of the stop stage and turned back on before a predetermined time period has elapsed.
3a. The apparatus of 3 wherein the flow portion includes a hydroelectric power generator that is driven by water flowing in the water flow path, and wherein the battery is recharged by electricity generated by the generator.
3b. The apparatus of 3a wherein the controller knows that the water has been turned off when the controller is no longer receiving electricity from the generator and the controller knows that the water has been turned on when the controller receives electricity from the generator.
3c. The apparatus of 3 wherein the visual and/or audio alert display includes a blinking stop signal and a repeating audio alert signal.
3d. The apparatus of 3 wherein the power portion includes a thermistor positioned to sense temperature of water in the water flow path and to send signals to the controller indicating the sensed temperature; and wherein the controller causes the shower session to start when the controller receives a signal from the thermistor that corresponds to a predetermined acceptable shower water temperature.
3e. The apparatus of 3d wherein the controller at the start of the shower session causes the display assembly to emit a visual signal and/or an audible signal to alert the user to the start of the shower session.
3f. The apparatus of 3 wherein the battery is a rechargeable 3.7 Volt lithium ion battery.
3g. The apparatus of 3 wherein the predetermined time period is between two and fifteen minutes.
4. Disclosed herein is a shower apparatus which comprises: a first unit which includes a water flow path adapted when the first unit is in position to provide a water flow path from a water supply source to an inlet of a shower head, and a hydroelectric power generator driven by water flowing in the water flow path; a second unit which includes a face that has at least one visual and/or audio indicator related to one or more stages of a shower session of the apparatus; wherein one of the first and second units includes a battery for powering the at least one visual and/or audio indicator; wherein at least one of the first and second units includes a battery charging circuit configured to recharge the battery using electricity from the generator; and wherein the face is repositionable relative to the first unit by a shower user and with the first unit in the position.
4a. The apparatus of 4 wherein the hydroelectric power generator includes a hydraulic turbine that converts the energy of water flowing in the path into mechanical energy and a hydroelectric generator that converts the mechanical energy into AC.
4b. The apparatus of 4 wherein the second unit is connected to the first unit by a ball-and-socket joint.
4c. The apparatus of 4 wherein the at least one visual and/or audio indicator includes an LCD and a speaker.
4d. The apparatus of 4 wherein the second unit includes the battery and the battery charging circuit.
5. Disclosed herein is a shower apparatus which comprises: a water flow path adapted when the apparatus is in position to provide a water flow path from a water supply source to a shower head; an audio and/or visual display assembly; and a controller configured to control the audio and/or visual display assembly through a shower session having at least a shower stage and a stop stage and to send at least one audio and/or visual alert signal from the audio and/or visual display assembly to a user in the event that water in the flow path is turned off during the shower session and before the start of the stop stage and subsequently turned back on before a predetermined time period has passed.
5a. The apparatus of 5 further comprising: a rechargeable battery for powering the audio and/or visual display assembly; and a hydroelectric power generator powered by water flowing in the water flow path and generating electricity to recharge the battery.
5b. The apparatus of 5a further comprising a recharging circuit between the generator and the battery and converting AC to DC.
5c. The apparatus of 5b wherein the recharging circuit includes a circuit board.
5d. The apparatus of 5 wherein the water flow path is part of a first unit and the audio and/or visual display assembly is part of a second unit, and the second unit is repositionable with respect to the first unit by a shower user with the apparatus in an operative position.
5e. The apparatus of 5d wherein a ball-and-socket joint connects the second unit and the first unit together and allows for the repositioning.
5f. The apparatus of 5 wherein the audio and/or visual display assembly delivers at least one audio signal during the shower session, and further comprising a mute button configured such that the user can cause the at least one audio signal to be turned off.
6. Disclosed herein is a shower stage indication process which comprises: providing a start indication to a shower user indicating that a shower session has started; providing a first indication to the shower user that the shower session is in a first stage thereof; providing a second indication to the shower user that the shower session is in a second stage thereof; providing a first stop indication to the shower user that the shower session is in a first phase of a stop stage of the shower session; providing a second stop indication to the shower user that the shower session is in a second phase of the stop stage; wherein the second stop indication is a more urgent indication than the first stop indication; wherein each of the indications is a visual and/or audible signal; and wherein the second stop indication includes beeping sounds and/or flashing lights.
6a. The process of 6 wherein the visual and/or audible signals emanate from an apparatus operatively positioned between a shower pipe and a shower nozzle.
6b. The process of 6 wherein the indications stop when the shower water is turned off.
6c. The process of 6 wherein the first and second stop indications include a stop symbol being illuminated.
7. Disclosed herein is a shower stage indication programming process which comprises: operatively connecting a controller of a shower apparatus to a computing device; wherein the shower apparatus includes: a water flow path adapted when the apparatus is in position to provide a water flow path from a water supply source to an inlet for a shower head; an audio and visual display assembly; and the controller; wherein the controller is configured to control the audio and visual display assembly through a shower session having at least a shower stage and a stop stage and with the apparatus in position; and with the computing device connected to a website, programming the controller by setting at least some of the audio displays and the visual displays through the website.
7a. The process of 7 wherein the operatively connecting uses a cable.
7b. The process of 7 wherein the shower session includes the shower stage, a subsequent rinse stage and the stop stage which is after the rinse stage, wherein the stop stage has a first stop session and a second stop session; and wherein the shower stage has a first time duration, the rinse stage has a second time duration and the first stop session has a third time duration.
7c. The process of 7b wherein the programming includes setting the first, second and third time durations.
7d. The process of 7b wherein the audio displays includes a first audio sound at the start of the shower stage, a second audio sound at the start of the rinse stage, and a third audio sound at the start of the first stop session; and the programming includes setting the first, second and third audio sounds.
7e. The process of 7b wherein the second stop session includes a repeating sound; and the programming includes selecting the repeating sound.
7f. The process of 7b wherein the controller causes the audio and visual display assembly to be activated into an alert mode session in the event that the water to the water flow path is turned off before the start of the first stop session and the water is subsequently turned back on before the passage of a predetermined time period.
7g. The process of 7f wherein the programming includes setting the predetermined time period.
7h. The process of 7f wherein the predetermined time period is generally three minutes.
7i. The process of 7f wherein the apparatus includes a hydroelectric power generator powered by water flowing in the water flow path and generating electricity which flows to the controller.
7j. The process of 7i wherein the apparatus includes a battery for powering the visual and audio display assembly and the controller converts the AC from the generator to DC which is delivered to the battery to recharge it.
7k. The process of 7i wherein electricity being delivered to the controller is a signal that water is flowing in the water flow path and electricity not being delivered to the controller is a signal that water is not flowing in the water flow path.
7l. The process of 7 wherein the shower apparatus includes a temperature sensor configured to sense temperature of water in the shower water path and to communicate the sensed water temperature to the controller; wherein the shower session is started when the controller receives a signal from the temperature sensor indicating that the water has reached a predetermined temperature; and wherein the programming includes setting the predetermined temperature.
8. Disclosed herein is a shower apparatus, comprising: a first unit which includes: a water supply inlet adapted to be positioned in fluid communication with a water pipe; a water supply outlet adapted to be positioned in fluid communication with a shower head; and a water flow path between the inlet and the outlet; a second unit which has a display assembly configured to convey to a user information concerning water flowing in the water flow path; and wherein a ball-and-socket joint connects the second unit to the first unit and is configured to allow the second unit to move in both rotational and pivotal directions relative to the first unit.
8a. The apparatus of 8 wherein: the ball-and-socket joint includes a first socket portion which is part of a first housing portion of the first unit, a second socket portion which is part of a second housing portion of the first unit, a first ball portion which is part of a first housing portion of the second unit, and a second ball portion which is part of a second housing portion of the second unit.
8b. The apparatus of 8a wherein the first and second housing portions of the first unit are configured to be attached together with the first and second ball portions attached together and the attached ball portions positioned between the first and second socket portions.
8c. The apparatus of 8 wherein at least one wire passes from the power unit to the display unit and through the ball-and-socket joint.
8d. The apparatus of 8 wherein the at least one wire passes through the ball of the ball-and-socket joint.
8e. The apparatus of 8d wherein the at least one wire includes a wire from a hydroelectric power generator in the first unit to a printed circuit board assembly in the second unit.
8f. The apparatus of 8d wherein the at least one wire includes a wire from a water temperature sensor in the first unit to a printed circuit board assembly in the second unit.
Also disclosed herein are novel packaging constructions for the apparatus.
BRIEF DESCRIPTION OF DRAWINGS
The drawings described herein are for illustrative purposes only of selected aspects of the present teachings and not all possible implementations, and are not intended to limit the scope of the present teachings.
FIG. 1 is a perspective view of an apparatus of the present disclosure shown in an installed position relative to a water pipe and a shower head and spraying water.
FIG. 2 is a rear perspective view of the apparatus of FIG. 1 in isolation.
FIG. 3 is a top perspective view showing the connection of the display unit to the power unit.
FIG. 4 is a top perspective view of the power unit of the apparatus.
FIG. 5 is a bottom perspective view of the power unit.
FIG. 6 is a side view of the power unit showing the components in exploded relation.
FIG. 7 is another perspective view similar to FIG. 6 but from a top angle.
FIG. 8 is a perspective view similar to FIG. 7 but from a bottom angle.
FIG. 9 is a side cross-sectional view of the power unit.
FIG. 10 is a perspective view of the power unit in a partially disassembled condition and showing the connecting wires.
FIG. 11 is a view similar to that of FIG. 10 but showing the wires passing through the ball joint and into the display unit.
FIG. 12 is a top perspective view of the display unit in isolation.
FIG. 13 is a view similar to FIG. 12 but from another angle.
FIG. 14 is a front perspective view of the display unit and showing the icons of the display screen thereof.
FIG. 15 is a side perspective view of the display unit showing the components in exploded relation.
FIG. 16 is a view similar to FIG. 15 but from a bottom angle.
FIG. 17 is a view similar to FIG. 16 but from a top angle.
FIG. 18 is a cross-sectional view of the display unit.
FIG. 19 is a flow chart showing an operation of the display assembly of the apparatus.
FIG. 20 is a flow chart showing an operation logic of the apparatus.
FIG. 21 is a block diagram of a circuit of the apparatus.
FIG. 22 is a detailed view taken on block A of the circuit of FIG. 21 .
FIG. 23 is a detailed view taken on block B.
FIG. 24 is a detailed view taken on block C.
FIG. 25 is a detailed view taken on block D.
FIG. 26 is a detailed view taken on block E.
FIG. 27 is a detailed view taken on block F.
FIG. 28 is a detailed view taken on block G.
FIG. 29 is a detailed view taken on block H.
FIG. 30 is a detailed view taken on block I.
FIG. 31A is a block diagram of the power unit and the display unit of the apparatus.
FIG. 31B is a block diagram of a remote control of the present disclosure for positioning in operative position relative to the display unit in the block diagram of FIG. 31B .
FIG. 32 is a top perspective view of the remote control of FIG. 31B .
FIG. 33 is a block diagram showing the interconnections of functional elements of the apparatus.
FIG. 34 is a functional schematic block diagram of the apparatus.
FIG. 35 is a screen shot of an operative page of a website which a user can use to program the display assembly of the apparatus.
FIG. 36 is a top perspective view of a top portion of a packaging insert of the present disclosure for the apparatus.
FIG. 37 is a bottom perspective view of the top portion of FIG. 36 .
FIG. 38 is a top perspective view of a bottom portion of the packaging insert and showing the apparatus fitted therein.
FIG. 39 is a perspective view of the apparatus of FIG. 1 , showing the display unit in an adjusted (articulated) position with respect to the power unit and the arrows showing how the position of the display unit relative to the power unit can be adjusted in rotational and pivotal directions.
DETAILED DESCRIPTION
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Referring to FIG. 1 , an apparatus of the present disclosure for monitoring and displaying shower water flow is illustrated generally at 100 . The apparatus is depicted in an operative position between a water pipe 110 and a shower head 120 . Generally, any standard shower head can be used including a handheld nozzle with a long flexible hose. The apparatus 100 can include a power unit 130 and a display unit 140 , connected together, for example, by a ball-and-socket joint 150 .
The ball-and-socket joint 150 allows a user to reposition the front face 156 with its LCD panel 160 and (waterproof) speaker 164 as desired relative to the power unit 130 , as can be understood by the arrows A 1 , A 2 in FIG. 39 . The user may want to reposition it because of his height, where he likes to stand (or sit) in the water spray W or where he likes to stand (or sit) in the shower stall relative to the front face 156 . The front face 156 conveys shower water information to him via the LCD panel 160 and the speaker 164 , as is described in detail in this disclosure.
The power unit 130 can also be referred to as a first unit, a recharging unit, a first portion, a water flow path unit, a water temperature unit, a power portion or the like. It can include a housing 180 having a front nipple 184 , a rear nipple 188 , and a shower water flow path 200 from the rear nipple to the front nipple. The front nipple 184 can have external threads 204 for screwing into a shower head 120 . The rear nipple 188 can have internal threads 206 for screwing onto a water pipe 110 .
A hydroelectric power generator 210 can be provided in the housing 180 to generate electricity from the water flowing in the water flow path 200 . And a temperature sensor 220 (such as a thermistor ( FIGS. 10, 11, 21 and 29 )) can also be provided in the housing 180 proximate to (in) the water flow path 200 to measure the temperature of the water. The generator 210 can have a generally round shape and can be generally two inches in diameter and generally 1.5 inches thick.
The operation/construction of the hydroelectric power generator 210 will now be described. A hydraulic turbine converts the energy of the flowing water in the water flow path into mechanical energy, and a hydroelectric generator converts this mechanical energy into electricity. The operation of the generator can based on the Faraday principles that when a magnet is moved past a conductor, it causes electricity to flow. In a large generator, electromagnets are made by circulating direct current through loops of wire wound around stacks of magnetic steel laminations. These field poles are mounted on the perimeter of the rotor. The rotor, which is attached to the turbine shaft, rotates at a fixed speed. When the rotor turns, it causes the field poles (the electromagnets) to move past the conductors mounted in the stator. This, in turn, causes electricity to flow and a voltage to develop at the output terminals of the generator.
The display unit 140 can also be referred to herein as a second unit, a second portion, a display assembly unit or the like. The display unit 140 can include a visual and/or audio display assembly 230 , which can include the LCD panel 160 and the speaker 164 , a printed circuit board assembly 240 , and a rechargeable battery 250 , which can be a rechargeable 3.7 Volt lithium ion battery.
The printed circuit board assembly 240 can have, for example, a capacitor, a circuit test button, a plurality of LEDs, a resister, an IR receive sensor, a DC-to-DC regulator, at least one battery charging control chip and a PIN slot connector.
The hydroelectric power generator 210 can generate three-phase AC by water flowing in the water path and the display unit 140 can include circuits that rectify, filter and stabilize the AC to 5V DC.
The display unit 140 can include the battery 250 , a battery charge control circuit and a bridge rectifier 254 (e.g., FIG. 31A ) between the power unit and the battery charge control circuit 256 (see FIG. 21 ). And the display assembly 230 can include an audio circuit and an LED display circuit. FIG. 21 shows the power unit 130 in the upper dotted line box and the display unit 140 in the lower dotted line box.
The printed circuit board assembly 240 can control the operation of the display assembly 230 . And the battery 250 can power the display assembly 230 . Wires 270 can pass through the ball-and-socket joint 150 and deliver AC to the printed circuit board assembly 240 , which converts it to DC, which is sent to the battery 250 to recharge it. Wires 270 from the temperature sensor 220 can similarly pass through the ball-and-socket joint 150 to the printed circuit board assembly (PCBA) 240 to communicate water temperature information, such as by voltage changes, to the assembly for controlling the shower session of the display assembly 230 . The temperature sensor 220 and the wires 270 can be seen in FIGS. 10 and 11 , for example.
The three wires 270 shown for the thermistor 220 can be power, ground and data wires. The thermistor 220 can have different resistance values in different water temperatures. The resistance values can be transferred to the MCU (microcontroller unit) 274 (on/of the PCBA), and the MCU will have different actions according to the different resistance values.
The display assembly 230 (and the remote control) can be powered by the battery 250 , which is recharged by the hydroelectric power generator 210 in the power unit 130 and powered by water flowing in the flow path. Wires 270 ( FIG. 10 , for example) from the power generator 210 can transmit the AC current to the display unit 140 where it is converted by the controller to DC current, which recharges the battery 250 . When the controller detects incoming electricity from the power generator 210 it knows that the water to the power unit 130 has been turned on and that it can start the shower session. Similarly, when the controller then detects no incoming electricity it knows that the water has been turned off and thus it can end the shower session.
Details of the components and the construction of the power unit 130 are shown in the exploded perspective views of FIGS. 6, 7 and 8 and the cross-sectional view of FIG. 9 . Referring thereto the two halves of the housing are illustrated, namely the top cover 280 with the nipple and the bottom cover 290 with nipple. Each housing cover 280 , 290 can have a respective half of the socket portion 294 , 298 of the ball-and-socket joint, as can be seen in FIG. 8 ; and FIG. 9 shows them mated with the covers assembled.
The covers 280 , 290 can be mated and held together with nuts 300 , receptacles 304 in the covers and screws 308 . Rubber plugs 320 can cover the screw ends, preventing water intrusion, but still allowing the power unit to be disassembled. The hydroelectric power generator 210 can include, as an example, a first o-ring 340 , a power inner housing 350 , a dynamo 360 , an impeller 370 , a power inner cover 380 and a second o-ring 390 , as shown in FIG. 6 .
Similarly, details of the components and construction of the display unit 140 are shown in the exploded perspective view of FIGS. 15, 16 and 17 and the cross-sectional view of FIG. 18 . The housing can include a display top cover 400 and a display bottom cover 410 , both of which include opposing halves of the ball 420 , 430 of the ball-and-socket joint. When the top and bottom covers 400 , 410 are assembled together the ball halves mate and the pegs 440 of the upper ball half fit into the openings 444 in the lower ball half.
Referring to FIGS. 15-18 , the display covers 400 , 410 can be mated and held together using receptacles in the covers and screws 444 . Rubber plugs 450 can cover the screw ends, preventing water intrusion, but still allowing the power unit to be disassembled. Inside the housing can be the LCD display 460 , the display inside housing 480 , the display seal 490 , the display o-ring 500 , the printed circuit board assembly 240 , and the battery 250 . On the side of the display bottom cover (or the bottom edge) can be a display button (mute button) 530 and a USB port 540 having a cover.
The display assembly 230 can include (for the LCD) three (or two) green LED lights 550 , three (or two) yellow LED lights 560 and three (or two) red LED lights 570 , and their operation can be controlled by the micro-controller 275 of the printed circuit board assembly 240 . Referring for example to FIG. 14 , one or two green lights can illuminate the word “Shower” 580 and a “bubbles” symbol 590 , and one green light can illuminate a Smiley face 600 in the color bar. One or two yellow lights can illuminate the word “Rinse” 610 and a “water drop” symbol 620 , and one yellow light can illuminate a Clock or stop watch symbol 630 in the color bar. One or two red lights can illuminate the “Stop” 640 and hand symbol 650 , and one red light can illuminate a Sad Face symbol 660 in the color bar. (The LEDs are illustrated, for example in FIGS. 26, 30, 31, and 34 .) FIG. 14 also illustrates the speaker opening for the audio sounds/signals.
The operation of the display assembly 230 for an exemplary shower session of the present disclosure can be understood with reference to the flow charts 670 and 680 of FIGS. 19 and 20 . A user turns the water on and water flows through the hydroelectric power generator 210 , causing electricity to be generated and transmitted to the printed circuit board assembly 240 , which awakens the circuit. The buzzer 690 plays back three beeps. (The buzzer ( FIGS. 21 and 27 ) in addition to emitting a buzzing sound, can be a speaker capable of emitting a variety of sounds including voice messages, as discussed herein.) The temperature sensor 220 is sensing the temperature of water flowing in the water flow path and sending corresponding signals to the PCBA 240 . The signals can be corresponding voltages and the sensor 220 can be a thermistor, as mentioned previously. The PCBA 240 can continually check the temperature or check it periodically, such as every sixty seconds. (See flow charts 670 and 680 .)
The thermistor 220 has different resistance values in different water temperatures, and the display unit 140 can include a microcontroller and the display assembly 230 . The different resistance values when actuated cause the microcontroller/MCU 274 to instruct the display assembly 230 to take different actions.
When the PCBA 240 receives a signal (from the thermistor 220 and via a wire) indicating that the shower water has reached a predetermined temperature, the timer in the PCBA starts the shower session. It can start it by causing the buzzer 690 to beep three times and the green LEDs to be illuminated. After the passage of a first time interval, representing the “shower” stage, the green LED lights are turned off and the yellow LED lights are illuminated. The first time interval can be programmable by the user/customer as discussed herein.
Turning the yellow LED lights on represents the start of the “rinse” stage of the shower session, which lasts for a second time interval. The second time interval can be programmable by the user as discussed herein.
After the passage of the second time interval, the first phase of the “stop” stage begins with the illumination of the red LED lights and the buzzer beeping three times. The first phase can last for a third time interval, and can also be programmable by the user.
As examples, the shower stage can last between five and seven minutes and the rinse stage can last between forty-five seconds and ninety seconds. And the first phase of the stop stage can last between forty-five seconds and ninety seconds.
After the passage of the third time interval, the second phase of the stop stage starts and it lasts until the water is turned off. During the second phase, the red LED lights can flash on and off and the buzzer can beep once each second. It can be a more urgent audio and/or visual display than that of the first phase, and also a more annoying one, e.g., more frequent, louder and/or shriller. Turning the water off causes the water switch to turn off, and after thirty seconds, for example, the apparatus 100 goes into a sleep mode. The sleep mode can be understood, for example, from the operating logic diagram of FIG. 20 .
As an example, the factory settings for the time periods can be six minutes for the shower stage, one minute for the rinse stage and one minute for the first phase of the stop stage, and three minutes to avoid the alert stage.
The grace period (first phase) can be approximately one minute and the audio stop display can be a continuous beeping sound or repeating message. The shower session can include a delay of three (or more) minutes prior to commencement of a second shower session.
In other words, the display unit 140 can play pre-recorded audio messages at specified time intervals like those discussed below.
First sound notation: Chime, Chime! Audible notation when the water temperature reaches pre-determined shower temperature (e.g., ninety degrees), thereby alerting the user that the water is now warm enough to shower, and thus preventing minutes, and gallons of hot water from going down the drain. (This event also starts the lighting sequence on the display unit 140 , accompanied by the Green Light, and illumination of the Smiley face 600 .) (See FIG. 14 .)
Second sound notation: When the allotted showering time (shower stage) has been reached an audible chime is played to remind the user that his shower (soaping) time is up, and to transition to a Rinse cycle, accompanied by a Yellow Light and a Stop Watch image or water drops 620 on the color bar. (See FIG. 14 .)
Third sound notation: When the allotted “Rinse” time allocation has been reached, there is a third sound notation accompanied by a red light, and an Open Palm image 650 on the color bar. (See FIG. 14 .)
Fourth sound notation: When the allotted time to “stop showering” has been reached, signaling the individual to exit the shower, a Red light, Frowning Face 660 appear on the color bar. (See FIG. 14 .)
Fifth sound notation: Should the user fail to turn the water off after being notified to “stop”: a continual “chime, chime, chime” sounds as the Open Palm image 650 ( FIG. 14 ) blinks on and off. This blinking and chiming continue until the water is turned off.
The apparatus can also have an “alert” mode, which can be considered as part of the shower session or as an adjunct thereto. The alert mode discourages users from short cutting the shower session by turning the water off before the start of the first phase (or alternatively the second phase) of the Stop Stage and then quickly (before the passage of a relatively short predetermined time period) turning the water back on, and thereby avoiding the (annoying) second phase (or the first and second phases) of the Stop Stage.
As an example of the alert mode if the user turns the water off before the Stop Stage of the shower session and then turns the water back on before a predetermined time period (such as three minutes or between two and fifteen minutes) has passed, the display assembly 230 emits an audio and/or visual alert such as beeping sounds accompanied by blinking lights. Another example can be blinking lights accompanied by a voice message from the speaker/buzzer, such as “please exit the shower,” “allotted shower time has been exceeded; please exit” or something similar. In other words, the alert “session” discourages a user from obtaining a long shower time by avoiding the full shower session, that is, by avoiding the annoying audio/visual signals of the stop stage.
In other words, should a person turn the water off, during for example the rinse stage, the timer continues normally, per programming instructions. The apparatus “carries on” with its orders and timing sequence. During Stop Supreme (the alert mode) the idea is to make annoying lights and sounds which last until the user turns the shower water off. Once the water is turned off, there is a program, such as a three-minute program, that runs internally. Should the water be turned back on, during that program, the Stop Supreme alert mode starts all over again, and the three minutes gets re-set back to the top.
Electricity being delivered to the controller from the hydroelectric power generator 210 signals that water is flowing in the water flow path, and electricity not being delivered to the controller signals that water is not flowing in the water flow path.
The apparatus can be sold or otherwise made available to the user with a predetermined temperature and the shower session fixed, or with the predetermined temperature and/or shower session customizable by the user. One way of customizing is to use a remote control unit ( FIGS. 31B and 33 ) 710 that operatively connects to the controller via an IR sensor 730 . Referring for example to FIGS. 31A and 31B , the display unit 140 can include an infrared sensor 730 that is configured to receive signals from the remote control. The remote control 710 can allow a user to re-program the controller or PCBA to change the volume, duration and/or sound of the audio signals, to change the times of at least one of the stages of a shower session of the apparatus and/or to change the water temperature setting of the start of the shower session. And referring again to FIGS. 31A, 31B and 32 , the remote control 710 can have an LCD panel 734 , a first button 740 for adjusting the volume of an audible display, a second button 760 for adjusting the length of a shower stage of the session, a third button 780 for adjusting the length of a rinse stage of the session, a fourth button 820 for adjusting the length of a stop stage (or a first phase of the stop stage) of the session, and a fifth button 840 for mute.
In other words, the infrared sensor 730 allows for easy re-programming without having to remove the apparatus 100 from the shower pipe 110 (see FIG. 1 ). The remote control 710 can be used to re-program: the volume (or the buzzer/speaker) to make it louder or softer; the time to make the shower session stages (e.g., shower, rinse) longer or shorter; and the (thermistor) temperature to raise or lower the temperature start setting.
Another way to customize/reprogram the operation of the display assembly 230 can be to plug one end of a cord into the USB port 540 of the display unit and the other end connected to a computer. With the computer accessing a website 850 (see FIG. 35 ) of this disclosure and synched with the controller, the user chooses by clicking on the appropriate areas on the page on the computer monitor the desired water shower temperature, the lengths of the wash, rinse and stop (first phase) stages, the audio selections for each of the stages, and/of the blinking and/or beeping rates for the alert session or mode.
More particularly, with the computer accessing the website and synched up to the apparatus 100 and its internal controller, the user can re-program the factory settings of the controller. The apparatus 100 can be synched up via the USB port 540 on the display unit 140 . Thereby, the user can program the desired starting temperature, the duration of the shower stage, the duration of the rinse stage, and the duration of the stop “grace” period phase. Using the computer/device interface 850 , the user can also select and re-program the factory set audio alerts, selecting from a list of sound effects and volumes. These sound effects and/or voice recordings can be used to alert the user that the shower temperature has been reached, the shower time is up, transition to rinse stage, the rinse time is up transition to the stop stage, and/or the grace period is over, turn the water off and exit the shower.
Again, personalized sound can be created and installed into the apparatus 100 via a personal computer and the USB port 540 . Virtually any audio message can be created on the computer and transferred to the apparatus 100 . Beeps, alarms, sirens, dogs barking, drums, musical cues, and even “record your own message” statements can be recorded via the personal computer via granted access to company website. Once customized and personalized on the website 850 , the audio message can be transferred from the computer into the apparatus 100 , via the USB port 540 . It thereby resembles a personal app for the shower. For example, the apparatus can be able to tell the user's child in the user's own voice, such as “Henry, your sister's waiting, get out of the shower!!”
With reference to FIG. 35 , for example, further descriptions of the PC interface 850 to personalize the apparatus follow.
A. Customer Programs the Time:
1. Customer attaches a USB cable to a port 540 in the apparatus 100 and attaches the other end of his cable to his computer.
2. Computer talks with the apparatus 100 and takes guest/customer to Company (e.g., WaterSmartTechnology) websites: Program “iMShowerSmart”
3. Program syncs with the computer.
4. Customer clicks and increases or decreases temperature(s) to the desired temperature(s) 870 .
5. Customer increases or decreases minutes for Shower (stage), by touching + or − icon 880 .
6. Customer increases or decreases seconds for Shower, by touching + or − icon 890 .
7. Customer increases or decreases minutes for Rinse (stage), by touching + or − icon 900 .
8. Customer increases or decreases seconds for Rinse, by touching + or − icon 910 .
9. Customer increases or decreases minutes for Shower (stage), by touching + or − icon 920 .
10. Customer increases or decreases seconds for Shower, by touching + or − icon 930 .
B. Customer Programs the Sound:
1. Customer selects sound effects, by highlighting the selection, pressing the play button to hear it, and if desired hitting the Import Sound tab 950 to import that sound effect into Audio Alert #1 then pressing the SET button.
2. Customer selects sound effects, by highlighting the selection, pressing the play button 960 to hear it, and if desired hitting the Import Sound tab 970 to import that sound effect into Audio Alert #2, then pressing the SET button.
3. Customer selects sound effects, by highlighting the selection, pressing the play button 960 to hear it, and if desired hitting the Import Sound tab 980 to import that sound effect into Audio Alert #3, then pressing the SET button.
4. Customer selects sound effects, by highlighting the selection, pressing the play button to hear it, and if desired hitting the Import Sound tab to import that sound effect into Audio Alert #4, then pressing the SET button.
Once all of the pre-sets have been loaded, the customer presses the OK button 990 and the data/programming is transferred to the computer program.
When the water reaches a pre-determined temperature it signals the audio deck, which can play the audio message selected. “Shower temperature has been reached” or whatever is chosen. Many people forget the shower is running, or wait long past its ready stage. There is a reminder, a nudge, pursuant to an aspect of this apparatus, such as “Hello! Shower's ready!” Thereby millions of gallons of hot water that otherwise would go directly down the drain can be saved.
An anti-theft chain (not shown) can also be added, to chain the apparatus 100 to the water supply pipe 110 (for example), thereby preventing theft of the apparatus such as when the apparatus is being used in public, non-residential locations.
Thus, the apparatus 100 can have one or more of the following advantages: shorten shower times; save energy; save water; slash carbon; extend the life of the boiler or water heater; reduce energy and extend the life of sewer systems and pumping equipment; reduce “water wars” among family members waiting for the shower; create general environmental awareness; create “shower courtesy” amongst people who share a shower stall; prompt users when the shower temperature is reached; and be a change agent, inspiring general conservation and environmental responsibility.
Accordingly, features of the present disclosure can include: built-in water generator to generate power to charge the battery of inside and supply to product; built-in temperature sensor to detect the water temperature; resettable buzzer volume by button and remote controller; resettable shower mode, rinse mode and stop mode time by remote controller; resettable initialization temperature setting by remote controller; rechargeable battery from micro USB from PC or most power and mobile power adapters; ten meter long range remote control; three colors LEDs for three types mode; easy install and uninstall; all settings (except buzzer volume resettable by remote and button) can use remote controller; and easy for the administrator to control and manage.
Exemplary specifications of the apparatus 100 can include Micro USB 5V 500MA Input voltage; 1050 mA/h polymer battery 350 ; a 3-phase motor; and 22 cm×7 cm×8.5 cm dimensions.
A battery voltage checking and charging capability can be included. For example, once the MUC (the controller of the PCBA) receives the Motor off trigger, the MCU checks the battery voltage. If the battery voltage ≧3.4V, the MCU goes into Stop Status. If the battery voltage <3.4V, LED4 flashes twice per second and there will be alert voice two seconds per thirty seconds, and this can last ten hours to alert the consumer to charge the battery. When the apparatus is charging from the USB port, the LED4 can be on during the charge and LED6 (e.g., FIG. 33 ) can be on once the charging is completed.
FIG. 21 is a circuit block diagram shown generally at 990 of the apparatus. FIG. 22 shows generally at 1000 the Dynamo motor power generation by water flow, namely three-phase AC is generated by the water flowing through the dynamo motor 210 is rectified, filtered and then stabilized to 5V DC by the DC To DC LDO. FIG. 23 shows generally at 1010 the battery charge control where power from the USB (Micro USB connector) 540 and the DC 5V rectifier (dynamo motor, see FIG. 22 ) are sent through that circuit that manages the charge cycle for the battery 250 . FIG. 24 shows generally at 1020 a battery protection circuit that protects the battery 250 from charge and discharge shorts and over current protection. FIG. 25 shows generally at 1030 the voltage transformer wherein voltage from the battery 250 is transformed to 2.8V to supply the MCU, LEDs, audio function and IR receiver.
FIG. 26 shows generally at 1040 the processor, which is the main MCU that stores logic for controlling timing function, LED display, audio output, audio volume control, IR input, temperature detection and battery voltage detection and warning. FIG. 27 shows generally at 1050 the audio amplifier and buzzer for providing the user with audio feedback. FIG. 28 shows generally at 1054 the IR sensor to interface with the IR remote for adjusting operating parameters such as time and audio volume. FIG. 29 shows generally at 1060 the sensor for detecting the temperature of water flow. FIG. 30 shows generally at 1070 the LED inductor and the LED display that provides the user with visual feedback.
FIG. 36 is a top perspective view of a top portion 1100 of a packaging insert for the apparatus 100 . FIG. 37 is a bottom perspective view of the top portion 1100 of the packaging insert. And FIG. 38 is a top perspective view of a bottom portion 1300 of the packaging insert and showing the apparatus 100 fitted therein. The insert 1100 , 1300 can be made from recycled paper and cardboard for sturdiness, and it can be form fitted to hold and protect the apparatus 100 .
Thus, the apparatus 100 herein can include one or more of the following features: built-in dynamo generator to generate power from the water flow to the power unit; built-in temperature sensor to detect water temperature; user-programmable initialization temperature setting by remote controller; user programmable buzzer (via button or IR remote); user-programmable shower timer (rinse mode and stop mode times programmable by remote controller); rechargeable battery with auxiliary USB power input; IR remote with ten meter long range remote control, three color LEDs with three types of modes; and configuration/construction for easy installation and removal.
Further, some of the novel aspects of the apparatus 100 are: (1) Any audio (up to seven seconds worth, for example) can be downloaded and played back at pre-determined time intervals. Even the user's own voice (or that of family members, friends or even celebrities) can be downloaded and used. (2) The apparatus can be water activated and automatically started when the water flows into it. (3) The volume can be increased or decreased via a remote control or via a computer. (4) The time lengths for the Shower: Rinse: Stop stages can be changed (by the user) via remote control or a computer. (5) Once a pre-determined shower temperature has been reached a temperature sensor initiates the timing sequences. (6) Sound effects, voice recordings, time allotments, temperature start settings can be downloaded via a USB cable and/or from a personal computer to the computer program. (7) No (additional or replacement) batteries are needed since the apparatus is powered by a water flow/mini-hydro electric power plant. (8) The shower display screen is position-adjustable via a ball and socket. (9) The shower timer is water-powered, uses red-yellow-green lights and endless sound effects and is operatively positionable between the water supply line and the shower head.
The apparatus 100 thus shortens shower time, thereby saving money, water and energy while cutting CO2 emissions. It increases water and energy conservation habits in people of all ages. It can cut heating and sewer fees and shower times by three to five minutes thereby saving five to ten gallons of water per shower.
The foregoing description of exemplary aspects of the present teachings has been provided for purposes of illustration and description. Individual elements or features of a particular aspect of the present teachings are generally not limited to that particular aspect, but, where applicable, are interchangeable and can be used in other aspects, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the present teachings, and all such modifications are intended to be included within the scope of the present teachings. The present disclosure further includes sub-assemblies (such as the display unit itself and/or the power unit itself and/or the remote control unit itself), as well as methods of using and/or making and/or assembling and/or programming the apparatus and/or components thereof. | A shower flow monitoring and display apparatus that is adapted to be installed inline between a shower arm and head. The apparatus provides different forms of feedback to the user to encourage water conservation. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of United Kingdom Patent Application No. 0714471.0, filed on Jul. 25, 2007, which hereby is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to an electronics module for a well installation, and a method of loading software and/or data to such a module.
BACKGROUND OF THE INVENTION
[0003] The control of a subsea fluid extraction well is normally effected by a subsea electronic control module (SEM) housed within, or located close to, a subsea control module (SCM) mounted on a well tree, situated on the sea bed at the well head. The SEM is provided with electric power and communications via an umbilical line to a control platform, which may be on a vessel or located on land. Typically, the SEM receives commands via the umbilical communication line to its internal electronics. These are then processed by the SEM, and the resulting electrical outputs are sent to electrically-operated production fluid control valves and/or directional control valves (DCVs) housed in the SCM, which control hydraulic power to hydraulically-operated valves. The SEM also feeds data relating to such operations back to the control platform. Additionally, the SEM electronics handles many other functions, which include the collection and interpretation of data from sensors distributed throughout the production system, such as pressure, temperature, fluid flow, microseismic, oil/water quality and, on more recent systems, compressed video and transmits them back to the control platform. The SEM also houses the electronics required to operate a High Integrity Pipeline Protection System (HIPPS) and the electronics for the communication system, such as modems and routers, or in more modern systems, Ethernet interfaces, as well as communication redundancy.
[0004] FIG. 1 shows a block diagram of a typical existing SEM. A modem 1 effects external communication, e.g. to the control platform, through an interface A. The modem 1 communicates internally to an SEM processing means 2 , which implements commands from the control platform in the form of outputs to driver circuits 3 . These in turn output a multiplicity of drives to external devices such as DCVs through interfaces B. External inputs from a multiplicity of interfaces C connect to signal conditioning electronic circuits 4 . These external inputs include for example signals from the SCM such as monitoring functions, e.g. pressure and temperature measurements, positions of valves etc which can have a variety of electrical interfaces. The circuits 4 convert these electrical inputs into a suitable interface for processing means 2 . The processing means 2 then processes the inputs and either effects control of the well via the interfaces B and/or outputs data via the modem 1 back to the control platform through the interface A. For the processing means 2 to operate, it is necessary to load data and software to it. This is carried out during factory testing and installation, and is achieved relatively slowly via the modem 1 through the interface A.
[0005] Typically, modern SEMs employ processors/microcontrollers to implement the functions described above which has resulted in very large software packages and data having to be loaded in. It takes typically seven hours to load the software/data on a current SEM, via its communication modem, due to the relatively slow speed of the modem. This has a major effect on both testing times and cost. Furthermore, the costs involved in having to take this length of time on the installation vessel at the point of installation are highly significant. One possible solution to this problem could be to add a high-speed data link to the SEM, but this would mean that an additional connector has to be added to the SCM electronic interface plate. However, with the prevailing trend to provide smaller and lighter well control systems containing SCMs, the surface area of the SCM connector end plate has become minimal and there is typically not enough room to add another connector. Furthermore, such a connector may be an expensive device.
SUMMARY OF THE INVENTION
[0006] It is an aim of the present invention to overcome these problems, namely to provide a system which enables rapid loading of software or data to a SEM, without requiring an additional connector.
[0007] This aim is achieved by incorporating a short range, high frequency, wireless transceiver, such as Bluetooth (RTM), to the internal electronics of a SEM. The existing wires connecting to the internal modem may be utilised as an antenna, and software/data loaded via this link. Thus no additional connector is required at the SCM end plate and if the carrier frequency of the transceiver is in the GHz region and thus wide band, data and software can be loaded rapidly. Since the electronics of the SEM, including the transceiver, is housed in a metal-screened container, spurious radiation from the transceiver is contained. The current cost of small transceivers such as Bluetooth (RTM) are insignificant compared with the costs involved with the long software/data loading times of existing systems.
[0008] Using the invention, the extensive quantity of software and data required by the processor in a modern SEM can be loaded in a fraction of the time that it takes to load via the normal modem interface, thus making major savings in time and cost in both the manufacturing and test of the product and its installation.
[0009] In accordance with a first aspect of the present invention there is provided an electronics module for a well installation as set out in the accompanying claims.
[0010] In accordance with a second aspect of the present invention there is provided a method for loading software and/or data to an electronics module for a well installation as set out in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:—
[0012] FIG. 1 schematically shows a known SEM arrangement; and
[0013] FIG. 2 schematically shows a SEM and loading means in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 2 schematically shows an SEM in accordance with the invention, together with means for loading software and/or data to the SEM. Components in common with the known SEM shown in FIG. 1 retain the same reference numerals. A transceiver 5 is located within the SEM, and connected to a port on the processing means 2 for communication therewith. The transceiver 5 has an RF input/output coupled, for example capacitively, to the existing modem external interface A. The modem interface A wiring functions as an antenna or aerial for the transceiver 5 in use. Firmware is stored in the processing means 2 , typically in ROM, at manufacture. This enables communication between the transceiver 5 and the processing means 2 .
[0015] In order to load the required software and/or data to processing means 2 , an external processor 7 is used, which is connected to a wireless transceiver 6 . The processor 7 may for example be a laptop computer, which carries the software/data required by the SEM. Transceiver 6 includes an antenna 8 to effect wireless communication with transceiver 5 via the wiring of modem interface A. In this way, data and/or software can be transmitted at high speed through the wireless interface.
[0016] Although the efficiency, as an antenna, of the existing modem wiring is relatively poor, it is adequate to permit successful communication, since the antenna 8 of the external transceiver 6 can be placed very close to the interface A during loading.
[0017] In an alternative embodiment of the present invention, not shown, an external processor 7 that has wi-fi capability is employed, together with a wi-fi compatible transceiver 5 in the SEM. With this arrangement, the need for a separate transceiver 6 is eliminated.
[0018] The above-described embodiments are exemplary only, and various alternatives are possible within the scope of the claims.
[0019] Although Bluetooth (RTM) and wi-fi have been specifically mentioned, any other wireless communication systems and protocols may be used provided that they are capable of handling the necessary volume of data at the required rate for satisfactory operation of the electronics module.
[0020] It is envisaged that the present invention may either be used to effect loading of the software and/or data in the first instance, or may be used as a back-up arrangement to current methods if necessary. | An electronics module for a well installation comprises a wireless receiver for receiving data and/or software from an external source. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 611383,614 filed Sep. 16, 2010.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This invention relates to exterior wall systems, and particularly to exterior wall barriers constructed from non-wood products including laminated panels having cementitious-type outer layers and a treated paper product core.
[0004] 2. Prior Art
[0005] People seek a “green,” durable, visual, audio, personal privacy, safety and fire barrier at the perimeter of their real property, due to high density population in a restricted area, movement or noise from outside the perimeter and threat from fire, crime or trespass upon their real property. Current exterior barriers, such as fencing, do not simultaneously provide solutions for acoustical, visual, audio, privacy and safety concerns, provide a fire barrier, or provide a ‘green’ solution to diminishing forest resources. Additionally, conventional fencing is prone to pest damage and deterioration due to exposure to exterior such as moisture, thus requiring continual maintenance to maintain functional and aesthetic value. Moreover, there is no exterior wall product in the prior art which facilitates adding accessories to the basic product. The instant invention addresses all these concerns in one system, utilizing ecologically sustainable, durable, nonflammable, sound-deflecting and absorbing, pest and exposure resistant, recycled and/or recyclable materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an upper perspective view of a modular interlocking wall system according to the invention;
[0007] FIG. 2 is an exploded perspective view of the nodular interlocking wall system shown in FIG. 1 ;
[0008] FIG. 2A is a close-up perspective view of a portion of the wall of he modular interlocking wall system shown in FIG. 2 ;
[0009] FIG. 3 is a sectional view of the modular interlocking wall system shown in FIG. 4 taken along lines 3 - 3 thereof;
[0010] FIG. 4 is a front elevation view of the modular interlocking wall system shown in FIG. 1 ;
[0011] FIG. 5 is a sectional view of the modular interlocking wall system shown in FIG. 4 taken along lines 5 - 5 thereof;
[0012] FIG. 5A is a close-up elevation view of a portion of the modular interlocking wall system shown in FIG. 5 showing the bottom of the wall panel and the bottom rail;
[0013] FIG. 6 is an upper perspective view of another embodiment of the invention without a bottom rail; and
[0014] FIG. 7 is an upper perspective view of yet another embodiment of the invention with a bottom rail.
DETAILED DESCRIPTION OF THE INVENTION
[0015] A modular inter-locking exterior wall system according to the invention, indicated generally at 10 in FIG. 1 , comprises top and base panels 12 , 14 . With additional reference to FIG. 2 , each panel 12 , 14 is a sandwich-like composite of a treated paper product core 16 bonded on two sides with skins 18 of a cementitious-type board. The core is fabricated to form a series of triangular cells 20 similar to the cross-section of corrugated board, and is commonly referred to as having a honeycomb-like construction, or simply as a honeycomb. See FIG. 2A . The paper core material may be treated with phenolic resins to increase resistance to moisture and pests. The composite forms a light-weight, strong, rigid panel with excellent acoustic and thermal insulating properties. Optionally, fire retardant may be added to the core material to augment the fire resistant properties of the surrounding skins 18 and increase the fire retarding properties of the composite panel. Suitable core material for the panels is available from Tricel Honeycomb Corporation, located in Gurnee, Ill., A suitable cementitious-type of material for the panel skins is Greene-board™ wall paneling available from Southern Cross Building Products, 3461 High Ridge Road, Boynton Beach, Fla. 33426. A suitable environmentally friendly, non-toxic adhesive is Simalfa® water-based adhesive available from Alfa Adhesives, Inc., 15 Lincoln Street, Hawthorne, N.J. 07506. A suitable environmentally friendly stucco covering for the panels is Parex® stucco available from Parex USA, 4125 E. LaPalma Ave., Suite 250, Anaheim, Calif. 92807.
[0016] The sandwiched composite panel core 16 is slightly and uniformly smaller in length and width than the length and width of the cementitious skins 18 , thereby creating a groove 20 of uniform depth around the perimeters of each of the panels 12 , 14 as shown in FIG. 2 .
[0017] The vertical support posts 22 are composed of a shaped, extruded, drawn, welded or molded material having perpendicularly extending flanges 24 , as seen in FIGS. 2 , 3 , and 5 , of uniform dimension configured to form an “X” shaped cross-section (see FIG. 5 ). The vertical support post 22 is designed to have a portion 26 cemented vertically into the ground, whereby the remainder 28 of the vertical support post 22 stands above ground. See FIG. 1 . The vertical grooves 20 on the ends 30 of the panels 12 , 14 are each designed to accept the flanges 24 , allowing the panels 12 , 14 to be supported vertically by the support posts 22 . It will be appreciated by those of skill in the art that posts 22 may be constructed with flanges that form a “T” shaped cross-section, such as when the post will be used to support one end of a wall. See, e.g., FIGS. 6 and 7 .
[0018] A base rail support 32 comprises a shaped, extruded, welded or molded material designed to horizontally support the bottom horizontal side 34 of the panels 12 , 14 at or below ground level. The base rail support 32 includes upwardly opening groove 35 , slightly wider than the panel width, allowing the panels 12 , 14 to slide into and mate with base rail support 32 on the lower horizontal long side 32 of the panels 12 , 14 . The base rail support 32 has notches at both ends to accept the tang 24 of the vertical support post 22 .
[0019] The top rail support 38 comprises a shaped, extruded, welded or molded material designed to horizontally cap and support the top horizontal side 40 of either of panels 12 , 14 . Like the base rail support 32 , the top rail support 38 has a downwardly opening groove 42 , slightly wider than the panel width, allowing the top horizontal long side 40 of panels 12 , 14 to slide into and mate with the top rail support 38 . A top channel 44 runs the length of the top rail support on the top surface, and is intended to enable accessories to be attached to the wall system 10 . See FIG. 5B .
[0020] The mid rail support 46 may be configured to have an “X” shaped cross-section like vertical support posts 22 or may be a flat bar, but is designed to horizontally support and connect two adjacent panels 12 , 14 as a means of increasing the vertical height of the wall assembly. The mid rail support 46 rests on and mates horizontally atop panel 14 and, like the lower base rail support 32 , has notches 48 on both ends to accept flanges 24 of posts 22 .
[0021] FIG. 4 shows a side elevation view of an assembled version of the embodiment of the modular interlocking wall system shown in FIGS. 1 and 2 . FIG. 3 shows the posts 22 inserted into the side grooves of top panel 12 . FIG. 5 shows the mid rail 46 inserted into the bottom groove of top panel 12 thereby supporting top panel 12 and also inserted into the top groove of bottom panel 14 for rigidifying and securing bottom panel 14 . FIG. 5 also shows top rail 38 capping and reinforcing top panel 12 and bottom rail 32 supporting bottom panel 14 as discussed above.
[0022] FIG. 6 shows another embodiment of a modular interlocking wall system according to the invention including a single panel 14 , two vertical support posts 56 having a “T” shaped cross-section and a top rail 50 .
[0023] FIG. 7 shows still another embodiment of a modular interlocking wall system according to the invention similar to the embodiment shown in FIG. 6 and including a bottom rail 54 .
[0024] The invention, without the accessories, comprises at least three interlocking components: (1) the vertically-mounted, vertical support posts 22 , (2) one of the panels 12 , 14 , and (3) the top rail support 1 . In alternate embodiments the wall system may include both panels 12 , 14 , base rail support 32 , and mid rail support 46 . No mechanical fasteners are necessary. All components can be permanently affixed to one another utilizing exterior grade sealant adhesive (e.g., silicone adhesive). Two 5 vertical support posts 22 are necessary to support one panel 12 , 14 , one top rail support 1 . All exposed surfaces are coated in a base finished coat layer of exterior grade stucco or similar. Collectively the components create an exterior wall system or assembly. Optional additional elements that enhance the invention include drip irrigation, low voltage lighting, mounted flower box, bird feeder, table, seating, water fall, solar panel, and the like.
[0025] One advantage of the invention is in its simplicity and the inter-changeability of its component parts. The vertical support post 22 allows the honeycomb composite panels 12 , 14 to be mounted at four different points (the four tangs 24 of the X). The notch 20 around the panel's edge allows it to mate in any direction on all four sides. The mid rail support 46 is the same extrusion configuration as the vertical support post 22 , and the top and base rail supports 38 , 32 are similar with the difference that the top rail support 38 may have a top channel 44 for top-mounted accessories.
[0026] This device may be utilized anywhere that there is open space which can be partitioned or where it may be desirable to create a private area. It can be mounted on or into flat ground, a hillside, around a pool, or the front or backside of a building. Where there are height restrictions, the panels 12 , 14 have different heights, allowing the device to be erected to several heights as desired by selectively using panel 12 alone, panel 14 alone, or both panels 12 , 14 . The device has the general appearance of a sturdy concrete stucco wall, yet has the space saving horizontal footprint of a conventional fence, is easy to assemble, and is constructed of environmentally friendly components.
[0027] A modular inter-locking exterior wall system provides en exterior panelized wall system providing privacy to real property, with materials that have green-certified content and/or are recyclable. The invention is modular, designed to erect in a similar (but simpler) fashion to conventional fencing with the aesthetic perceptibility of a concrete stucco wall.
[0028] It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A modular interlocking exterior wall system comprises one or more laminated panels formed of a paper product core sandwiched between two cementitious skins, two vertical posts having laterally extending flanges which interlock in vertical grooves formed in the sides of the panels, and a top rail having a downwardly opening top groove which receives and reinforces the horizontal top edge of the top panel, wherein bottom portions of the posts are anchored below ground. An optional bottom rail has an upwardly opening groove for receiving and supporting the bottom edge of the bottom panel, and laterally extending flanges of an optional mid rail are received in top and bottom grooves, respectively, of bottom and top panels to interlock and reinforce the panels. |
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This is a division of application Ser. No. 08/279,635 filed Jul. 22, 1994, now U.S. Pat. No. 5,675,941, which is a continuation-in-part ("C.I.P.") of applications Ser. No. 08/012,986 filed Jan. 29, 1993, now U.S. Pat. No. 5,408,793 and Ser. No. 08/076,261 filed Jun. 11, 1993, now abandoned, Ser. No. 08/012,986 is in turn a continuation of Ser. No. 782,436 filed Oct. 25, 1991, now abandoned which is a divisional of 477,715 filed Feb. 9, 1990 (issued as U.S. Pat. No. 5,094,044) which is a divisional of Ser. No. 206,849 filed Jun. 15, 1988, now abandoned, a divisional of Ser. No. 559,911 filed Dec. 9, 1983 which issued a U.S. Pat. No. 4,776,145. Ser. No. 08/076,261 is a continuation of Ser. No. 07/797,904 filed Nov. 26, 1991, now abandoned, which is a continuation-in-part of Ser. No. 396,377 filed Aug. 21, 1989 (issued as U.S. Pat. No. 5,134,830) which is a C.I.P. of Ser. No. 915,269 filed Oct. 3, 1986 (issued as U.S. Pat. No. 4,879,859) which is a C.I.P. of Ser. No. 559,911 filed Dec. 9, 1983, now U.S. Pat. No. 4,776,145.
BACKGROUND OF THE INVENTION
This application represents a continuous evolution of the subject inventor's inventive technology relating to prestressed tanks or containment vessels. The field of the invention is containment structures and their construction which structures can be used to hold solid,liquids or gases. This invention is particularly useful in the construction of domed structures, utilizing a membrane and circumferential prestressing.
There has been a need for the improved construction of these types of structures as conventional construction has proven difficult and costly. Furthermore, these structures generally do not lend themselves to automation. For example, the current practice has been to construct roofs or domes of such tanks on scaffolding, shoring, framing or decking which is quite costly and time consuming, in contrast to the invention claimed herein where the roof is prefabricated and raised on a cushion of air.
Certain of these conventional structures have utilized prestressed concrete, reinforced concrete or steel tank construction, which are discussed below. Others have utilized Fiber Reinforced Plastic (FRP) and some have utilized inflated membranes.
Turning first to prestressed concrete tanks, their construction have typically utilized prestressing and shotcreting applied by methods set out in detail in U.S. Pat. Nos. 3,572,596; 4,302,978; 3,869,088; 3,504,474; 3,666,189; 3,892,367 and 3,666,190 issued to the subject inventor which are incorporated herein by reference. As set forth in these references, a floor, wall and roof structure is typically constructed out of concrete using conventional construction techniques. The wall is then prestressed circumferentially with wire or strand which is subsequently coated with shotcrete. The machinery used for this purpose is preferably automated, such as that set forth in the above patents. Shotcrete is applied to encase the prestressing and to prevent potential corrosion. As set out in more detail in these patents, and particularly U.S. Pat. No. 5,094,044, which is incorporated herein by reference, prestressing is beneficial in that concrete is not very good in tension but is excellent in compression. Accordingly, prestressing places a certain amount of compression on the concrete so that the tensile forces caused by the fluid inside the tank are countered not by the concrete, but by the compressive forces exerted on the concrete by the prestressing materials. Thus, if design considerations are met, the concrete is not subjected to the substantial tension forces which can cause cracks and subsequent leakage.
Major drawbacks of the above prestressed concrete tank structure are the need for expensive forming of the wall and roof and for substantial wall thickness to support the circumferential prestressing force which places the wall in compression. Furthermore, cracking and imperfections in the concrete structure can cause leakage. Also, conventional concrete tanks are generally not suitable for storage of certain corrosive liquids and petroleum products.
We now turn to tanks constructed using regular reinforcing. This second major category of concrete tanks typically utilize regular reinforcing (in contrast to prestressing), and no membrane. These tanks are inferior to the tanks utilizing circumferential prestressing because, while regular reinforcing makes the concrete walls stronger, it does not prevent the concrete from going into tension, making cracking and leakage an even greater possibility. Typically, reinforcing does not come into play until a load is imposed on the concrete is structure. It is intended to pick up the tension forces because, as previously explained, the concrete cannot withstand very much tension before cracking. Yet reinforcing does not perform this task very well because, unlike circumferential prestressing which preloads the concrete, there are no prestressing forces exerting on the concrete to compensate for the tension asserted by the loading. Moreover, as compared to prestressed concrete tanks, these reinforced concrete tanks require even more costly forming of wall and roof, and even greater wall thicknesses to minimize tensile stresses in the concrete, problems greatly eliminated with the subject invention.
Turning now to inflated membranes, such membranes, have been used for airport structures where the structure consists of the membrane itself. Inflated membranes have also been used to form concrete shells wherein a membrane is inflated and used as a support form. Shotcrete, with or without reinforcing, is sometimes placed over the membrane and the membrane is removed after the concrete is hardened. Another form of this construction is exemplified by conventional "Binishell" structures. Information regarding such structures is in the Disclosure Statement and in U.S. Pat. No. 3,462,521. These structures are constructed by placing metal springs, and regular reinforcing bars over an uninflated lower membrane. Concrete is then placed over the membrane and an upper membrane is placed over the concrete to prevent it from sliding to the bottom as the inflation progresses. The inner membrane is then inflated while the concrete is still soft. After the concrete has hardened, the membranes are typically removed. A major drawback of the afore-described conventional structures is the high cost connected with reinforcing and waterproofing them for liquid storage. Moreover, with regard to the "Binishell" structures, because of the almost unavoidable sliding of the concrete, it is difficult if not impossible to avoid honeycombing of the concrete and subsequent is leaks. Also Bini does not teach the utilization of membranes in conjunction with circumferential prestressing, in contrast to using mere reinforcing. As a result, these structures have not been very well received in the marketplace and have not, thus far, displaced the more popular and commercially successful steel, reinforced concrete and prestressed concrete tanks and containment vessels. Substantial improvements to these types of membrane structures are set out in U.S. Pat. Nos. 4,879,959; 5,134,830; 4,776,145; 5,094,044 issued to the subject inventor which are incorporated by reference, but which do not accomplish the advantages of the subject invention.
Another general category of existing tanks are those made of fiberglass. These fiberglass tanks have generally been small in diameter, for example, in contrast to the prestressed or steel tanks that can contain as many as 30 million gallons of fluid. The cylindrical walls are often filament-wound with glass rovings. To avoid strain corrosion, (a not very well understood condition wherein the resins and/or laminates fracture, disintegrate or otherwise weaken) the tension in fiberglass laminates is typically limited to 0.001 in/in (or 0.1%) strain by applicable building codes or standards and by recommended prudent construction techniques. For example, the American Water Works Association (AWWA) Standard for Thermosetting Fiberglass, Reinforced Plastic Tanks, Section 3.2.1.2 requires that "the allowable hoop strain of the tank wall shall not exceed 0.0010 in/in." A copy of this standard is provided in the concurrently filed Disclosure Statement. Adhering to this standard means, for example, that if the modulus of elasticity of the laminate is 1,000,000 psi, then the maximum design stress in tension should not exceed 1,000 psi (0.001×1,000,000). Consequently, large diameter fiberglass tanks have required substantially thicker walls than steel tanks. Considering that the cost of fiberglass tanks has been close to those of stainless steel, another common type of tank, and considering the above strain limitation, there are not believed to have been any viable large diameter fiberglass tanks built world-wide since fiberglass became available and entered the market some 35 years ago. Another reason why large fiberglass tanks have not been viable, is the difficulty of operating and constructing the tanks under field conditions, water tanks, for example are often built in deserts, mountaintops and away from the pristine and controlled conditions of the laboratory. Resins are commonly delivered with promoters and catalysts for a certain fixed temperature, normally room temperature. However, in the field, temperatures will vary substantially. Certainly, variations from 32° F. to 120° F. may be expected. These conditions mean that the percent of additives for promoting the resin and the percent of catalyst for the chemical reaction, which will vary widely under those temperature variations, need to be adjusted constantly for the existing air temperatures. Considering that these percentages are small compared to the volume of resin, accurate metering and mixing is required which presents a major hurdle to on-site construction of fiberglass tanks, The above problems have been remedied to a great extent by the teachings of the undersigned inventor's U.S. Pat. Nos. 4,879,856; 5,134,830; 4,884,747; 5,076,495 and 5,092,522 which are hereby incorporated by reference, and regarding which the subject patent represents a further evolution and improvement. There have also been problems with seismic anchoring of the above tanks, some of which have been solved by the techniques and apparatus disclosed in Mr. Dykman's U.S. Pat. Nos. 5,105,590 and 5,177,919, which are also hereby incorporated by reference.
SUMMARY OF INVENTION
In a first aspect of the present invention, a prestressed tank is disclosed, with the dome formed by first deploying or forming a membrane on a base, placing rigidifying material and/or prestressing or reinforcing on the membrane as needed, allowing the same to harden after it has been shaped in the form of a dome by the selective introduction of air between the floor and the membrane (forming in effect a preformed dome), constructing the walls of a tank upon the base and around said preformed dome, and then raising or floating the pre-formed dome on a cushion of air by the use of compressed air pumped under the membrane. After the dome is raised to a predetermined height, it. is then anchored to the walls of the tank.
In another aspect of the subject invention, these tanks, which can be constructed at relatively low cost and are suitable for most liquids in sizes to 50 million gallons (MG)--include an advanced hybrid construction of a prestressed concrete (PC) wall and dome design with a light-cured fiber reinforced plastic (FRP) lining (or membrane) covering the floor and the inside surface of the walls and dome. These tanks can also be constructed with a FRP-AL (aluminum) floating roof--with a prefabricated FRP dome--or with a reinforced concrete (RC) FRP-lined flat slab roof supported by FRP-RC columns.
In another embodiment, a separate dome or lid can be manufactured using this same process of forming a membrane, using air to shape the membrane into a dome, placing rigidifying material placed thereon and allowing the same to harden forming a composite structure.
In one aspect of the invention, the walls are a composition of fiber reinforced plastic, concrete, shotcrete, regular reinforcing steel and circumferential prestressing.
In another aspect of the invention an outer membrane is used to protect the above construction from the elements.
In yet another aspect of the invention exterior or interior insulation is used to compensate for large temperature gradients.
In another aspect of the present invention, seismic countermeasures or anchors are used to protect the contemplated structure against earthquakes and other tremors. To eliminate instability or possible rupture, the tank walls are anchored to the base through seismic cans. The cans are substantially oriented in a radial direction in relation to the center of the structure, permitting the seismic forces to be taken in share by the seismic anchors. The walls of the structure are free to move in or out in the radial direction allowing the structure to distort substantially into an oval shape thereby minimizing bending moments in the wall. Thus, when a seismic disturbance occurs, the force acting on the structure can be transmitted and distributed to the footing parallel to and around the circumference of the tank.
In another aspect of the present invention, a floating roof is used to minimize combustible vapor between the roof and the liquid which may be subject to explosion. Typical tanks of this type are gasoline and jet fuel tanks.
In yet another aspect of the invention, using more accurate analysis and construction means set forth by this invention, the thickness of the walls can be substantially reduced and more easily constructed. The automated means of construction recommended, the automated rotating tower apparatus and the floating roof concept can substantially facilitate construction and decrease the costs for a large variety of tanks for water, sewage, chemicals, petrochemicals and the like.
The invention described herein provides an excellent example of how combining the strengths of FRP and PC can be used to construct structures with increased usefulness, liquid tightness and corrosion resistance. Prestressed concrete excels in structural performance whereas FRP excels in liquid tightness and corrosion resistance. The combination enables one to build very large tanks for an almost unlimited range of liquids, faster and cheaper than heretofore possible. This development has been the culmination of 40 years of experience in tank design and construction covering some 2 billion gallons of storage and 8 years of intensive development work.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevation view of a circular domed roof composite structure, containment vessel or tank which forms part of the subject invention.
FIG. 2 shows a plan view of tank wall and wall-footing construction.
FIG. 3 shows a cross-section of the wall-floor-footing construction.
FIG. 4 shows a cross-section of the outer membrane and outer footing to which it is anchored.
FIG. 5 shows a typical wall section and partial view of the inside wall surface; also showing the seismic bars extended into the wall footing.
FIGS. 6A, 6B, and 6C show the dome in various stages of construction.
FIG. 6A shows the FRP floor membrane (100), which has been formed around the central column (118), with appropriate layers of rigidifying material laid thereon (135) before the setting of the same and before air has been introduced to shape it into the form of a dome.
FIG. 6B shows the membrane (100)/rigidifying material (135) composite structure after air has been used to shape it into a dome and after the rigidifying material has cured to create a preformed rigid roof. Air seals (106) between the roof (15) and the walls (104) are also shown to allow the dome to be raised or floated into its final position with air.
FIG. 6C shows the preformed dome roof (15) fastened in place near the top of the walls (104) after it was raised on a cushion of air and without the use of any scaffolding.
FIG. 7 shows a cross-section of a flat slab roof and column construction.
FIG. 8 shows a cross-section of a floating roof construction.
FIG. 9 shows a cross-section of wall and footing and a side view of the tank construction machinery required to build this new type of tank.
FIG. 10 shows the shear resistance pattern from the seismic anchors with the direction of seismic forces in the north-south direction.
FIG. 11 shows a typical tower which revolves around the periphery of the tank structure on wheels or similar means and which allows the prestressing, shotcreting, light curing and other machinery to be utilized to construct the tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an elevation of a dome-roofed tank of the type constructed utilizing the novel methods and materials disclosed herein. Simply, walls (104) are seen resting on a pad (10) and also serve to support roof (15). On the assumption that his is a liquid holding tank, the high liquid level is shown by dotted line (20).
FIGS. 2 shows a plan view on wall and walls footing. In FIG. 2, the walls (104) are cylindrical in nature and of FRP-PC construction. A monolithic FRP floor (100) or membrane is constructed on a one-inch thick cement mortar leveling pad (102) and partially on the wall footing (91). The floor (100) is made up of a liner or membrane formed, in the best mode, of four one-sixteenth inch thick layers of relatively flexible double-bias knit glass fabric impregnated with high elongation light curable vinyl ester resins which cover the entire floor area inside of the tank, the underside of the wall and portion of the wall footing. The floor membrane can also be made of other materials. Floor 100 is preferably placed on two layers of ten mil (10 mil) polyethylene sheeting which covers the concrete levelling pad (102) and wall-footing (91). This allows the walls to slide inwardly in a radial direction (such as when prestressing takes place or the liquid level changes) in a more efficient manner and prevents the FRP from sticking to the floor. The resins can be cured by conventional UV-light curing type lamps and by mechanisms as discussed in part in U.S. Pat. No. 5,094,044 to Mr. Dykmans which is incorporated herein by reference. The walls (generally shown by number 104) are likewise constructed with an inner liner (106) or membrane made up of four sheets of one-sixteenth inch thick double-biased knit fabric with high elongation-type light curable vinyl ester resins on the inside. A double seal is preferably made between the floor (100) and wall lining (106) by an approximately 18" wide splice lining (93) on the inside and (92) on the outside (covering the floor and the wall up to about 18")--again made from 4 layers of double-bias knit glass fabric impregnated with high elongation-type light curable vinyl ester. The inside corner of wall and floor is further strengthened with a FRP core of the same glass/vinyl/ester construction.
Turning now to the walls (104), as shown in FIG. 3, the floor lining (100), wall lining (106) and splice linings (93) form a combined membrane which is the inner layer of the tank. Outside this inner membrane--which lines the inside of the walls (106)--are layers of shotcrete, reinforcing steel and wrapping composite wall (104) (FIG. 3). Brochure 1293 entitled "Typical P.C. Machinery and Tanks" included in the Disclosure Statement and incorporated herein by reference shows the shotcreting in progress. More specifically shown in FIG. 51 this composite wall (104) consists of layers of shotcrete 104A, wrapped wire 104B and vertical reinforcing bars 104C. As also shown in FIG. 6C, the prestressed wrapping material (104B) used to prestress the walls (104) may initially be 5 mm diameter hot dipped galvanized high tensile wire. Other material which may be used is 5 mm (0.196") S-2 glass wire--wound on specially designed reels of 8 ft in diameter constructed to accommodate 65,000 feet of material per reel. Other types of prestressing, of course, can also be used.
We turn now to a description of prestressing machinery. That machinery--shown in FIG. 9 (commercially to be called the DYK 6)--consists of a motorized revolving tower (112) and a radial truss (114) which supports the radially rolling overhead carriage (122). A prototype of the DYK 6 machine may be seen in DYK-TECH's brochure 1293 entitled "Typical PC Machinery and Tanks" included in the Disclosure Statement and incorporated herein by reference. Radial truss (114) is connected on one side to revolving tower (112) and on the other side to a swivel (116) in the center of the tank which is supported by a cylindrical center tower (118) bolted to a 10 ft or larger diameter reinforced concrete slab (120). Carriage (122) moves in or out radially on the truss and is controlled electronically. Attached to the outside of this carriage (122) are extendible vertical posts (124 and 126)--driven up or down by electric motors--which are electronically controlled for their up or down movements. The swivel (116) permits simultaneous conveyance of concrete, mortar, water and compressed air by placing, compacting and finishing apparatus mounted on posts (124) and (126). Mounted on top of rolling tower (112) is a diesel driven generator (113) to provide power for light curing and electric motors. Inside the rolling tower is a wire wrapping assembly (122A) (such as that shown in U.S. Pat. Nos. 3,572,596; 4,302,978; 3,504,474; 3,666,189; 3,892,367 and 3,666,190 and in the 2-page color brochure No. 1293 entitled "Typical PC Machinery and Tanks" included in the Disclosure Statement and which are incorporated herein by reference.) Outside the tower (112) is a nozzle assembly such as that shown in brochure No. 1293 above but not shown in FIG. 9, which are electronically controlled as to raising and lowering. The rolling tower is supported by hydraulic wheel motors, the rotation of which are also electronically controlled, which cause the tower to roll around the tank and used, for example, in shotcrete applications, wire wrapping, light curing and concrete placement of the roof.
Turning now to the foundation, as illustrated in FIG. 3, the construction of the tank starts with preparing the pad or foundation starting with a compacted subgrade--meeting freeway subgrade standards--followed by the construction of a concrete footing (91), concrete leveling pad (102); and, as illustrated in FIGS. 6A, 6B and 9, a thickened center concrete slab (120) 10 ft in diameter (or larger), to support the center tower (118), which in turn supports the radial truss (114) and carriage (122) used for performing operations on the roof. FIG. 4 illustrates a typical outer footing 91A, to which is anchored an outer inflated membrane 106A which is used to protect and shield the construction of the tank from the elements. See U.S. Pat. Nos. 4,884,747, 4,879,959 which are incorporated herein by reference and also describe such outer membrane.
We now describe construction of the FRP floor. As shown in FIGS. 3 and 6A, the completion of the foundation is followed by the installation of the 1/4" thick FRP floor (100) which, in the best mode, consists of 4 layers of light curable prepregs--reinforced with biaxial glass matt--which typically are delivered to the jobsite rolled up (carpet like) in a black polyethylene cover to prevent premature curing by daylight. While conventional FRP is cured by combining resins with promoters and catalysts, light cured resins are cured by UV (ultraviolet) rays available in sunlight and special conventional heatlamps such as used for skin tanning. These are then rolled out in continuous layers--for example, side by side in a North-South direction--with overlapping joints, and subsequent layers always retaining the top black polyethylene cover, until the next layer of prepregs is placed. The first layer of prepregs will have a black polyethylene cover on both sides to prevent, for example, the FRP from sticking to the concrete floor and footing and to facilitate the relatively small radial wall movements thereby tending to preserve the integrity of the wall-floor connection during; i.e., circumferential prestressing and fluctuating water depths. Upon completion of the rolling out of these "carpets", the prepregs are cut circumferentially to the desired radius followed by light curing. (See U.S. Pat. No. 5,094,044 issued to the subject inventor and application Ser. No. 08,076,261 filed Jun. 11, 1993 by the subject inventor, and information in the Disclosure Statement which are all incorporated herein by reference.) After the floor (100) of the tank has been light cured--generally within 24 hours--as shown in FIG. 6A, a second 1/4" thick FRP layer or membrane (134) will be constructed--and light cured--on top of the FRP floor lining 100. What will become the inside liner of the dome (15), is constructed in the same manner as the floor (100) which was detailed earlier.
We now discuss the installation of the prestressing machinery. As shown in FIG. 6A, a center hole--somewhat larger than the outside diameter of the round center tower support 118--is then cut out of the two FRP linings (for both the floor (100) and the dome (15)) after which the center tower (118)--which supports the swivel (116)--is erected and bolted down to the 10 ft diameter reinforced concrete tower support slab (120), followed by the raising of the external rolling tower (112) which revolves on a circular pathway outside of what will be the walls. This is also shown in FIG. 11 and disclosed in U.S. Pat. No. 3,572,596 issued to the subject inventor. Radial truss (114) is then installed spanning tower (112) and center tower (118). Installation of the remaining components of the prestressing (DYK 6) machinery then follows. Brochure 1293 entitled "Typical PC Machinery and Tanks" authored by Mr. Dykmans and attached to the Disclosure Statement shows the prototype of this DYK 6 machine.
Construction of the FRP-PC dome can now take place. Simultaneous with the erection of the prestressing (DYK 6) machinery, work proceeds on the installation of the dome reinforcing (136) (see FIG. 6C) and concrete (135) (see FIGS. 6A & 6B) upon the dome lining (134).
Upon completion of the installation of the reinforcing steel (135), the concrete (136) is placed upon the dome lining 134, vibrated and screened in one continuous process--aided by conventional screeds and vibrators attached to posts 124 (2 each) and 126 (2 each) positioned on either side of carriage (122) on the radial truss (114), on the revolving DYK 6 machine (see FIG. 9). Concrete placement is facilitated by the system's ability to pump concrete through the swivel (116) to the discharge point on one of the leading post (126) adjacent to the carriage (122). The other posts (124) and (126) can be used to facilitate vibrating, screening and floating of the concrete. A retarding agent can be added to the concrete to sufficiently delay the concrete "set-up" time--which is the starting point of the concrete hardening process to allow the "inflation" of the membrane to create the dome. The FRP liner, when cured is an inflatable or flexible membrane capable of stretching and inflation. The inflation of the membrane and concrete thereon (shown in FIG. 6B) is accomplished with compressed air introduced by conventional means (not shown) between the dome membrane (134) and floor membrane (100)--until the slab has become a substantially spherical dome shell of the desired rise (See FIG. 6B). The concrete will then be re-vibrated, screeded and floated with the aid of the revolving DYK 6 machinery shown in FIG. 9. (See FIG. 6B) Where necessary the periphery of the membrane may be thickened or weighed to hold the edges of the dome membrane down, whereas the center is free to move up during the inflation process, to arrive at the desired shape of the dome.
Once the dome membrane (100) and concrete composite (135) has been raised to the desired shape, the dome concrete is now permitted to harden into what may be called a pre-fab dome structure as shown in FIG. 6B. Whereas smaller domes may have sufficient reinforcing without the need for additional circumferential prestressing, larger domes will require circumferential prestressing of the dome ring which may be done, for example, with FRP tape wrapping (140, see FIG. 6B), wound wire, or other prestressing material before the wall construction is started.
We now turn to the embodiment in FIG. 7, depicting a flat slab roof supported by columns. As with the dome-shaped roof, the work will start by constructing the FRP membrane on the floor (explained previously)--followed by cutting the center hole--the erection of the center support tower (118) and then the assembly of the rest of the (DYK 6) prestressing machinery. During erection of the (DYK 6) prestressing machinery, 1" thick FRP column location pads (119) are glued to the FRP floor lining (100)--followed by the installation of FRP column-roof connector rings (121)--the erection of the FRP column tubings or sleeves (142)--the gluing of the re-bar support blocks (123) (which also serve as FRP anchors to the concrete)--the installation of the reinforcing steel (122), and the pouring, screeding, vibrating and finishing of the concrete with the DYK 6 prestressing machine. The FRP column tubings (142)--which can be furnished in any transportable length in diameters to 16", are then plumbed, braced and then filled with reinforcing steel and concrete. They will harden into rigid columns (119a)
The subject invention contemplates a variety of roofs including a floating roof as shown in FIG. 8. The construction procedure of these roofs is similar to the flat slab roof of FIG. 7. The floating roof would have a PRP lining (147) enclosing a light-weight core 150. A double spring-loaded Teflon-coated neoprene seal (148) is used to contain liquid emissions and rain water which will be drained off through flexible hoses connected between the discharge points on the roof and the drain pipes coming through the floor.
The invention also contemplates using prefabricated FRP roofs of the type illustrated schematically in FIG. 8. Roof 143 is shown in phantom. These roofs would be trucked in and installed after the wall has been completed.
After the floor and dome have been constructed, attention will be given to building the walls of the tank. In a preferred embodiment as shown in FIG. 1, rigid prefabricated FRP wall forms (30) are first constructed. Preferably, they are 8 ft wide by 40 to 50 ft long and are extendible for greater liquid heights and adjustable for the desired wall radius. These wall forms will then be erected and braced to anchors in the concrete dome or flat slab concrete roof while they are still on the floor. The 1/4" thick FRP wall membrane is constructed in a similar manner as the floor membrane except that the rolled-up "carpets" will be attached to the form at the top and rolled down to the footing. The wall membrane will then be light-cured in a spirally upward or downward motion around the tank with a bank of UV emitting lights--attached to the spray escalator on the DYK 6 machine.
Seismic anchors can be integrally constructed with the walls. Turning to FIG. 3 (and as also illustrated in the publication "the DYK 6 concept" provided with the Disclosure Statement), the connection utilizing seismic bars (154) does indeed reduce bending stresses in the wall as discussed earlier. These rectangular stainless steel bars (154) are solidly encased in the wall and are positioned in rectangular stainless steel cans (156) cast in the concrete footing. A close fit between the bars (154) and the radial walls of these cans (156) constrains these bars to be essentially prevented from moving circumferentially. (FIG. 10) On the other hand, there is ample room in these cans (156) to permit the bars (154) to slide freely in the radial direction inside these cans (156).
For example, let one assume that seismic forces, are acting in the North-South direction. (See FIG. 10) Each N-S force acting on these bars is essentially the resultant of 2 forces: one radial and one circumferential. The radial components are the ones typically creating the vertical bending moments in the wall, so the goal is to minimize these radial forces. This is accomplished by permitting the seismic bars (154) to move freely in the radial direction. That leaves the circumferential component to contend with. As shown in FIG. 10, the magnitude of these circumferential forces change with either the sine or the cosine of the angle between the radial direction of these cans and the N-S line or the E-W line. See U.S. Pat. Nos. 5,177,919 and 5,105,590 on the subject issued to the subject inventor and incorporated herein by reference. Thus, for a N-S seismic direction load--the maximum circumferential forces develop on the true East and West points gradually reducing to zero at the true North and South points. The sum of all the North-South components on these bars equal the seismic force acting on the tank.
We now turn to FIGS. 3 and 5, to analyze the wall construction upon completion of the FRP floor (100), vertical re-bar supports (105) (See FIG. 5) will be attached to the FRP lining (106) which can be shaped in a manner that they will also serve as mechanical anchors of the lining to the wall. This will, be followed by installation of multiple layers of vertical re-bars (104C), pneumatic mortar (104A) and wire wrapping (104B). (See FIG. 5) The pneumatic mortar application is a continuous process, accomplished by the (DYK 6 Machinery revolving around the perimeter of the structure similarly as shown in brochure 1293. The material is applied in a spiral motion--either going up or down by apparatus contained in the carriage 122 which for this purpose is raised and lowered on the outside of rolling tower 112. Mortar and compressed air is pumped by conventional means from the ready mix truck (also shown in brochure 1293) and compressor (not shown-adjacent the ready mix truck) through separate hose lines which are run, first under the floor and then come up through the circular center slab, up the central tower 118, through the swivel (116) (see FIG. 9)--then moving radially on radial truss 114 to the vertical tower (112) where they connect to the nozzle on the spray escalator 122B. In cold regions of Canada and Alaska or where necessary polyurethane insulation can be sprayed on the exterior wall surface to minimize the differential temperature effect. Likewise, a barrier of polyurethane insulation can be installed between the inside wall membrane and the wall composite when hot liquids will be stored inside the tank. Another way to overcome large temperature differentials would be to bury the tank in the ground.
Stripping of the wall forms can start before the wall construction has been completed after sufficient wall thickness has been built up to withstand wind pressures without the assistance of the form support.
After the walls have been constructed, the stage is set for raising of the dome--or flat roof--with compressed air to its final position. This will start immediately after the circular wall (104) has been completed. In a preferred embodiment, to avoid ripping of the roof, the air pressure will be kept somewhat below what is needed to raise the roof. The remainder force may be provided by a series of small winches placed at equal distances around the circumference of the roof and at each column. They will be regulated in a manner that the roof will be raised evenly in a controlled manner. In its final position, support brackets (152) (see FIG. 6C and 7) will be installed and a FRP closure connection (107) is made between the upper wall lining and the FRP inside roof lining. In one embodiment, the flat roof (105) (see FIG. 7) is further supported by stainless steel support plates (153)--resting on FRP seal plates on top of the columns--which are bolted to anchor bolts in the concrete slab of flat roof (105), around each column. Subsequently the air pressure is released.
A pre-fabricated FRP ventilator (not shown) may then be installed after the center tower (118) has been removed. At the same time the center hole in the floor is closed with a FRP plate adequately overlapping the floor while appropriate connections being made to accommodate protruding pipe.
FRP staircases or ladders can then be attached to the outside wall surface. Flanged pipe nipples for inside or outside pipe connections can be installed in the wall or dome. Whenever possible it would be better to install all supply, discharge, scour, overflow and redundant pipes (for possible future use) under the floor--entering the tank floor in pre-planned locations--preferably--where possible--in the center slab area of the tank.
In another preferred embodiment, the tank may be analyzed 3-dimensionally with a finite element program. In the structural analysis, the wall cylinder and the dome shell are considered a composite consisting of layers of concrete, steel and FRP as detailed in the right hand bottom corner of photos 1 to 16 of the Dyk 6 Concept color brochure filed with the Disclosure Statement. Each layer of this composite can be analyzed for the stresses and deformations developed in that layer which can be presented graphically and in color in the form of stress contours and deformation curves including pin pointed locations of the maximum and minimum stresses, which is depicted in preliminary form in the Dyk 6 Concept brochure.
The tank analysis may consider the following stress and deformation causing conditions--including buckling--for tank empty and tank full conditions:
1. prestressing during and after wrapping;
2. internal liquid loads--static and dynamic (seismic);
3. uniform and asymmetrical backfill pressures on the wall--static and dynamic;
4. snow and other roof live loads--static and dynamic;
5. wind loads on roof and wall--both pressure and suction;
6. differential summer temperatures--aggravated by differential sun temperatures;
7. differential winter temperatures.
Again, the referenced Dyk 6 Concept brochure (See Disclosure Statement), shows, in color, the maximum, shotcrete compression in the wall without consideration of temperature differential conditions in contrast when winter temperature and snow loads are taken into account. Note the difference in compression of 925 psi versus 1,345 psi. This brochure also shows the result of no summer differential temperature allowance. Compare the steel tension in the wall with that in photo 4 where summer differential temperature has been allowed. Note the difference in steel tension of 10,472 psi versus 20,881 psi. Summarizing the brochure, which because it is in color might be more informative than the drawings, photo 5 shows a compressive stress of 423 psi in the dome without summer temperature differentials whereas photo 6 shows a compressive stress of 1,345 psi when differential temperatures--sun included--are allowed for. Photo 7 shows a steel tension of 12,780 psi if no winter temperature differential has been allowed whereas photo 8 shows a steel tension of 21,760 psi when winter temperature differential and snow loads are allowed for. Photo 9 shows the wall buckling factor of 12.07 when no temperature differential has been allowed whereas photo 10 shows a buckling factor of 2.2. for summer differential temperature--sun included--has been allowed whereas photo 11 shows a buckling factor of 2.1 when winter differential temperature and snow load have been allowed. A buckling factor of 2 essentially means a safety factor of 2. Photo 12 shows the differential surface temperatures generated by the sun on dome and wall.
Also, for example with regard to seismic disturbances, the walls of the structure are free to move in or out in the radial direction allowing the structure to distort substantially into an oval shape thereby minimizing bending moments in the wall. This effect may be seen in photos 13, 14, 15 and 16 of the Dyk 6 Concept brochure. In photos 13 and 15, the "Base Restraint is Radial--Free and Circumferential-Locked." In photos 14 and 16, the "Base Restraint is Radial-Locked after full prestress and Circumferential-Locked." The difference in steel stress is 20405 psi in photo 13 and 34,224 psi in photo 14. The difference in shotcrete compression is 260 psi in photo 15 and 1,382 psi in photo 16. Thus, when a seismic disturbance occurs, the force acting on the structure can be designed to be transmitted and distributed to the footing parallel to and around the circumference of the tank.
A sun temperature--applied at right angles to the surface--can be assigned a certain value over and above the air temperature. A realistic figure would be 50 D.F. This assumption was used in the case of photo 12 in the Dyk 6 Concept brochure reference the yellow letters in the white border line area in the top left area of the photo. If the sun position to that surface is less than 90 degrees, one could use the sine value of the angle between the sun and the surface under consideration. The analysis of the tank takes into account the direction of the sun to the vertical line of tank revolution (see photo 12 upper middle area), the N-S-E-W coordinates and the relative angle of the sun to each wall, roof or floor element--whether the sun shines on the outside surface of covered tanks or on the inside and outside surface of open top tanks. Furthermore--since concrete cannot take tensile stresses--they are automatically zeroed out when they develop at any point to insure true tensile stresses in the reinforcing steel. Page 1 of brochure 0794, attached to the Disclosure Statement, offers attractive cost data and construction times for 50 year rated open top and fixed dome roof tanks. Reference the comparisons on page 2 of brochure 0794, these costs do not only compare favorably with carbon steel tanks--they are also substantially lower than RC and PC tanks.
Thus, an improved dome structure is disclosed. While the embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention therefore is not to be restricted except in the spirit of the appended claims. | The present invention is directed to improved tank or containment vessels and processes and apparatus for their construction. The tanks or containment vessels usually consist of circular walls resting on a base and a dome supported by the walls. The dome of the subject prestressed tank is formed by deploying or creating a membrane on the base, applying one or more layers of rigidifying material (and prestressing or reinforcing material if needed) on the membrane and then forming said membrane into a dome before the rigidifying material sets by the selective introduction of compressed air at appropriate locations between the base and the membrane. The hardening of the rigidifying material results in a composite preformed rigid roof or dome having a membrane liner and an overlay of composite construction. Once the walls are created, air pressure can be further utilized to raise this preformed composite dome upward to a predetermined height after which it is fastened to the walls. An appropriate air seal may be used to prevent excessive leakage of air between the walls and the dome and to assist in the raising of the dome. Utilizing this air cushion procedure to raise the dome to its proper location, eliminates the need of scaffolding and other costly support structures. Integral seismic anchors may be also used to complete the construction process to protect the structure against earthquakes and other tremors by anchoring the dome to the tank walls and the tank walls to the base in a manner whereby the seismic forces are translated parallel to the wall instead of radially to the wall. |
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[0001] This application is a continuation-in-part of and claims priority to and the benefit of U.S. patent application Ser. No. 11/226,573 filed Sep. 14, 2005, entitled System, Method, and Apparatus for a Corrosion-Resistant Sleeve for Riser Tensioner Cylinder Rod, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates in general to offshore drilling rig riser tensioners and, in particular, to an improved system, method, and apparatus for corrosion-resistant riser tensioner cylinder rods having an outer sleeve retained with an annular layer of epoxy.
[0004] 2. Description of the Related Art
[0005] Some types of offshore drilling rigs utilize “push-up” or “pull-up” type riser tensioners. The riser tensioner incorporates cylinder rods to maintain tension on the riser. The cylinder rods are subjected to a very corrosive environment caused by exposure to drilling muds, completion fluids, and general offshore environments. As a result, the rods currently being used are made from either a solid nickel-based alloy or a laser-clad cobalt-based layer that is applied to a steel alloy rod. Both of these current rod options are expensive and, in the case of cladding, result in long lead times with multiple process requirements in geographically remote locations. Consequently, there is a higher probability for damaged parts and scrap or scrappage. Thus, an improved design for riser tensioner cylinder rods would be desirable.
SUMMARY OF THE INVENTION
[0006] One embodiment of a system, method, and apparatus for improving the cylinder rods for riser tensioners. The present invention overcomes the shortcomings of the prior art by placing a thin tube or pipe over a pre-machined steel alloy rod. The tube is formed from a corrosion-resistant alloy and is bonded to the rod with, e.g., a thin layer of epoxy. This design results in a much lower manufacturing cost (approximately one-third less than current technology) and shorter manufacturing lead times. The manufacturing process for installing the sleeve requires injection and curing of the epoxy between the pipe and rod.
[0007] In one embodiment, the rod is machined with threaded end connections that serve to ultimately connect the rod assembly to the piston and rod extension of the cylinder assembly. The tubing is slid over the outer diameter of the rod and temporarily connected with two end connectors that center the tubing on the rod. The connectors also act as ports for injecting the epoxy which is pumped into the annular space on one end. The excess epoxy exits the opposite end and the retained epoxy is cured. The end connectors are then removed and the assembled part is ground to a final outer diameter before installation. The piston is connected and the rod clevis is made up to the cylinder rod and utilizes a double seal arrangement that prevents external pressure or corrosive fluids from entering the cured epoxy in the annular space. Advantageously, this process eliminates straightness and warping issues that commonly occur with prior art cladding operations.
[0008] The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the features and advantages of the invention, as well as others which will become apparent are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only an embodiment of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
[0010] FIG. 1 is a partial sectional view of one type of floating platform with a riser supported by a tensioning mechanism constructed in accordance with the invention;
[0011] FIG. 2 is a partially sectioned side view of one embodiment of a piston rod for a riser tensioning mechanism and is constructed in accordance with the invention;
[0012] FIG. 3 is a sectional side view of one embodiment of a piston rod and end connectors for manufacturing thereof and is constructed in accordance with the invention; and
[0013] FIG. 4 is an enlarged sectional side view of one embodiment of a portion of the piston rod and one of the end connectors of FIG. 3 in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIG. 1 , one type of riser tensioning mechanism 10 is depicted. Although mechanism 10 is depicted as a “pull-up” type, one skilled in the art will recognize that the present invention is equally suitable for “push-up” type and other types of tensioning mechanisms.
[0015] A riser 12 extends downwardly from a platform 14 to a subsea wellhead (not shown). Riser 12 has a longitudinal axis 16 and is surrounded by a plurality of hydraulic cylinders 18 . Each hydraulic cylinder 18 has a cylinder housing 24 having a chamber (not shown). A piston rod 26 has a rod end 28 that extends downward from each cylinder housing 24 and hydraulic cylinder 18 . The piston ends of rods 26 opposite rod ends 28 are disposed within the respective chambers (not shown) of cylinder housings 24 . Hydraulic fluid (not shown) is contained within the housing 24 for pulling piston rods 26 upward. Each hydraulic cylinder 18 also has accumulator 30 for accumulating hydraulic fluid from hydraulic cylinder 18 and for maintaining high pressure on the hydraulic fluid. A riser collar 32 rigidly connects to riser 12 . The piston rods 26 attach to riser collar 32 at the rod ends 28 . Cylinder shackles 34 rigidly connect cylinder housings 24 to platform 14 .
[0016] In operation, the riser tensioning mechanism 10 pulls upward on riser 12 to maintain tension therein. Riser collar 32 connects to riser 12 and engages riser 12 below platform 14 and cylinder receiver 18 . Hydraulic fluid pressure is applied to hydraulic cylinders 18 so that riser 12 is maintained in constant tension. Riser collar 32 supports the weight of riser 12 in order to create a tensional force in riser 12 . Hydraulic cylinders 18 automatically adjust to changes in platform 14 position to allow for relative movement between riser 12 and platform 14 . In the event of a failure in one of the four hydraulic cylinders 18 , the remaining hydraulic cylinders 18 will continue to support riser 12 in tension without excessive bending moments being applied to the hydraulic cylinders 18 .
[0017] Referring now to FIG. 2 , one embodiment of a piston rod 26 constructed in accordance with the present invention is shown. Piston rod 26 is the structural or load carrying member of the rod assembly, which includes a covering 74 and adhesive 75 that are shown greatly exaggerated in size for ease of understanding. Covering 74 serves as a barrier to protect the structural steel inner member from the outside corrosive fluids and atmospheric conditions typically found in offshore platforms.
[0018] As described above, piston rod 26 has axis 20 and includes a threaded rod end 28 for coupling with riser collar 32 , and a piston end 70 that locates in and moves axially relative to cylinder housing 24 . Piston rod 26 also comprises a solid shank 72 that extends and is located between ends 28 , 70 . Piston rod 26 is formed from a pre-machined steel alloy, such as commonly available inexpensive steel alloys that are not corrosion resistant.
[0019] In one embodiment, the outer surface of shank 72 is enveloped by and protected with a thin, corrosion-resistant material covering 74 . In one embodiment, it is only shank 72 that is covered by covering 74 . Covering 74 may have a radial thickness 76 in a range on the order of 0.005 to 1.0 inches. The covering 74 itself may comprise many different forms including a tube, pipe, coating, or still other suitable coverings for protecting piston rod 26 from corrosion.
[0020] A layer of adhesive 75 is located between covering 74 and shank 72 . Adhesive 75 , which may comprise epoxy or other bonding agents has a radial thickness 77 in a range on the order of approximately 0.0025 to 0.5 inches. The layer of epoxy serves to bond the sleeve to the outer diameter of the rod, and also to support or “back up” the thin sleeve from collapse due to external pressure while the rod translates in and out of the cylinder assembly under pressure.
[0021] One embodiment of a method for joining covering 74 to piston rod 26 is depicted in FIGS. 3 and 4 . In this embodiment, the covering 74 is formed from a thin tube 74 of corrosion-resistant alloy, such as nickel or cobalt-based alloys. Tube 74 may be joined to piston rod 26 via a series of operations. In one embodiment, a pre-cut length of tubing 74 is placed around the outer surface of shank 26 . Tubing 74 closely receives the outer surface of shank 26 , but forms a thin annular recess there between.
[0022] A set of end connectors 81 , 83 are threadingly secured to the ends 28 , 70 of piston rod 26 . The annulus between tube 74 and shank 72 is sealed by end connectors 81 , 83 at each end of piston rod 26 . The end connectors 81 , 83 serve to center the tube 74 relative to rod 26 and are provided with inlet and exit ports 85 , 87 , respectively. The inlet and exit ports 85 , 87 are axially aligned with exterior tapers 89 formed between shank 72 and ends 28 , 70 to provide fluid communication with the annulus.
[0023] In one embodiment, the annulus is pressurized via inlet port 85 with adhesive 75 which is pumped through the annulus before being released at exit port 87 . The annulus is pressurized and/or metered with adhesive 75 to completely fill the annulus volume and remove all air pockets.
[0024] Alternatively, a vacuum may be formed between ports 85 , 87 to evacuate the annulus and pull the adhesive through the annulus. The adhesive 75 is cured after annulus has been filled, and the end connectors 81 , 83 are removed. Any necessary trimming of tube 74 is performed and the exterior surface of tube 74 is ground to a desired surface finish and outer diameter. The part may be ground between centers located at each end of the structural steel rod and following this operation is ready to be assembled into the cylinder. The piston is connected and the rod clevis is made up to the cylinder rod and utilizes a double seal arrangement that prevents external pressure or corrosive fluids from entering the cured epoxy in the annular space.
[0025] While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. For example, although this embodiment is described with tubing only covering the shank, other embodiments may require greater or lesser surface coverage of the structural steel member. | A corrosion-resistant alloy tube is formed and bonded to a pre-machined steel alloy rod to form a riser tensioner cylinder rod. During assembly, an epoxy is injected into an annular space between the tube and rod and then cured. The bonded tube is ground to a desired surface finish prior to installation and utilizes a double seal arrangement that prevents external pressure or corrosive fluids from entering the cured epoxy in the annular space. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of application Ser. No. 12/139,100, filed on Jun. 13, 2008, which is a divisional of application Ser. No. 11/702,810, filed on Feb. 6, 2007, now U.S. Pat. No. 7,472,589 B1, issued Jan. 6, 2009, which is a continuation-in-part of application Ser. No. 11/438,764, filed on May 23, 2006, which is a continuation-in-part of application Ser. No. 11/268,311, filed on Nov. 7, 2005, now U.S. Pat. No. 7,197,923 B1, issued Apr. 3, 2007.
TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to testing and evaluation of subterranean formation fluids and, in particular to, a single phase fluid sampling apparatus for obtaining multiple fluid samples and maintaining the samples near reservoir pressure via a common pressure source during retrieval from the wellbore and storage on the surface.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background is described with reference to testing hydrocarbon formations, as an example.
It is well known in the subterranean well drilling and completion art to perform tests on formations intersected by a wellbore. Such tests are typically performed in order to determine geological or other physical properties of the formation and fluids contained therein. For example, parameters such as permeability, porosity, fluid resistivity, temperature, pressure and bubble point may be determined. These and other characteristics of the formation and fluid contained therein may be determined by performing tests on the formation before the well is completed.
One type of testing procedure that is commonly performed is to obtain a fluid sample from the formation to, among other things, determine the composition of the formation fluids. In this procedure, it is important to obtain a sample of the formation fluid that is representative of the fluids as they exist in the formation. In a typical sampling procedure, a sample of the formation fluids may be obtained by lowering a sampling tool having a sampling chamber into the wellbore on a conveyance such as a wireline, slick line, coiled tubing, jointed tubing or the like. When the sampling tool reaches the desired depth, one or more ports are opened to allow collection of the formation fluids. The ports may be actuated in variety of ways such as by electrical, hydraulic or mechanical methods. Once the ports are opened, formation fluids travel through the ports and a sample of the formation fluids is collected within the sampling chamber of the sampling tool. After the sample has been collected, the sampling tool may be withdrawn from the wellbore so that the formation fluid sample may be analyzed.
It has been found, however, that as the fluid sample is retrieved to the surface, the temperature of the fluid sample decreases causing shrinkage of the fluid sample and a reduction in the pressure of the fluid sample. These changes can cause the fluid sample to approach or reach saturation pressure creating the possibility of asphaltene deposition and flashing of entrained gasses present in the fluid sample. Once such a process occurs, the resulting fluid sample is no longer representative of the fluids present in the formation. Therefore, a need has arisen for an apparatus and method for obtaining a fluid sample from a formation without degradation of the sample during retrieval of the sampling tool from the wellbore. A need has also arisen for such an apparatus and method that are capable of maintaining the integrity of the fluid sample during storage on the surface.
SUMMARY OF THE INVENTION
The present invention disclosed herein provides a single phase fluid sampling apparatus and a method for obtaining fluid samples from a formation without the occurrence of phase change degradation of the fluid samples during the collection of the fluid samples or retrieval of the sampling apparatus from the wellbore. In addition, the sampling apparatus and method of the present invention are capable of maintaining the integrity of the fluid samples during storage on the surface.
In one aspect, the present invention is directed to an apparatus for obtaining a plurality of fluid samples in a subterranean well that includes a carrier, a plurality of sampling chambers and a pressure source. In one embodiment, the pressure source is selectively in fluid communication with at least two sampling chambers thereby serving as a common pressure source to pressurize fluid samples obtained in the at least two sampling chambers. In another embodiment, the carrier has a longitudinally extending internal fluid passageway forming a smooth bore and a plurality of externally disposed chamber receiving slots. Each of the sampling chambers is positioned in one of the chamber receiving slots of the carrier. The pressure source is selectively in fluid communication with each of the sampling chambers such that the pressure source is operable to pressurize each of the sampling chambers after the fluid samples are obtained.
In another aspect, the present invention is directed to a method for obtaining a plurality of fluid samples in a subterranean well. The method includes the steps of positioning a fluid sampler in the well, obtaining a fluid sample in each of a plurality of sampling chambers of the fluid sampler and pressurizing each of the fluid samples using a pressure source of the fluid sampler that is in fluid communication with each of the sampling chambers.
In a further aspect, the present invention is directed to an apparatus for obtaining a fluid sample in a subterranean well. The apparatus includes a housing having a sample chamber defined therein. The sample chamber is selectively in fluid communication with the exterior of the housing and is operable to receive the fluid sample therefrom. A debris trap piston is slidably disposed within the housing. The debris trap piston includes a debris chamber and, responsive to the fluid sample entering the sample chamber, the debris trap piston receives a first portion of the fluid sample in the debris chamber then displaces relative to the housing to expand the sample chamber.
In one embodiment, the debris trap piston includes a passageway having a cross sectional area that is smaller than the cross sectional area of the debris chamber. In this embodiment, the first portion of the fluid sample passes from the sample chamber through the passageway to enter the debris chamber. Also in this embodiment, the first portion of the fluid sample is retained in the debris chamber due to pressure from the sample chamber applied to the debris chamber through the passageway. Alternatively or additionally, a check valve may be disposed in an inlet portion of the debris trap piston to retain the first portion of the fluid sample in the debris chamber.
In another embodiment, the debris trap piston may include a first piston section and a second piston section that is slidable relative to the first piston section such that the debris chamber is expandable responsive to the fluid sample entering the debris chamber. In this embodiment, as engagement device may be disposed between the first piston section and the second piston section to prevent additional movement of the first piston section relative to the second piston section after expanding the debris chamber to a preselected volume.
In an additional aspect, the present invention is directed to a method for obtaining a fluid sample in a subterranean well. The method includes the steps of disposing a sampling chamber within the subterranean well, actuating the sampling chamber such that a sample chamber within the sampling chamber is in fluid communication with the exterior of the sampling chamber, receiving a first portion of the fluid sample in a debris chamber of a debris trap piston slidably disposed within the sampling chamber, displacing the debris trap piston within the sampling chamber to expand the sample chamber and receiving the remainder of the fluid sample in the sample chamber.
The method may also include passing the first portion of the fluid sample through the sample chamber and through a passageway of the debris trap piston before entering the debris chamber and retaining the first portion of the fluid sample in the debris chamber by applying pressure from the sample chamber to the debris chamber through the passageway. Additionally or alternatively, a check valve disposed in an inlet portion of the debris trap piston may be used to retain the first portion of the fluid sample in the debris chamber.
In certain embodiments, the method may include expanding the debris chamber responsive to the fluid sample entering the debris chamber by sliding a first piston section relative to a second piston section and preventing additional movement of the first piston section relative to the second piston section after expanding the debris chamber to a preselected volume.
In yet another aspect, the present invention is directed to a downhole tool including a housing having a longitudinal passageway. A piston, including a piercing assembly, is disposed within the longitudinal passageway. A valving assembly is also disposed within the longitudinal passageway. The valving assembly includes a rupture disk that is initially operable to maintain a differential pressure thereacross. The valving assembly is actuated by longitudinally displacing the piston relative to the valving assembly such that at least a portion of the piercing assembly travels through the rupture disk, thereby allowing fluid flow therethrough.
In one embodiment, the piercing assembly includes a piercing assembly body and a needle that is held within the piercing assembly body by compression. In this embodiment, the needle has a sharp point that travels through the rupture disk. In addition, the needle may have a smooth outer surface, a fluted outer surface, a channeled outer surface or a knurled outer surface. In certain embodiments, the valving assembly may include a check valve that allows fluid flow in a first direction and prevents fluid flow in a second direction through the valving assembly once the valving assembly is actuated by the piercing assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
FIG. 1 is a schematic illustration of a fluid sampler system embodying principles of the present invention;
FIGS. 2A-H are cross-sectional views of successive axial portions of one embodiment of a sampling section of a sampler embodying principles of the present invention;
FIGS. 3A-E are cross-sectional views of successive axial portions of actuator, carrier and pressure source sections of a sampler embodying principles of the present invention;
FIG. 4 is a cross-sectional view of the pressure source section of FIG. 3C taken along line 4 - 4 ;
FIG. 5 is a cross-sectional view of the actuator section of FIG. 3A taken along line 5 - 5 ;
FIG. 6 is a schematic view of an alternate actuating method for a sampler embodying principles of the present invention;
FIG. 7 is a schematic illustration of an alternate embodiment of a fluid sampler embodying principles of the present invention;
FIG. 8 is a cross-sectional view of the fluid sampler of FIG. 7 taken along line 8 - 8 ; and
FIGS. 9A-G are cross-sectional views of successive axial portions of another embodiment of a sampling section of a sampler embodying principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring initially to FIG. 1 , therein is representatively illustrated a fluid sampler system 10 and associated methods which embody principles of the present invention. A tubular string 12 , such as a drill stem test string, is positioned in a wellbore 14 . An internal flow passage 16 extends longitudinally through tubular string 12 .
A fluid sampler 18 is interconnected in tubular string 12 . Also, preferably included in tubular string 12 are a circulating valve 20 , a tester valve 22 and a choke 24 . Circulating valve 20 , tester valve 22 and choke 24 may be of conventional design. It should be noted, however, by those skilled in the art that it is not necessary for tubular string 12 to include the specific combination or arrangement of equipment described herein. It is also not necessary for sampler 18 to be included in tubular string 12 since, for example, sampler 18 could instead be conveyed through flow passage 16 using a wireline, slickline, coiled tubing, downhole robot or the like. Although wellbore 14 is depicted as being cased and cemented, it could alternatively be uncased or open hole.
In a formation testing operation, tester valve 22 is used to selectively permit and prevent flow through passage 16 . Circulating valve 20 is used to selectively permit and prevent flow between passage 16 and an annulus 26 formed radially between tubular string 12 and wellbore 14 . Choke 24 is used to selectively restrict flow through tubular string 12 . Each of valves 20 , 22 and choke 24 may be operated by manipulating pressure in annulus 26 from the surface, or any of them could be operated by other methods if desired.
Choke 24 may be actuated to restrict flow through passage 16 to minimize wellbore storage effects due to the large volume in tubular string 12 above sampler 18 . When choke 24 restricts flow through passage 16 , a pressure differential is created in passage 16 , thereby maintaining pressure in passage 16 at sampler 18 and reducing the drawdown effect of opening tester valve 22 . In this manner, by restricting flow through choke 24 at the time a fluid sample is taken in sampler 18 , the fluid sample may be prevented from going below its bubble point, i.e., the pressure below which a gas phase begins to form in a fluid phase. Circulating valve 20 permits hydrocarbons in tubular string 12 to be circulated out prior to retrieving tubular string 12 . As described more fully below, circulating valve 20 also allows increased weight fluid to be circulated into wellbore 14 .
Even though FIG. 1 depicts a vertical well, it should be noted by one skilled in the art that the fluid sampler of the present invention is equally well-suited for use in deviated wells, inclined wells or horizontal wells. As such, the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.
Referring now to FIGS. 2A-2H and 3 A- 3 E, a fluid sampler including an exemplary fluid sampling chamber and an exemplary carrier having a pressure source coupled thereto for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 100 . Fluid sampler 100 includes a plurality of the sampling chambers such sampling chamber 102 as depicted in FIG. 2 . Each of the sampling chambers 102 is coupled to a carrier 104 that also includes an actuator 106 and a pressure source 108 as depicted in FIG. 3 .
As described more fully below, a passage 110 in an upper portion of sampling chamber 102 (see FIG. 2A ) is placed in communication with a longitudinally extending internal fluid passageway 112 formed completely through fluid sampler 100 (see FIG. 3 ) when the fluid sampling operation is initiated using actuator 106 . Passage 112 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when fluid sampler 100 is interconnected in tubular string 12 . As such, internal fluid passageway 112 provides a smooth bore through fluid sampler 100 . Passage 110 in the upper portion of sampling chamber 102 is in communication with a sample chamber 114 via a check valve 116 . Check valve 116 permits fluid to flow from passage 110 into sample chamber 114 , but prevents fluid from escaping from sample chamber 114 to passage 110 .
A debris trap piston 118 separates sample chamber 114 from a meter fluid chamber 120 . When a fluid sample is received in sample chamber 114 , piston 118 is displaced downwardly. Prior to such downward displacement of piston 118 , however, piston section 122 is displaced downwardly relative to piston section 124 . In the illustrated embodiment, as fluid flows into sample chamber 114 , an optional check valve 128 permits the fluid to flow into debris chamber 126 . The resulting pressure differential across piston section 122 causes piston section 122 to displace downward, thereby expanding debris chamber 126 .
Eventually, piston section 122 will displace downward sufficiently far for a snap ring, C-ring, spring-loaded lugs, dogs or other type of engagement device 130 to engage a recess 132 formed on piston section 124 . Once engagement device 130 has engaged recess 132 , piston sections 122 , 124 displace downwardly together to expand sample chamber 114 . The fluid received in debris chamber 126 is prevented from escaping back into sample chamber 114 by check valve 128 in embodiments that include check valve 128 . In this manner, the fluid initially received into sample chamber 114 is trapped in debris chamber 126 . This initially received fluid is typically laden with debris, or is a type of fluid (such as mud) which it is not desired to sample. Debris chamber 126 thus permits this initially received fluid to be isolated from the fluid sample later received in sample chamber 114 .
Meter fluid chamber 120 initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor 134 and a check valve 136 control flow between chamber 120 and an atmospheric chamber 138 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A collapsible piston assembly 140 in chamber 138 includes a prong 142 which initially maintains another check valve 144 off seat, so that flow in both directions is permitted through check valve 144 between chambers 120 , 138 . When elevated pressure is applied to chamber 138 , however, as described more fully below, piston assembly 140 collapses axially, and prong 142 will no longer maintain check valve 144 off seat, thereby preventing flow from chamber 120 to chamber 138 .
A floating piston 146 separates chamber 138 from another atmospheric chamber 148 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A spacer 150 is attached to piston 146 and limits downward displacement of piston 146 . Spacer 150 is also used to contact a stem 152 of a valve 154 to open valve 154 . Valve 154 initially prevents communication between chamber 148 and a passage 156 in a lower portion of sampling chamber 102 . In addition, a check valve 158 permits fluid flow from passage 156 to chamber 148 , but prevents fluid flow from chamber 148 to passage 156 .
As mentioned above, one or more of the sampling chambers 102 and preferably nine of sampling chambers 102 are installed within exteriorly disposed chamber receiving slots 159 that circumscribe internal fluid passageway 112 of carrier 104 . A seal bore 160 (see FIG. 3B ) is provided in carrier 104 for receiving the upper portion of sampling chamber 102 and another seal bore 162 (see FIG. 3C ) is provided for receiving the lower portion of sampling chamber 102 . In this manner, passage 110 in the upper portion of sampling chamber 102 is placed in sealed communication with a passage 164 in carrier 104 , and passage 156 in the lower portion of sampling chamber 102 is placed in sealed communication with a passage 166 in carrier 104 .
In addition to the nine sampling chambers 102 installed within carrier 104 , a pressure and temperature gauge/recorder (not shown) of the type known to those skilled in the art can also be received in carrier 104 in a similar manner. For example, seal bores 168 , 170 in carrier 104 may be for providing communication between the gauge/recorder and internal fluid passageway 112 . Note that, although seal bore 170 depicted in FIG. 3C is in communication with passage 172 , preferably if seal bore 170 is used to accommodate a gauge/recorder, then a plug is used to isolate the gauge/recorder from passage 172 . Passage 172 is, however, in communication with passage 166 and the lower portion of each sampling chamber 102 installed in a seal bore 162 and thus servers as a manifold for fluid sampler 100 . If a sampling chamber 102 or gauge/recorder is not installed in one or more of the seal bores 160 , 162 , 168 , 170 then a plug will be installed to prevent flow therethrough.
Passage 172 is in communication with chamber 174 of pressure source 108 . Chamber 174 is in communication with chamber 176 of pressure source 108 via a passage 178 . Chambers 174 , 176 initially contain a pressurized fluid, such as a compressed gas or liquid. Preferably, compressed nitrogen at between about 7,000 psi and 12,000 psi is used to precharge chambers 174 , 176 , but other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired. Even though FIG. 3 depicts pressure source 108 as having two compressed fluid chambers 174 , 176 , it should be understood by those skilled in the art that pressure source 108 could have any number of chambers both higher and lower than two that are in communication with one another to provide the required pressure source. As best seen in FIG. 4 , a cross-sectional view of pressure source 108 is illustrated, showing a fill valve 180 and a passage 182 extending from fill valve 180 to chamber 174 for supplying the pressurized fluid to chambers 174 , 176 at the surface prior to running fluid sampler 100 downhole.
As best seen in FIGS. 3A and 5 , actuator 106 includes multiple valves 184 , 186 , 188 and respective multiple rupture disks 190 , 192 , 194 to provide for separate actuation of multiple groups of sampling chambers 102 . In the illustrated embodiment, nine sampling chambers 102 may be used, and these are divided up into three groups of three sampling chambers each. Each group of sampling chambers can be referred to as a sampling chamber assembly. Thus, a valve 184 , 186 , 188 and a respective rupture disk 190 , 192 , 194 are used to actuate a group of three sampling chambers 102 . For clarity, operation of actuator 106 with respect to only one of the valves 184 , 186 , 188 and its respective one of the rupture disks 190 , 192 , 194 is described below. Operation of actuator 106 with respect to the other valves and rupture disks is similar to that described below.
Valve 184 initially isolates passage 164 , which is in communication with passages 110 in three of the sampling chambers 102 via passage 196 , from internal fluid passage 112 of fluid sampler 100 . This isolates sample chamber 114 in each of the three sampling chambers 102 from passage 112 . When it is desired to receive a fluid sample into each of the sample chambers 114 of the three sampling chambers 102 , pressure in annulus 26 is increased a sufficient amount to rupture the disk 190 . This permits pressure in annulus 26 to shift valve 184 upward, thereby opening valve 184 and permitting communication between passage 112 and passages 196 , 164 .
Fluid from passage 112 then enters passage 110 in the upper portion of each of the three sampling chambers 102 . For clarity, the operation of only one of the sampling chambers 102 after receipt of a fluid sample therein is described below. The fluid flows from passage 110 through check valve 116 to sample chamber 114 . An initial volume of the fluid is trapped in debris chamber 126 of piston 118 as described above. Downward displacement of the piston section 122 , and then the combined piston sections 122 , 124 , is slowed by the metering fluid in chamber 120 flowing through restrictor 134 . This prevents pressure in the fluid sample received in sample chamber 114 from dropping below its bubble point.
As piston 118 displaces downward, the metering fluid in chamber 120 flows through restrictor 134 into chamber 138 . At this point, prong 142 maintains check valve 144 off seat. The metering fluid received in chamber 138 causes piston 146 to displace downward. Eventually, spacer 150 contacts stem 152 of valve 154 which opens valve 154 . Opening of valve 154 permits pressure in pressure source 108 to be applied to chamber 148 . Pressurization of chamber 148 also results in pressure being applied to chambers 138 , 120 and thus to sample chamber 114 . This is due to the fact that passage 156 is in communication with passages 166 , 172 (see FIG. 3C ) and, thus, is in communication with the pressurized fluid from pressure source 108 .
When the pressure from pressure source 108 is applied to chamber 138 , piston assembly 140 collapses and prong 142 no longer maintains check valve 144 off seat. Check valve 144 then prevents pressure from escaping from chamber 120 and sample chamber 114 . Check valve 116 also prevents escape of pressure from sample chamber 114 . In this manner, the fluid sample received in sample chamber 114 is pressurized.
In the illustrated embodiment of fluid sampler 100 , multiple sampling chambers 102 are actuated by rupturing disk 190 , since valve 184 is used to provide selective communication between passage 112 and passages 110 in the upper portions of multiple sampling chambers 102 . Thus, multiple sampling chambers 102 simultaneously receive fluid samples therein from passage 112 .
In a similar manner, when rupture disk 192 is ruptured, an additional group of multiple sampling chambers 102 will receive fluid samples therein, and when the rupture disk 194 is ruptured a further group of multiple sampling chambers 102 will receive fluid samples therein. Rupture disks 184 , 186 , 188 may be selected so that they are ruptured sequentially at different pressures in annulus 26 or they may be selected so that they are ruptured simultaneously, at the same pressure in annulus 26 .
Another important feature of fluid sampler 100 is that the multiple sampling chambers 102 , nine in the illustrated example, share the same pressure source 108 . That is, pressure source 108 is in communication with each of the multiple sampling chambers 102 . This feature provides enhanced convenience, speed, economy and safety in the fluid sampling operation. In addition to sharing a common pressure source downhole, the multiple sampling chambers 102 of fluid sampler 100 can also share a common pressure source on the surface. Specifically, once all the samples are obtained and pressurized downhole, fluid sampler 100 is retrieved to the surface. Even though certain cooling of the samples will take place, the common pressure source maintains the samples at a suitable pressure to prevent any phase change degradation. Once on the surface, the sample may remain in the multiple sampling chambers 102 for a considerable time during which temperature conditions may fluctuate. Accordingly, a surface pressure source, such a compressor or a pump, may be used to supercharge the sampling chambers 102 . This supercharging process allows multiple sampling chambers 102 to be further pressurized at the same time with sampling chambers 102 remaining in carrier 104 or after sampling chambers 102 have been removed from carrier 104 .
Note that, although actuator 106 is described above as being configured to permit separate actuation of three groups of sampling chambers 102 , with each group including three of the sampling chambers 102 , it will be appreciated that any number of sampling chambers 102 may be used, sampling chambers 102 may be included in any number of groups (including one), each group could include any number of sampling chambers 102 (including one), different groups can include different numbers of sampling chambers 102 and it is not necessary for sampling chambers 102 to be separately grouped at all.
Referring now to FIG. 6 , an alternate actuating method for fluid sampler 100 is representatively and schematically illustrated. Instead of using increased pressure in annulus 26 to actuate valves 184 , 186 , 188 , a control module 198 included in fluid sampler 100 may be used to actuate valves 184 , 186 , 188 . For example, a telemetry receiver 199 may be connected to control module 198 . Receiver 199 may be any type of telemetry receiver, such as a receiver capable of receiving acoustic signals, pressure pulse signals, electromagnetic signals, mechanical signals or the like. As such, any type of telemetry may be used to transmit signals to receiver 199 .
When control module 198 determines that an appropriate signal has been received by receiver 199 , control module 198 causes a selected one or more of valves 184 , 186 , 188 to open, thereby causing a plurality of fluid samples to be taken in fluid sampler 100 . Valves 184 , 186 , 188 may be configured to open in response to application or release of electrical current, fluid pressure, biasing force, temperature or the like.
Referring now to FIGS. 7 and 8 , an alternate embodiment of a fluid sampler for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 200 . Fluid sampler 200 includes an upper connector 202 for coupling fluid sampler 200 to other well tools in the sampler string. Fluid sampler 200 also includes an actuator 204 that operates in a manner similar to actuator 106 described above. Below actuator 204 is a carrier 206 that is of similar construction as carrier 104 described above. Fluid sampler 200 further includes a manifold 208 for distributing fluid pressure. Below manifold 208 is a lower connector 210 for coupling fluid sampler 200 to other well tools in the sampler string.
Fluid sampler 200 has a longitudinally extending internal fluid passageway 212 formed completely through fluid sampler 200 . Passageway 212 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when fluid sampler 200 is interconnected in tubular string 12 . In the illustrated embodiment, carrier 206 has ten exteriorly disposed chamber receiving slots that circumscribe internal fluid passageway 212 . As mentioned above, a pressure and temperature gauge/recorder (not shown) of the type known to those skilled in the art can be received in carrier 206 within one of the chamber receiving slots such as slot 214 . The remainder of the slots are used to receive sampling chambers and pressure source chambers.
In the illustrated embodiment, sampling chambers 216 , 218 , 220 , 222 , 224 , 226 are respectively received within slots 228 , 230 , 232 , 234 , 236 , 238 . Sampling chambers 216 , 218 , 220 , 222 , 224 , 226 are of a construction and operate in the manner described above with reference to sampling chamber 102 . Pressure source chambers 240 , 242 , 244 are respectively received within slots 246 , 248 , 250 in a manner similar to that described above with reference to sampling chamber 102 . Pressure source chambers 240 , 242 , 244 initially contain a pressurized fluid, such as a compressed gas or liquid. Preferably, compressed nitrogen at between about 10,000 psi and 20,000 psi is used to precharge chambers 240 , 242 , 244 , but other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired.
Actuator 204 includes three valves that operate in a manner similar to valves 184 , 186 , 188 of actuator 106 . Actuator 204 has three rupture disks, one associated with each valve in a manner similar to rupture disks 190 , 192 , 194 of actuator 106 and one of which is pictured and denoted as rupture disk 252 . As described above, each of the rupture disks provides for separate actuation of a group of sampling chambers. In the illustrated embodiment, six sampling chambers are used, and these are divided up into three groups of two sampling chambers each. Associated with each group of two sampling chambers is one pressure source chamber. Specifically, rupture disk 252 is associated with sampling chambers 216 , 218 which are also associated with pressure source chamber 240 via manifold 208 . In a like manner, the second rupture disk is associated with sampling chambers 220 , 222 which are also associated with pressure source chamber 242 via manifold 208 . In addition, the third rupture disk is associated with sampling chambers 224 , 226 which are also associated with pressure source chamber 244 via manifold 208 . In the illustrated embodiment, each rupture disk, valve, pair of sampling chambers, pressure source chamber and manifold section can be referred to as a sampling chamber assembly. Each of the three sampling chamber assemblies operates independently of the other two sampling chamber assemblies. For clarity, the operation of one sampling chamber assembly is described below. Operation of the other two sampling chamber assemblies is similar to that described below.
The valve associated with rupture disk 252 initially isolates the sample chambers of sampling chambers 216 , 218 from internal fluid passageway 212 of fluid sampler 200 . When it is desired to receive a fluid sample into each of the sample chambers of sampling chambers 216 , 218 , pressure in annulus 26 is increased a sufficient amount to rupture the disk 252 . This permits pressure in annulus 26 to shift the associated valve upward in a manner described above, thereby opening the valve and permitting communication between passageway 212 and the sample chambers of sampling chambers 216 , 218 .
As described above, fluid from passageway 212 enters a passage in the upper portion of each of the sampling chambers 216 , 218 and passes through an optional check valve to the sample chambers. An initial volume of the fluid is trapped in a debris chamber as described above. Downward displacement of the debris piston is slowed by the metering fluid in another chamber flowing through a restrictor. This prevents pressure in the fluid sample received in the sample chambers from dropping below its bubble point.
As the debris piston displaces downward, the metering fluid flows through the restrictor into a lower chamber causing a piston to displace downward. Eventually, a spacer contacts a stem of a lower valve which opens the valve and permits pressure from pressure source chamber 240 to be applied to the lower chamber via manifold 208 . Pressurization of the lower chamber also results in pressure being applied to the sample chambers of sampling chambers 216 , 218 .
As described above, when the pressure from pressure source chamber 240 is applied to the lower chamber, a piston assembly collapses and a prong no longer maintains a check valve off seat, which prevents pressure from escaping from the sample chambers. The upper check valve also prevents escape of pressure from the sample chamber. In this manner, the fluid samples received in the sample chambers are pressurized.
In the illustrated embodiment of fluid sampler 200 , two sampling chambers 216 , 218 are actuated by rupturing disk 252 , since the valve associated therewith is used to provide selective communication between passageway 212 the sample chambers of sampling chambers 216 , 218 . Thus, both sampling chambers 216 , 218 simultaneously receive fluid samples therein from passageway 212 .
In a similar manner, when the other rupture disks are ruptured, additional groups of two sampling chambers (sampling chambers 220 , 222 and sampling chambers 224 , 226 ) will receive fluid samples therein and the fluid samples obtained therein will be pressurize by pressure sources 242 , 244 , respectively. The rupture disks may be selected so that they are ruptured sequentially at different pressures in annulus 26 or they may be selected so that they are ruptured simultaneously, at the same pressure in annulus 26 .
One of the important features of fluid sampler 200 is that the multiple sampling chambers, two in the illustrated example, share a common pressure source. That is, each pressure source is in communication with multiple sampling chambers. This feature provides enhanced convenience, speed, economy and safety in the fluid sampling operation. In addition to sharing a common pressure source downhole, multiple sampling chambers of fluid sampler 200 can also share a common pressure source on the surface. Specifically, once all the samples are obtained and pressurized downhole, fluid sampler 200 is retrieved to the surface. Even though certain cooling of the samples will take place, the common pressure source maintains the samples at a suitable pressure to prevent any phase change degradation. Once on the surface, the samples may remain in the multiple sampling chambers for a considerable time during which temperature conditions may fluctuate. Accordingly, a surface pressure source, such a compressor or a pump, may be used to supercharge the sampling chambers. This supercharging process allows multiple sampling chambers to be further pressurized at the same time with the sampling chambers remaining in carrier 206 or after sampling chambers have been removed from carrier 206 .
It should be understood by those skilled in the art that even though fluid sampler 200 has been described as having one pressure source chamber in communication with two sampling chambers via manifold 208 , other numbers of pressure source chambers may be in communication with other numbers of sampling chambers with departing from the principles of the present invention. For example, in certain embodiments, one pressure source chamber could communicate pressure to three, four or more sampling chambers. Likewise, two or more pressure source chambers could act as a common pressure source to a single sampling chamber or to a plurality of sampling chambers. Each of these embodiments may be enabled by making the appropriate adjustments to manifold 208 such that the desired pressure source chambers and the desired sampling chambers are properly communicated to one another.
Referring now to FIGS. 9A-9G and with reference to FIGS. 3A-3E , an alternate fluid sampling chamber for use in a fluid sampler including an exemplary carrier having a pressure source coupled thereto for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 300 . Each of the sampling chambers 300 is coupled to a carrier 104 that also includes an actuator 106 and a pressure source 108 as depicted in FIG. 3 .
As described more fully below, a passage 310 in an upper portion of sampling chamber 300 (see FIG. 9A ) is placed in communication with a longitudinally extending internal fluid passageway 112 formed completely through the fluid sampler (see FIG. 3 ) when the fluid sampling operation is initiated using actuator 106 . Passage 112 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when the fluid sampler is interconnected in tubular string 12 . As such, internal fluid passageway 112 provides a smooth bore through the fluid sampler. Passage 310 in the upper portion of sampling chamber 300 is in communication with a sample chamber 314 via a check valve 316 . Check valve 316 permits fluid to flow from passage 310 into sample chamber 314 , but prevents fluid from escaping from sample chamber 314 to passage 310 .
A debris trap piston 318 is disposed within housing 302 and separates sample chamber 314 from a meter fluid chamber 320 . When a fluid sample is received in sample chamber 314 , debris trap piston 318 is displaced downwardly relative to housing 302 to expand sample chamber 314 . Prior to such downward displacement of debris trap piston 318 , however, fluid flows through sample chamber 314 and passageway 322 of piston 318 into debris chamber 326 of debris trap piston 318 . The fluid received in debris chamber 326 is prevented from escaping back into sample chamber 314 due to the relative cross sectional areas of passageway 322 and debris chamber 326 as well as the pressure maintained on debris chamber 326 from sample chamber 314 via passageway 322 . An optional check valve (not pictured) may be disposed within passageway 322 if desired. Such a check valve would operate in the manner described above with reference to check valve 128 in FIG. 2B . In this manner, the fluid initially received into sample chamber 314 is trapped in debris chamber 326 . Debris chamber 326 thus permits this initially received fluid to be isolated from the fluid sample later received in sample chamber 314 . Debris trap piston 318 includes a magnetic locator 324 used as a reference to determine the level of displacement of debris trap piston 318 and thus the volume within sample chamber 314 after a sample has been obtained.
Meter fluid chamber 320 initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor 334 and a check valve 336 control flow between chamber 320 and an atmospheric chamber 338 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A collapsible piston assembly 340 includes a prong 342 which initially maintains check valve 344 off seat, so that flow in both directions is permitted through check valve 344 between chambers 320 , 338 . When elevated pressure is applied to chamber 338 , however, as described more fully below, piston assembly 340 collapses axially, and prong 342 will no longer maintain check valve 344 off seat, thereby preventing flow from chamber 320 to chamber 338 .
A piston 346 disposed within housing 302 separates chamber 338 from a longitudinally extending atmospheric chamber 348 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. Piston 346 includes a magnetic locator 347 used as a reference to determine the level of displacement of piston 346 and thus the volume within chamber 338 after a sample has been obtained. Piston 346 included a piercing assembly 350 at its lower end. In the illustrated embodiment, piercing assembly 350 is threadably coupled to piston 346 which creates a compression connection between a piercing assembly body 352 and a needle 354 . Alternatively, needle 354 may be coupled to piercing assembly body 352 via threading, welding, friction or other suitable technique. Needle 354 has a sharp point at its lower end and may have a smooth outer surface or may have an outer surface that is fluted, channeled, knurled or otherwise irregular. As discussed more fully below, needle 354 is used to actuate the pressure delivery subsystem of the fluid sampler when piston 346 is sufficiently displaced relative to housing 302 .
Below atmospheric chamber 348 and disposed within the longitudinal passageway of housing 302 is a valving assembly 356 . Valving assembly 356 includes a pressure disk holder 358 that receives a pressure disk therein that is depicted as rupture disk 360 , however, other types of pressure disks that provide a seal, such as a metal-to-metal seal, with pressure disk holder 358 could also be used including a pressure membrane or other piercable member. Rupture disk 360 is held within pressure disk holder 358 by hold down ring 362 and gland 364 that is threadably coupled to pressure disk holder 358 . Valving assembly 356 also includes a check valve 366 . Valving assembly 356 initially prevents communication between chamber 348 and a passage 380 in a lower portion of sampling chamber 300 . After actuation the pressure delivery subsystem by needle 354 , check valve 366 permits fluid flow from passage 380 to chamber 348 , but prevents fluid flow from chamber 348 to passage 380 .
As mentioned above, one or more of the sampling chambers 300 and preferably nine of sampling chambers 300 are installed within exteriorly disposed chamber receiving slots 159 that circumscribe internal fluid passageway 112 of carrier 104 . A seal bore 160 (see FIG. 3B ) is provided in carrier 104 for receiving the upper portion of sampling chamber 300 and another seal bore 162 (see FIG. 3C ) is provided for receiving the lower portion of sampling chamber 300 . In this manner, passage 310 in the upper portion of sampling chamber 300 is placed in sealed communication with a passage 164 in carrier 104 , and passage 380 in the lower portion of sampling chamber 300 is placed in sealed communication with a passage 166 in carrier 104 .
As described above, once the fluid sampler is in its operable configuration and is located at the desired position within the wellbore, a fluid sample can be obtained into one or more of the sample chambers 314 by operating actuator 106 . Fluid from passage 112 then enters passage 310 in the upper portion of each of the desired sampling chambers 300 . For clarity, the operation of only one of the sampling chambers 300 after receipt of a fluid sample therein is described below. The fluid flows from passage 310 through check valve 316 to sample chamber 314 . It is noted that check valve 316 may include a restrictor pin 368 to prevent excessive travel of ball member 370 and over compression or recoil of spiral wound compression spring 372 . An initial volume of the fluid is trapped in debris chamber 326 of piston 318 as described above. Downward displacement of piston 318 is slowed by the metering fluid in chamber 320 flowing through restrictor 334 . This prevents pressure in the fluid sample received in sample chamber 314 from dropping below its bubble point.
As piston 318 displaces downward, the metering fluid in chamber 320 flows through restrictor 334 into chamber 338 . At this point, prong 342 maintains check valve 344 off seat. The metering fluid received in chamber 338 causes piston 346 to displace downwardly. Eventually, needle 354 pierces rupture disk 360 which actuates valving assembly 356 . Actuation of valving assembly 356 permits pressure from pressure source 108 to be applied to chamber 348 . Specifically, once rupture disk 360 is pierced, the pressure from pressure source 108 passes through valving assembly 356 including moving check valve 366 off seat. In the illustrated embodiment, a restrictor pin 374 prevents excessive travel of check valve 366 and over compression or recoil of spiral wound compression spring 376 . Pressurization of chamber 348 also results in pressure being applied to chambers 338 , 320 and thus to sample chamber 314 .
When the pressure from pressure source 108 is applied to chamber 338 , pins 378 are sheared allowing piston assembly 340 to collapse such that prong 342 no longer maintains check valve 344 off seat. Check valve 344 then prevents pressure from escaping from chamber 320 and sample chamber 314 . Check valve 316 also prevents escape of pressure from sample chamber 314 . In this manner, the fluid sample received in sample chamber 314 is pressurized.
While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus for actuating a pressure delivery system of a fluid sampler. The apparatus includes a housing ( 302 ) having a longitudinal passageway and defining first and second chambers ( 338, 348 ). A piston ( 346 ) is disposed within the longitudinal passageway between the first and second chambers ( 338, 348 ). A valving assembly ( 356 ) is disposed within the longitudinal passageway. The valving assembly ( 356 ) is operable to selectively prevent communication of pressure from a pressure source of the fluid sampler to the second chamber ( 348 ). The valving assembly ( 356 ) is actuated responsive to an increase in pressure in the first chamber ( 338 ) which longitudinally displaces the piston ( 346 ) toward the valving assembly ( 356 ) until at least a portion of the piston ( 346 ) contacts the valving assembly ( 356 ), thereby releasing pressure from the pressure source into the second chamber ( 348 ) and longitudinally displacing the piston ( 346 ) away from the valving assembly ( 356 ). |
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TECHNICAL FIELD
This invention relates to a portable sports floor system, more particularly one which is formed of a plurality of components which may be easily interconnected to form an integrated sports surface.
BACKGROUND OF THE INVENTION
Portable panel sports floor systems are typically comprised of individual panels which when positioned correctly and attached to adjacent panels, form a sports surface for activities such as basketball, volleyball, aerobics and dance. The typical mechanism for one panel to attach to the adjacent panel varies and includes such means as countersunk machine screws in the surface of the panels, subfloor locking pins and latches, as well as machine screws placed in strategically placed subfloor brackets.
A portable sectional flooring systems such as U.S. Pat. No. 3,141,392 to Schneider which depicts individual panels which form an integrated floor when connected. Panel to panel connection is achieved by manually angling, aligning, and forcing panels into connecting positions. Disconnecting panels requires manual lifting and angling for panels to swing out of alignment.
Another portable panel connecting design is described in U.S. Pat. No. 5,070,662 to Niese. The Niese patent incorporates set screws which are exposed at the perimeter surface of the panels. The panels must be aligned and forced into position prior to engaging the set screws which bind adjacent panels together. A system such as U.S. Pat. No. 3,967,428 to Niese typifies the basic design of common portable sports floors currently in use.
The Niese design and other portable panel systems commonly used today are comprised of individual panels set in a staggered pattern to provide offset integration. Common panels typically provide a sports surface such as hardwood flooring which is attached by means of mechanical fasteners, normally flooring staples or cleats, to the subfloor. The subfloor often includes plywood sheeting as an upper subfloor surface which is mechanically attached to a lower series of sleepers such as softwood runners.
Resiliency typically provided in hardwood sports floor systems incorporate individual pads manufactured in a variety of elastomeric materials. Resilient pads are of different shapes and sizes and is commonly manufactured through molding or extrusion. Examples of pads currently in use below sports floor systems are described in patents such as U.S. Pat. No. 4,879,857 to Peterson, U.S. Pat. No. 4,890,434 to Niese, and U.S. Pat. No. 5,369,710 to Randjelovic.
There are many other types of resilient pads currently in use, and these are commonly attached to the underside of the hardwood subfloor system Inclusion of resilient pads in portable floor systems require additional precautions in regards to the effects of panel movement during assembly and disassembly. U.S. Pat. No. 5,303,526 to Niese, as well as U.S. Pat. No. 4,860,516 to Koller, describe a design which provides resilient pads incorporated in portable floor systems.
It is the object of the invention to provide a substantially improved method for assembly and disassembly of panels which comprise a portable sports floor system. An object of the invention includes a more efficient apparatus and manner of installation which significantly reduces labor necessary during assembly and is more efficient during disassembly, also significantly reducing labor.
Another object of this invention includes a manner of assembly and disassembly which significantly improves the handling and reduces wear to the flooring panels.
It is further an object of the invention to provide a sports system including a manner of integrated resiliency. This object of the invention includes designs to protect resilient material incorporated into the portable panels from negative effects associated with assembly, use, disassembly, and storage.
It is known that portable panels require placement and alignment prior to connecting to adjacent panels. As described in the Niese patent, installers must hit the side of the floor section with a large rubber mallet to move them into proper position. The procedure of striking the side edges of the panels to provide alignment is detrimental to the integrity of the floor system and causes unwanted wear to the panels.
The description of the invention which follows illustrates a design which mechanically aligns portable panels without the use of mallets or other non preferred force. This procedure eliminates the wear and labor required to forcefully align each panel. The invention provides mechanical alignment while at the same time providing connection to adjacent panels.
Current designs which require force during placement also require force during removal. The description of the invention shall illustrate a manner of mechanically disassembling portable panels. This process is a time saving method and eliminates the necessity of mallets or pry bars for removal of panels prior to transfer and storage.
Portable panels require correct alignment along the opposing side and end of adjacent panels. The placement of known system panels requires maneuvering in two directions. The invention incorporates a design which introduces concurrent movement to both the side edge and end edge during the mechanical installation process.
Also, the mechanical installation process can be performed from an end edge that does not abut an adjustemnt panel therby eliminating installation problems associated with access to the abutting ends.
To achieve the preferred attachment of portable panels the invention provides a concealed mechanical drive design which when activated draws adjacent panels tightly together at the side joints.
The invention further provides a means to mechanically push panels apart at side joints again by activating the concealed drive design.
The preferred method of the invention provides panel-to-panel end attachments which also draw the panels together as the concealed mechanical drive mechanism is activated
The invention provides release of the end attachment by again activating the concealed mechanical drive.
Since the invention preferably incorporates elastomeric material in the form of resilient pads, it is important that adjacent panels deflect in unison to prevent vertical ridges from occurring in the floor's surface during sports activities. The mating of the side and end edges during panel-to-panel connection requires particularly tight integration to form a singular reaction to active loads. As the panel side and end mating tolerance must be minimal to accomplish the preferred interaction it increases the invention's effectiveness of drawing together and interlocking panels through mechanical means rather than manual force. The latter of which can negatively influence the tolerance required to assure that adjacent panels move in unison when one or the other panel is deflected.
Resilient panel systems requiring such tight interlocking tolerance to provide preferred and even deflection at panel joints are more difficult to disassemble. The invention provides a mechanical method to disassemble panels, again without the manual force associated with current resilient portable panel design.
The first preferred method of portable panel construction consists of an upper layer of flooring such as tongue and groove random length hard maple, although any practical wood specie is an acceptable floor surface. The flooring surface may also include square edge wooden planks or a synthetic surface.
The sports surface is preferably attached to an upper subfloor of plywood or composite board sheeting. The most preferred attachment of the surface flooring is by means of flooring cleats or staples, although the surface flooring such as square edge wooden planks and synthetic material would preferably be attached by an adhesive layer.
The preferred method of the invention includes attachment of the upper subfloor to lower subfloor supports of nominal two inch by three inch softwood runners. While the most preferred method of attaching the upper subfloor sheeting to the softwood runners is by means of staples, adhesive may also be provided between the upper and lower subfloor panels.
The first preferred method of the invention includes isolated resilient pads attached to the underside of the softwood runners. The resilient pads may be of any type of elastomeric material and provided in a wide variety of shapes. The resilient pads are preferred to be attached by means of staples or adhesive.
It is further preferred to provide a partial encasement of the softwood runners to protect the resilient pads. The partial encasement is designed in a manner to provide a full rigid surface for support between the portable panels and substrate, and to allow wanted deflection of the floor system when impacted by athletic loads. Unlike the Niese and Kohler designs resiliency can be added to the floor system at a later date should the owner decide to initially purchase a standard non padded system. This feature is provided by attachment of resilient pads and extruded encasement later described through drawing details.
The standard portable panel of the first preferred construction is normally four feet by eight feet in size, although nominal four feet by four feet panels are also required to start alternating panel rows, thereby creating a staggered pattern of panels in the floor system. The eight foot edge of a standard panel is referred to as the side edge and includes a synthetic tongue or groove encasement on the edge of the upper subfloor sheeting. The tongue and groove which oppose each other on adjacent panels are drawn tightly together by mechanical assembly. The playing surface or top surface extends over the tongue and groove located below, thereby concealing the pieces when the floor system is in use.
The four foot edge of a standard panel is referred to as the end edge, and includes either male or female interlocking attachments connected to the lower subfloor runners. The female attachments are slightly angled to accept the male flange attachments as the panel side edges are drawn together. This design allows the panel to be drawn tightly in two directions simultaneously thereby providing both side edge and end edge integration. The playing surface also extends beyond the end edge connectors also concealing them from view when the floor system is in use.
The first preferred embodiment of the invention includes a driving mechanism located in slots of particularly located runners. The driving mechanism is constructed in a manner to activate a latching device forward or backward by means of a standard power tool, either electric, manual or battery powered. The latching device in the first preferred method is a simple hook extending from the drive mechanism. The hook is easily latched to opposing plates strategically located in adjacent panel side edges. The hook is attached to the driving mechanism in a manner which maintains its position without revolving as the drive mechanism is engaged and turning. This design allows adjacent panels to be drawn together or separated mechanically as preferred. These descriptions and other teachings of the invention will be further illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a top view of a full portable panel including exposed views of panel-to-panel attachment connectors and an exposed view of a panel attachment drive mechanism.
FIG. 2 is a side view of a drive mechanism and associated construction taken along lines 2--2 of FIG. 1.
FIG. 3 is a perspective view of the power tool drive head as referenced in FIG. 1.
FIG. 4 is a perspective view of the male connecting end of the drive mechanism as referenced in FIG. 1.
FIG. 5 is a perspective view of a panel side edge female connector as referenced in FIG. 1.
FIG. 6 is a perspective view of a panel end edge male connector as referenced in FIG. 1.
FIG. 7 is a perspective view of a panel side edge female connector as referenced in FIG. 1.
FIG. 8 is an end view of resilient pads and resilient pad encasement.
FIG. 9 is a side view of initial side panel alignment prior to engaging the drive mechanism and also depicts side panel alignment after mechanical release.
FIG. 10 is a side view of interlocked side panel alignment affected by the drive mechanism.
FIG. 11 is a top view including open views of panel alignment prior to activating the drive mechanism as well as post alignment after activating mechanical release.
FIG. 12 is a top view of a typical portable panel connection providing open view of both the side panel and end panel attachment.
FIG. 13 is an alternative end view of resilient pads and resilient pad encasement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).
FIG. 1 is a top view representing a portable panel 13 incorporating a flooring or top surface 14 of random length hardwood strips. The upper subfloor 15 is provided in plywood sheeting attached to the lower subfloor surface 16 typically constructed of softwood runners.
The preferred embodiment of the invention includes a drive mechanism 17 featuring a threaded rod 18 and related driving rod attachments which align in a grooved slot 19 provided in one or more of the lower softwood runners 20. The softwood runners 20 are one way to encase the drive mechanism 17, which may alternatively be encased a number of different ways, such as in a separate encasement attached to the underside of the upper subfloor 15. The encasement may be manufactured of metal, plastic or other suitable material.
Threaded rod 18, the driving force, is activated by a battery powered or electric drill attached via a socket to the hex head 21 of the threaded rod 18. The hex head 21 is only one of numerous ways to provide an attachment or engagement mechanism for the threaded rod 18, but may also be, by way of example, an allen wrench head, a T head or others which can be mechanically attached to.
Threaded rod 18 may be threaded in a variety of different ways, such as at both ends instead of throughout its entire length, or only threaded at the end where the traveling mechanism is located, with drive ends having stops on both sides of the limiting plate 22, or it may have limiting plate 22 adjacent to hex head 21 and only one pair of locking nuts 23 on the back side of limiting plate 22.
The role of the limiting plate 22 may also be filled by providing other stationary material intersected by the threaded rod 18, such as hard blocks affixed in the grooved slot 19 and intersected by the threaded rod 18. The limiting plate 22 may also included attachments such as U shaped brackets or other shapes which insert at the end of the runner 20.
The locking nuts 23 are one of the ways the invention can be accomplished in the preferred embodiment, but could for instance be replaced by other limiting attachments such as pins which penetrate the threaded rod 18 and protrude adjacent to the limiting plate 22, or by welded stops on each side of the limiting plate 22.
Included in the drive mechanism 17 is a limiting plate 22 which is countersunk into a right angle slot provided in softwood runner 20. The limiting plate 22 is intersected by the driving rod 18 to pass freely through the limiting plate 22. Locking nuts 23 are attached to the driving rod 18 on opposing sides of the limiting plate 22. The trailing end of the threaded threaded rod 18 intersects threaded holes in the lead end of a traveling mechanism 24. The trailing end of the traveling mechanism 24 provides attachment for a male connector 25 which extends from the side edge of the panel 13 when the traveling mechanism 24 is forwarded. When the traveling mechanism 24 is reversed, the male connector 25 aligns below the side edge of the panel 13.
The traveling mechanism 24 may be provided in one of a number of different ways, such as in the form of a solid steel plate with an attached coupling which is intersected by the threaded rod 18. The steel plate may be manufactured in a design which provides a notch in the protruding end to hook to the female side connector 26. The traveling mechanism 24 may also be provided in a design with two threaded ends such as a turn buckle allowing the threaded rod 18 to move through the lead end and a stationary threaded male connector 25 to be permanently attached to the trailing end for attachment to the female side connector 26.
The traveling mechanism 24 may still further be provided in a design which includes an elongated bracket with a threaded nut attached at the lead end which is intersected by the threaded rod 18. The trail end of the elongated bracket may have a cross member such as a machine screw or other attachment which forms a female hook for attachment to a male connector on an opposing panel. The traveling mechanism 24 may be provided in many different materials such as hard plastic, aluminum or other moldable product, or cast iron which is manufactured with a threaded section and hooking section.
The side panel male connection 25 may be provided in a number of alternative ways, such as in the form of a hooking design specifically manufactured into the traveling mechanism 24 by creating a bend or a notch to create a male hook for the opposing female connector 26. The side panel male connector 29; may also be provided in the form of a female connector which would connect to an opposing male connector on the adjacent panel, or in the form of a downward angle which overlaps an upward angle on the adjacent panel.
The side panel female connectors 26 may likewise be provided in one of a number of different ways, an alternative of which may be provided in the form of extruding softwood runners 20 with holes provided in the surface for attachment by hooking mechanisms of adjacent panels, or in the form of extending brackets mounted to the softwood runners 20 to provide a hooking location for the adjacent panels. The side panel female connectors 26 may also be provided by attaching them strategically to other components of the panel such as the underside of a plywood subfloor to provide a stationary attachment for adjacent panels, or in a design including a flange which is set vertically and perpendicular into the softwood runner.
The exposed views of the panel 13 in FIG. 1 includes side and end connectors for interlocking panels. As detailed in FIG. 1, the lower side edge provides two female connectors 26, each one secured into the lead end of particular softwood runners 16 by means of wood screws 27. The female side connectors 26 are preferably manufactured of 1/8" steel plate and each provides an anchoring hole 28. The anchoring holes 28 may also be provided in the female connectors in any shape which allows the adjacent panels connector to hook as desired.
The end edges of the panel 13 provide panel end edge male connectors 29 and panel end edge female connectors 30. The male connectors 29 are properly located and attached to the side edge of the right outermost softwood runner 16 by means of wood lag bolts 31. The panel end edge male connector 29 is preferably manufactured of 1/8" steel plate. The panel end edge male connector 29 may also be provided as a flat plate and spacer attached to the softwood runner 16, the flat plate being manufactured to extend beyond the spacer, allowing it to hook into the opposing panel end edge female connector 30.
The panel end edge male connector may also be provided as an extending pin protruding from a steel plate connected to the softwood runner 16. The pin which is preferably tapered penetrates the adjacent connector on the opposing panel. The adjacent female connector to the pin would be provided as a steel plate with an anchoring hole positioned perpendicular to the pin.
The panel end edge male connector may be manufactured out of many different materials, examples of which are hard plastic, aluminum, moldable material or of cast iron, to provide a panel end edge connector 29 which secures into the opposing panels end edge connector as the panels are drawn together during assembly.
The panel end edge female connectors may likewise be manufactured out of many different materials, examples of which are hard plastic, aluminum, moldable material or of cast iron. The connector provides a tapered fit for the preferred connection to the adjacent panels opposing connectors as the panels are drawn together. The manufacture of components in this manner may include anchorage holes for attachment of connectors to softwood runners 16.
FIG. 2 shows a side view of the drive mechanism 17. The threaded driving rod 18 is shown with the hex head 21 available for connection by a socket which is driven by a battery or electric drill. Two sets of locking nuts 23 are shown on opposing sides of the limiting plate 22 which is fitted into a slot provided perpendicular to the softwood runner 20. As shown, the locking nuts 23, are set back slightly on each side of the limiting plate 22. The limiting plate 22 provides an oversized passage hold for the threaded rod 18 thereby restricting shifting of the threaded rod 18 forward or backward when the hex head 21 is engaged.
The preferred design of the traveling mechanism 24 is detailed including two threaded penetration areas which are intersected by the threaded rod 18. As the hex head 21 is engaged and the threaded rod 18 revolves, the traveling mechanism 24 either moves forward or backward, depending on whether the hex head 21 is turned clockwise or counterclockwise. The traveling mechanism 24 also provides two penetration areas for the male connector 25 which is held stationary by a holding nut 32 located at the open penetration point of the traveling mechanism 24.
Other elements of the preferred portable panel design are shown in FIG. 2. The flooring or top surface 14 of random length hardwood strips are shown attached by means of flooring fasteners 33 to the upper subfloor surface 15 which is preferably plywood sheeting attached to the lower softwood runner 20. The softwood runner 20 is provided in a dimension which is shorter at the male connector 25 end than the upper subfloor surface 15 and flooring surface 14 above. This allows the male connector 25 to align fully below the upper subfloor surface 15 when the traveling mechanism 24 is reversed.
Also, shown in FIG. 2 is the panel side edge tongue 34 arrangement and panel side edge groove 35 arrangement. The preferred material of the tongue 34 and groove 35 is an extruded material such as hard plastic or aluminum. Both the tongue 34 and groove 35 provide a C shaped design to capture the side edges of the upper subfloor panel 15. The edges of subfloor panel 15 are machined to allow the flanges 36 of the tongue 34 and groove 35 to fit flush to the top and bottom of the upper subfloor 15. The flanges 36 are preferred to be glued to the upper subfloor 15 and flush countersunk screws 37 are also provided.
Additionally FIG. 2 shows a cut away side view of the resilient pad encasement 38. This is provided preferably in an extruded plastic or aluminum offering a channel on the underside of the pad encasement 38. The channel provides clearance for the head of the anchor bolts 39 as the portable panel is deflected under athletic loads. An exposed view of the pad encasement 38 illustrates positioning of resilient pads 40 which support the underside of the softwood runner 20.
The tongue and groove along the side edge of the panels may be provided in other manners, including a design incorporating a single flange extending from the back side of the tongue 34 and groove 35. The single flange may be inserted and anchored into a horizontal slot provided in the face of the side edge of the upper subfloor 15. The provisions along the side edge may be provided by manufacturing a shoulder into the side edge of the upper subfloor 15 to accommodate a tongue 34 and groove 35 arrangement which does not include a flange or flanges. The tongue 34 and groove 35 may be set into and attached to the shoulder of the upper subfloor 15.
The resilient pad encasement 38 may be provided in the form of a U shaped channel which partially encases the softwood runners. The side walls are provided in a vertical dimension greater than the thickness of the resilient pads 40 with adequate extension along side edges of the softwood runners. The extended walls of the U channel allow oblong slots on FIG. 2 to be placed in preferred locations adjacent to the side edges of the softwood runners. The oblong slots are penetrated by means of anchors which are screwed into the side walls of the softwood runners. As the floor is impacted the oblong slots allow the sleeper to deflect into the U channel without interference by the anchors.
FIG. 3 is a perspective view of the hex head 21 attached to the threaded rod 18 which passes through the limiting plate 22. Also shown are the locking nuts 23 attached to the threaded rod 18, in close proximity to each side of the limiting plate 22. The grooved slot 19 is also illustrated as provided in the softwood runner 20. Other construction as previously described includes the flooring surface 14, the upper subfloor 15, and the side edge groove 35. Also, a perspective view of the resilient pad encasement 38 and resilient pad 40 is included. As shown, the grooved slot 19 in the softwood runner 20 provides clearance for a drive socket to be attached to the hex head 21.
FIG. 4 is a perspective view of the male connector 25 which is attached to the traveling mechanism 24 and held into position with the holding nut 32. Also illustrated is the threaded rod 18 which intersects the traveling mechanism 24. The softwood runner 20 is shown including the grooved slot 19 which provides clearance and conceals the drive mechanism 17 and maintains the traveling mechanism 24 in the proper alignment. The resilient pad encasement 38 is also shown in this perspective view.
FIG. 5 shows a view of the panel side edge female connector 26 including the provision of the anchoring hole 28. Also included is a view of the panel side edge groove 35 which is attached to the upper subfloor 15 which provides support and attachment to the flooring or top surface 14. The panel side edge female connector 26 is fitted into a slot provided in the softwood runner 16 and attached by means of wood lag bolts. A view of the resilient pad encasement 38 is also included in this view as positioned below the softwood runner 16.
FIG. 6 details the panel end edge male connector 29 which is attached to the outermost right softwood runner 16 of the panel by means of wood lag bolts 31. The male connector 29 provides a slight taper at the lead end to assure alignment into the panel end edge female connector as described in FIG. 7. The view also shows the preferred attachment of the upper subfloor 15 and flooring surface 14 which aligns beyond the male connector 29 for protection during moving and storage.
FIG. 7 details the panel end edge female connector 30 which is connected to the outermost left softwood runner 16 of the panel by means of wood lag bolts 42. The connector 30 is preferably manufactured as a steel bracket providing an upper and a lower flange positioned in an upper and lower slot 43 provided in the runner 16. The inner vertical clearance of the connector 30 is provided in the same overall vertical dimension of the panel end edge male connector previously described in FIG. 6. The upper and lower slots 43 are provided at a preferred angle to the softwood runner 16 to influence the adjacent panel into a tight alignment during connection. The flooring surface 14 and upper subfloor 15 are detailed in the preferred manner in relationship to the connector 30 and softwood runner 16 allowing clearance to the end edge male connector of the adjacent panel.
FIG. 8 is an end view of the resilient pad encasement 38 which is affixed to a softwood runner 16 by means of a wood lag bolt 39. Individual resilient pads 40 are attached to the encasement 38 preferably by means of adhesive. A channel 45 is provided in the underside of the encasement 38 to allow clearance between the head of the wood lag bolt 39 and the substrate. The penetration area provided in the encasement 38 is oversized to the wood lag bolt 39 to allow vertical movement of the softwood runner 16 while the resilient pad encasement 38 remains stationary. Flange areas along each side of the encasement 38 align slightly higher than the lower edge of the softwood runner 16. This maintains the alignment of the encasement 38 in the proper position especially during assembly and disassembly of portable panels. FIG. 8 also details the flooring surface 14 which is attached to the upper subfloor 15 by means of a flooring fastener 33. The upper subfloor 15 is attached to the softwood runner 16 by means of subfloor staples 46.
FIG. 9 details the panel-to-panel side alignment prior to mechanical connection as well as after mechanical disconnection. The panel side edge male connector 25 is interlocked with the opposing panel side edge female connector 26. The anchorage of the female connector 26 to the softwood runner 16 is provided by means of the wood lag bolts 27. The anchoring hole 28 provided in the female connector 26 is tapered in a manner to provide ease of alignment when the male connector 25 of the opposing panel is placed. The position of the panels as detailed in FIG. 9 shows the traveling mechanism 24 in the forward extended position and limited threaded rod 18 protruding through the traveling mechanism 24. A cap 47 is attached to the end of threaded rod 18 to prevent disassembly of the threaded rod 18 from the traveling mechanism 24. The flooring surface 14 extends beyond the upper subfloor side edge tongue 34 and groove 35.
FIG. 10 details the opposing panel side edges in an interlocked position. The traveling mechanism 24 is detailed after moving into the reversed position as a result of clockwise movement of the threaded rod 18. The flooring surface 14 of the opposing panels are shown in position during assembly. Also detailed are the panel side edge tongue 34 and groove 35 assemblies which are interlocked below the flooring surface 14. Disassembly of the panels is facilitated by movement of the threaded rod 18 in the counterclockwise direction thereby forwarding the traveling mechanism 24. In turn the male connector 25 pushes against the side edge of the anchorage hole 28 of the female connector 26 forcing the opposing panels to separate as detailed in FIG. 9.
FIG. 11 is a top view detailing alignment of a portable panel 13 prior to interlocking mechanically to adjacent panels. Exposed views show the panel male side edge connectors 25 in position with the opposing panel female side edge connectors 26. Also detailed are panel end edge male connectors 29 in position to interlock with the opposed panel end edge female connectors 30. This detail illustrates the preference to angle the female connectors 30 slightly in relation to the opposing male connectors 29 to facilitate a movement of the panel 13 both toward the side and end edge as the panel 13 is mechanically interlocked.
FIG. 12 details the connectors as the panel 13 is in the interlocked position. The panel side edge male connectors 25 are detailed in the reverse position aligning the opposing panel side edge female connectors 26 below the edge of the panel 13. The panel end edge male connectors 29 and opposing female connectors 30 are interlocked as the panel 13 is mechanically moved into position.
FIG. 13 illustrates an alternative embodiment of an encasement for the resilient pad within the contemplation of this invention, similar to FIG. 8. The encasement 99 is affixed by penetrating softwood runner 16 with bolt 98.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | A resilient portable sports floor system, more particularly one which is formed of a plurality of components which may be easily interconnected to form an integrated sports surface. The floor system includes a plurality of floor panels, each floor panel including a playing surface and four sides, at least one floor panel attachment mechanisms on each side of the floor panel, and a drive mechanism attached to each of said floor panels and attached to a floor panel attachment mechanism, the drive mechanism including a threaded rod. When the threaded rod is rotated it moves the drive mechanism with respect to the floor panel. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to and claims the priority of U.S. Utility patent application Ser. No. 12/875,986, filed Sep. 3, 2010 which in turn is related to and claims the priority of U.S. Provisional Patent Application Ser. No. 61/239,649, filed Sep. 3, 2009; the disclosures of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to construction of a structural support column. More specifically, the present invention relates to a method and apparatus for building an expanded base pier to bypass weak soils and transfer structural loads to underlying strong soils.
BACKGROUND OF INVENTION
Heavy or settlement-sensitive facilities that are located in areas containing soft or weak soils are often supported on deep foundations, consisting of driven piles or drilled concrete columns. The deep foundations are designed to transfer the structure loads through the soft soils to more competent soil strata.
In recent years, aggregate columns have been increasingly used to support structures located in areas containing soft soils. The columns are designed to reinforce and strengthen the soft layer and minimize resulting settlements. The columns are constructed using a variety of methods including the drilling and tamping method described in U.S. Pat. Nos. 5,249,892 and 6,354,766; the driven mandrel method described in U.S. Pat. No. 6,425,713; the tamper head driven mandrel method described in U.S. Pat. No. 7,226,246; and the driven tapered mandrel method described in U.S. Pat. No. 7,326,004; the disclosures of which are incorporated by reference in their entirety.
The short aggregate column method (U.S. Pat. Nos. 5,249,892 and 6,354,766), which includes drilling or excavating a cavity, is an effective foundation solution when installed in cohesive soils where the sidewall stability of the hole is easily maintained. The method generally consists of: a) drilling a generally cylindrical cavity or hole in the foundation soil (typically around 30 inches); b) compacting the soil at the bottom of the cavity; c) installing a relatively thin lift of aggregate into the cavity (typically around 12-18 inches); d) tamping the aggregate lift with a specially designed beveled tamper head; and e) repeating the process to form an aggregate column generally extending to the ground surface. Fundamental to the process is the application of sufficient energy to the beveled tamper head such that the process builds up lateral stresses within the matrix soil up along the sides of the cavity during the sequential tamping. This lateral stress build up is important because it decreases the compressibility of the matrix soils and allows applied loads to be efficiently transferred to the matrix soils during column loading.
The tamper head driven mandrel method (U.S. Pat. No. 7,226,246) is a displacement form of the short aggregate column method. This method generally consists of driving a hollow pipe (mandrel) into the ground without the need for drilling. The pipe is fitted with a tamper head at the bottom which has a greater diameter than the pipe and which has a flat bottom and beveled sides. The mandrel is driven to the design bottom of column elevation, filled with aggregate and then lifted, allowing the aggregate to flow out of the pipe and into the cavity created by withdrawing the mandrel. The tamper head is then driven back down into the aggregate to compact the aggregate. The flat bottom shape of the tamper head compacts the aggregate; the beveled sides force the aggregate into the sidewalls of the hole thereby increasing the lateral stresses in the surrounding ground.
The driven tapered mandrel method (U.S. Pat. No. 7,326,004) is another means of creating an aggregate column with a displacement mandrel. In this case, the shape of the mandrel is a truncated cone, larger at the top than at the bottom, with a taper angle of about 1 to about 5 degrees from vertical. The mandrel is driven into the ground, causing the matrix soil to displace downwardly and laterally during driving. After reaching the design bottom of the column elevation, the mandrel is withdrawn, leaving a cone shaped cavity in the ground. The conical shape of the mandrel allows for temporarily stabilizing of the sidewalls of the hole such that aggregate may be introduced into the cavity from the ground surface. After placing a lift of aggregate, the mandrel is re-driven downward into the aggregate to compact the aggregate and force it sideways into the sidewalls of the hole. Sometimes, a larger mandrel is used to compact the aggregate near the top of the column.
U.S. Pat. No. 7,604,437 is related to a mandrel for making aggregate support columns wherein flow restrictors are provided to prevent upward movement of aggregate through the mandrel during driving of the mandrel. The mandrel contemplated in this art relates to formation of an aggregate support column such as described in U.S. Pat. Nos. 6,425,713 and 7,226,246 discussed above.
U.S. Pat. Nos. 4,992,002 and 6,773,208 relate to methods for casting a partially reinforced concrete pier in the ground. One method involves the use of an elongate mandrel with a cupped foot having a larger cross-sectional area than the mandrel, wherein flowable grout that is placed in the mandrel flows through openings located near the bottom of the mandrel into the space between the mandrel and the foot. The other method involves the installation of an elongate hollow tubular casing that is then filled with fluid concrete that is allowed to set while the casing remains in the ground. Each of these references is merely to concrete hardened inclusions and does not allow for the additional stability and strength provided by a pier that has an expanded base.
In the area of soil improvement, it is often desirable to install a stiff inclusion into the ground to transfer loads through a soft or weak soil layer. Although these soil layers may also be treated by non-cementitious aggregate columns, non-cementitious columns are typically confining-stress dependent (i.e., they rely on the strength of the sidewall soils to prevent bulging). Occasionally, it is desirable to utilize cementitious inclusions to bypass weak soils and transfer loads to underlying strong soils. The object of the present invention is to efficiently form a strong and stiff expanded base (either cementitious or non-cementitious) at the bottom of the column and to provide an efficient means for the introduction of grout, concrete, post-grouted aggregate, or other cementitious material through the upper portions of the column to form a cementitious inclusion.
BRIEF DESCRIPTION OF INVENTION
The present invention relates to a system for constructing a support column. A mandrel has an upper portion and a tamper head. A feed tube extends through the mandrel for feeding aggregate, concrete, grout, or other flowable materials to the tamper head. The tamper head includes a lower enlarged chamber with a reducing surface at an upper portion thereof for compacting aggregate or concrete and restricting upward flow of aggregate or concrete during compaction. The tamper head is of a size providing an enclosed region for allowing cementitious materials to be placed therein.
The invention may comprise a valve mechanism movable between an open position and a closed position for closing off the feed tube from communication with the tamper head during tamping operations and may comprising stiffening members secured between the reducing surface and the mandrel for providing load support during tamping operations. The invention may further comprise chains attached or notches within the interior of the tamper head for restricting upward flow of material into the feed tube during downward movement of the mandrel. A second tube may extend through the mandrel on the side of the feed tube for allowing cementitious material to flow upward through the second tube for inspection of the cementitious material during pumping. A hopper may be located at the top of the mandrel for feeding aggregate into the feed tube of the mandrel. A closure cap may be on an end of the feed tube opposite the tamper head and a concrete supply tube may be connected to the feed tube, and an air pressure source may be connected to the feed tube for evacuating concrete from the feed tube through air pressure supplied thereto.
A method of constructing such support columns with the system is also disclosed and may include providing the tamper head of a shape with a defined lower enlarged chamber having a reducing surface at an upper portion thereof for compaction and for restricting upward flow of material into the feed tube during tamping, the tamper head further sized to provide an enclosed region for allowing cementitious material to be placed therein; driving the mandrel assembly into a ground surface to a given depth thereby forming a cavity; lifting the mandrel assembly to release an initial charge of aggregate or concrete from the tamper head into a bottom of the cavity; re-driving the mandrel assembly to compact the aggregate or concrete at a bottom of the cavity and to form an expanded base, the expanded base having a width greater than the tamper head; and withdrawing the mandrel assembly while continuously feeding cementitious material or aggregate to be subsequently fully or partially treated with grout through the feed tube, thereby forming a cementitious inclusion at least partially within the cavity, the cementitious inclusion having a width of the cavity and being formed on top of the expanded base.
The method may further comprise introducing a pipe through the feed tube and tamper head after formation of the expanded base, placing aggregate during the withdrawing step to partially surround the pipe, and introducing cementitious material into the pipe following aggregate placement to treat the aggregate.
A method of constructing an expanded base pier with known expanded base volume is also disclosed. The method includes providing a mandrel assembly comprising a single-wall tube portion and a tamper head, the tube portion having an exterior diameter, wherein the tube portion is connected to the tamper head at an opening thereof for allowing flowable material to flow into the tamper head, and wherein the tamper head comprises a defined lower enlarged chamber having an interior diameter greater than the exterior diameter of the tube portion and further comprising a reducing surface at an upper portion thereof and comprising a plurality of chain links for compaction and for restricting upward flow of the flowable material into the tube portion during tamping, the tamper head further sized to provide an enclosed region for allowing the flowable material to be placed therein. The method also includes providing a non-moveable sealed top plate on an end of the tube portion opposite the tamper head and a separate flowable material supply tube coupled to the tube portion via a sealed connection; providing a pressure gauge for monitoring air pressure within the tube portion; driving the mandrel assembly having an initial volume of the flowable material into a ground surface to a given depth thereby forming a cavity; lifting the mandrel assembly to release the initial volume of the flowable material from the tamper head into a bottom of the cavity while adding a secondary volume of flowable material; re-driving the mandrel assembly wherein the plurality of chain links constrict and restrict to compact the initial and secondary volumes of flowable material at a bottom of the cavity and to form a unitary expanded base, the expanded base having a width greater than the width of the tamper head; measuring air pressure within the tube portion during the driving, lifting, and re-driving steps to determine a pressure drop indication; calculating a unitary expanded base volume based on the pressure drop indication and initial and secondary volumes added for comparison with a design expanded base volume; and upon reaching the design expanded base volume, withdrawing the mandrel assembly while continuously discharging cementitious material from the tamper head, thereby forming, after curing, a stiff cementitious inclusion having a width substantially equal to the width of the cavity and being formed above the expanded base.
The tamper head in the method may be filled with the initial charge of the flowable material before driving.
The method may further include introducing the flowable material into the enclosed region.
The method may further include providing the mandrel assembly with a second tube adjacent the tube portion and fluidly connected to the enlarged chamber to allow for an inspection of the flowable material during pumping.
The method may further include providing an air pressure source connected to the feed tube for evacuating flowable material from the feed tube through air pressure supplied thereto.
The flowable material may include one or more of aggregate, concrete, grout, and cementitious material.
The method may further include providing an air pressure release valve for reducing pressure in the feed tube or providing a pressure gauge for monitoring pressure within the feed tube.
An apparatus for constructing an expanded base pier with known expanded base volume is also disclosed and includes a mandrel assembly comprising a single-wall tube portion and a tamper head, the tube portion having an exterior diameter, wherein the tube portion is connected to the tamper head at an opening thereof for allowing flowable material to flow into the tamper head, and wherein the tamper head comprises a defined lower enlarged chamber having an interior diameter greater than the exterior diameter of the tube portion and further comprising a reducing surface at an upper portion thereof and comprising a plurality of chain links for compaction and for restricting upward flow of the flowable material into the tube portion during tamping, the tamper head further sized to provide an enclosed region for allowing the flowable material to be placed therein; a non-moveable sealed top plate on an end of the tube portion opposite the tamper head and a separate flowable material supply tube coupled to the tube portion via a sealed connection; and a pressure gauge for monitoring air pressure within the tube portion during driving, lifting, and re-driving steps of constructing an expanded base pier to determine a pressure drop indication for calculating a unitary expanded base volume based on the pressure drop indication and initial and secondary volumes added for comparison with a design expanded base volume.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following detailed description made with reference to the drawings, wherein:
FIG. 1 is a side cross-section view of a first embodiment of a mandrel;
FIG. 2 is a side cross-section view of a second embodiment of the mandrel with a valve;
FIG. 3 is a side cross-section view of a third embodiment of the mandrel with internal upward flow restrictors;
FIG. 4 is a side cross-section view of a fourth embodiment of the mandrel with a grout return pipe;
FIGS. 5A-5E illustrate a method of constructing a pier with the mandrel of FIG. 1 ;
FIGS. 6A-6F illustrate an alternate method of constructing a pier with one embodiment of the mandrel of the invention;
FIG. 7 is a side cross-section view of an alternative embodiment of the mandrel using a closed top system to allow air pressure to build;
FIG. 8 is a more detailed view of the operation of a closed top system including use of an external air source;
FIG. 9 is a graph showing results of load tests performed on columns made according to Example I as compared to reference piers;
FIGS. 10 and 11 are graphs showing results of load tests performed on columns made according to Example III;
FIGS. 12A-12E illustrate a method of constructing a pier with the mandrel of FIG. 8 according to Example IV; and
FIG. 13 is a graph showing measured and computed air pressures associated with the steps in the method according to Example IV.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the attached figures, various embodiments of a new and novel mandrel for forming an expanded base pier, as part of a hardened inclusion, is provided.
FIG. 1 illustrates an embodiment of a base mandrel assembly ( 1 ) contemplated herein. In this embodiment, a tamper head ( 2 ) is formed as a unitary structure attached to one end of a mandrel feed tube or feed pipe ( 4 ) to form the mandrel assembly ( 1 ). The feed pipe ( 4 ) can typically be 4″ to 12″ in diameter and has an upper end (not shown) opposite the tamper head ( 2 ) in which aggregate, concrete, grout, and other flowable material can be fed. The tamper head ( 2 ) typically comprises an enlarged lower chamber ( 3 ), typically 10″ to 24″ in diameter. The reducing surface ( 5 ) from the lower chamber walls to the feed pipe walls serves the function as a compaction plate for compacting aggregate or concrete as described hereinbelow, as well as serving as an upward flow restrictor while the initial aggregate is being driven such that the aggregate or concrete forms a “plug” within the chamber ( 3 ) and does not flow back up into the feed pipe ( 4 ). The reducing surface ( 5 ) may be angled as shown in FIG. 2 . The lower chamber ( 3 ) at the bottom of the head allows for formation of a densified bottom expanded base and provides an enclosed area for the placement of grout or concrete. Stiffeners ( 6 ) can also be placed between the feed pipe ( 4 ) and lower chamber ( 3 ) to assist in load transfer during driving.
FIG. 2 illustrates an embodiment of a base mandrel similar to FIG. 1 , but includes a special mechanical valve mechanism ( 7 ) that may be used to further block the flow of aggregate or concrete from the lower chamber ( 3 ) into the feed pipe ( 4 ). The valve mechanism ( 7 ) seats against the reducing surface ( 5 ) of the feed pipe ( 4 ) and physically restricts the flow of aggregate, or concrete, back up into the feed pipe during downward driving (as opposed to the “plug” formed as described above with reference to FIG. 1 ). When the feed pipe ( 4 ) is lifted, the mechanical valve mechanism ( 7 ) opens to allow the downward flow of grout, concrete, or other flowable material through the feed pipe ( 4 ) and into the lower chamber ( 3 ). The mechanical valve mechanism ( 7 ) may be manipulated by a pipe extending to the top of the mandrel or by a mechanism that pins the valve mechanism ( 7 ) to the sidewalls of the feed pipe ( 4 ).
The purpose of the valve mechanism ( 7 ) envisioned with reference to FIG. 2 is to allow subsequent compaction of the bottom aggregate or concrete expanded base initially placed and formed. For instance, the mandrel would first be driven in the ground with the lower chamber ( 3 ) charged with aggregate or concrete. The feed pipe ( 4 ) would then be lifted, and the mechanical valve mechanism ( 7 ) would open. Grout or concrete would then be added through the feed pipe ( 4 ). The mechanical valve mandrel assembly ( 1 ) would then be driven back down, thereby allowing for further compaction of the aggregate or concrete at the bottom to form an expanded base.
FIG. 3 illustrates another variation of the embodiment of FIG. 1 . More specifically, restrictor elements such as chain links ( 8 ) are attached within the tamper head ( 2 ) so that upon tamping, the chain links ( 8 ) move inward to constrict the aggregate or concrete in the lower chamber ( 3 ) and restrict aggregate or concrete from flowing upward into the feed tube ( 4 ). It is also envisioned that internal notches may be provided in lieu of chains in order to provide non-mechanical (or passive) upward flow restriction.
FIG. 4 illustrates a further embodiment of a mandrel similar to that shown in FIG. 1 but which includes a special provision for ensuring grout placement. Instead of having only a single chute feed pipe or tube ( 4 ) as shown in FIG. 1 , the embodiment contemplated with reference to FIG. 4 has a feed pipe including a mandrel feed pipe ( 4 ) and a grout return pipe ( 9 ) that is used to ensure that a continuous column of grout is installed. Positive flow of grout from the top of the grout return pipe ( 9 ) demonstrates that the mandrel is full of grout before or during mandrel extraction (lifting) operations.
A method of use is shown with reference to FIGS. 5A-5E , which shows an installation sequence with the base mandrel depicted in FIG. 1 . Step A ( FIG. 5A ) shows placing a mound ( 10 ) of the aggregate on the ground surface. Step B ( FIG. 5B ) shows driving the mandrel assembly ( 1 ) through the mound ( 10 ) of aggregate (to form an initial charge of aggregate) and to the final driving elevation. During the driving process, the aggregate (and chain links ( 8 ) in a constrict/restrict “bunched” form) in the lower chamber ( 3 ) forms a plug ( 11 ) in the neck of the feed pipe ( 4 ) at the bottom of the tamper head ( 2 ). The valve mechanism ( 7 ) shown in FIG. 2 or the chain links ( 8 ) shown in FIG. 3 may be used within the tamper head ( 2 ) to facilitate plugging. Step C ( FIG. 5C ) shows lifting of the mandrel assembly ( 1 ) wherein the aggregate plug ( 11 ) or initial charge remains in place at the bottom of the hole (it is understood that the initial charge may also be added after driving of a closed tamper head, such as with a sacrificial cap covering the bottom opening of the tamper head). Step D ( FIG. 5D ) shows re-driving the mandrel assembly ( 1 ) one or more times to compact the aggregate at the bottom of the hole and to form an expanded base ( 12 ). Grout or concrete ( 13 ) may then be pumped through the feed pipe as shown. Step E ( FIG. 5E ) shows placing grout or concrete ( 13 ) from the element up from the bottom while removing the mandrel. When the grout return pipe ( 9 ) as shown in FIG. 4 is used in conjunction with Step E of the construction process, grout continuity within the mandrel shaft is determined if grout continues to flow out of the grout return pipe ( 9 ) during extraction. The finished support column comprises an expanded base with a cementitious inclusion located thereon.
An alternative method of use can also be used with reference to FIGS. 5A-5E . Step A consists of filling the lower chamber ( 3 ) of the tamper head ( 2 ) with concrete. This may be achieved by driving the tamper head ( 2 ) through a mound ( 10 ) of concrete as shown in FIG. 5A or by pumping concrete through the feed tube ( 4 ) while the tamper head ( 2 ) is resting on the ground surface. In this case, the ground surface seals the concrete from flowing out of the bottom of the lower chamber ( 3 ). As shown in FIG. 5B , the tamper head ( 2 ) with chain links ( 8 ) is then driven to design elevation with the concrete at the bottom of the tamper head ( 2 ) forming a plug ( 11 ) at the bottom of the assembly mandrel ( 1 ). The valve mechanism ( 7 ) shown in FIG. 2 or the chain links ( 8 ) shown in FIG. 3 may be used within the tamper head ( 2 ) to facilitate plugging. Step C shows the retraction (lifting) of the assembly ( 2 ) to allow the concrete to flow out of the bottom of the tamper head ( 2 ). Step D shows the placement of additional concrete ( 13 ) through the feed pipe ( 4 ) and the subsequent or simultaneous lowering of the mandrel assembly ( 1 ) onto the previously placed concrete to force the concrete outward thus forming an expanded base ( 12 ). Step E shows the simultaneous placement of grout or concrete ( 13 ) through the feed tube ( 4 ) while extracting the mandrel assembly ( 1 ) to the ground surface. This technique forms an expanded base pier comprised of concrete at the expanded base ( 12 ) and concrete within the pier shaft (or inclusion) on top of the expanded base ( 12 ).
The benefits of the system contemplated herein are the efficient formation of an expanded base ( 12 ) that allows load to be transferred to the bottom of the pier and the very quick and efficient formation of the grouted inclusion by rapidly raising the mandrel while placing grout or concrete ( 13 ). While the method sequence of FIGS. 5A-5E depicts the use of the base mandrel shown in FIG. 1 , it is envisioned that the method could principally be used with any of the mandrels shown in FIGS. 1-4 .
FIGS. 6A-6F shows an alternative construction sequence where Steps A through C ( FIGS. 6A-6C ) are generally as described above with reference to the initial charge of aggregate being in the lower chamber (see FIGS. 5A-5C ). In Step D ( FIG. 6D ) of this sequence, the mandrel assembly ( 1 ) is lowered engaging the chain links ( 8 ) to compact the aggregate and a secondary disposable pipe ( 14 ) is inserted into the mandrel assembly ( 1 ) to rest on the expanded base ( 12 ). In Step E ( FIG. 6E ) the mandrel assembly ( 1 ) is raised and additional aggregate ( 15 ) is allowed to fill the annular space between the disposable pipe ( 14 ) and the sidewall of the cavity ( 16 ). A hopper ( 17 ) can be used to place the aggregate ( 15 ) within the feed pipe ( 4 ). The aggregate ( 15 ) placed in this step is not compacted. In Step F ( FIG. 6F ) the disposable pipe ( 14 ) is then used as a conduit to place grout into the inclusion by filling the voids in the loose aggregate ( 15 ) around the disposable pipe ( 14 ). Typically, the disposable pipe ( 14 ) is not removed but can be cut at ground level or just below ground level and made part of the permanent inclusion. Additionally, while FIGS. 6D-6F depict representative grout ports at the bottom end of disposable pipe ( 14 ), it is understood that such ports or other openings can be located partially or fully along the length of disposable pipe ( 14 ).
FIG. 7 illustrates a further embodiment of a mandrel similar to that shown in FIG. 1 but which includes a closed system for the placement of concrete, grout, or other flowable materials. The mandrel of this embodiment includes an external feed tube ( 18 ) that enters the mandrel feed tube ( 4 ) near the top of the mandrel to allow for the passage of a flowable material. The external feed tube ( 18 ) is used to pump concrete, grout, or other flowable materials into the mandrel feed tube ( 4 ). The top of the mandrel is sealed with a top plate ( 21 ) making this a closed system. An air pressure gage ( 20 ) may optionally be installed to measure the internal air pressure within the mandrel and allow for the use of a pressure release valve ( 22 ) to facilitate removal of excess internal pressure during pumping. The mandrel system of FIG. 7 may be used in conjunction with the construction sequences shown in FIGS. 5A-5E .
FIG. 8 illustrates yet another embodiment of the mandrel similar to that shown in FIG. 7 . In this embodiment, an air source, such as compressor ( 24 ), may optionally be used to apply elevated air pressure to trapped air ( 23 ) within the mandrel feed pipe ( 4 ) to evacuate concrete ( 13 ) from the mandrel.
The following examples illustrate further aspects of the invention.
EXAMPLE I
As an example, an embodiment of the system of the present invention was used to install a support column, also described herein as an expanded base pier (“EBP”), at a test site in Iowa. The test site was characterized by 4 feet of sandy lean clay underlain by sand. This testing program was designed to compare the load versus deflection characteristics of this embodiment of the EBP to reference piers constructed in successive lifts, such as a pier constructed by the tamper head driven mandrel method. The reference piers of this example had a nominal diameter of 20 inches and an installed length of 23 feet. One reference pier was constructed of aggregate only to a diameter of 20 inches. Another reference pier was constructed with a grout additive, commonly referred to as grouted pier, to a diameter of 14 inches.
In this embodiment of the invention, the EBP was formed by filling the extractable mandrel ( FIG. 3 ) with a combination of open graded aggregate and fluid grout. The mandrel had a lower chamber ( 3 ) outside diameter of 14 inches and a feed pipe ( 4 ) outside diameter of 12 inches. The mandrel included the chain links ( 8 ) shown in FIG. 3 . The mandrel of this embodiment was connected at its open end (opposite the tamper head) to an open hopper for filling and was attached to a high frequency hammer which is often associated with driving sheet piles. The hammer is capable of providing both downward force and vibratory energy. The full mandrel was advanced to a depth of 23 feet below the ground surface. The mandrel assembly was then raised 3 feet and lowered 3 feet a total of 3 times to form a bottom expanded base. Each raising and lowering of the mandrel is referred to as a “stroke.” The mandrel was then raised 3 feet, lowered 2 feet, and then slowly extracted to the ground surface allowing a column of grout and aggregate to be placed in the cavity created during mandrel installation. The EBP was constructed with a base diameter of 20 inches, and a shaft diameter of 14 inches. Once the mandrel was fully extracted, a 1 inch diameter reinforcing steel rod was inserted the full length of the EBP. A concrete cap was then poured above the EBP to facilitate load testing.
The reference piers and the EBP were load tested using a hydraulic jack pushing against a test frame. FIG. 9 shows the results of the load test of the EBP compared with the reference piers. At a top of pier deflection of 0.5 inches, the reference pier with aggregate supported a load of about 23,300 pounds, the reference pier with grout supported a load of about 50,000 pounds, and the EBP supported a load of about 70,300 pounds. At a top of pier deflection of 1 inch, the reference pier with aggregate supported a load of about 38,800 pounds, the reference pier with grout supported a load of about 62,700 pounds, and the EBP supported a load of about 97,000 pounds. The load carrying capacity of the pier constructed in accordance with this embodiment of the present invention showed a 2.5 to 3 fold improvement when compared to a reference pier with aggregate, and a 1.4 to 1.5 fold improvement when compared to a reference pier with grout. The difference in the behavior relative to the grouted pier is caused by the formation of the bottom expanded base during the construction of the EBP according to the invention.
EXAMPLE II
As another example, the system of another embodiment of the present invention was used to install five EBP elements at a test site in Virginia. The test site was characterized by hard clay. Prior to installation of the EBP, 30 inch diameter drill holes were excavated to a depth of 8 feet below the ground surface. The voids were then loosely backfilled with sand. The EBP elements of this example were formed within the backfilled holes.
In this embodiment of the invention, the EBP was formed by filling the mandrel described in FIG. 7 with concrete. The mandrel of this embodiment featured a “closed top” as opposed to the “open hopper” configuration as described with reference to Example I. The mandrel in this embodiment was attached to a similar hammer as in the embodiment of Example I. The full mandrel was advanced to a depth of 8 feet below the ground surface. The mandrel was then raised 3 feet, and then lowered 2 feet for three repetitions to create the expanded base. A process of raising the mandrel 3 feet, and then lowering 1 foot was then used to complete the full length of the pier. Once the concrete had cured, each of the piers was excavated and the pier base and shaft diameters were measured.
The lower chamber in this embodiment had a nominal 12 inch diameter outer dimension. The excavated and measured piers had an average nominal diameter of 18 inches. Expanded bases at the bottoms of the piers exceeded 24 inches demonstrating the effectiveness of this construction technique.
EXAMPLE III
As yet another example, the embodiment of the present invention from Example II was used on a site in Washington, D.C. The site was characterized by 20 to 30 feet of soft clay and clayey sand underlain by dense sand or hard clay. The embodiment of the present invention at the site was used to support mechanically stabilized earth (MSE) walls and embankments. The mandrel used for this project was similar to that used in Example II. The lower chamber in this embodiment had a nominal 18 inch diameter outer dimension. In this example, two fully concrete EBP were constructed and subsequently load tested. In this example of the embodiment, the EBP were constructed with a 24 inch diameter expanded base, and an 18 inch diameter shaft.
In this embodiment of the invention, the EBP was formed by filling the mandrel (such as in FIG. 7 or FIG. 8 ) with concrete. The full mandrel was then advanced to a depth of 26 feet below the ground surface for Test Pier 1 and to a depth of 36.5 feet below the ground surface for Test Pier 2. The mandrel was then raised 4 feet, and then lowered 3 feet. The process of raising the mandrel 4 feet, and then lowering 3 feet was completed for a total of 4 cycles at the test piers to create an expanded base. After the expanded base was created, the mandrel was extracted at a constant rate while pumping concrete into the mandrel. Once the concrete had cured, each of the piers was load tested.
The load tests were performed using Statnamic load test methods. FIG. 10 shows the results of the load test on Test Pier 1 (26 feet below ground surface) and FIG. 11 shows the results of the load test on Test Pier 2 (36.5 feet below the ground surface—two test load cycles on this test pier). Both Test Pier 1 and Test Pier 2 supported a test load of approximately 425 kips at 1 inch of top of pier deflection, with a maximum supported load of approximately 575 kips.
EXAMPLE IV
As yet another example, a method of use is shown with reference to FIGS. 12A-12E , which shows an installation sequence with the base mandrel depicted in FIG. 8 . The method shown in FIGS. 12A-12E uses air pressure measurements to determine the volume of concrete or aggregate that is flowed both into and out of the mandrel. In FIGS. 12A-12E , the mandrel assembly ( 1 ) includes the chain links ( 8 ), the air pressure gage ( 20 ) and the air source ( 24 ) supplying an air input port ( 25 ) near the top of the feed pipe ( 4 ).
During installation, mandrel air pressure and volumes of pumped concrete were recorded for each installation step. The results of the measurements are shown by the data labeled “Measured Pressure” in FIG. 13 . The measurements were then compared to the theoretical or pressure/volume relationship (labeled “Theoretical Pressure”) for ideal gasses represented by the equation: PV=nRT, wherein P is air pressure, V is air volume, n is number of moles of air (constant), R is a constant, and T is temperature in degrees Kelvin. The volume (V) of air inside the mandrel at any step may be determined by the initial mandrel volume less the volume of pumped concrete and adjusted for the volume of concrete placed during construction. Once the air volume in the mandrel is known, then the air pressure that should correspond to this volume can be computed. Similarly, once the pressure is measured, then the volume of air and concrete in the mandrel can be computed.
Step A ( FIG. 12A ) shows placing a mound ( 10 ) of the aggregate on the ground surface (wherein the air pressure of air within mandrel feed pipe ( 4 ) is equal to atmospheric pressure, namely 14.7 pounds per square inch (psi), as shown in FIG. 13 ). Step B ( FIG. 12B ) shows driving the mandrel assembly ( 1 ) through the mound ( 10 ) of aggregate (to form an initial charge of aggregate) and to the final driving elevation. During the driving process, the aggregate and the “bunched” chain links ( 8 ) in the lower chamber ( 3 ) forms a plug ( 11 ) in the neck of the feed pipe ( 4 ) at the bottom of the tamper head ( 2 ). Further, grout or concrete ( 13 ) is pumped into the feed pipe ( 4 ) (see FIG. 8 ). A certain amount of trapped air ( 23 ), which is now under pressure, is within the mandrel feed pipe ( 4 ). The air pressure is measured at the end of this initial filling of the mandrel. The measured air pressure can be compared to the theoretical air pressure as shown on FIG. 13 .
Step C ( FIG. 12C ) shows lifting of the mandrel assembly ( 1 ) wherein the aggregate plug ( 11 ) or initial charge remains in place at the bottom of the hole. Again, the mandrel feed pipe ( 4 ) includes both a volume of pressurized trapped air ( 23 ) and a volume of grout or concrete ( 13 ) wherein there is a drop in air pressure due to exiting of the aggregate. Step D ( FIG. 12D ) shows re-driving the mandrel assembly ( 1 ) to compact the aggregate at the bottom of the hole (with corresponding slight increase in air pressure). Steps C and D can be repeated one or more times to form an expanded base ( 12 ) (see repeated steps and measurements in FIG. 13 ). Grout or concrete ( 13 ) continues to be pumped through the feed pipe as shown. Step E ( FIG. 12E ) shows placing grout or concrete ( 13 ) for the element up from the bottom while removing the mandrel until air pressure in the mandrel again reaches atmospheric pressure.
During Steps C, D, and E, the pump strokes were measured to determine the volume of grout or concrete ( 13 ) flowed into the mandrel feed pipe ( 4 ) on the down stroke. Then, because the volume of the mandrel is known, the volume of air remaining in the mandrel was determined. Then, when the mandrel is pulled to the ground surface at the end of Step E, the volume of grout or concrete ( 13 ) placed was computed and the drop in air pressure was measured.
FIG. 13 shows excellent correlation between the measured and computed air pressures for each step indicating the veracity of the procedure. Thus, the present measuring system provides an excellent means of determining concrete volumes at every step in the process.
The foregoing detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the invention. Other embodiments having different structures and operations do not depart from the scope of the invention. The term “the invention” or the like is used with reference to certain specific examples of the many alternative aspects or embodiments of the applicant's invention set forth in this specification, and neither its use nor its absence is intended to limit the scope of the applicant's invention or the scope of the claims. This specification is divided into sections for the convenience of the reader only. Headings should not be construed as limiting of the scope of the invention. The definitions are intended as a part of the description of the invention. It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation. | A system for constructing a support column includes a mandrel with an upper portion and a tamper head. A feed tube extends through the mandrel for feeding flowable material to the head. The tamper head includes a lower enlarged chamber with a reducing surface at an upper portion and includes a plurality of chain links for compacting material and restricting upward flow of aggregate. The tamper head is of a size providing an enclosed region for allowing cementitious materials to be placed therein. A non-moveable sealed top plate and a separate flowable material supply tube is included via a sealed connection. A pressure gauge for monitoring air pressure within the tube portion is included and allows a support column including a cementitious inclusion on top of an expanded base to be built with a known unitary expanded base volume calculated based on pressure drop indications. |
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Ser. No. 09/784,848, filed Feb. 16, 2001 under the title “AUTOCLAVED AERATED CONCRETE PANELS AND METHODS OF MANUFACTURING, AND CONSTRUCTION USING AUTOCLAVED AERATED CONCRETE PANELS”, and Ser. No. 09/741,787, filed Dec. 21, 2000 under the title “METHODS OF MANUFACTURING AND CONSTRUCTING A HABITABLE, CEMENTITIOUS STRUCTURE”, by the inventor hereof, where the contents thereof are incorporated herein in their entirety.
FIELD OF THE INVENTION
[0002] This invention is directed to the field of manufacturing and building structures, such as dwellings, and more particularly to a system for manufacturing structures of cementitious materials of an autoclaved aerated cementitious concrete.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a system for manufacturing structures of cementitious materials, and to unique techniques for finishing various features of the structures. The construction industry is basically unchanged in materials and processes for hundreds of years, while during this same time most other industries have been revolutionized. The consequence is that there is vast room, and need, for improvement in the construction industry, for the lack of improvement has resulted in escalating costs and a compounding of negative impact on the environment.
[0004] The construction industry has sought alternative building The construction industry has sought alternative building materials and techniques in order to limit the traditional expenses of construction. The costs include the high energy costs of manufacturing, increasing scarcity of quality materials and the rising cost of available materials, and increasingly expensive construction labor. Regrettably, the majority of solutions employed so far have only resulted in an increasingly inferior quality to finished product. Consumers desire to lessen the negative environmental impact (i.e.: deforestation, mining and pollution from manufacturing) and negative health effects (i.e.: fluorocarbons and other harmful gases, mold from decay) of some building materials. These factors have forced home builders in particular to consider new construction materials. These new materials must be versatile, easy to use, durable, and energy efficient.
[0005] An alternative to the conventional building materials is what may be called Autoclaved Aerated Concrete, hereinafter referred to as “AAC”. AAC is superior to current building materials and is extremely environmentally friendly. That is, the teachings hereof will substantially reduce global warming by preserving forests. While this invention applies to any cementitious material which can employ the teachings of this invention, AAC is a preferred material and the further description will be so limited.
[0006] AAC was invented in the early 1900's and consists of a mixture of cement, aluminum powder, lime, water and finely ground sand. This mixture expands dramatically, and this “foamed” concrete is allowed to harden in a mold, followed by curing of the hardened mixture in a pressurized steam chamber, or autoclave. Commercial production of AAC began in the 1930's, and presently more than 31 million cubic meters have been produced worldwide.
[0007] Compared to wood, steel and standard concrete, AAC is a clearly superior material as it is fire proof, termite proof, self insulating, sound insulating, non decaying and does not rust. Compared to concrete, AAC weighs 30% less than traditional concrete masonry units. Additionally, AAC is well known as an environmentally friendly construction material with certain manufacturing plants receiving recognition as being “Green Factories.” Compared to the energy consumed in production of many other basic building materials, only a fraction is required to produce AAC. Raw materials consumption is very low for the amount of finished product produced. In the manufacturing process, no pollutants or toxic by-products are produced. AAC is also completely recyclable.
[0008] AAC is an inorganic material that contains no toxic substances. It does not slowly decompose nor emit a gas. Since AAC is both a structural and insulation material it allows the elimination of other materials that can contribute to poor indoor air quality. Due to its inorganic structure, AAC also eliminates the food source condition required to be present for microbial growth to occur. Thus, AAC is resistant to water penetration and decay. As it is a solid cementitious building material, insect (roaches, ants) and rodent (rats, mice) infestation is impossible within walls and floors as there are no cavities as now occurs in standard frame construction.
[0009] Further, AAC is non-combustible, so in the case of fire it can help prevent the fire from spreading to other rooms. During a fire, no toxic gases or vapors are ever emitted from inorganic AAC. As building methods using AAC include using solid blocks and panels with very simple connection details, the ease of construction helps to ensure a monolithic, highly fire-resistant wall.
[0010] AAC buildings, as described by this invention, can be very energy efficient. This efficiency is due to a combination of high R-value, thermal mass and air-tightness. AAC is the only product currently available that meets Germany's stringent energy codes without added insulation. It is well documented that the R-value of a mass product need not be as high as that of light frame construction, to perform thermally efficiently.
[0011] AAC products are unfinished. Depending on the building use or the aesthetic requirements, AAC may be coated with an exterior surface finish of approved stucco, stone, brick-veneer, wood siding with furring, or a combination thereof. On the interior AAC usually has sheetrock installed over furring strips due to utilities and numerous joints of blocks.
[0012] While the construction industry recognized certain advantages in the use of AAC components for building, no system exists to effectively take advantage of the superior qualities of AAC in a cost effective manner. In fact, even though AAC is itself considered a vastly superior construction material than current construction industry standard wood, steel and/or concrete, the prior methodologies employed in AAC construction cause ACC to be so much more labor intensive and costlier than current standard construction materials, that the negatives of prior methodologies of AAC construction basically outweigh AAC's inherit advantages and so prohibit AAC from being considered as a viable alternative. The teachings of this invention not only eliminate these prohibitive negatives, they so facilitate the construction of AAC habitats that AAC habitats now can be built in less time and for less end use cost than conventional materials, with the underlying theme being the construction industry's prerequisite “simpler, better, cheaper” motto.
DESCRIPTION OF PRIOR ART
[0013] Despite the early development of AAC as a potential building material, there is little in the patent prior art. There is a recent patent, U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994, which relates to only a manufacturing process using a modified composition for AAC. While it is helpful in finding a beneficial use for what is now a waste product, it in no way addresses any of previously mentioned problems prohibiting AAC's market acceptance. So while it is helpful in finding a beneficial use for what is now a waste product, it fails in that AAC still has no way of being successful in construction industry, so it is dependent upon this invention for its success.
[0014] The present invention is a synergistic whole, completed structure as a precast concrete system and may appear similar to U.S. Pat. No. 5,761,862 to Hendershot et al., Jun. 9, 1998, but that is due only to also emulating a residential structure, as the very nature of material used and processes employed are incompatible. Of the searched Prior Art, it is the closest, yet upon closer inspection it is vastly different in every respect. Hendershot uses a very complex steel reinforcing and joint system, bonding system requiring flared coil loops and sheebolts, structural bearing system requires complex precast steel mechanism, and a hip roof cannot be constructed as even simple dormers are reduced to nothing more than exterior architectural accents placed over constructed roof All prior art requires great quantities of steel reinforcing, steel brackets, mechanisms and/or laborious, precise manufacturing processes facilitating site construction.
[0015] Wall process: U.S. Pat. No. 6,098,357 Franklin et.al., Aug. 8, 2000, cites well the problems of all prior art's various block wall systems. Yet, itself requires additional materials for architectural finish, its process of uniquely formed and dimensional blocks greatly exceed the minimal three block vertical height of current art, requires additional steel anchor system, does not even address the problem of utility locations in walls and it is composed of inferior material lacking all the innate attributes of AAC. Referring again to U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994, fails in its design in FIG. 5 and description to be so unfeasible that they are only intended as an example of product and no way intended as representative of a construction system. The present invention's processes and articles of manufacture allow for the temperature transfer system which heats/cools the wall for specific purpose of countering exterior environment's temperature effects on wall material. Most prior art is concerned with radiant heating of interior and not stabilizing the insulate properties of the wall's material, therefore their design and processes are either inadequate or unfeasible.
[0016] In this invention's support beam system for roof, etc., the prior art of U.S. Pat. No. 4,285,179, Goidinger, employs a lightweight cementitious material in panel form that has longitudinal cavities that are filled with heavy standard type concrete and optionally reinforcing steel which makes vertical wall panels load bearing. The roof beam system hereof with optional reinforcing channel, is novel for following reasons: 1) Goidinger is specifically vertical walls, 2) due to incompatible uses are structurally and dimensionally dissimilar, 3) while Goidinger has internal cavities formed by sandwiching formed wide panel halves together, the solid rectangular beams hereof have much thicker exterior AAC for distinct purpose of receiving “R” screws or similar fasteners and can be shaped in angles to equal roof panel's pitch, 4) beams can have corrugated shaped channel system adding strength and additionally preventing added cement from adhering too quickly to dry sides preventing added cement from adhering too quickly to dry sides and clogging cavity and therefore preventing it from being completely filled, which can be a serious failure problem of Goidinger, and lastly 5) has a utility channel. It is unobvious as no other prior art has specific use of: 1) weaker material used for a structural purpose of receiving fasteners, 2) used solely for structural, load bearing beams spanning space, as without the present invention screws and interlocking beam ends it was almost impossible to engineer such a system for practical application. In regards to beam's interlocking ends, there is no prior art in cementitious material, but U.S. Pat. No. 4,409,763, Rydeem, Oct. 18, 1983 uses a great wood system of one vertically oriented dowel to secure a plurality of intersecting beam ends onto a post, but has no method for a suspended, self supporting, load bearing beam system spanning space. Again, all other prior art in cementitious materials employ complex, heavy-duty steel brackets, support/reinforcing, etc., and still cannot accomplish process of invention.
[0017] Presently, there is great waste in conventional roof construction to accomplish the desired architectural look of multiple hips, ridges and valleys. In U.S. Pat. No. 5,794,386, to Klein, Aug. 18, 1998, there is taught a roofing system. More specifically, the patent is directed to a roof panel for sloped roofs and includes a self-supporting reinforced plate of cementitious materials, wherein the reinforcement above the plate has bars running along the slope of the roof. Compared to the present invention it is a very complicated, costly combination of cement and steel reinforcing.
[0018] Another aspect of this invention's roof system is its gravity induced internalized gutter system. All prior art with internalized gutter systems for pre-cast concrete panels (Meyers, U.S. Pat. No. 723,175; Novoa, U.S. Pat. No. 3,603,052; Rook, U.S. Pat. No. 6,006,480) rely on force from additional moisture to push accumulated previous moisture out of a level, straight gutter system, and the results are problems of residual moisture and accumulated debris causing damage to gutter system and structure. U.S. Pat. No. 929,684, Mills & Taylor, Aug. 3, 1909, is an example of common design deficiency allowing moisture to run down the face so that debris residue leaves streaks and moisture angle water deflection system.
[0019] No prior art addresses either processes or compositions of matter of this invention's roofs water proofing system. Only U.S. Pat. No. 5,981,030 Haupt et al, Nov. 9, 1999 has a figure similar in appearance, but by closer inspection thereof, and by reading the detailed description, the following incompatibilities, physical differences and new unrelated processes become clear: 1) is not used for waterproofing but rather water retention which defeats process of facilitating removal of vapor from AAC roof panels, 2) its process is a solid mass for water retention and not air cavities for venting, 3) the materials used are completely different and incompatible, 4) while absorber ( 4 ) is held in place by fleece ( 1 ) and joined to base material ( 5 ) by a laminate ( 2 ), there is no continuity as absorption is confined to small areas ( 6 ), the laminate does not coat entire product but on specific areas ( 6 ), the fleece has no structural purpose other than to hold absorber ( 4 ), 4 ) quilted absorber areas are of various sizes and perforated coating film contradict teaching of this invention. There is no prior art, nor proven commercial product for matter of composition which will be a satisfactory alternative roof water proofing system. Heretofore AAC roofs were forced to use conventional roofing materials that are labor intensive, costly, add tremendous weight to roof system, and are for the most part environmentally harmful.
[0020] While there are pre-cast roof panel systems in the prior art, none could emulate the ridges and valleys of contemporary rooflines. Current methods of wood construction use nominal 4′×8′ sheets of processed wood, i.e. plywood, which results in large amounts of waste.
[0021] When an existing wood structure requires roofing replacement, prior art systems had no satisfactory way to permanently fasten AAC panels to the wood rafters, nor was there a roofing product light enough for wood structure to support both the AAC panels followed by the heavy roofing material.
[0022] In areas requiring sound control, such as near airports, etc., there was no cost effective way to sound proof the roof of a house while simultaneously making it energy efficient and environmentally friendly.
[0023] For multi-story buildings, Prior Art U.S. Pat. No. 723,175, Meyers, Mar. 17, 1903 is only prior art of a remote reference to ring/bond beam floor panel and corbel ring/bond beam as the patent shows a wall with floor and roof being incorporated into a single monolithic unit without a separate ring/bond beam. The processes it employs of a mold into which concrete is poured is incompatible with this invention which uses pre-cast pieces.
[0024] U.S. Pat. No. 5,143,498, Whitman, Sep. 1, 1992 has a screw with a chamber with laterally disposed openings that are to disperse liquid sealant. The Whitman screw has a single chamber for dispersing sealant which attaches to rubber material as material presses against openings and exterior wall of screw's shaft, which may work for it as it has a screw head which remains exposed outside material and a tight configuration of threads ideal for rubber. U.S. Pat. No. 5,249,899, Wilson, Oct. 5, 1993 employs a shaft for dispersing an adhesive through openings located in a recessed thread which works for it since it is used for pre drilled, machined metals, but would be useless in cementitious product as dust would clog. U.S. Pat. No. 5,516,248, DeHaitre, May 14, 1996 has a plurality of outwardly projecting serrations which burr into the work piece for self locking, but the design is limited to that sole use and design is counter productive in a cementitious material. Standard rebar requires drilling a hole, inserting rebar and then mortar, and in method cannot hold inclined pieces in place.
[0025] While there are many references to prior art for tools of routing and reciprocating saws with plunging process, U.S. Pat. No. 5,682,934, Rybski, Nov. 4, 1997; U.S. Pat. No. 5,240,052, Davison, Aug., 31, 1993 references are closest related to this invention, yet they are more complex, confined to independent actions performed on individual pieces at a work station requiring pieces to be later combined with other pieces at site, and are restricted by complexity of guide or design's dimensional limitations as systems lose feasibility when enlarged so cannot create and finish large openings and/or architecturally finish large surfaces of permanent placed, vertically positioned structural material.
[0026] U.S. Pat. No. 721178, E. P. Golden, Feb. 24, 1903 does not apply to joint finishing tool as it is for process of removing a prescribed depth of material surface and not just cleaning off an excess of a different material from surface, the patent shows it has two wheels to each side of blade vs. one elongated wheel which serves additional function of smoothing out and imprinting residual material, FIG. 4 shows pressure is exerted on rear positioned blade vs. on rear rolling pin like wheel which drives neutral front positioned blade.
[0027] U.S. patent to Planchon, Mar. 22, 1995 shows a reciprocating saw blade with unique tip for starting a hole and cutting, but not a good method for holding tool in position while blade starts hole as one of problems will be maintaining blade in starting hole without opening template guide and tool guide arms.
[0028] It is now understood that all prior art and standard industry methodologies employ complex, expensive and labor-intensive combinations of concrete with heavy-duty steel reinforcing and structural support systems/beams that employ complex steel fastening systems.
SUMMARY OF THE INVENTION
[0029] Present invention was forced to develop new processes, machines, articles of manufacture and compositions of matter for the effective use of cementitious AAC panels, blocks and shapes for the construction of environmentally friendly habitats. Upon review of Introductory Figures of Prior Art/Current Methodology, it will be noticed that there is not one component that is not either completely unique or modified in such a manner that the resultant process is completely new. Entire structural habitat can be constructed of cementitious product without use of steel support beams, interlocking steel brackets, bolts or other common steel parts (only rebar as building code requires), gutters, down spouts, wood trim, casing, and /or molding, nor conventional roofing materials, yet has the same degree of functionality as a conventional dwelling with these features.
[0030] It was discovered that large, precisely dimensioned elements of AAC allow for rapid construction as compared to conventional brick and CMU (concrete block). Their greater dimensional accuracy requires less on site adjustment. The combination of large size and dimensional accuracy allows greatly increased productivity. Due to the light-weight of AAC, reduced equipment demands are realized.
[0031] The walls employ processes of minimizing vertical blocks. There are two wall block sizes: mini-wall and wall block. Their differing contributions to wall process will be detailed later. But each wall block has invention's utility channel and is coordinated with other blocks of invention's processes. Each block serves a specific function in the wall itself as well as replacing as many as four separate items required in current construction.
[0032] Invention's process of constructing walls of cementitious blocks, such as AAC, is superior in minimal quantity of two vertical components (wall block and top block—with casing block for openings) and three vertical components (base block, mini-wall block and top block—with casing block for openings), structural pieces are pre-finished and simply installed as specified (base, casing, top, crown), are constructed so utilities are inside walls which have finished surface including architectural effects ready for painting.
[0033] Openings for windows and doors use present art's casing block with utility chase system and are dimensionally located with components of this invention's process on one foot centers so entire dwelling is an unified dimensional process thereby a standard 8′ high wall uses three components vertically and horizontally can have virtually no waste. Invention's alternative process of wall block system allows for all advantages of vertical three block system with less labor as requires only invention's utility channel slot at base which coordinates with utility channel in other articles of manufacture such as casing blocks, etc. To fully appreciate wall block system, to be cost effective in manufacturing and field requires adding 6″ of length to AAC industry's standard 20′ slurry mold so three full lengths of 82″ wall blocks and matching casing blocks can be produced without waste.
[0034] Returning to the current manufacturing capabilities, casing blocks, etc. are horizontally dimensional for 1′ and 2′ center construction. Single wall block is not called a panel as steel reinforcing is not required which is substantial savings. Casing blocks can be omitted and architectural effect added into wall blocks and Top Block using invention's tools.
[0035] One example of an advantage of this invention over prior methodology of AAC construction and prior art of CMU block, by using the traditional solid blocks and/or panels there was no good means to provide a finished interior wall without first using wood furring strips and externally positioning electrical utility boxes and wiring which further meant that wood studs and sheetrock or dry wall panels were required; consequently basically requiring two wall systems, or, alternatively routing and then inserting conduit and then having to repair walls. All this added substantial extra labor and material costs to the construction using AAC panels and blocks. Current art's internal “utility channel” system allows all utilities to be placed inside wall during construction and with special “fishing curve” and “multi conduit” inserts allow utilities to be placed within wall even after construction. The current art's utility channel system, inserts and architectural finish provide a structurally superior finished wall with surface simply requiring paint and/or wallpaper as a normal finished sheetrock wall. Current art eliminates all labor and/or forest materials of constructing an additional wall system. Current art even eliminates need for finished wood trim by architecturally finished blocks and invention's tools that are designed to finish vertical, and even upside down, surfaces. Current art's unique wall block system has not only saved labor and materials as compared to conventional AAC construction, it has actually made AAC less expensive and labor intensive than standard construction materials and methodologies.
[0036] The top course of a wall is constructed using top block/beam that is dimensionally sized at +/−16″. It can be manufactured as a block or a continuous beam, as it can be reinforced and even house invention's air duct system. An industry standard 2′ wide panel can be substituted for top block, as wall block's unique shape is critical for process.
[0037] A common design problem is resultant gap between the top of a wall where it meets a sloped roof. The crown block with sloped top fits perfectly into this space and allows for architectural continuity. The crown block allows for sloped roofs and, if left with a level top, even additional floor systems to rest on architecturally finished structural components.
[0038] As previously noted, AAC buildings can be very energy efficient. A recent study in the U.S. shows that an 8″ AAC wall performs better than a conventional 2″×6″ wood stud wall system with R-30 Insulation. AAC is ideal for variable temperatures so that the outside temperature is dissipated by change before it can permeate block and effect interior. The only disadvantage to AAC's thermal insulate value is in a location where there are continuous days of below freezing temperatures as occurs during winters in northern United States and Canada, the cold eventually permeates the AAC block. A test in Pennsylvania not using current art for AAC, showed when AAC is exposed to a constant temperature, such as freezing, over a period of time, it was found that a winter's heating expense was the same as a standard 2×4 wood frame home. This is one reason why AAC plants are presently located only in Southern areas, an ideal climate of moderate, fluctuating temperatures. Current art solves this problem through its temperature transferring system manufactured in blocks and panels and is available for climates requiring it. Warm or cool air is simply circulated through holes in exterior half area of blocks. The manufacturing of transfer channels is unique in that the tubes inserted into the pan mold are two conical tubes with threaded ends, one male and one female, which after curing are separated by tool which is inserted into larger end and engages indentations and is twisted to unscrew tubes. The purpose for conical shape is ability to ease withdrawing longer sections of pipe from cementitious material thereby enabling even 20′ lengths to be more easily removed.
[0039] The utility chase and block wall systems are only a few of the numerous other embodiments and claims of this application which each individually and combined, address specific areas of improvement in AAC construction.
[0040] The structural beam system is placed on walls and is unique in being constructed of reinforced AAC or alternatively can be comprised of two cementitious materials, having a center fiber and steel reinforced concrete and outer casing of AAC which accepts the screws hereof, flange bar and/or hollow bar, which are used to fasten roof panels to beams.
[0041] The beams can have reinforcing center formed by two halves with longitudinal slots joined and filled, even HVAC duct and a utility channel can be placed inside so trades simply pierce AAC where desired openings are to be located.
[0042] Currently the AAC industry does not use AAC for its roof systems in residential application because the required structural steel support beams, etc., rendered it impractical, so industry methodology is to attach a conventional wood and asphalt shingle roof on top of AAC walls. Current art is able to feasibly employ an entire AAC roof system with no steel I beams, support columns, brackets, braces, bolts, etc. The structural beam system allows for all conventional roof designs to be possible, which was previously thought unfeasible with cementitious products due to weight, fastening systems and difficulty of working with product.
[0043] Invention's roofing system maximizes AAC's innate attributes by combining structure, insulation, gutter, water deflection, and waterproofing all in one. One of the more important ideas of invention is the AAC roof panel's waterproofing system. The AAC roof panels employ current art's cost effective waterproofing systems, both systems are environmentally friendly products to manufacture, and the consumer use of either invention will relieve landfills of 100,000 of tons of current industry asphalt shingle refuse currently being dumped every year. The current art is designed to never have to be replaced, only re-coated every 10+ years. Roof repairs are easily discovered and can be repaired by an unskilled homeowner. Professional roofers will appreciate ease of application. Both systems not only waterproof, but also remedy problem of AAC's requirement for vapor permeability (to be able to “breathe”) so moisture build up does not occur inside habitat. These are only systems known to be able to be applied directly to roof surface and still facilitate vapor permeability.
[0044] The indivisible internalized gutter system is similar in that it eliminates costly additional gutter systems that must be maintained and replaced. The water deflection system not only adds aesthetic enhancement but provides process through its unique reverse (upward) angles to cause water to separate from face preventing unsightly runs as well as help dissipate negative effect of water runoff. The gutter down spout box eliminates need for unsightly down spouts and add architectural accent. Because of new roof system interior space is greatly increased by volumes as attic insulation is not required. insulation is not required.
[0045] The new beam and panel roof system of this invention greatly increases interior space by creating habitable areas in roof vaults that previously were inhospitable, namely wasted attic space.
[0046] The waste-free system taught herein allows for flexible custom application of AAC roof panels so contemporary roof lines are realized. The waste-free roof system can be implemented for hips as well as valleys.
[0047] When teachings of this invention are applied to install AAC panels over existing roof structures, they overcome weight, fastening and aesthetic concerns. An unanticipated use may be for sound proofing by removing existing asphalt shingles, etc., and screwing AAC panels directly over wood decking into rafters. The unique screw for installing AAC panels into wood have wide flanges in the area to cover the AAC material. The wood threads on the tip are used to permanently secure the panel into the wood. The threads actually help to control the depth of penetration of the screw, followed by a light weight, environmentally friendly coating.
[0048] When constructing multiple stories, invention's ring/bond beam floor panel eliminates several time and material consuming steps. The floor panel has unique modification of top row if reinforcing stopping 1′ short of panel end (same as for roof panel for gutter system). This allows invention's ring/bond beam slot to be manufactured. Construction is simply placing beam on top of wall with panel end flush to exterior wall face, inserting required rebar into slot, installing the screws hereof through slot into wall below, which screws engage other reinforcing in panel. The heads of screws can be left protruding into slot and rebar tied to them, then add mortar and immediately next course of block, and continue on with next wall. This eliminates all the following current methodology: 1) place panel end short of face of exterior wall, 2) mortar a block flush to face of exterior wall leaving a gap between panel end and block, 3) place rebar into gap and add lots of mortar, 4) wait day for ring/bond beam to set and then continue construction.
[0049] An alternative improvement in time and costs for multiple story construction is method of constructing walls without laying floors or roof until all walls are constructed. This method saves cost trips which can add up to thousands of dollars, as well as additional costs of down labor time for wall crews waiting for crane to finish, The method is for a crown block to be used that protrudes into interior area and forms a ledge for supporting floor system. When all walls are constructed crane simply sets all floor panels into interior area and roof panels onto crown block ledge, all in same day by use of invention screws. The crown blocks serve as ledge as well as architectural finish.
[0050] Corbel ring/bond beam is similar, as wall face is routed, using invention's routing system, to receive a pre-cast, reinforced AAC beam. Simply mortar and fasten into place using the screws hereof and then floor or roof can be set on corbel ring/bond beam. This process using unique articles of manufacture allow for quick, strong permanent placements of floor and roof panels where before an entire wall assembly system was required.
[0051] Stairs providing access between floors are now able to be cost effectively constructed of cementitious material that immediately gives fire protection. Stairs will not creak and have benefit of muffling a lot of the noise transmitted by standard wood stairs. Current methodology for constructing stairs, especially curved and suspended stairways, require a very skilled craftsman, but now unskilled labor can construct a superior stairway in less time.
[0052] The invention screw is an indispensable article of manufacturing which facilitates many of invention's processes. The auger type invention screw now makes it possible in one motion to set steel reinforcing into cementitious product without pre-drilling a hole and having to wait for mortar to set. An example of one advantage, a roof panel set on a 12/12 pitch can be set in place with invention screws into wall and invention's beam support system and left with no other support. The invention screw locks all pieces together with threads and counter sunk head. An entire roof system can be installed, then the worker comes back and fills all invention screws with mortar at end of day for them to set up overnight. Next day roof is waterproofed.
[0053] A few nuances of the invention screw are advantage of invention's flanges on screw head are to gouge out AAC so head can counter sink and simultaneously help lock in place. Unlike any other screw, the invention screw has the ability to be drilled very close to surface without breaking AAC apart because of its auger process alleviating pressure that a standard solid shaft creates. The chambers' unique design actually allows mortar and screw process to make one monolithic piece of separate pieces in one step.
[0054] Invention's alternative, the flange bar, is a modified rebar with most of the advantages of the invention bar except it requires pre-drilled holes. Invention's flange bar allows direct bonding and reinforcing as code requires with superior results of centering rebar in hole, allowing mortar to fill hole around rebar, secure rebar directly to cementitious material, hold cementitious pieces in place by flanges imbedded in walls of hole preventing shifting movements, flanges greatly increase holding power. The “R” screw has advantage of one step process while flange bar has less expensive manufacturing costs and can be cut at any length at a point removed from a flange so that a hammer drill can be placed over shaft and the shaft used as a bit.
[0055] A hybrid of both the invention screw and flange bar is hollow bar which combines best attributes of both inventions into one unit. It uses invention's cutting device that in cutting uses a crimping action that results in serrations which through bar's twisting action grind AAC into dust and force into hollow core. It has a helix-action with auger flanges which leaves slots for special epoxy (not regular mortar) to be inserted around bar.
[0056] By use of the invention's nail screw, the result is synergism in that now one item replaces two previously separate processes with the benefits of both and modifications eliminating detriments. A problem with fastening items into a cementitious product is that the cement is not like wood which holds by a constant expansion pressure upon inserted object, cement holds by a gripping and/or binding to concrete. Therefore when object is removed it can rarely be reinserted into same hole with effective holding power. The invention screw overcomes this problem by gathering dust in its tip which binds, by prongs near head which pierce and hold, torque more pressure via screw head and by ability to reinsert finish nail in hollow shaft and re-explode tip. While prior art, such as Helifix, has advantages of piercing and twisting to hold in AAC, it requires long sections of shaft to work effectively and still wiggles and can work free without mortar. The screw hereof has variable degrees of hold, and via nail exploding tip, has unique process of being permanently set and still retain ability to be removed without damage to AAC or fastener and then even reused in same hole.
[0057] Door slabs can be composed of AAC giving great fire safety and sound insulation to rooms. As AAC is non-combustible, current art even has an AAC door that is unique in allowing a four-hour fire rated wall having a specially designed opening.
[0058] Tools biggest advantages are ability to be used on vertical plane surface and enabling unskilled workers to make finished openings and other modifications in thick walls, as well as finished trim designs. Most of the tools combine steps so that what required two or more tools and several processes in prior art can now be done with invention's machines, articles of manufacture and processes with one tool and in one step.
[0059] Invention's air duct system uses AAC insulate characteristic and duct's structural reinforcing for unexpected result of a manufactured structural component: 1) an internal duct system that is installed during construction of habitat as it is an integral, structural part of habitat, 2) is an insulated forced air duct system which reinforces cementitious material, 3) reduces volume weight of top beam, 4) requires no additional framing, etc., to hide it, and 5) uses process of varying opening sizes custom installed at site to regulate required air supply. Blocks and beams can also be used with a standard sized hole becoming the air duct with no other duct work required.
[0060] An advantage of the present invention is its ability to emulate the aesthetic appeal of industry's standard habitats while being composed of a completely different, unique cementitious material. It is the invention's synergy that allows it to overcome problems preventing AAC's acceptance by construction industry. Each of the present embodiments is crucial to whole as it is synergistic, i.e. without support beam system, roof panel system would not feasible, and without invention screws and light-weight roof waterproof coating system the support beam system would not be feasible. AAC systems are environmentally friendly. In contrast, conventional wood structures create a problem of waste, while this system reduces waste to almost nothing. What waste there is can be dealt with by the teachings hereof. It was discovered that the waste hereof is to grind the AAC into powder and then, by optionally adding proper nutrients and fertilizers, turn the mixture into a yard enhancer so that no waste has to be removed from the building site.
[0061] The manner by which the system hereof applies the processes, machines, articles of manufacture and compositions of matter will become apparent in the description which follows, particularly when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0062] FIG. 1 is an exploded perspective view of a partial, two a story cementitious dwelling constructed in accordance with the teachings of this invention, showing specifically a first floor construction, with portions removed, a second floor with a partial roof to override the first floor, and a partial roof section to override the remainder of the first floor.
[0063] FIG. 2A is a partial perspective view of a wall, with a door and a window opening, using in section, a base block and mini-wall block combination, top block/beam and optional curved block wall, showing architecturally finished coordinated seam system that enables thin coatings previously considered insufficient.
[0064] FIG. 2B is a continuing partial perspective view of a wall, with a door and a window opening, omitting base block and mini-wall block and substituting them with a wall block and big base block showing architecturally finished coordinated seam system revealing a sloped and architecturally finished crown block on top.
[0065] FIG. 2C is a continuing partial perspective view of a wall, using a second story on floor panels, with a door and a window opening, substituting top block with top beam over openings and omitting wall block and substituting full wall blocks, with architectural features added after installment.
[0066] FIGS. 2 BB- 1 & 2 are two partial perspective views of wall blocks that are routed with a vertical chase and shaped edges, where FIG. 2B B- 1 is an example of architectural design routed on face by tools of invention.
[0067] FIG. 2C C is a partial perspective view of an elongated, vertically oriented casing block, showing incorporated utility chase and a curved insert to facilitate pulling/fishing electrical wiring or cable through the blocks. It is adjoining a finished wall block.
[0068] FIG. 2D is a partial perspective view of a top block which dimensionally compliments wall block to allow precise height dimension for doors and window openings, showing the invention's casing and utility channel as well as industry standard slot for reinforcing.
[0069] FIG. 2D D is top block beam that combines functions of a header for openings and a bond beam for wall and can house utility channel and invention's enclosed, insulated duct system.
[0070] FIG. 2E is a partial perspective crown block, having crown molding, showing a tapered top wall with a longitudinal slot and crown block used as floor support system.
[0071] FIG. 2F are two views, perspective and plan, showing a special molded plastic insert to convert a utility chase into a multi-chamber chase.
[0072] FIGS. 2G and 2H are several views illustrating curved AAC blocks and manufacturing procedures, along with exemplary shapes for said curved blocks.
[0073] FIGS. 2I and 2J are a series of views showing a preferred manner of providing temperature transfer within an AAC dwelling.
[0074] FIG. 2K is a view of inserts to form a temperature transfer system.
[0075] FIGS. 3A through 3I are different views illustrating various aspects of a roofing beam support system according to this invention.
[0076] FIGS. 4A through 4D are different views illustrating various aspects of this invention's water proofing system, and gutter/down spout system, as applied to roof and invention's moisture removal system.
[0077] FIGS. 4F through 4H are views illustrating the waste-free roof panel system according to the present invention.
[0078] FIGS. 5A and 5B are two views showing further this invention's panel bond beam system. invention's panel bond beam system.
[0079] FIG. 5C is a cross sectional view of a wall detail showing invention's panel bond beam in conjunction with invention's wall block and top beam with duct system, routed with casing block design for spanning opening.
[0080] FIG. 6 is a partial side view illustrating invention's corbel bond beam system which allows floor and roof panels to be secured directly to a cured cementitious mid wall sections.
[0081] FIGS. 7A through 7D are different views illustrating a preferred auger screw, “R” screw for securing AAC materials according to this invention.
[0082] FIG. 7A A is an exploded perspective view illustrating a preferred hollow bar, a hybrid of a unique screw and flange bar which replaces standard rebar, and selected tools used to cut, crimp and create serrated ends in hollow bar.
[0083] FIGS. 7 AAA through 7 CCC are different views illustrating a preferred flange bar, showing a modified rebar as used in fastening and holding pieces in position until grout can be added.
[0084] FIGS. 7E and 7F illustrate fastening devices for installing panels onto wood and steel roofs supports.
[0085] FIGS. 8A through 8D are various views illustrating a dual functioning screw for attaching items to AAC materials.
[0086] FIGS. 9A through 9C are selected views of an AAC stair case assembly.
[0087] FIG. 10 is a top view of an improved firewall with opening and door.
[0088] FIGS. 11A through 11D are various views of routing tools, such as a hand held utility chase cutting tool.
[0089] FIGS. 12A through 12C are various views of a tool for inserting wires into utility channel and fastening in place.
[0090] FIGS. 13A through 13C are various views of a duct system for manufacturing structures according to the invention hereof, including architecturally finished seam system.
[0091] FIG. 14 is a perspective view of a pair of AAC crushing rollers members for converting and transforming the AAC waste into a suitable fertilizing base for trees, soil conditioner, and the like.
[0092] FIG. 15 is a side view of a joint cleaner for removing and smoothing excess grout from a seam.
[0093] FIG. 15A is a perspective view of the joint cleaner of FIG. 15 .
[0094] FIG. 16 is a partial side view of a double edge cutting blade for creating openings in AAC walls.
[0095] FIG. 16A is a perspective of a portable cutting tool using the double cutting blade of FIG. 16 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0096] The present invention relates to a system for manufacturing structures and habitats of cementitious materials, more particularly by the use of an autoclaved aerated concrete. The invention will now be described with regard to the several Figures, where like reference numerals represent like components or features throughout the various views. Though the invention has applicability to a variety of cementitious materials, the further description, for convenience, will be restricted to the use of autoclaved aerated cementitious (AAC) materials. Turning now to the several Figures, FIG. 1 is a perspective view of an AAC constructed structure 10 according to the techniques of this invention, while FIGS. 2A to 2 C illustrate sections of structure wall blocks 200 A and 200 B.
[0097] AAC blocks are typically formed by first preparing a slurry of the AAC mixture and placing same into current industry standard, large mold measuring approximately 4′ wide by 24″ deep and 20′ long. After the slurry sets, the form may be lifted out of the tray and cut into the desired sizes. Industry standard panels are always steel reinforced and sized 2′ wide by +/−8″ thick and when used for walls are +8′ long (for vertical height). Most blocks are usually 8″ wide by 8″ tall×24″ long with only one USA plant manufacturing a jumbo block of 2′×4′×8″.
[0098] The system hereof shows manufacturing modifications of 8″×16″ for top block, which is coordinated with wall block of industry standard 2′×4′ but new dimensional length of 82″ which requires modifying mold length by additional 6″, from the prior art, so three lengths of 82″ wall block as well as coordinated casing block can be manufactured without waste. Accordingly, one preferred size is wall block 200 B having an elongated dimension of standard pre-hung doors with only jambs to slip flush into invention's casing block system so that no additional wood trim is required or customizing blocks at site. Further, through the use of the large blocks 241 , and the unique and precise manufacturing techniques, it is now possible to construct a habitat with the architecturally finished structural components. That is, the blocks 12 have specifically located architectural finish along the edges of faces that will be abutting at joints of the blocks and hides the seams and surface deflection. This eliminates the need for extra surface finish, wood molding, other material or labor. The finish need only be a paint or a superficial layer of smooth stucco, as known in the art.
[0099] As illustrated in FIGS. 1 and 2 A, the system hereof is amenable to the use of curved wall sections 205 . FIGS. 2G and 2H illustrate techniques for manufacturing the curved wall sections 205 . That is, alternative curved blocks 205 are manufactured by wires, as known in the industry, but modified by being connected to a computerized, mechanical arm which cuts AAC as pattern and arrows as illustrated. There are presently no curved blocks being manufactured anywhere in the world to the knowledge of Applicant.
[0100] For more frigid climate construction applications, reference is made to FIGS. 2I and 2J , showing the invention's temperature transfer system. The manufacturing of transfer channels 54 is unique in that the tubes 251 inserted into the pan mold 250 are two conical tubes with threaded ends 255 , one male and one female, which after curing are separated by tool 253 which is inserted into larger end and engages indentations 252 and is twisted to unscrew tubes. Optional flange 254 on female conical tube holds it stationary while male tube is first unscrewed and withdrawn. The purpose for tool and conical shape is ability to ease withdrawing longer sections of pipe from cementitious material, as tool employs fulcrum to initially break tube free and then conical shape allows for no resistance as withdrawn. This now allows for extremely long voids/channels to be easily created. Also ends the need for coring of individual blocks as is currently done since blocks cut with void suffice.
[0101] The temperature transfer system of this invention allows for excess heat, usually wasted and/or lost, to be realized and circulated 58 via air channels 54 throughout exterior walls 200 A and panels 40 of habitat. System can employ a geothermal 56 and solar 55 storage tank 52 .
[0102] After the cementitious materials are prepared, construction can begin. Initially a superior concrete foundation, or footer with slab is poured, as known in the art, to present a base for receiving the AAC blocks. The blue prints, as known in the art, are measured and laid out on floor by a qualified individual. Correct designations are marked on floor for openings, block type, location of outlets, etc. From this point a small crews of four unskilled workers using a level, trowel and drill can construct a quality habitat in half the time of a comparable “stick built.”
[0103] A first step in constructing invention is the wall system, FIGS. 2A through 2C . The process comprises selecting a discontinuous first course of elongated AAC base blocks ( FIG. 2A ) for placement on a pre-built foundation. A base block 201 is one solid structural finished component that is load bearing, utility receiving, architecturally finished and uniquely dimensionally processed. The respective +/−10″ tall×+/−9″ wide blocks are oriented with a longitudinal slot, called a utility channel 202 , see also FIG. 2I , exposed along the upper surfaces or/and along the vertical face thereof, into which utilities 217 , 216 , 123 , 124 are inserted and later covered by subsequent course and/or preformed, dimensional type of cementitious board 229 which fits perfectly between notch 225 at the base and start of architectural finish 208 so that there is no seam and it becomes integral part of design.
[0104] Alternatively, the base block 201 may be omitted and the mini-wall blocks 200 A substituted with wall blocks 200 B, see FIG. 2B . Wall blocks have a custom notch design near base 202 ( FIG. 5B ) that is covered by flooring and/or optional baseboard. Another alternative ( FIG. 2C ) may be the omission of casing blocks and instead, wall blocks 200 B are architecturally routed, including utility chase. All blocks work with the present invention's utility channel system.
[0105] Whatever block process is used, the blocks are cemented into place and leveled, except where door openings 212 are located. Initial leveling is critical as all subsequent courses of blocks can be laid directly on the base course without further delay as subsequent leveling since AAC blocks are dimensionally accurate.
[0106] Continuing description using base block 201 , as apparent, the purpose of the slot, as best seen in FIG. 5A , is to receive utilities, i.e. electrical wiring. After utilities and all inserts, etc. are placed in the utility channel 202 , then a thin cover composed of plastic or paper may be placed over utility channel 202 opening to prevent special AAC mortar 19 from falling into utility channel 202 when constructing subsequent blocks and panels, as mortar would obstruct future installments of utilities which can be pulled/fished. Additional utilities can be placed on top of the base block 202 which are accepted into the utility channel 202 in base of second course 200 . The base blocks 201 are +/−10″ high and +/−1″ wider than mini-wall blocks 200 A and have architectural base board finish 208 which recesses and reduces base block to width of subsequent mini-wall block 200 A. The base block 201 also has optional variably sized recessed notch 225 at base for overlapping the flooring. Reference numerals 208 & 225 create the invention's unique attribute of being architecturally and functionally equivalent to a baseboard; so even while housing utilities, it is structural and functional as well as having ornamental finish.
[0107] Outlets 216 may be located into the base block 201 by cutting opening using special rotor plunging tool and template guide. Outlet boxes, etc., fit exactly into opening formed by template guide and are fastened into place, preferably using a proprietary nail screw as illustrated in FIGS. 8A through 8D .
[0108] Thereafter, a method of vertically orienting and cementing comparably designed, plural mini-wall blocks 200 A onto at least certain of the first course of blocks, where the height of each block is a multiple of a nominal dimension of “X”, where a typical miniwall block is 6′, and “X” equals 2′. Mini-wall blocks 200 A are preferably 72″ high, do not require wire reinforcing as does standard wall panels that have manufacturing difficulties and additional costs, but have advantages of panels in quick installation and can be routed, see FIGS. 2 BB- 1 & 2 BB- 2 . Mini-wall blocks 200 A can have utility chase system 202 integrated into ends and sides to form horizontal and vertical utility channels.
[0109] Alternatively to mini-wall blocks mounted on base blocks is a method of employing wall blocks 200 B, FIGS. 2A & B. Wall blocks are +/−6′-10″ tall so top equals height of standard door with frame. Wall blocks which have hidden utility channel machined into bottom, FIG. 5C . Additionally, specially designed tools are able to architecturally finish wall blocks 200 B with casing design and utility channel allowing for omission of casing blocks.
[0110] In any case, thereafter, plural elongated casing blocks 203 , FIG. 2C C, preferably the height of wall blocks, are vertically oriented around the first horizontal course where openings 212 for doors and windows are to be placed. Invention's casing blocks 203 , FIG. 2C C, are used for window and door openings and are structural, integral components of wall which have architectural finish 208 and can have a utility channel 202 . Electrical switch boxes 216 can be located in casing blocks 203 at door openings and are constructed similarly to outlet boxes 203 in base blocks. The slots for the utility channel are of such a width that when windows and doors are installed their frames conceal slots and only caulk or shoe mold is required to finish. The top beam has casing block's architectural finish where openings are located.
[0111] Casing blocks have vertical and horizontal “X” factors. Vertically, the same dimensional vertical “X” equals wall blocks 200 A & 200 B, so their top heights are level. This level height is optimized at +/−6′-10″ to match rough opening for doors and windows. Horizontally, casing blocks are “X” equals 2′ or 1′, so that either 17+/−″ wide for full size openings (ex: 36″ (3′-0″ door)+ 2 +/−″ (¾″+¾″ frames & gap), +34″+/−(two 17″ Casing Blocks)=1′ center), or 14″ for half size openings (ex: 30″ (2′-6″ door)+2+/−″ (¾″+¾″ frames & gap), +28″+/− (two 14″ Casing Blocks)=1′ center). The walls are constructed on 1′ centers with minimal waste. By disciplining design using matching units a wall can be constructed without having to cut 2′ wide wall blocks. Doors and windows with ¾″ jambs can slide under subsequent course and into opening, requiring nothing else to flush finish other than trim or caulk, as the architectural finish 208 on blocks blend into door and window frames and become one architectural unit when painted. Conventional finishes have architectural finish added onto wall and so protrude away from wall, while present invention has finish recessing into structural walls as walls are thick enough to use the invention's time and material saving process.
[0112] A simplified wall process is for the tools, see FIGS. 11A through 11D , hereof to architecturally finish 243 wall blocks FIG. 2C , at openings and create utility channel 202 so that a casing block is not required, as wall block has features of casing block machined into it. The width of opening is flexible so that only top block/beam 206 acting as header spans or big base block 241 , see FIG. 2B , used under window are cut to fit. Big base blocks 241 are basically wall blocks turned horizontally so all window openings can have standard height from floor of 24″ and variable width. This is preferred method of all options.
[0113] Where the utility channel 202 intersects with other blocks or changes angles, in a preferred embodiment, a curved insert 214 , FIG. 2A , sized to be slidably placed into the longitudinal slots 202 , may be placed into perpendicularly converging utility slots to provide a continuous curved path for easy wiring of the erected structure in future after direct access is closed off. By this arrangement, and with pre-positioned openings extending to the inside from the longitudinal slots, the entire structure may be suitably wired with recessed utility boxes to present a wall surface suitable for finishing.
[0114] Where architectural finishes 208 for casing blocks 203 and top block/beam 206 B meet, an architectural insert 213 is placed to cover incompatible intersection, see FIG. 2B .
[0115] Top block beams 206 , FIG. 2D , are placed as a horizontally oriented course of comparably designed AAC blocks, where the longitudinal slots 202 over the openings, such as doors and window openings, and casing finish 208 are exposed downwardly toward the opening. An optional architectural finish 208 can give a crown molding appearance to top block where floor panel 59 , FIG. 5A , will rest on top block 206 . Top block are preferably manufactured as beams and have enclosed air duct system and reinforcing channel that coordinates with roofs beam system.
[0116] Thereafter, the top most course of wall, comprised of invention's +/−16″ top block beam 206 , is placed on wall blocks 200 A, 200 B, not 200 C, and/or casing blocks 203 . Top block can have variation of architectural finish 208 as casing blocks for windows and doors, as well as continuous design to equal crown molding, which allows for one structural component, top block, to replace four standard pieces: header, filler, casing and crown. Additionally, top block is of specific dimension so that base block, mini-wall block and top block form a minimum 8′ high wall. A unique feature of this invention is the provision of an effective method to construct a dwelling using primarily precut and sized blocks of cementitious material. By the use of such cementitious blocks containing specific dimensions unique to this invention process and not in prior art, an 8′ high wall can be constructed using only two blocks (or three if using base block) which blocks have specific, unique design and functions beyond just dimensional advantage. Blocks are additionally modified with predetermined slots and openings termed utility chase system for utilities, i.e. electrical wiring, plumbing, etc., facilitating construction of habitat.
[0117] Further, also employing tools for finished architectural routing for either the base block, casing, features for openings, and/or crown block, smooth finished walls are transformed into architectural finished walls with no additional materials.
[0118] For rounded walls and/or corners, if desired, one may employ arch shaped rounded blocks 205 , where the rounded shapes of such blocks may be accomplished by inserting rounded mold ( FIG. 2G ) into an industry standard AAC pan. Alternatively, a computerized mechanical arm may run wires through cementitious material ( FIGS. 2H ) in a unique pattern producing curved blocks with very little waste, and which waste is able to be recycled as it is still in green stage before autoclaving. This finishes wall construction processes.
[0119] The corbel bond beam system ( FIG. 6A ) is the system's approach to attach floor and roof panels directly into the mid wall section surface instead of on top of walls that requires a great deal more construction effort and material. The corbel slot is formed at manufacturing or on-site field routed using the proprietary tools according to this invention, see FIG. 11A , with different bit. The corbel bond beam 60 , which is reinforced with rebar 35 , is set into the slot with mortar and fastened with the proprietary screw 70 , note FIGS. 7 A through 7 AAA, or the invention's alternatives, which engage rebar reinforcing.
[0120] When there are multiple floors, floor panels can be placed directly on top of first level wall top block/beam ( FIG. 5A ) with panel end flush to exterior wall. Floor panels, according to this invention, may use invention's bond beam slot 50 and proprietary auger screws 70 to effectively replace several steps of prior methodology. In prior art systems, a bond beam was to first drill vertical holes into top of wall, then short sections of rebar were mortared into holes, and thereafter a long, horizontal rebar was tied off to vertical rebar. This necessitated a space between end of floor panel and a block placed flush to exterior face of wall. The bond beam was formed in the gap between panel end and wall block using rebar and mortar. This method required additional material, labor and days of curing time before subsequent floors could be constructed. The present invention eliminates several steps and materials and allows construction to continue uninterrupted.
[0121] Floor panels 59 , see FIG. 5B , hereof have unique bond beam slot 50 achieved by manufacturing AAC similarly to roof panels for a proprietary gutter system, see FIGS. 4A through 4D , where upper course(s) of steel reinforcing 52 stops short of panel end than other layers so slot can be routed and bit not hit reinforcing steel. Rebar 35 is horizontally laid in bond beam slot 50 and tied to screws 70 and then bond beam slot is filled with mortar 19 as base block 201 , which is the first course of next wall, is laid.
[0122] An alternative floor support system is illustrated in FIG. 5B for a crown block 207 B to be placed into wall during construction to support floor system. This invention's method allows for wall construction to continue until all walls are constructed before floors and roof panels are installed. When floor panels are installed, the gap between end of floor panel and wall is filled halfway with rebar 35 and mortar 19 and becomes bond beam. The upper half of gap is left a void and becomes a utility channel 202 for wires 217 and other utilities to be inserted. Outlets 216 are placed in floor panel using invention's method in area void of reinforcing. Finish floor covers uniquely located utility channel or small gap that can be filled with additional mortar.
[0123] Where stairs are employed to travel between floors, the invention's stair system is employed as shown in FIGS. 9A through 9C which are partial views of stairs made entirely of AAC. There is no prior art of cementitious stairs being supported only at ends and reinforced by adjoining steps. All prior art uses either steel reinforcing throughout or supports in middle of stair, which extends to ground along total run of stairs.
[0124] The invention's stair system uses cementitious blocks 90 which have an angled slot 91 that corresponds to the desired pitch of the stairs. The angle support brackets 92 are secured to the wall at the desired pitch of stairs, which pitch corresponds to slot 91 in cementitious block. Blocks are simply slipped onto support bracket at top of stairs in gap, see FIG. 9B , reference numeral 93 , between brace and floor and then slid down and mortar 19 to secure onto top of previous block. Optionally, a screw 70 can be used for additional fastening. The angle iron 92 with special slot 91 makes a permanent structural unit. Mortar placed on ends of stairs additionally bonds stairs to AAC walls. Face of cementitious AAC blocks can be routed to have a tread 94 and/or other architectural advantages. The advantages allow for additional safety of fire proof stairs cases which are devoid of squeaking.
[0125] Thereafter, if there is not to be an additional floor, on the top most course of wall comprised of top block, a crown block 207 , FIG. 2A , featuring a sloped top wall 228 is cemented to the top course. The slope is comparable to the roof slope so that the roof panels may be supported thereon and secured by suitable fastening means. FIG. 4B further shows a tapered crown block 207 secured to the top of the wall for mounting a roof panel ( 40 ) and roof support members. The crown block has a slope equal to the roof panel pitch and is manufactured by taking a standard base block width and cutting in half so that mirror sides equal slope pitch of roof. The interior face is routed to resemble crown molding. The result of this inventive technique is a single structural piece of cementitious material that has architectural attributes of finished wood trim and is used to bond pitched roof panels to flat walls. Crown blocks with a level top, instead of angled to the roof pitch, can also be used to add height and design features to any wall.
[0126] The roof is constructed by first securing AAC roof panels 40 to the roof support beam system, beams 30 , 31 , 32 , where a typical roof has a plurality of beams arranged in specific load and stress managing pattern.
[0127] The construction method may be continued by positioning the invention's support beam system, see FIGS. 3A-3F , on walls. The cementitious beams are comprised solely of cementitious material with steel reinforcing, and optionally can have invention's reinforcing channel 36 , see FIG. 3F . Support beams require only mortar and fasteners as unique interlocking design, FIGS. 3C & 3D , eliminates need for interlocking brackets, bolts, or other mechanisms. All types of roof pitches and designs, including hip and valley, FIG. 3A , are now possible for a purely cementitious roof and support system.
[0128] The supporting beam system with reinforcing channel 36 is constructed by placing rebar into channel (and utilities), tying all rebar together, which can include rebar coming from foundation/slab, then drilling holes into beam and pouring mortar into beams 38 , FIG. 3F , so that incredibly strong support beams result. The invention allows for AAC surrounding hard concrete reinforcing channels to receive fasteners 70 and so secure roof panels to supporting beam system. Invention's roof system requires no brackets, braces, bolts, etc., as does all prior art. At most what may be required are tension tie rods for certain hip roof designs to give walls extra support.
[0129] The construction process is continued by placing roof panels 40 , see FIGS. 3E and 3F , on supporting beam system. When a roof is resting on standard 8 ′ wall instead of a second floor FIG. 4B , then a fourth level of blocks comprised of crown block 207 can be used. As best seen in FIG. 4B , a series of crown blocks 207 , preferably eight (8) inches in height, are cemented to the planar surface 229 , where the crown block 207 features a slanted upper surface 228 for receiving an angled roof panel 40 . The panel 40 may be secured to the crown block 207 by invention screws 70 , as shown in FIG. 7A , and mortar 19 as known in the art, on planner surface. Crown blocks, FIG. 2E , can also be structural for openings with cavity 227 being filled with rebar and cement.
[0130] The beam system utilizes the invention's optional reinforcing channels 36 , FIG. 3F , which can be used in addition to standard reinforcing to facilitate easy construction and provides even stronger support due to internal bond beam/utility channel tying together the entire habitat. Beams can have a squared edge corrugated pipe 36 inserted into the AAC mold during manufacturing. The AAC fits between the square corrugation in pipe and holds fast and is strong enough to remain intact during initial construction. The hollow corrugated pipe ( 36 ) at site has rebar 35 placed inside, as well as any utility conduits 26 desired, which conduits can be accessed for lights, etc.
[0131] Roof beams are erected and fastened so that the hollow core formed by corrugated pipe, which is termed reinforcing channel 36 , align each other at intersection/joint of beams. After beams are joined together and set with proprietary screws 70 , the AAC mortar is pumped throughout the reinforcing channel system 36 resulting in an incredibly strong beam system that ties the entire structure together. This reinforcing channel system also allows invention screws to fasten roof panels into the softer AAC portion of the beam. Optionally, FIG. 3H , a standard concrete beam 19 can be constructed and then an AAC beam 30 adhered with mortar to top of concrete beam so result is a dual material beam which has softer cement for fasteners on top and harder, reinforced concrete on bottom. The concrete beams can be constructed and poured at site with foundations.
[0132] While any type of pipe can make reinforcing channel, the reasons for using optional corrugated pipe or corrugated, helical conical mold insert 255 ( FIG. 2K ) which unscrews from mold, are: 1) the corrugation gives extra surface strength and adds additional strength to reinforcing channel when filled with concrete as two cementitious materials bind against each other; 2) the corrugation prevents AAC outside and cement inside from separating from pipe during stress flexing; and 3) the corrugated pipe allows mortar to flow throughout entire system as AAC is known to absorb moisture so quickly that if system had only exposed AAC the mortar may quickly adhere to channel walls, possibly clogging channel and thus prevent mortar from reinforcing certain areas.
[0133] The roof panel system is then fastened to the beam system. The teaching of the present invention's waste-free system is illustrated, in part, in FIG. 4E . This simplifies construction by manufacturing a standard length precast cementitious panel for the entire roof system. Once the length is determined, the parts (A), (B), (C), and (D) are simply cut off site and delivered and installed in a manner which emulates contemporary roof lines without waste. The cut angles of 30° and 60° ( FIG. 4G ) are turned to meet each other, i.e. (A) to (A) through (D) to (D). When laid at a 45° angle incline, FIG. 4H , or as known in the art “ 12/12” pitch, and installed on the invention's teachings of the beam system, FIG. 3A , it creates a perfectly mirrored hip or valley, FIG. 14F . The roof layout, FIG. 4E , becomes simplified and cost effective with zero-waste. Also, what is lost as just uninhabitable attic space under typical roof constructions becomes finished living area, FIG. 4H , by the teachings of this invention.
[0134] The roof panel system is then fastened to the beam system and roof panels waterproofed. The roof design is identical for both sections A and B of invention's roof waterproofing system ( FIG. 4A ). Section A is a perspective of a finished stage using a different water proofing material 47 than Section B's segment which is shown at an initial stage in its construction using the technology hereof. It is important to note that the invention's water proofing system for roof panels is of four distinct processes/features, namely: 1) water proof coating 47 &/or 41 ; 2) the facia water deflection system 45 ; 3) integrated gutter system 44 ; and, 4) gutter box 48 which replaces down spouts. The gutter box 48 comprises a generally rectangular housing portion 61 , see FIG. 4D , having at least one wall opening 62 for receiving water overflow from the angled gutter slot 63 , a tapered lower wall 64 , and a pair of outer walls 65 that feature water outflow slots 66 at the bottom of said outer walls 65 , note the water flow arrows. The roofs water proofing system is constructed as follows:
[0135] FIG. 4A , section A, 47 is a composition of matter for a roofing material, having the following characteristics: waterproof, climate durable, chemical resistant, vapor permeable (“breathes”,) high modulus of elasticity (stretchable), durable (10+ year use expectancy), can be continuously re-coated so no waste material has to go to landfills, can be tinted for various colors, and bonds well to AAC. It is simply applied by spray or roller.
[0136] FIG. 4A , section B, as a preferred system, incorporates a polyester/nylon mesh 42 , having alternate sections of a tight mesh 43 and a loose mesh, and is placed over the AAC panels in the direction of the ridge down to the eaves. Next, an elastomeric composition 41 is applied to the mesh, and, as a result of the porosity of the loose mesh, the elastomeric composition goes through the loose mesh and adheres to the AAC panels. However, the elastomeric material will not go through the tight mesh 43 such that an air channel 47 is created between the tight mesh 43 and the AAC panels 40 . Further, another coat of the elastomeric material 41 may be applied for extra wear resistance. The respective air channels 47 allow moisture in the AAC panels to escape, i.e. breathe. Additionally, the air channels 47 also function as air is drawn up through the channels from the eaves end of roof to the top ridge vent 48 by use of naturally occurring temperature and wind where it may be vented 48 to the atmosphere.
[0137] The integrated gutter system of this invention uses industry standard AAC roof panels with a modification in steel reinforcing. Since gutters ( FIGS. 4A and 4B ) 44 , may be routed out of the roof panel 40 , the top rows of embedded reinforcing rods 52 , see FIG. 4B , extend short of the edge similar to bond beam panels ( FIG. 5B ). There is no need for all the structural reinforcing at the gutter location as AAC is strong enough by itself An angled routed groove 44 may be added to the AAC panels to transmit moisture out of the roof assembly and act as an integrated gutter system to gutter box 46 hereof. No prior art of cementitious materials with integrated gutter systems employ a gravity driven water removal method. All prior art relies on inferior water pressure method as subsequent water forces previous water toward down spout box and off the roof. The prior art's use of water pressure has negative results of residual moisture remaining in trough which eventually causes water damage due to debris build up and/or freezing. Invention's down spout box 46 , FIG. 4D , disperses moisture out and away from habitat by curved wall and wide slot at base. The interior ridges and various platform heights of curved wall near slot break up the mass of water into smaller droplets so as it is propelled out of box large volumes of water do not overburden any one area too much.
[0138] Finally, the facia water deflection system 45 is one and the same material as the roofing and is one continuous niece of roofing material, specifically shaped to have reversing angles with a series of sharp angles so it is impossible for water coming off the roof to run down its face, but rather gravity pulls water off its face at several different places, which not only deflects water away from house but also breaks water down into smaller droplets so it does not damage landscaping beneath. Therefore, facia design is not just a cosmetic architectural feature, it is an unique functioning aspect of the roofs waterproofing and moisture removal system much different than existing plumb facia boards and molding which recess with angles but not reversing angles. An integral functioning process advantage of the finished ends of the roof panels lies in its water deflection that is multifaceted. The reversed angle routed end makes it impossible for excess moisture from the roof to run down face of the panel end/roof facia. This overcomes two failures of the prior art, namely: 1) moisture carrying naturally occurring debris running down vertical facia causes unsightly streaks; and 2) moisture running down facia is easily blown back toward habitat. By means of the instant invention, the need for additional labor and material of drip edge is avoided, while adding unique architectural enhancement to the habitat.
[0139] Therefore, the present invention's roof panel design and process of moisture removal system is comprised of a single cementitious material identical to the roof and is actually roof material itself and thus an indivisible component of roof consisting of two distinct components: 1) a downwardly angled trough 44 which feeds moisture to a down spout or the down spout box of this invention; and 2) a facia 45 with square edges and upward, reverse angle pitches having a multi faced formed edge of cementitious roof. This roof system is then coated with either of the two water-proofing materials 47 , or 41 . Both moisture removal attributes are part of the present invention's roofing system and work in conjunction with each other as one moisture removal system.
[0140] Doors are possible with AAC, as seen in FIG. 10 , so that even four hour rated fire wall 204 may be possible with an operating door 100 which is composed of AAC. The door face can have all types of architectural or decorative effects as a standard wood door. The wall is composed of standard wall blocks 200 A, 200 B but uses casing blocks 203 having custom fire thwarting design and latch system 101 . The door can be held in place by special heat resistant piano type hinge 103 or the internal hinge 104 hereof, which has special sliding hinge pin so all mechanical parts are protected within fire proof AAC.
[0141] Now that the individual embodiments of materials and structure of habitat are understood, what needs to be explained is the preferred fasteners and tools of this inventive system. The auger screw ( FIGS. 7-7C ) is a preferred method of securing, not just to fasten, but to actually bond AAC together. The screw 70 acts as an auger screw and gets its name from the fact it provides more structural advantages than standard rebar but does so with the ease of a screw, especially as screw engages any steel reinforcing in the panels and elsewhere. As noted above, a fastener 70 can be used to secure a roof beam 30 and/or panel 40 to the crown block 207 .
[0142] One difficulty is that prior art fasteners, such as the Helifix, can work free over time without mortar holding pieces fast, consequently if mortar in joints ever failed then system is in jeopardy. Also, the Helifix is inadequate in size to secure large, heavy pieces of cementitious material, and due to need for cement to assist bonding, simply increasing size does not solve its design inadequacies. To improve the fastening capabilities of AAC materials, such as the roof beam to the crown block, a new and unique fastener had to be developed.
[0143] Though different, U.S. Pat. No. 5,143,498, to Wiftman, and granted Sep. 1, 1992, teaches a rubber roofing material fastening device that includes an optional liquid sealer to facilitate the process of affixing roof items to the upper surface of a roof The fastening device has a longitudinally extending centrally located chamber that is coaxially aligned with the longitudinal central axis of the fastening device. The chamber has a plurality of laterally disposed openings that extend from the chamber to the outer surface of the fastening device. The chamber is adapted to receive a liquid sealant at an opening in the upper surface and disperse same through such lateral openings. The exterior surface of the screw shaft is formed with screw threads having a dual set of helically wound, threaded members. The external, most radially outer portions of the threads are grooved with serrated teeth to enhance the holding power of the fastening device.
[0144] The screw fastener member 70 , FIGS. 7-7C , of this invention is comprised of a solid core 71 , preferably “hour glass” in shape, within an annular wall 72 to define three elongated cavities, one passing through the center to each side, and two opposite each other on outer sides separated by the center cavity. The three elongated cavities create two functioning processes with the two cavities opposite each other performing the same process, namely, the center cavity is a mortar chamber 73 and the side cavities are dust chambers 74 . Along the annular wall there are provided plural openings 75 in communication with the mortar chambers. Additionally, there are provided plural openings on the annular wall and in pointed end 78 in communication with the dust chambers with at least one cut-out window having a scraper blade 76 , which is a portion of the cut-out of the wall extending tangentially from the annular wall 72 . In operation, the dust chambers 74 captures AAC dust created by scraper 76 , as well as through opening in pointed end 78 . The scrapers 76 serve two functions: 1) to enlarge hole area around shaft 72 so that an air space is created between the AAC and shaft 72 , which space will be filled with mortar flowing out of mortar chamber 73 via opening 75 ; and, 2) remove from the enlarged hole all lose AAC dust so that mortar flowing out of mortar chamber 73 has a good surface for bonding. The head portion 77 removably receiving a square head power screw driver as an air ratchet, which square opening is an opening through to the mortar chamber and through which mortar is poured into cavity after driver bit has placed screw member 70 .
[0145] Additionally, at head 77 is the termination of helical thread arrangement 79 at an open slot 77 A so that the entire screw can be counter sunk into AAC. Finally, exterior of the shank 72 , from the head portion 77 to the opening, is pointed at one end 78 , and includes said large angled helical screw arrangement 79 with wide threads. It will be seen that this is in sharp contrast to the very shallow angle and narrowness of the helical threads of a conventional screw. The design of thread of this invention is unique to its application for maximum hold with least negative torque influence thereon, and damage to the AAC. The result of the invention is a screw which has all the advantages, and more, of rebar but can be installed in one easy step directly through numerous pieces of AAC and secures in place each piece of AAC, regardless of where AAC is located, i.e., slope, angle, etc. which before this invention was not possible.
[0146] Alternative fastening inventions are the hollow bar ( FIG. 7A A) and flange bar ( FIG. 7A AA). The hollow bar has a dust chamber 74 within annular wall 72 with advantage of provided plural cut-out windows having a scraper blade 76 , which is a portion of the cut-out of the wall extending tangentially from the annular wall 72 . In operation, the dust chambers 74 captures AAC dust created by scraper 76 , as well as through opening in pointed end 78 . The scrapers 76 serve two functions: 1) to enlarge hole area around shaft 72 so that an air space is created between the AAC and shaft 72 , which space will be filled with mortar being poured into gap around exterior of shaft at entrance to hole; and, 2) remove from the enlarged hole all lose AAC dust so that mortar has a good surface for bonding. The design of thread of this invention is unique to its application for maximum hold with least negative torque influence thereon, and damage to the AAC and the gaps 705 in thread are for purpose of allowing mortar poured into opening created by flanges to flow continuously down between screw wall and AAC and around threads sections. The result of the invention is a screw which has all the advantages, and more, of “R” screw, but can be manufactured for less cost and be custom cut at site to variable lengths as thread gap 705 and opening pattern repeats itself.
[0147] The crimping tool for cutting and forming hollow bar has multiple blades which form functions of: 1) crimping tube which helps hollow bar enter AAC and grind it, 2) cut it, and 3) form teeth out of cut end for two functions: 3A) on end entering AAC, teeth cut and grind up AAC 706 and feed AAC dust up into dust chamber 74 , and, 3B) end used for driving hollow bar into AAC works as would a normal head on a screw would, as it designed to receive a drill bit and teeth have gaps which can receive a Phillips head screw driver bit and allow hollow bar to be counter sunk. Alternately, the bit fits over the end and tightens onto the tube.
[0148] The flange bar is similar to industry rebar except invention is modified by unique flanges 701 which are positioned and angled 705 to act like screw threads and design of being wider 704 and thicker 703 at bar and then narrowing with receding leading edge 704 and getting thinner towards end 703 provides service of keeping bar centered in hole by resistance of flanges against wall as it is inserted and as flanges bite into walls they bind cementitious pieces together and prevent shifting and/or movement while mortar is added around bar it sets up. It has advantages of inexpensive to manufacture and length being custom cut from long bar on site, but has disadvantage of it requiring pre drilling a hole. The fastener 75 , FIG. 7E , is a screw for installing AAC panels onto a wood or steel rafter system, where the fastener features a pair of concentric shaft portions, with the upper portion having broad helical threads, and lower portion with much smaller helical threads. It has the advantage of using these multipurpose threads which are designed for surface area contact, where the tight or lower threads 725 serve the purpose of starting the fastener into the AAC and then properly imbedding into the wood or steel rafters, FIG. 7F . The upper or loose threads 79 properly hold the AAC without stripping or damaging the AAC, as well as to prevent the fastener from going too far into the AAC, as the axial length of the threads 79 correspond to the thickness of the AAC panels 40 . The fastener has features of AAC gougers 77 B and countersink head 77 A, that facilitates environmentally friendly one coat coverage of roofing material 47 , as taught by the present invention, and replaces conventional heavy roofing shingles, etc., to make this invention possible and practical.
[0149] Another fastening device, the nail screw 80 , shown in partial views in FIGS. 8-8D , has particular utility in securing smaller items to a cementitious material, such as AAC. It can be comprised of a strong, hard plastic instead of steel. It is unique by its ability to be driven into the AAC with a hammer, while further having the ability to be withdrawn by means of a rotational hand tool, i.e., hand or powered screw driver 81 ( FIG. 8C ). This device overcomes problems of prior art in that it will not easily work free over time and yet is removable using the correct tool without damage the item to be secured and/or AAC. The fastener member 80 hereof is comprised of a triangular threaded 82 elongated shank 82 , with very low number of revolutions around shank and is pointed at one end 85 . The pointed end has openings 83 that aid the “N” screw to grip AAC by gathering and compacting AAC dust that presses against AAC wall. The “N” screw is topped at the opposite end by a head portion, where the head portion includes prongs 84 for piercing AAC to provide additional holding of the screw member 80 in place. On the top side of head is a slot 81 for removably receiving a screw driver head, as known in the art, to remove the screw 80 from location. The design allows for unique multiple applications in the same location that no other fastener with such simple construction provides in AAC. Additionally, the elongated shank can be hollow 85 and a standard finish nail 86 be driven through which explodes the tip 87 and further anchors hammer nail. To remove the hammer nail, one first applies a needle nose pliers to remove the finish set nail 86 and then a screw driver and the screw's threads supply enough torque for AAC wall to force exploded tip to re-close and remove screw 80 from the AAC.
[0150] Turning further to the tools of FIGS. 11-11E , a table 90 ( FIG. 11A ) is of a block and panel architectural fabricator. The table 90 has router bits 110 , 111 , 112 with the potential for variable positions, and ability for different bits 110 , 112 on each router cutting simultaneously so each side of block, panel and/or beam has desired architectural features, including utility chase 111 as an example in FIG. 11C , reference numerals 201 , 203 and beams 30 , 31 , 32 . FIG. 11D is a partial view of a hand held version cutting a casing block 203 . The most unique aspect of the tools hereof is the ability through combined use of the tools and template system of FIG. 16 to fabricate finished openings for windows and doors in a solid AAC wall.
[0151] A tool used for cutting utility chases into erected walls is illustrated in FIG. 11A , which is a partial top view of a hand held utility chase cutter 192 with the bit 120 which simultaneously cuts a notch ( FIG. 2B B) for sheetrock 209 and the chase 203 . It uses the template guide system 160 , 163 hereof ( FIG. 11A ) as does most of the hand held cutting tools. FIG. 11A shows utility chase 202 with sheetrock 209 installed using screws 80 , covering water supply 123 and waste pipes 124 . The utility chase cutter can be used for vertical as well as horizontal runs. Since the bit protrudes beyond the face of the interior wall, it is able to cut down behind the base block and up behind the crown block. Then a standard drill can cut holes for utilities through floor panel. The chase is covered using a single cut to size a piece of sheetrock. The tools hereof have the capabilities of special dust collecting systems.
[0152] There is very limited waste product of AAC according to the preferred practice of this invention, but what waste there is can be easily handled by systems known in the art. Such systems can crush waste cementitious pieces into dust, so they do not have to be taken to landfills, which means habitats manufactured by the instant invention can be constructed with little or no waste AAC from the site having to go to a landfill, thereby lessening construction costs and providing an environmentally friendly practice. The resulting dust may then be used as fertilizer for grass, etc.
[0153] As blocks of AAC are set in place, excess mortar can be forced out beyond the wall face. To solve this problem FIG. 15 shows a partial perspective of present invention joint finisher 150 . The joint finisher has a unique roller 152 which serves several useful function namely, keeps blade 151 at optimal angle for removing excess AAC mortar from block face at joints and roller smoothes out any residual trace amounts of mortar, and the spring pressured cleaning blade 153 removes AAC which may accumulate on the roller, so that now one movement replaces prior art's several tools and motions.
[0154] The hand held finishing tool shown ( FIG. 11D ) and may be used with a template guide so that an architecturally finished opening results where there was once just a wall. The window is simply slipped in and caulked and/or finish nailed. No additional wood trim or casing is required. The outlet and switch openings, beam notches, etc. require a different type of template guide having prongs. The guiding arms may be kept perpendicular by level bubble on support arm 160 . In difficult positions, such as a corner notch, an angled template guide is used and, as the rotor zip type tool goes around a guide, a chunk of AAC is removed which allows the beam to seat into wall and be finished with mortar and screw.
[0155] For easing an electrician's job of installing electrical wire ( FIG. 12A ) into a utility channel, the wire inserting tool 170 has a long, specifically angled bar 170 with ability to slip into utility channel 202 and wheel 175 enables installer to simply walk along while the wire feeding wheel 171 by design aligns and lifts wire onto roof of channel where staple fastener 172 shoots a unique staple 174 which does not easily pull out around wire and into the AAC.
[0156] The internal air duct system 180 of this invention, see FIGS. 13A-13B , can be housed in the top beam 206 A and structural beam system. A PVC type pipe may be placed within the cementitious material (AAC) which benefits the AAC by reducing its weight and simultaneously reinforcing it, and further the AAC is benefits the air duct by insulating it, hiding the duct system to enable easy access for vents 181 . The vents 181 can have various sizes for openings as engineered for facilitating desired air flow, and regulated by vent opening size and proximity to air return vents. The system can be located at a centralized location and initial service ducts run through a chase 184 shared by other main utilities, and then hooked up to the internal duct system. The duct corners 182 , as seen in FIG. 13B , are installed by deep socket, large tubular bit 185 which goes around exterior of air duct 180 , and creates a void 183 . The duct is then cut back at a required depth 166 to align with the duct in the adjoining piece, and the AAC is cleared so that the corner coupling 182 slips into the void and over the duct in the top beam 206 A, and likewise in second top beam 206 A, thereby creating a continuous duct system with rounded corners. A manufacturing process of creating void around the duct is to have an inflatable sleeve 186 ( FIG. 2K ) placed on the pipe while in the mold before slurry is introduced. After the mold is removed, the sleeve is deflated and removed. At the site, by this embodiment, the AAC is simply cut back as required and duct's corner coupling 182 slipped on.
[0157] There is limited waste product with the AAC according to the preferred practice of this invention, but what waste there is can be easily handled by the machine 140 that can crush waste cementitious pieces 142 into dust 141 , so they do not have to be taken to landfills. This means habitats manufactured by the instant invention can be constructed with little or no waste AAC from the site having to go to a landfill, thereby lessening construction costs and providing an environmentally friendly practice. The resulting dust may then be used as fertilizer 144 for grass, trees, etc.
[0158] As blocks of AAC are set in place, excess mortar can be forced out beyond the wall face. To solve this problem, FIGS. 15 and 15 A show a joint finisher 150 according to the invention. The joint finisher 150 has a unique roller 152 which serves several useful functions, namely, keeps blade 151 at an optional angle for removing excess AAC mortar from the block face at joints and the roller smoothes out any residual trace amounts of mortar, while the spring pressured cleaning blade 153 removes AAC which may accumulate on the roller. The result, one tool replaces the prior art's tools and motions.
[0159] The hand held finishing tool shown in FIG. 11D may be used with a template guide so that an architecturally finished opening results where there was once a wall. The window is simply slipped in and caulked and/or finished nailed. No additional wood trim or casing is required. The outlet and switch openings, beam notches, etc. require a different type of template guide having prongs. The guiding arms may be kept perpendicular by level bubble on the support arm 160 . In difficult positions, such as a corner notch, an angled template is used and, as the rotor zip type tool goes around a guide, a chunk of AAC is removed which allows the beam to seat into the wall and be finished with mortar and screw.
[0160] It is recognized that changes, variations and modifications may be made to the method of this invention, and to the securing device, particularly by those skilled in the art, without departing from the spirit and scope thereof Accordingly, no limitation is intended to be imposed thereon except as set forth in the accompanying claims. | This disclosure is a system which includes processes, machines, articles of manufacture and compositions of matter required to construct a habitable structure comprised of a cementitious product, preferably autoclaved aerated concrete (“AAC”), formed in unique blocks, panels and beams. This results in an extremely environmentally friendly habitable dwelling, residential or commercial, which, due to the resultant synergy of embodiments, when compared to a similar structure employing prior art and/or current industry's standard materials and methods of construction, is structurally superior and simultaneously yields substantial savings in labor, time and costs. |
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FIELD OF THE INVENTION
The present invention is generally related to methods of sampling subterranean formations of low permeability particularly tight gas bearing formations.
BACKGROUND
The oil and gas industry typically conducts comprehensive evaluation of underground hydrocarbon reservoirs prior to their development. Formation evaluation procedures generally involve collection of formation fluid samples for analysis of their hydrocarbon content, estimation of the formation permeability and directional uniformity, determination of the formation fluid pressure, and many other parameters. Measurements of such parameters of the geological formation are typically performed using many devices including downhole formation testing tools.
Recent formation testing tools generally comprise an elongated tubular body divided into several modules serving predetermined functions. A typical tool may have a hydraulic power module that converts electrical into hydraulic power; a telemetry module that provides electrical and data communication between the modules and an uphole control unit; one or more probe modules collecting samples of the formation fluids; a flow control module regulating the flow of formation and other fluids in and out of the tool; and a sample collection module that may contain various size chambers for storage of the collected fluid samples. The various modules of such a tool can be arranged differently depending on the specific testing application, and may further include special testing modules, such as NMR measurement equipment. In certain applications the tool may be attached to a drill bit for logging-while-drilling (LWD) or measurement-while drilling (MWD) purposes.
Among the various techniques for performing formation evaluation (i.e., interrogating and analyzing the surrounding formation regions for the presence of oil and gas) in open, uncased boreholes have been described, for example, in U.S. Pat. Nos. 4,860,581 and 4,936,139, assigned to the assignee of the present invention. An example of this class of tools is Schlumberger's MDT™, a modular dynamic fluid testing tool, which further includes modules capable of analyzing the sampled fluids. In a variant of the method the sampler is located between a pair of straddle packers to isolate a section of a well which can then be fractured and sampled.
To enable the same sampling in cased boreholes, which are lined with a steel tube, sampling tools have been combined with perforating tools. Such cased hole formation sampling tools are described, for example, in the U.S. Pat. No. 7,380,599 to T. Fields et al. and further citing the U.S. Pat. Nos. 5,195,588; 5,692,565; 5,746,279; 5,779,085; 5,687,806; and 6,119,782, all of which are assigned to the assignee of the present invention. The '588 patent by Dave describes a downhole formation testing tool which can reseal a hole or perforation in a cased borehole wall. The '565 patent by MacDougall et al. describes a downhole tool with a single bit on a flexible shaft for drilling, sampling through, and subsequently sealing multiple holes of a cased borehole. The '279 patent by Havlinek et al. describes an apparatus and method for overcoming bit-life limitations by carrying multiple bits, each of which are employed to drill only one hole. The '806 patent by Salwasser et al. describes a technique for increasing the weight-on-bit delivered by the bit on the flexible shaft by using a hydraulic piston.
Another perforating technique is described in U.S. Pat. No. 6,167,968 assigned to Penetrators Canada. The '968 patent discloses a rather complex perforating system involving the use of a milling bit for drilling steel casing and a rock bit on a flexible shaft for drilling formation and cement.
U.S. Pat. No. 4,339,948 to Hallmark discloses an apparatus and methods for testing, then treating, then testing the same sealed off region of earth formation within a well bore. It employs a sealing pad arrangement carried by the well tool to seal the test region to permit flow of formation fluid from the region. A fluid sample taking arrangement in the tool is adapted to receive a fluid sample through the sealing pad from the test region and a pressure detector is connected to sense and indicate the build up of pressure from the fluid sample. A treating mechanism in the tool injects a treating fluid such as a mud-cleaning acid into said sealed test region of earth formation. A second fluid sample is taken through the sealing pad while the buildup of pressure from the second fluid sample is indicated.
Methods and tools for performing downhole fluid compatibility tests include obtaining an downhole fluid sample, mixing it with a test fluid, and detecting a reaction between the fluids are described in the co-owned U.S. Pat. No. 7,614,294 to P. Hegeman et al. The tools include a plurality of fluid chambers, a reversible pump and one or more sensors capable of detecting a reaction between the fluids. The patent refers to a downhole drilling tool for cased hole applications.
In the light of above known art it is seen as an object of the present invention to improve and extend methods of sampling downhole formations, particular “tight” formations of low permeability. Prominent examples of such tight formations are shale gas formations.
The sampling of tight shale gas formation, which can be very thick, poses a problem to existing sampling tools and methods as the reservoir fluids are not easily extracted from the formation. Hence it is not easy to determine whether a newly drilled section of tight formation is potentially productive or not, even though important technical and economic decisions depend on correct answers to this question.
Among the methods used are formation sampling with a straddle packer configuration, underbalanced drilling, which allows for influx from the reservoir into the drilled well, and exploration fracturing. The latter is an extensive fracturing process on par in cost and complexity with normal fracturing operations.
However none of the known methods are entirely satisfactory as formations can be too tight for the typical one square meter of wellbore wall between the pair of packers to produce a significant sample. Underbalanced drilling on the other hand is typically vastly more expansive and dangerous compared to conventional drilling and the reservoir depth of any gas influx is difficult to determine with the necessary precision. There is further the suspicion that tight formations may not release trapped gas until fractured.
Therefore it is seen as the only reliable method to fully fracture the formation for a comprehensive test. However fracturing thick formations along their entire length becomes a very expansive operation as shale gas formation may stretch for more than 1000 m and considering that exploration fracturing may only cover 20 m to 50 m intervals at a time and at a cost of several million dollars per interval. The problem of deriving new and improved testing methods is therefore one of great importance for tight formations.
SUMMARY OF INVENTION
Hence according to a first aspect of the invention there is provided a method of sampling a subterranean formation, including the steps of creating a side bore into the wall of a well traversing the formation, sealing the wall around the side bore to provide a pressure seal between the side bore and the well, pressurizing the side bore beyond a pressure inducing formation fracture while maintaining the seal, pumping a fracturing fluid adapted to prevent a complete closure of the fracture through the side bore into the fracture, and reversing the pumping to sample formation fluid through the fracture and the side bore.
The side bore is preferably drilled in direction of the maximum horizontal stress, if this direction is prior knowledge.
In a preferred embodiment the fracturing fluid adapted to prevent a complete closure of the fracture can carry either solid proppant or a corrosive component which is capable of etching away at the exposed surface of a fracture.
The method is furthermore best applied to formations of low permeability, which are believed to confine the spread of a fracture to the desired directions. A formation is considered to be of low permeability if the permeability at the test location is less than 100 mD (millidarcy) or less than 20 mD or even less than 10 mD. The methods is believed to be superior to existing sampling method for tight reservoirs, particularly shale gas reservoirs.
The method enables fracturing opening with minimal use of hydraulic fluids. With the new method the amount of fracturing fluid used and carried within the tool body can be less than 50 liters, preferable less than 20 liters and even less 5 liters including proppant or acidizing components of it. Besides being sufficiently small to be carried downhole with the body of tool, the small amount of fluid allows for the use of more specialized and hence more expensive fracturing fluids. Such specialized fluids include for example fluids with a sufficiently high density to keep proppant buoyant.
These and other aspects of the invention are described in greater detail below making reference to the following drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a typically deployment of a formation drilling and sampling tool while performing steps in accordance with an example of the present invention;
FIG. 2 illustrates the step of drilling a side bore to an existing well in accordance with an example of the present invention;
FIGS. 3A and 3B illustrate the step of fracturing the formation in the vicinity of a side bore in accordance with an example of the present invention; and
FIGS. 4A and 4B illustrate the step of sampling the formation in the vicinity of a side bore through a fracture in accordance with an example of the present invention.
DETAILED DESCRIPTION
In FIG. 1 , a well 11 is shown drilled through a formation 10 . The well 11 includes an upper cased section 11 - 1 and a lower openhole section 11 - 2 . The lower openhole section is shown with a layer 12 of formation damaged and invaded through a prior drilling process which left residuals of the drilling fluids in the layer surrounding the well.
In this example of the invention, a wireline tool 13 is lowered into the well 11 mounted onto a string of drillpipe 14 . The drill string 14 is suspended from the surface by means of a drilling rig 15 . In the example as illustrated, the wireline tool includes a formation testing device 13 - 1 combined with a formation drilling device 13 - 2 . Such tools are known per se and commonly used to collect reservoir fluid samples from cased sections of boreholes. The CHDT™ open hole drilling and testing tool as offered commercially by Schlumberger can be regarded as an example of such a tool. The connection to the surface is made using a wireline 13 - 3 partly guided along the drill string 14 (within the cased section 11 - 1 of the well 11 ) and partly within the drill string (in the open section 11 - 2 ).
The operation of this combined toolstring in a downhole operation in accordance with an example of the invention is illustrated schematically in the following FIGS. 2-4 .
In the example, it is assumed that the stresses around the well 11 have been logged using standard methods such acoustic or sonic logging. At a target depth, the tool 13 is oriented such that it is aligned in directions of the maximum horizontal stress. It is in this direction that fractures typically open first when the whole well is pressurized in a normal fracturing operation. The mounted tool 13 can be rotated by rotating the drill string 14 and thus assume any desired orientation in the well 11 .
Making use of the conventional operation mode of the CHDT tool 13 , the body 20 of the tool as shown in more detail in FIG. 2 includes a small formation drill bit 210 mounted on an internal flexible drill string 211 . While the tool is kept stationary using the sealing pad 22 and counterbalancing arms (not shown), the flexible drill 210 can be used to drill a small side bore 212 into the formation 10 surrounding the well 11 .
In the example, a 9 mm diameter hole 212 is drilled to an initial depth of 7.62 cm (3-in) before reaching the final depth of 15.24 cm (6-in). The drilling operation is monitored with real-time measurements of penetration, torque and weight on bit. The bit is automatically frequently tripped in and out of the hole to remove cuttings. The bit 210 trips can be manually repeated without drilling if a torque increase indicates a buildup of cuttings.
After the drilling of the side bore 212 , reservoir fluids are produced to clean it of any cuttings that could adversely affect the subsequent injection. After the clean-out, the pressure in the side bore 212 is increased by pumping a (fracturing) fluid either from a reservoir with the tool or from within the well through the tool.
As shown in FIG. 3A , the pump module 230 , which is a positive displacement pump when using the CHDT tool, is activated in reverse after completing the clean-out of the side bore 212 and a fluid is injected from an internal reservoir 231 through an inner flow line 232 of the tool into the side bore 212 . In the example the internal reservoir carries a highly viscous fracturing fluid mixed with a proppant. The fracturing fluid can include polymers or visco-elastic surfactants as known in the art of fracturing from the surface. The proppant can be sand or other particulate material including granular or fibrous material. To pump such viscous fluid it can be necessary to use actively controlled valves in the pump in place of simple spring loaded valves which have a propensity of clogging in the presence of a flow containing solid particles.
It is important for the present invention that the pad 22 maintains during the injection stages a seal against the well pressure Pw. The sealing pad in the present example seals an area of 7.3 cm by 4.5 cm. A pressure sensor 233 is used to monitor the pressure profile versus time during the operation. Any loss of seal can be noticed by comparing the pressure in the side bore with the well pressure Pw.
The injection pressure can be increased steps of for example 500 kPa increments, with pressure declines between each increment. Eventually the formation breakdown pressure is reached and a fracture 31 as shown in FIG. 3B develops at the location of the side bore 212 .
In the carbonate formation of 1-10 mD of the example the fracture initiation pressure was established as 19080 kPa. The fracturing fluid 32 and the proppant it carries fill the fracture as shown in FIG. 3B .
In the steps as illustrated in FIG. 4A and FIG. 4B , the pumping direction is reversed and initially the fracturing fluid is cleaned from the fracture leaving the proppant 33 behind. The role of the proppant is to prevent a closure of the fracture and hence maintain a channel of higher permeability through which formation fluid is drawn into the tool. Once the fracturing fluid ceases to block the fracture, formation fluids such as shale gas can enter the flow path into the tool as shown in FIG. 4B .
An optical analyzing module 40 as available in the MDT tool can be used to switch the tool from a clean-out mode to a sampling mode, in which the fluid pumped into a sampling container (not shown).
By confining the pressure to single location and smaller volume a much smaller volume of fluid is required for the fracturing testing. Conventional fracturing tests on open hole formations with pairs of straddle packers generate fractures by pressurizing the much larger volume of the well between the two packers and create hence much larger fractures. With new method volume of less than 100 liters or 50 liters, or even less 20 liters appear sufficient to perform the tests. In turn these small volumes enable the use of smaller high differential pumps which typically have a slow pump rate without extending the downhole test time.
Furthermore given the small volumes needed for the fracturing dedicated and expensive fracturing fluids can be used in the present invention which would otherwise be ruled out for fracturing from the surface for economic reasons.
For example very heavy liquids with densities up to 2.95 g/ml are available from commercial sources. Among these liquids are organic heavy liquids (TBE, bromoform), tungstate heavy liquids such as lithium heteropolytungstates (LST). The latter liquid can reach a density up to 2.95 g/mL at 25 C, and a density of 3.6 g/mL at elevated temperatures.
These heavy liquids will keep the proppant neutrally buoyant in the sample chamber and remove the need to use viscous fracturing fluids. Viscous fluids can damage the permeability of the induced fracture, and may have to be remedied by other “breaker” fluids. Suspending the proppant with buoyancy can be applied in a simpler fashion but is practical when only a small volume of the fluid is required, and when the weight of fracturing fluid does not influence the fracturing pressure. These conditions are not given in conventional fracturing operations when the fracturing fluid fills the well bore from reservoir to surface, and contributes to the pressure with its hydrostatic weight.
Another alternative method for preventing a complete closure of a fracture created is to include in the fluid a corrosive or acid component that damages the surfaces of the induced fracture thus preventing it from resealing. The acid achieves the same purpose as the proppant. This alternative is seen as more practical when small fluid volumes are involved, for example chosen from the range of 5-20 liters, than for conventional fracture operations where the entire well bore from reservoir to surface has to be filled with the fluid.
Moreover, while the preferred embodiments are described in connection with various illustrative processes, one skilled in the art will recognize that the system may be embodied using a variety of specific procedures and equipment. Accordingly, the invention should not be viewed as limited except by the scope of the appended claims. | There is provided a method of sampling a subterranean formation. The method includes the steps of creating a side bore into the wall of a well traversing the formation, sealing the wall around the side bore to provide a pressure seal between the side bore and the well, pressurizing the side bore beyond a pressure inducing formation fracture while maintaining the seal, pumping a fracturing fluid adapted to prevent a complete closure of the fracture through the side bore into the fracture, and reversing the pumping to sample formation fluid through the fracture and the side bore. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates generally to a decorative decal system for louvered devices such as venetian blinds or mini-blinds and more specifically relates to a series of adhesive backed decal strips for application to louvered blinds or windows.
BACKGROUND OF THE INVENTION
In the past various types of decorative and utilitarian attachments have been applied to louvered blinds or windows. An example of an early decorative device for venetian blinds is shown in U.S. Pat. No. 2,074,482 issued to E.J. Martens which shows hollow blind slats with decorative fillers inserted therein.
U.S. Pat. No. 3,472,305 issued to M.S. Lefes shows adhesive back insulation strips for attachment to venetian blind slats, however, these strips do not have a decorative design. U.S. Pat. No. 5,029,413 issued to B. Jovanovic shows a vertical window blind with transparent vanes covered with multicolored shapes to resemble stained glass. This is not a decal but a particular design of manufactured window blind.
Other examples of decorative or utilitarian attachments to louvered blinds are shown in U.S. Pat. Nos. 4,899,491, 4,911,220 and 4,930,562. None of these patents, however show the use of a fragmented decorative pattern or indicias which when assembled together on a series of louvers will form a unitary pattern.
OBJECTS OF THE INVENTION
It is a primary object of this invention to provide a simple inexpensive decal system for easily applying decorative patterns or indicia to louvered structures such a venetian blinds or mini-blinds.
Another object of this invention is to provide a decal system with individual decal strips which can be easily aligned in the correct position on individual louvers of a window blind to provide a unitary decorative pattern on the blind.
Another object of this invention is to provide a decal system which requires no cutting or pasting but is in ready to apply form.
These and other objects of the invention will become more fully apparent in the following specification and the attached drawings.
SUMMARY OF THE INVENTION
This invention is a decorative decal system for louvered devices having a plurality of elongated louvers supported in substantially parallel relationship to each other and each louver being rotatable about a respective longitudinal axis of such louver for opening and closing the louvered device, a marginal edge of each of said louvers overlapping a marginal edge of the next adjacent louver, thereby providing a hidden portion on the next adjacent louver, when the louvers are in a closed position and the remainder of each next adjacent louver being a visible portion, the system comprising a set of elongated strips of flexible sheet material having an adhesive layer on the bottom side of each strip, and a decorative design segment imprinted on the top side of each strip, each strip being of sufficient width to at least cover the visible portion of a louver to which it is applied when the louvered device is closed, the design segments of the strips forming a composite pattern when attached to louvers of a louvered device in the proper sequence and alignment and a removable bottom cover sheet protecting the adhesive layer of each strip until it is removed to permit the strip to be attached to a louver.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of an embodiment of the invention including a top cover sheet;
FIG. 2 is a top plan view with the top cover sheet removed from all the strips of the decal to show the appearance of the decal;
FIG. 3 is a cross-sectional view taken on line 3--3 of FIG. 1;
FIG. 4 is a fragmentary perspective view of a typical venetian blind showing how the decal strips are applied to the top of the louvers;
FIG. 5 is a fragmentary front elevational view of a louvered blind showing how the louvers overlap each other and showing the overlap of the decal pattern from one louver to another;
FIG. 6 is a front elevational view of a louvered window blind showing the blind closed and the unitary pattern visible from the front of the blind;
FIG. 7 is a fragmentary front elevational view of another embodiment of the invention showing the decal of the invention mounted on a transparent louvered window to simulate a stained glass window; and
FIG. 8 is a cross sectional view through two typical louvers of the embodiment shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIGS. 1 and 3 the overall decal system or assembly in indicated by the numeral 10. A plurality of elongated flexible decal strips 12 are attached by a bottom adhesive layer 14 to a bottom cover or support sheet 16. The decal strips 12 are preferably made of a flexible plastic sheet material such as vinyl film or other material with a suitable adhesive on the bottom side which permits the decal to be applied to a window blind louver or other surface but later removed without leaving an adhesive residue. One example of a suitable material for the decal strips 12 is SCPM-3 Application tape manufactured by 3M Company. It is a 4 mil vinyl material with easy remove adhesive on one side thereof. Each decal strip 12 is covered by a top cover sheet 18 or pre-masking tape of paper or other suitable material having an adhesive layer 20 which permits easy removal from the top surface of the decal strip 12 without adhesive residue. The top cover sheet 18 is preferably translucent to permit a decorative design segment 22 to show through the cover sheet 18 to aid in properly positioning it each strip 12 in a desired location on a louver so that all the assembled decal strips 12 when mounted on a series of louvers will form a decorative pattern in the desired location on a blind or other louvered structure.
In FIG. 1 it can be seen that one of the cover sheets 18 is pulled back to reveal a portion of the decorative design segment 22. FIG. 2 shows the appearance of the decal assembly 10 mounted on the bottom or support sheet 16 with all the strips of translucent top cover sheet 18 removed.
In applying the decal, however, the top cover sheet 18 is normally left on the decal strips 12 until after they are applied to the louvers, since the cover sheet contains a center guide line 24 as shown in FIG. 1 for aligning the strips 12 on the louvers to which they are attached.
As shown in FIG. 4 each strip 12 is applied in a certain sequence to louvers or slats 26 of a blind 28 having vertical cords 30 which hold the louvers 26 in parallel relationship to each other. While for simplicity, only center cords 30 are shown, in a typical blind there are outer edge cords or bands which are used to change the angle or orientation of the louvers for opening and closing the blind.
FIG. 5 shows two typical louvers 26 with a decal strip 12 attached to each louver. In many typical blinds having louvers of a certain width and curvature, a decal strip 12 may cover the entire width of each louver, however, the strips 12 need not cover the entire width of a louver but should be wide enough to extend a certain distance D1 beneath the overlap of the next adjacent louver. This assures that when the louvers 26 are partially open or slightly out of alignment, that there will be continuity of the decorative design or pattern. The decal strip 12 can be of a width which may, when used on some widths of louvers, terminate a short distance D2 from the top edge of the louver when the blind is closed.
In placing the strips 12 on the louvers 26, the center line 24 on the top cover 18 should be aligned with a mark made on the center of the first louver to receive a decal strip 12 and the bottom edge of the strip should be aligned with the bottom edge of the louver unless the strip 12 is not a full width strip. When a bottom strip such as strip 12b (shown in FIGS. 1 and 2) is less than full width, it should be attached to the top portion of the louver 26. Thereafter, each successive decal strip 12 can be aligned with the previous strip 12 by aligning the center line 24 with the center line 24 on the previous strip. After the strips 12 are all in the proper position on the louvers 26 of a blind 28 to create a unitary pattern as shown in FIG. 6, the top cover sheets 18 are removed from the decal strips 12 leaving the pattern fully visible.
FIG. 7 shows another embodiment of the invention in which, instead of applying the decal to a louvered blind, the decal strips 16 are applied to a louvered window 32 having a plurality of louvers or slats 34 which may be either transparent or translucent glass or plastic material. In FIG. 8 the louvers 34 are shown as being made from glass. To provide the illusion of a stained glass window, the decal design segment 22 may be made transparent or translucent in various colors and the different color sections may be separated by thick borders 36 which simulate leaded borders of a typical stained glass window.
It will be recognized that the width of the decal strips 12 can vary depending upon the width of the louvers or slats of the blind or window, however the main criterion for determining the width is that the decorative pattern covers all the exposed width of the louver so that the pattern is uninterrupted and forms a unitary design on the blind or window. In a typical mini-blind each louver would be 1" (2.54 cm) wide and when the blinds are closed, there would be 7/32" (0.56 cm) overlap of each louver over the next adjacent louver and there would be 25/32" (1.98 cm) width showing on the front surface of each louver and therefore that same width of decal would show when attached to the louver.
While this decal system is primarily designed for use on louvers which can be opened or closed, it can also be applied to a fixed louver assembly.
These and various other modifications can be made herein without departing from the scope of the invention. | A decorative decal system for louvered devices such as venetian blinds dr mini-blinds which uses a series of easily removable adhesive backed decal strips for application to louvered blinds or windows. Each decal strip contains a segment of a decorative design or other indicia and when all segments are applied to series of louvers in a blind the group of decal strips forms a unitary pattern on the blind. |
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BACKGROUND OF THE INVENTION
The present invention relates to a method of controlling the forward and/or rearward movement of a percussion drill for producing holes in soil, including control phases of a reversible slide valve control arrangement. The present invention also relates to a percussion drill for carrying out such a method, with the drill comprising a control device for a flow medium for controlling movement of the drill in the forward and the rearward directions of travel, a housing having a percussion piston disposed in it, the percussion piston striking the housing and being adapted for reciprocating movement therein in response to pressure exerted by the flow medium and comprising an axial guide and lateraI control channels which cooperate with control channels of the control device wherein the control device is a rotary slide valve control device, comprising a control slide valve that is disposed for indexed or stepped rotation in a housing closure means and is connected to a flow medium feed pipe of the housing sealing device.
A first prior art percussion drill (DE-PS 26 34 066-Schmidt dated Sept. 20, 1984) comprises a partially hollow percussion piston that is adapted for reciprocating movement in a housing. A reversible control device for a flow medium extends into the hollow percussion piston and controls the movements thereof and thus indirectly also the forward or reverse movements of the percussion drill. The control device is seated in a screw-threaded end piece that seals off one end of the percussion drill housing and through which also the compressed air is supplied and discharged.
The control device is constructed so as to be integral with the screw-threaded end piece and has a stepped control tube, with that end thereof that extends into the hollow portion of the percussion piston, carrying a pot-shaped control sleeve in which are two diametrically disposed elongated axially parallel control slots. A first tubular part of the screw-threaded end piece engages over a thinner part of the control tube, while a second tubular part, constructed as an intermediate control sleeve, engages over the pot-shaped control sleeve, both tubular parts being connected via webs. The percussion piston slides in an axially reciprocating manner on this intermediate control sleeve. The stepped control tube is mounted for stepped rotation in the screw-threaded end piece and its intermediate control sleeve. For cooperation with the elongated control slits in the control tube, the intermediate control sleeve has matching slits, and immediately adjacent to them are discharge slits which make it possible, in appropriate switching positions, for exhaust air to flow out from the space between the percussion piston head and the housing through transverse ports at the end of the percussion piston. However, compressed air also flows through these transverse ports, through the elongated control slits upstream of the percussion piston head until the latter reverses its movement in the housing from the forward direction to the rearward direction. This compressed air brakes or arrests the percussion piston relatively abruptly at its front, dead center position upon reverse movement of the percussion drill, because the air pressure for moving the percussion piston in the direction of the percussion drill head drops abruptly and throughout the rest of the movement, and in return builds up similarly strongly and quickly upstream of the percussion piston head.
A second percussion drill (DE-PS 27 22 297-Tkac et al dated Mar. 22, 1984) which was developed after the first drill, comprises a partially hollow percussion piston that is adapted for reciprocating movement in a housing, and a reversible control device, for flow medium, which extends into the percussion piston and controls the movements thereof and thus indirectly also the forward or reverse movement of the percussion drill. The control device is seated in a screw-threaded end piece that seals off one end of the percussion drill housing, with the compressed air also being supplied and discharged through the end piece.
The control device has, seated in the screw-threaded end piece, a stepped and rotatable control tube comprising, on the end thereof which is received in the hollow portion of the percussion piston, an annular control step that projects on the outside surface and has on its free end face two diametrically disposed, elongated, axially parallel control slots which are open at the front end and on which, at the axially corresponding locations on the rear stepped end face, there are elongated control projections that have the same outside diameter as the annular control step. The percussion piston slides thereon in an axially reciprocating manner. Close to that end of the piston which is towards the screw-threaded end piece are two diametrically opposed transverse bores through which, in suitable switching positions, exhaust air can flow out of the space between the percussion piston head and the housing. However, compressed air also flows out through these transverse ports, through the elongated control slots, and upstream of the percussion piston head, until the piston head changes its direction of movement in the housing from the forward direction to the rearward direction. This compressed air which flows in permanently upstream of the percussion piston provides a relatively abrupt braking action for the piston.
This abrupt braking is a substantial disadvantage of both of the prior art percussion drills because in both cases considerable reaction forces act on the housing of the percussion drill during reverse movement, thus resulting in a very uneven and inefficient movement, particularly in soft ground. Furthermore, the compressed air consumption is very high since all of the compressed air which arrives in front of the percussion head flows out to the atmosphere through the screw-threaded end piece and is therefore lost. This constitutes a very high energy loss.
It is therefore an object of the present invention to improve the arrangements for controlling a percussion drill in such a way that the intense and abrupt loadings, and the compressed air consumption, are substantially reduced while at the same time the efficiency of the equipment is improved. It is also an object of the present invention to achieve a decided improvement in the efficiency of a percussion drill when driving a cable or bore hole, in other words during forward movement, by making more percussion energy available without thereby increasing the consumption of compressed air and without having to apply more energy to achieve a higher air pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which:
FIG. 1 is a cross-sectional view of one exemplary embodiment of the percussion drill according to the present invention, with the position shown being the forward impact, dead center position of the percussion piston during forward movement of the drill;
FIG. 2 is a detailed perspective view of a first exemplary embodiment of a control slide valve that forms part of a percussion drill according to the invention;
FIG. 3 is a detailed cross-sectional view of the percussion drill in the region of the control slide valve according to FIG. 1 during forward movement, after commencement of the changeover to rearward movement of the percussion piston;
FIG. 4 is a detailed view of the percussion drill according to FIG. 3 during forward movement, after commencement of the control phase for progressive braking of the
FIG. 4A is an enlarged fragmentary in the direction of arrow A in FIG. 4;
FIG. 5 is a detailed view of the percussion drill according to FIG. 3 during reverse movement, after commencement of the braking phase;
FIG. 6 is a detailed view of the percussion drill according to FIG. 4 during reverse travel, after commencement of the gentle braking phase;
FIG. 7 is a detailed view of the percussion drill according to FIG. 5, during reverse travel, after commencement of discharge of exhaust air and prior to the percussion piston striking the screw-threaded end piece; and
FIG. 8 shows a second exemplary embodiment of the control slide valve.
SUMMARY OF THE INVENTION
The method of the present invention is characterized primarily in that the control process, for operation of the drill in the rearward travel direction, is optimized by incorporating a gentle braking phase, and/or in that the control process, for operation of the drill in the forward travel direction, comprises at least one control phase for progressive braking of the percussion piston, with the discharge of compressed air from the drill being quantitatively controllable as a function of the position of the piston during rearward travel.
The percussion drill of the present invention is characterized primarily in that the control slide valve comprises at least one first control channel disposed at a distance from its end face and at least one second control channel offset in relation to the first control channel in the peripheral direction; a control channel of the percussion piston selectively passes over either of the first and second control channels as required, the control passage of the piston being adapted to be connected to exhaust air passages of the percussion drill; and in that either the distance between the first control channel and the end face of the control slide valve is at least greater than the length of the control passage of the percussion piston, which for controlling rearward travel cooperates with the first control channel, and/or the second control channel is constructed as a quantitative control channel for the measured discharge of flow medium for the control phase with progressive braking of the percussion piston.
Further specific features of the present invention will be described in detail subsequently.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings in detail, it is intended first to explain the construction of the percussion drill, then the way it works, and afterwards the method of controlling it because this method will be more readily understood when the reader has knowledge of the construction and manner of operation.
Referring to FIGS. 1 and 2, a percussion drill comprises a hollow, cylindrical housing 1 having a percussion head 2, and a partly hollow-cylindrical percussion piston 4 that is adapted to be reciprocated or moved back and forth in the housing 1 by means of compressed air as the flow medium and that is maintained parallel with the housing axis by a guide pin 3. On its outside surface, the percussion piston 4 has longitudinally extending transfer ports or channels 5 for compressed air; these channels start at two diametrically opposed transverse bores 6 that are inclined to the percussion piston axis. One end of a control slide valve 7 extends into the hollow, cylindrical end of the percussion piston 4, with the other end of the valve 7 being disposed for indexed or stepped rotation in a screw-threaded end piece 8 which serves to seal the housing 1: the slide valve is however, immovably seated and is operatively connected to a compressed air supply means 9. This supply means also serves as a means of adjusting the rotational position of the control slide valve 7 which has, between a longitudinal slot and an exhaust air port, a sealing ring (not shown) to provide a seal with respect to the percussion piston. Furthermore, the control slide valve 7 has a bore 10 for the compressed air, with that end of the bore that penetrates the hollow end of the percussion piston 4 widening out and opening into the piston chamber or space 11 of the percussion piston 4. In the widened-out portion of the bore 10, the control slide valve 7 has two diametrically disposed longitudinal slots 12 that are disposed at a distance (a) from the end face 13 of the control slide valve 7. This distance (a) is preferably at least greater than the longitudinal dimension of the control channel, i.e. the transverse bore 6, that cooperates with the first control channel or slot 12. Two diametrical exhaust air channels 14 are disposed in the control slide valve 7 at those ends of the longitudinal slots 12 that are remote from the end face 13; the channels 14 are disposed adjacent to the slots 12 but are preferably offset therefrom by 90°. These exhaust air channels 14 discharge air into the exhaust air space 15 between the screw-threaded end piece 8 and the end 16 of the percussion piston 4 opposite the end piece 8. The transverse cross-sectional areas of the channels 14 steadily increase from the end at which the longitudinal slots 12 are provided towards the end at which the screw-threaded end piece 8 is situated. In particular, this transverse cross-section is triangular, but it can also be of any other suitable shape. Furthermore, the generatrix 17 of the surfaces of the channels 14 need not be flat or linear, but may follow any desired concave or convex curve. What is essential however is that the exhaust air channel at its end closest to the longitudinal slots, should end virtually in a point, and that from there its cross-section should increase axially only very slowly in a peripheral zone and then discharge into the exhaust air space 15, which is connected to the atmosphere via air outlet passages 18.
The mode of operation of the control device for the percussion drill will initially be described for forward travel, i.e. movement of the percussion drill into the ground or soil, that is for the actual drilling process.
Referring to FIGS. 3 and 4, assuming that the percussion piston 4 is positioned with its head located at the percussion head end of the housing 1 and abutting against this housing, the transverse bores 6 are, generally speaking, at a distance in front of the leading edge V v , with respect to forward travel, of the control slide valve 7. The slide valve is in a position in which the longitudinal slots 12 are offset by 90° with respect to the transverse bores 6. If compressed air is flowing through the bore 10 of the control slide valve 7, then the air passes through the transverse bore 6 and along the transfer channels 5 upstream of the head of the percussion piston 4 on which, by virtue of the different surface areas of the percussion piston head and of its inner cylindrical cross-section in the piston space 11, the air exerts a repulsive force on the percussion piston 4. The piston is accelerated and moves rearwardly towards the screw-threaded end piece 8 until the transverse bores 6 move beyond the leading edge V v . Movement of the percussion piston 4 is now slowed by the compressed air present in the piston space 11 and, by virtue of its kinetic energy, the piston 4 continues to slide, with the transverse bore 6 moving beyond the trailing edge H v , with respect to forward travel, of the control slide. As a result of the fact that the exhaust air channels 14 virtually commence with zero cross-section, the control phase for progressive braking of the percussion piston 4 commences with the discharge of exhaust air. Thus, the percussion piston 4 is progressively slowed or braked in that initially the dispensed or regulated discharge of exhaust air produces only a minimal pressure drop on the upstream side of the head of the percussion piston 4, so that the piston loses little kinetic energy and thus travels a greater distance, before reaching its rear dead center position of reverse movement at which it is completely braked and the pressure drop is completed than is the case in the prior art where there is an abrupt pressure drop at the trailing edge H v , with respect to forward travel. Thus, there also is a greater distance available for the subsequent acceleration of the percussion piston 4 during its forward movement prior to impact, than in the equipment according to the state of the art. Therefore, this produces substantially more kinetic energy for the percussion piston 4 and thus more powerful impacts, i.e. a greater forward travel per impact, than with prior art equipment. This means a substantially enhanced efficiency since both working time and compressed air, i.e. energy, can be saved due to there being fewer impacts per unit length of the bore hole. Starting from this rear dead center position, the percussion piston 4, as mentioned, is accelerated and, shortly after it runs over the leading edge V v , with respect to forward travel, of the control slide valve 7, it strikes the percussion head. This is followed by the next impact cycle for forward movement operation of the percussion drill.
Referring to FIGS. 5, 6 and 7, for reverse or rearward travel of the percussion drill, for example when producing a blind hole, in order to be able to withdraw the drill from the hole, let it be assumed that the percussion piston 4 is in its rearmost position, i.e. closer to the screwthreaded end piece. In comparison with the setting for forward travel the control slide valve 7 is rotated by 90°, so that the longitudinal slots 12 can cooperate with the transverse bores 6 so that air can flow through. As compressed air flows in through the bore 10, the compressed air passes into the piston space 11 and the percussion piston 4 is accelerated in the direction of the percussion head 2. During this forward movement, each transverse bore 6 runs over the corresponding leading edge V 4 , with respect to rearward travel, which is on the same side of the longitudinal slot 12 as the screwthreaded end piece. As long as the transverse bores 6 are disposed over the longitudinal slots 12, compressed air flows through the two bores 6 into the transfer channels 5 and in front of the head of the percussion piston 4, so that the forward movement is intensely braked, but not completely, so that the percussion piston 4 is still allowed to run over the end edges of the longitudinal slots 12, the gentle braking edges W, without however running over the end face 13 of the control piston, i.e. without reaching the forward dead center position of movement during movement along the distance (a). During this phase of movement, no compressed air arrives in front of the head of the percussion piston 4, so that braking takes place more gently than when there is a permanent supply of compressed air upstream of the head, as with prior art equipment. By virtue of the length of the longitudinal slots 12, the braking phase can be monitored and controlled in conjunction with the distance (a). By virtue of the energy stored in the air cushion upstream of the head of the percussion piston 4, the return of the piston is accelerated until its transverse bores 6 pass beyond the trailing edge H r , with respect to rearward travel, and the air can escape to the atmosphere from the air cushion via the exhaust air space 15 and the air outlet passages 18, as a result of which the end of the percussion piston 4 which is at the same end as the screw-threaded end piece strikes the screw-threaded end piece 8, so that the percussion drill can move backward out of the bore hole. This is followed by a new percussion cycle.
The gentle braking phase, which is controlled by the length of the longitudinal slots 12 in conjunction with the distance (a), ensures a substantially reduced loading on the percussion drill than was possible with prior art equipment; this is reflected in a substantially increased effective life. Furthermore, the gentle braking phase that can be controlled in this way achieves a substantially reduced consumption of compressed air, resulting in lower running costs. The lower reaction forces on the housing during the braking phase produce a smoother reverse or rearward travel, even in loose or wet soil, and builds up only negligible shell friction. Furthermore, the control slide valve is substantially more stable, which in turn makes for a longer working life. In addition, the control slide valve can be more accurately produced.
In the case of a percussion drill that has a gentle braking phase during reverse travel, and a progressive braking phase during forward travel, overall the following advantages can be enjoyed; lower running costs, shorter working times, and increased working life.
With regard to the method of controlling the forward movement of the percussion drill, starting from a percussion piston position to the rear, i.e. when the percussion piston 4 is in the vicinity of the screw-threaded end piece 8, air is fed to the piston chamber 11 causing the percussion piston 4 to be accelerated in a forward direction, toward the percussion head 2, until the transverse bores 6 pass beyond the leading edge V v , whereby compressed air is forced through the bores 6 and through the transfer channels 5 upstream of the front face of the percussion piston. This takes place just prior to the percussion piston 4 striking the percussion head 2. Due to the build-up of pressure on that end face of the percussion piston 4 which faces the percussion head, the return movement is accelerated, the transverse bores 6 first passing the leading edge V v and immediately afterwards the trailing edge H v . It is at this point that the control phase of the progressive braking of the percussion piston 4 during return in the forward movement-impact cycle commences. Since the exhaust air channels 14, just after they are covered by the transverse bores 6, have an extremely small cross-section so as to initiate this progressive braking phase compared with the large cross-section exhaust air channels which are used in the control method according to the state of the art), initially only very little air is discharged, the quantity increasing gradually according to the configuration of the exhaust air channels 14. This means that the percussion piston 4 has a higher kinetic energy for substantially longer than in the case of an exhaust air channel which is of large cross-section. Thus, its dead center position for reversal of movement is shifted substantially farther to the rear, i.e. closer to the screw-threaded end piece 8. The greater distance of this rear dead center position, in relation to the leading edge V v , which represents the forward point of reversal, gives rise to a substantially higher percussion piston speed at the end of the longer acceleration path, and thus to a more powerful impact. Thus, one impact cycle, for forward travel, is concluded.
In the case of the control method for the reverse or rearward movement of the percussion drill, again starting from a percussion piston position to the rear, i.e. in a percussion piston position close to the screw-threaded end piece 8, the supply of compressed air again accelerates the percussion piston 4 in a forward direction, toward the percussion head 2, until the transverse bores 6 pass over the leading edge V r , with respect to reverse travel, of the control slide valve 7. From this moment onward, compressed air is passed through the longitudinal slots 12 and the transfer channels 5 upstream of the percussion piston 4, and the braking phase is initiated. By virtue of the approximately selected length of the longitudinal slots 12, the percussion piston 4 is guided over the end edges of the longitudinal slots 12, the gentle braking edges W, and is gently braked within the distance (a) between the edges W and the end face 13 of the control slide valve 7 by the cushion of air that still remains upstream of the percussion piston 4 even though no further compressed air has been supplied. Afterward, the air cushion accelerates the percussion piston in its return stroke until the piston passes over the trailing edge H r , with respect to return travel, of the control slide valve 7, and the air of the air cushion escapes to the atmosphere via the transverse bores 6, the exhaust air space 15, and the air outlet channels 18, shortly after which the piston strikes the screw-threaded end piece 8 in an unbraked condition, causing the percussion drill to be propelled out of the bore hole. The next impact cycle for the reverse travel of the percussion drill then commences.
In a second embodiment, shown in FIG. 8, the control slide valve 7 can be constructed without a step or shoulder behind the longitudinal slots 12 and the exhaust air channels 14, which instead may open out into exhaust air passages 15 that are adjacent to the air outlet channels 18 of the screw-threaded end piece 8. Such a construction of the control slide valve 7 has the advantage that it is more stable, so that wear and tear in the control portion is reduced, resulting in an increased working life and an improved functioning, even after many hours of operation.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims. | A percussion drill provided with additional control phases in the form of a gentle braking phase for controlling the rearward movement, and a progressive braking phase for controlling forward movement. To this end, the control slide valve of the drill has a clearly defined gentle braking control edge, a new type of control channel having a cross-section which is variable along its length. The main advantages which are achieved as a consequence are substantially reduced compressed air consumption, substantially smoother operation even in relatively loose soil, and a considerably prolonged effective life. |
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FIELD OF INVENTION
[0001] This invention relates to rotating tools for generating rotation to use with equipment installed within a bore casing of an oil well-bore, especially for coil-tubing applications.
BACKGROUND
[0002] Oil wells are generally formed by drilling a bore into the earth for accessing buried crude oil deposits, and then installing a variety of equipment within the bore to enable pumping of crude oil up to the earth's surface. During drilling, hollow metallic tubes (also known as ‘casings’) are inserted within the bore to prevent walls of bore from collapsing. In a deep enough bore, multiple hollow casings are installed vertically one above the other by screwing ends of adjacent sections with each other. The entire assembly of attached casings is commonly known as ‘bore casing’.
[0003] Once a bore casing is formed, a variety of equipment (including crude oil pumping equipment and sensor equipment) is installed within the bore casing. In an operational oil well, crude oil is pumped to the surface of the earth from the buried crude oil deposits with the help of pumping equipment installed in the bore casing. However, the oil well production unit is vulnerable to failure of installed equipment within the bore casing, which can be caused by mechanical fatigue or electrical shorts or other problems, which can be exacerbated by changed conditions within the well-bore.
[0004] During installation of pumping equipment, or during troubleshooting of failed equipment in an operational oil well-bore, it is often necessary to retrieve equipment from the bore casing (also known as fishing). Retrieval of equipment which may be imperfectly installed or lie stuck within the bore casing, can be accomplished by grasping it with an overshot tool (having jaws) connected to the coiled tubing. Jaws of an overshot are generally opened and closed by rotation provided to the overshot. Additionally, rotation provided by the overshot can help to set free stuck equipment. Since the coil tubing cannot be rotated easily—but it can be moved up and down linearly from a drum powered by a drive motor, a mechanical transfer of linear motion of the coil tubing into rotational motion is required.
[0005] A rotating tool can be used in a well-bore with coil tubing in conjunction with a drilling jar. See e.g. U.S. Pat. No. 8,151,910 (incorporated by reference). While the drilling jar generates impacts and resultant shock waves along the coil tubing to aid in freeing the tubing or stuck equipment, the rotating tool generates rotation for the overshot and rotation for freeing the stuck equipment. The current designs of rotating tools do not work well with the hard accelerations needed to be applied to the coil tubing (it must be jerked up or down, or both) to generate the jarring effect. The current designs tend to rotate too freely, which can cause tools designed to operate when rotated to be unintentionally activated. The rotating tool described below solves these problems with the existing rotating tools.
SUMMARY
[0006] The invention is a rotating tool for inducing rotation. When included in coiled tubing of an oil well-bore, the rotating tool of the present invention is useful for operating or freeing target equipment within the bore casing of an oil well-bore. One end of the rotating tool is connected with an end of coiled tubing reeled into the oil well-bore, and its other end is connected to target equipment on which rotation is to be induced. The rotating tool converts linear motion (up or down) of the coiled tubing into rotation. The rotation hence produced is used to operate the target equipment; e.g., opening/closing jaws on an overshot.
[0007] In a rotating tool, a sliding assembly, including a shaft, slides within a housing assembly. Linear displacement of the shaft in one direction is converted into rotational motion in a first rotational direction through a tubular gear, which in turn induces rotation of the housing assembly and the target equipment in the first rotational direction.
[0008] The housing assembly includes a upper-sub, a barrel, a lower-sub and a first longitudinal bore. A mandrel of the sliding assembly is connected to the coiled tubing and is used to drive the shaft linearly through the first longitudinal bore. The upper-sub is screwed to one end of the barrel, the lower-sub is screwed to the opposite end of the barrel, and the distal end of the lower-sub is connected to the target equipment. The proximal end of the lower-sub includes a first set of axially-extending gear teeth.
[0009] The surface of the shaft includes axially-extending helical grooves. The tubular gear surrounds the grooved surface of the shaft and engages with the helical grooves through one or more adjustable screws which extend transversely through threaded holes in the tubular gear. Adjusting the extent to which the adjustable screws extend into the grooves can be used to exert varying degrees of pressure by the adjustable screws on the bottom of the grooves, and thereby varying the force required to make the tubular gear travel along the helical grooves (and the shaft). One end of the tubular gear includes a second set of multiple axially-extending gear teeth which mate with the corresponding first set of axially-extending gear teeth of the lower-sub, but permit rotation in one direction only.
[0010] Within the rotating tool, axial movement of the tubular gear is prevented beyond longitudinal separation between the lower-sub and a tubular head of the shaft. When the shaft is moved axially in a first linear direction and when the tubular gear is pushed against the lower-sub, the adjustable screws of the tubular gear slide along the helical grooves and cause the tubular gear to rotate in a first rotational direction. Since the second set of gear teeth of the tubular gear matingly engage with the first set of gear teeth of the lower-sub, rotation of the tubular gear also causes the lower-sub to rotate in the first rotational direction. And the rotation of the lower-sub also causes the entire housing assembly and the target equipment to rotate in the first rotational direction.
[0011] As described further below, the adjustment of the screws facilitates fishing operations where equipment is stuck and must be dislodged by activating a jar. Embodiments of the present invention will be discussed in greater details with reference to the accompanying figures in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a cross-sectional view of a first embodiment of a rotating tool.
[0013] FIG. 1B is an expanded cross-sectional view of the portion of FIG. 1A shown as expanded by the lead lines.
[0014] FIG. 2A illustrates a cross-sectional view of a tubular gear used in the first embodiment.
[0015] FIG. 2B is an elevational view of the tubular gear.
[0016] FIG. 3 is a perspective view illustrating engagement of the shaft and the tubular gear in the first embodiment.
[0017] FIG. 4 is an elevational view of the lower-sub.
[0018] FIG. 5 is an elevational view of the lower-sub engaged with the tubular gear.
[0019] FIG. 6A is a cross-sectional view of the rotational tool in a “ready for down-stroke” position.
[0020] FIG. 6B is a cross-sectional view of the rotational tool in a “ready for up-stroke” position.
[0021] FIG. 7 illustrates a coil tubing set up for fishing including a rotating tool of the present invention and a drilling jar.
[0022] It should be understood that the drawings and the associated descriptions below are intended and provided to illustrate one or more embodiments of the present invention, and not to limit the scope of the invention. Also, it should be noted that the drawings are not be necessarily drawn to scale.
DETAILED DESCRIPTION
[0023] Reference will now be made in detail to a first embodiment of a rotating tool of the invention with reference to the accompanying FIGS. 1A to 6B . As illustrated in these figures, rotating tool 100 comprises a mandrel 102 , an upper-sub 104 , a barrel 106 , a shaft 108 , a tubular gear 110 , a piston 112 and a lower-sub 114 . The mandrel 102 , the shaft 104 , and the piston 112 together form a longitudinal sliding assembly which is slideable within a housing assembly formed by the upper-sub 104 , the barrel 106 , and the lower-sub 114 . To form the housing assembly, internally threaded portion 116 and 118 of the barrel 106 are screwed on to the upper-sub 104 , and the lower-sub 114 respectively. Each of the upper-sub 104 , the barrel 106 , and the lower-sub 114 include a longitudinal cylindrical bore, and all three bores are aligned along a longitudinal axis of the barrel assembly so as to provide a passage for the sliding assembly to slide through. In FIG. 1A , the passage for sliding assembly to slide within the lower barrel is illustrated as path 122 .
[0024] Mandrel 102 includes sliding cylinder 124 , an outer cylinder 126 and a longitudinal bore 128 extending through the sliding cylinder 124 and the outer cylinder 126 . A portion of the longitudinal bore 128 which lies in the outer cylinder 126 widens towards end 130 of the outer cylinder 126 and is internally threaded for connecting the rotating tool 100 to coiled tubing (shown in FIG. 7 ).
[0025] Shaft 108 comprises of a tubular head 132 , an externally grooved cylindrical region 134 and a longitudinal bore 136 extending through the head 132 and threaded cylindrical region 134 . Portion of the sliding cylinder 124 which lies proximate to its end 138 is externally threaded (shown as externally threaded portion 140 in FIG. 1A ). The externally threaded portion 140 is screwed into one end of the tubular head 132 of shaft 108 . Piston 112 is a tubular cylinder and includes a longitudinal bore 142 . Portion of the shaft 108 which lies proximate to its end 120 is externally threaded and is screwed into one end of the piston 112 .
[0026] Tubular gear 110 surrounds a portion of the grooved cylindrical region 134 and is engaged to its grooves 153 through adjustable screws 144 as best seen in FIG. 1B and FIG. 3 . Depth of engagement of ball 145 at the tip of screw screws 144 in grooves 153 of grooved cylindrical region 134 can be adjusted by rotating the screws in or out through their corresponding threaded holes 146 in tubular gear 110 . Ball 145 is optional at the tip of screws 144 , and no ball or other types of interfaces with the grooves 153 are within the scope of the invention. A magnified view of engagement of tubular gear 110 with grooves 153 of grooved cylindrical region 134 is also illustrated in FIG. 1B . A compressible helical spring 148 surrounds threaded cylindrical region 134 , as best seen in FIG. 3 . Longitudinal extension of spring 148 is restricted to within of the linear edges of a dynamic region 150 , which is bounded by the barrel 106 , the externally helically grooved region 134 , the tubular head 132 , and the tubular gear 110 .
[0027] The lower-sub 114 further includes a first set of multiple axially-extending gear teeth 152 (as best seen in FIG. 4 ), an externally threaded tapered arm 154 , an additional reduced diameter bore 156 connected to path 122 (as best seen in FIGS. 1A, 6A and 6B ). In an installed coiled tubing assembly, the tapered arm 154 is preferably screwed into to a mating lower portion of the coiled tubing which extends into the oil well-bore, or directly connected with a fishing tool (such as an overshot) as described below and shown in FIG. 7 . In a coiled tubing assembly having the rotating tool 100 installed, bore 128 , bore 136 , bore 142 , path 122 , and bore 156 together provide a fluid flow path for a fluid (flowing along the coil tubing) to pass through rotating tool 100 .
[0028] FIGS. 2A and 2B illustrates structure of tubular gear 110 in greater detail. Tubular gear 110 includes two holes 146 and a second set of multiple axially-extending gear teeth 158 . Holes 146 are internally threaded to allow screwing or unscrewing of the threaded portion of screw 144 through them. When fully screwed in, ball 145 at the tip of screws 144 can engage with the lower portion of grooves 153 of threaded cylindrical region 134 .
[0029] To prevent leakage of fluid flowing through the rotating tool 100 (for example, drilling fluid flowing through the coiled tubing) into the dynamic region 150 through the interface between the piston 112 and path 122 , rubber O-rings 160 are provided around piston 112 (illustrated in FIG. 1 and FIG. 3 ). A detailed perspective view of the assembly of the shaft 108 , the spring 148 , the tubular gear 110 (cross-sectional view), and the piston 112 with O-rings 160 as installed in rotating tool 100 is shown in FIG. 3 .
[0030] As shown in FIG. 5 , the second set of gear teeth 158 of the tubular gear 110 matingly fits into the first set of gear teeth 152 of the lower-sub 114 . In such a mated assembly, rotation of tubular gear 110 (as it travels down the helical groove in shaft 108 ) would also cause the lower-sub 114 to rotate in same rotational direction.
[0031] Operation of the rotating tool 100 for producing rotation during down-stroke will now be explained in detail with reference to FIGS. 6A-6B . As illustrated in FIG. 6A , to initiate a down-stroke, the mandrel 102 is pushed down into the housing assembly through the upper-sub 104 by reeling out coil tubing 702 from drum 704 (as illustrated in FIG. 7 ). As sliding cylinder 124 is pushed in by this action, the shaft 108 (along with the piston 112 ) gets pushed into path 122 . Since tubular gear 110 is engaged with grooves 153 of the shaft 108 through screws 144 , axial force is also exerted on the tubular gear 110 . Since axial movement of the tubular gear 110 is prevented beyond the lower-sub 114 , the exerted force causes engaged tips of screws 114 to slide through the helical grooves 153 of the shaft 108 . Sliding of screws 114 through helical grooves 153 of shaft 108 causes the tubular gear 110 to rotate in a first rotational direction (for example, in clockwise direction in the present embodiment). Since gear teeth 158 of the tubular gear 110 are matingly engaged with gear teeth 152 of the lower-sub 114 , rotation of tubular gear 110 also causes the lower-sub 114 to rotate in a first rotational direction. Still further, since the lower-sub 114 connected with the barrel 106 , rotation of lower-sub 114 further causes the entire housing assembly to rotate in the first rotational direction. As a result of rotation, tubular gear 110 (through screws 144 ) also moves up the groove towards the tubular head 132 . Finally, when the entire length of sliding cylinder 124 is moved into the housing assembly (as illustrated in FIG. 6B ), the down-stroke concludes, and the tubular gear 110 sits closer to the tubular head 132 . Further, the spring 148 lies compressed between the tubular head 132 and the tubular gear 110 .
[0032] During up-stroke, the pushing force on mandrel 102 is released and a pulling force is applied on mandrel 102 (and to the shaft 108 ) by reeling in coil tubing 702 from drum 704 (as illustrated in FIG. 7 ). When the shaft 108 is pulled out, linear movement of the tubular gear 110 towards the upper-sub 104 is opposed by the spring 148 , but the spring 148 now gradually begins to uncompress into the additional availability of space in dynamic region 150 . Pressure released from uncompressing spring 148 forces tubular gear 110 towards lower-sub 114 . As a result of force exerted by the uncompressing spring, the screws 144 of the tubular gear 110 start to sliding in a reverse direction along the grooves 153 of the shaft 108 . Such a sliding causes the tubular gear 110 to rotate in a counter-clockwise direction (i.e. opposite to rotational direction during the down-stroke). However, due to structure and mating profile of gear teeth 152 and 158 , rotation of tubular gear 110 in counter-clockwise direction does not induce any rotation on the lower-sub 114 (and hence in the housing assembly). During up-stroke, teeth 158 simply slidingly rotate over the mated gear teeth 152 (the teeth 158 and 154 only lockingly engage in one rotational direction).
[0033] The sensitivity of rotating tool 100 to produce desired a desired amount of rotation per unit of pushing force on the mandrel 102 during down-stroke can be adjusted by the degree of engagement of screws 144 with the grooves 153 of the shaft 108 . Pressure exerted by screws 144 at the bottom of the grooves 153 can be adjusted. Higher friction between the tips of the screws 144 and grooves 153 of the shaft 108 , would result in lesser rotation of tubular gear 110 per unit force applied on mandrel 102 . To achieve larger amount of rotation per unit of pushing force, friction between screws 144 and grooves 153 of shaft 108 should be reduced, and screws 144 should not be driven to an extent that their respective tips become tightly engaged with the grooves 153 of the shaft 108 .
[0034] When screws 144 is driven in through the hole 146 , ball 145 at the tip of screw 144 engages firmly with the groove of the shaft 108 . Driving the screw 144 deeper into hole 146 would push the metallic ball 145 tightly against the groove of shaft 108 , and hence the ball 145 would engage with a greater pressure and friction with the groove of shaft 108 . Hence, positioning of screw 144 within hole 146 can be used to adjust the magnitude of pressure exerted by the metallic ball 145 on the grooves 153 of shaft 108 . In other words, level of engagement of tubular gear with grooves 153 of the shaft 108 can be adjusted by driving the screw 144 suitably within hole 146 . The structure and dimensions of hole 146 , screw 144 and the metallic ball 145 can be chosen suitably to ensure that while being engaged with the groove of the shaft 108 , the ball 145 remains engaged with the hole 146 too, and that driving of screw 144 into hole 146 , or any rotation of tubular gear 110 around the shaft 108 does not result in losing the engagement of metallic ball 145 with the hole 146 . As an example, to ensure that driving of screw 144 into hole 146 does not result in losing the engagement of metallic ball 145 with the hole 146 , the hole may be constructed in a manner such that driving the screw 144 into the hole 146 is restricted beyond a threshold.
[0035] FIG. 7 shows the assembly of coil tubing 702 , reeled from a drum 704 by a drive motor 710 and an injector 712 in an oil well-bore casing 706 . The coil tubing 702 is connected with a drilling jar 708 and with a rotating tool 100 , which drives an overshot 700 having jaws 716 . To retrieve a target equipment 714 from a well bore, the coil tubing 702 is reeled down from the drum by a drum 704 by a drive motor 710 and an injector 712 . To avoid dislodging the equipment 714 and having it fall down the well bore, lowering of coil tubing 702 slows as it nears the equipment 714 . At the time of contact between the distal end of the overshot 700 and the equipment 714 , lowering is immediately stopped. The adjustable screws 144 in the rotating tool 100 have been set so that there is little friction between them and the helical grooves 153 of shaft 108 , and rotation of the lower-sub 114 (or the housing assembly) and the overshot 700 is induced by relatively modest downward acceleration of the assembly of coiled tubing 702 by the motor 710 . The rotation closes the jaws 716 of the overshot on the equipment 714 so that the equipment 714 is grasped by jaws 716 . Finally, the assembly of coiled tubing 702 is reeled up (carrying up the equipment 714 grasped in jaws 716 ).
[0036] In the event the equipment 714 is lodged or stuck in the well bore and needs to be freed by activating the jar 708 , the assembly of coiled tubing 702 must be rapidly accelerated up or down to induce a jarring impact. Additionally, where it is known that equipment 714 is stuck firmly, one can tighten screws 144 before lowering the assembly of coiled tubing 702 , and then contact the stuck equipment 714 with a solid impact on it by the overshot 700 , before activating the overshot jaws 716 to close, using another strong downward force (which may help dislodge the stuck equipment 714 ).
[0037] Alternatively, the first try to grasp and release stuck equipment 714 can be done with the screws 144 in a loosened setting, so the equipment 714 is not accidentally dislodged. The jaws 716 are then closed with a downward force on the assembly of coil tubing 702 . If attempts to release the equipment 714 fail, with or without firing the jar 708 , the jaws 716 can be opened by applying another rotational force through the rotating tool 100 by pushing the mandrel 102 downwardly again (following an up-stroke of it). The assembly of coil tubing 702 can then be reeled up to the surface without the equipment 714 , the screws 144 tightened, and then lowered again so that overshot 700 impacts the stuck equipment 714 , before grasping it again with jaws 716 and firing the jar 708 again, if necessary. The impact of the overshot 700 may be enough to help free the equipment 714 .
[0038] In different embodiments the pitch of the grooves 153 on shaft 108 can be varied, so as to reach a specified degree of rotation for each operating cycle of a rotating tool 100 , i.e., one full downstroke or upstroke of mandrel 102 . In operations where after grasping equipment 714 , jar 708 is activated to file bi-directionally several times to aid in dislodging the stuck equipment 714 , the pitch on grooves 153 can still allow control of the grasp strength of the jaws 716 . For example, first the equipment 714 is grasped with a grip strength sufficient to lift it, but not significantly more—in the event equipment 714 has components which could be damaged by an over-strength grasp by jaws 716 . Then, if the equipment 714 cannot readily be lifted by reeling drum 704 up, one would activate the drilling jar 708 . Assuming that three cycles of activating the jar 708 bi-directionally (where it fires six times in total) would power a calibrated overshot 700 to exert a force increase between 1,000-50,000 psi at its jaws 716 , such increase would then be applied by jaws 716 on the equipment 714 —before one again attempts to lift it. This feature avoids the risk of damaging equipment in the event the overshot's 700 grip strength at its jaws 716 is not calibrated, and if the number of activations of jar 708 is not controlled.
[0039] Various other types of fishing tools and coil tubing set-ups can also be used in an oil well-bore. It is to be understood that the foregoing description and embodiments are intended to merely illustrate and not limit the scope of the invention. Other embodiments, modifications, variations and equivalents of the invention are apparent to those skilled in the art and are also within the scope of the invention, which is only described and limited in the claims which follow, and not elsewhere. | Disclosed is a rotating tool for inducing rotation, e.g., for activating and operating coil tubing tools for fishing target equipment in a bore casing of an oil well-bore. The rotating tool is connected with an end of coiled tubing reeled into the oil well-bore, and its other end is connected to a target equipment on which rotation is to be induced. The rotating tool converts linear motion in a first direction of the coiled tubing into rotation, and the rotation hence produced operates a coil tubing tool e.g., opening/closing jaws on an overshot. The rotating tool includes adjustable screws which allow the rotation resistance to be adjusted. |
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CLAIM OF PRIORITY
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application, are hereby incorporated by reference in their entirety under 37 CFR 1.57. This application is a continuation of U.S. patent application Ser. No. 13/027140, filed Feb. 14, 2011, which claims the benefit of U.S. Provisional Patent Application No. 61/338248, filed Feb. 16, 2010, both of which are hereby incorporated in their entirety by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This application relates to improved box culverts, box culvert assemblies, and methods of using box culverts.
[0004] 2. Description of the Related Art
[0005] Box culverts are commonly used in the construction and/or road maintenance industry to form culverts. Typically, box culverts comprise box-like concrete structures with openings extending entirely through their central portions. Two or more boxes are generally arranged under the roadway in abutted, linear fashion, with the openings facing one another so as to form one long opening under the roadway. The boxes are typically pushed, or abutted up against one another, until a line of boxes has been formed with an opening extending through them.
[0006] Once assembled, the boxes can be used for directing water, mud, debris, etc. from one side of the road to another, thereby inhibiting the accumulation of water, mud, or debris on the roadway itself. The boxes are generally pushed tight enough together so as to form a sealed line of boxes which inhibit leakage of water or debris outside of the culvert.
SUMMARY OF THE INVENTION
[0007] An aspect of at least one of the embodiments disclosed herein includes the realization that during assembly of two or more boxes, it is desired to place each box in close and/or sealed contact with another box, without allowing excess mud, debris, or other material to come between the two boxes. Pushing one box culvert along the ground until it contacts and/or seals against a second box can often lead to ineffective sealing between the two boxes due for example to the dirt which is disturbed by pushing the box culvert along the ground. It would be advantageous to have a box culvert assembly which generally does not require the boxes to slide along the ground or soil, but also creates a strong contact and/or seal between the boxes.
[0008] Thus, in accordance with an embodiment, a box culvert assembly can comprise first and second four-sided concrete boxes coupled to one another, the first and second boxes having first ends, second ends, and openings extending between the first and second ends. The first box can comprise a protruding ledge, the protruding ledge comprising a first portion, a second portion, and a third portion in between the first and second portions, the first and second portions having a greater thickness than the third portion. The second box can comprise a recessed ledge having surfaces for contacting and supporting the first and second portions; and wherein a gap exists between the third portion and the recessed ledge.
[0009] In accordance with another embodiment, a method of constructing a box culvert can comprise providing a first box culvert, the first box culvert having a first end comprising a platform having two receiving surfaces located adjacent two corners of the box, the two receiving surfaces being elevated lower than a third surface extending between the two receiving surfaces. The method can further comprise providing a second box culvert, the second box culvert having a second end comprising a protruding lip having first and second lip ends, the first and second lip ends having a greater thickness than that of a remainder of the lip. The method can further comprise lowering the second end of the second box culvert onto the first end of the first box culvert at an angle such that the first and second lip ends contact the two receiving surfaces, and the two receiving surfaces support the second box culvert, and pivoting the second box culvert about the receiving surfaces, such that the first and second ends are joined together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features and advantages of the present embodiments will become more apparent upon reading the following detailed description and with reference to the accompanying drawings of the embodiments, in which:
[0011] FIG. 1 is a perspective view of two boxes that form a box culvert assembly;
[0012] FIG. 2A is a front elevational view of either of the boxes from FIG. 1 ;
[0013] FIG. 2B is a back side elevational view of either of the boxes from FIG. 1 ;
[0014] FIG. 3 is a partial cross-sectional view of the box of FIG. 2A , illustrating a thin protruding ledge:
[0015] FIG. 4 is a partial cross-sectional view of the box of FIG. 2A , illustrating a lip that extends around at least a portion of the box:
[0016] FIG. 5 is a partial cross-sectional view of the box of FIG. 2A , illustrating a thick protruding ledge:
[0017] FIG. 6 is a partial cross-sectional view of the box of FIG. 2B , illustrating a recessed ledge and further including some sealant type material along a surface;
[0018] FIG. 7 is a partial cross-sectional view of the box of FIG. 2B , illustrating a recessed area extending around at least a portion of the box;
[0019] FIG. 8 is a partial cross-sectional view of the box of FIG. 2B , illustrating recessed ledges for receiving a protruding ledge from another box, as well as sealing pads;
[0020] FIG. 9 is a side elevational view of a method of lowering a first box onto a second box and pivoting the first box into place about the second box;
[0021] FIG. 10 is a schematic illustration of two boxes connected to one another, including padding and a sealed gap area formed between the two boxes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] An improved box culvert assembly 10 is disclosed herein. The embodiments disclosed herein are described in the context of a concrete box culvert assembly comprised of a plurality of concrete boxes for placement under a road because the embodiments disclosed herein have particular utility in this context. However, the embodiments and inventions herein can also be applied to types of boxes, culverts, and/or structures configured for other types of environments, and comprised of materials other than concrete.
[0023] With reference to FIGS. 1 , a box culvert assembly 10 can comprise at least two boxes 12 . Each of the boxes 12 can be formed from concrete or other suitable material, and can have a first wall 14 , a second wall 16 , a third wall 18 , and a fourth wall 20 , with the first, second, third, and fourth walls surrounding an opening 22 extending through the box 12 . The box 12 can further comprise a front face 24 on one end of the box 12 , and a back face 26 on the other end of the box 12 , with each of the faces 24 , 26 extending generally around the opening 22 .
[0024] Each box 12 can further comprise a first front side attachment feature 28 . The first front side attachment feature 28 can be formed as part of the front face 22 . The first front side attachment feature 28 can be used to connect and/or attach a first box 12 to a second box 12 during assembly of a culvert. For example, and as described further herein, the first front side attachment feature 28 can be used to lower and pivot a first box 12 onto a second box 12 . In some embodiments, the first front side attachment feature 28 can comprise a protruding ledge (e.g. a tongue) extending generally along an edge of wall 14 . The first front side attachment feature 28 can be configured to rest upon and/or seal against at least a portion of a first back side attachment feature 30 of a second box 12 .
[0025] With continued reference to FIG. 1 , the first back side attachment feature 30 can also be used to connect and/or attach a first box 12 to a second box 12 during assembly of a culvert. For example, the first back side attachment feature 30 can be used to lower and pivot a first box 12 onto a second box 12 . In a preferred arrangement, the first back side attachment feature 30 can receive and support at least a portion of the first front side attachment feature. The first back side attachment feature 30 can comprise, for example, a recessed ledge, such as for example a groove, formed as part of the back face 26 of box 12 and extending generally along an edge of wall 14 .
[0026] With continued reference to FIG. 1 , the front face 24 can further comprise a second front side attachment feature 32 . The second front side attachment feature 32 can be used to connect and/or attach one box 12 to another box 12 during assembly of a culvert. For example, the second front side attachment feature 32 can comprise a peripheral lip protruding from the front face 24 and extending generally along an edge of walls 18 , 20 , and 16 .
[0027] The back face 26 can comprise a second back side attachment feature 34 . The second back side attachment feature 34 can be used to connect and/or attach one box 12 to another box 12 during assembly of a culvert. For example, the second back side attachment feature 34 can comprise a recessed area 34 extending generally along an edge of walls 18 , 20 , and 16 for receiving the second front side attachment feature 32 .
[0028] With continued reference to FIG. 1 , the first front side attachment feature 28 can comprise first and second portions 36 , and a third portion 38 extending between the first and second portions 36 . As illustrated in FIG. 1 , the first and second portions 36 can have a greater thickness than the third portion 38 . For example, the first and second portions can have a thickness (the thickness having a direction extending in a direction between walls 14 and 20 ) which is approximately twice that of the thickness of third portion 38 . In some embodiments, the first and second portions can have a thickness which is at least twice that of the thickness of the third portion. In some embodiments, the first and second portions can have a thickness which is at least three times that of the thickness of the third portion. In some embodiments, the first and second portions can have a thickness which is at least four times that of the thickness of the third portion. Other ranges are also possible. In some embodiments, the thickness of the first and second portions can be at least 2 inches. In some embodiments, the thickness of the first and second portions can be at least 3 inches. In some embodiments, the thickness of the first and second portions can be at least 4 inches. Other ranges are also possible. In some embodiments, the third portion 38 can comprise a relatively thin protruding ledge of concrete, and the first and second portions, positioned on either end of third portion 38 , can comprise relatively thick protruding portions of concrete. In some embodiments, the first, second, and third portions 36 , 38 can have the same thickness, forming one protruding lip. In some embodiments, the first and second portions can protrude from corners of the box 12 . In some embodiments, the first and second portions can protrude over a recessed area of the front face 24 adjacent the second front side attachment feature 32 . In some embodiments, the first and second portions can be configured to support the weight of the box 12 .
[0029] With continued reference to FIG. 1 , the first back side attachment feature can comprise first and second surfaces 40 , and a third surface 42 extending between the first and second surfaces 40 . As illustrated in FIG. 1 , the first and second surfaces 40 can have an elevation (the elevation having a direction extending between walls 14 and 20 , with wall 20 being higher than that of wall 14 ) lower than that of the third surface 42 . In other embodiments, the elevations can vary. In some embodiments, the first, second, and third surfaces all have the same elevation, forming a single platform (e.g. all the surfaces can comprise one surface). Additionally, the third surface 42 can generally form part of a relatively thin ledge extending between first and second surfaces 40 .
[0030] With continued reference to FIG. 1 , the back face 26 can further comprise fourth and fifth surfaces 44 . The fourth and fifth surfaces 44 can be located adjacent the first and second surfaces 40 , and can be elevated lower than the first and second surfaces 40 . The fourth and fifth surfaces 44 can be used to receive first and second portions 36 from another box 12 . For example, the first and second portions 36 can comprise first and second inner ledges 46 (only one of which is shown in FIG. 1 ). The first and second inner ledges 46 can be located on either side of third portion 38 , and can be configured to rest upon and/or seal against the fourth and fifth surfaces 44 when the two boxes 12 are assembled.
[0031] With reference to FIGS. 2A and 2B , the front face 24 and back face 26 can have a substantially similar appearance when viewed directly head-on. Surfaces and portions of the front face 24 which generally protrude outwardly can have corresponding recessed areas on back face 26 , and surfaces and portions on the back face 26 which generally protrude outwardly can have corresponding recessed areas on front face 24 . Additionally, the protruding and recessed portions of front face 24 and back face 26 can be angled (e.g. inclined) so as to guide and facilitate connection of corresponding portions on the back face 26 and/or front face 24 of another box 12 .
[0032] For example, and with reference to FIGS. 2A and 3 , the third portion 38 of first front side attachment feature 28 can have an angled surface 38 a facing generally towards the wall 20 of box 12 (e.g. facing towards the bottom of the box 12 ). With reference to FIGS. 2B and 6 , the third surface 42 of first back side attachment feature can be angled and facing generally away from wall 20 of box 12 (e.g. facing towards the top of box 12 ). When boxes 12 are assembled, the angled surfaces 38 a and 42 can facilitate ease of assembly. Additionally, and as explained further below, the angled surfaces 38 a and 42 and/or overall configuration of the third portion 38 and third surface 42 can create a space (e.g. gap) between the third portion 38 and third surface 42 for insertion of sealing fluid or other material.
[0033] With reference to FIGS. 2A and 4 , the wall 18 can comprise the second front side attachment feature 32 , such as for example a lip. The second front side attachment feature 32 can comprise an angled surface 32 a facing generally away from wall 16 (e.g. facing away from the inside of the box 12 ). As described above, the second front side attachment feature 32 can extend around walls 18 , 20 , and 16 . With reference to FIGS. 2B and 7 , the wall 16 can comprise a recessed area 34 . The recessed area 34 can comprise an angled surface 34 a facing generally towards wall 18 (e.g. facing towards the inside of box 12 ). When boxes 12 are assembled, the angled surfaces 32 a and 34 a can facilitate ease of assembly.
[0034] With reference to FIGS. 2A and 5 , the first and second portions 36 can comprise angled surfaces 36 a facing generally towards the wall 20 of box 12 (e.g. facing towards the bottom of the box 12 ). With reference to FIGS. 2B and 8 , the first and second surfaces 40 can be angled (e.g. inclined), and can generally face away from wall 20 (e.g. face away from the inside of box 12 ). The fourth and fifth surfaces 44 can also, or alternatively, be angled, and can generally face away from wall 20 (e.g. face away from the inside of box 12 ). Thus, when boxes 12 are assembled, the angled surfaces 36 a , 40 , and/or 44 can facilitate ease of assembly.
[0035] While the angles (e.g. inclinations) of the surfaces 38 a , 32 a , 36 a , 42 , 34 a , 40 , and 44 illustrated in FIGS. 3-8 are shown as being approximately 5 degrees with respect to first wall 14 , other angles can also be used, including but not limited to angles greater than or less than 5 degrees. Additionally, the angles can vary from surface to surface. For example, the angle (e.g. inclination) of surface 38 a can be different from that of surface 42 . The angle of surface 38 a can additionally, or alternatively, be different from that of surface 34 a.
[0036] With reference to FIGS. 9 and 10 , a method for assembling the boxes 12 is shown. As illustrated in FIG. 9 , to assemble two of the boxes 12 , one of the boxes 12 can first be resting flat on the ground (e.g. the box on the right in FIG. 9 ). The other box 12 can then be lowered from above, usually by a mechanical device such as a crane, such that portions of the other box 12 contact and pivot about portions of the box 12 already on the ground.
[0037] For example, a box 12 can be lowered until the first and second portions 36 of the box 12 are resting upon the first and second surfaces 40 of the box 12 already on the ground. The crane can be supporting a portion of the weight of the box 12 as it is lowered into place and placed into contact with the box 12 already on the ground. Once contact is made, the lowered box 12 can swing into the box 12 already on the ground, such that the second front side attachment feature 32 fits into the recessed area 34 , and the second inner ledges 46 rest on the fourth and fifth surfaces 44 . In some embodiments, the first and third portions 36 , 38 can support at least ⅓ of the weight of the box 12 as it is being lowered into place on first and second surfaces 40 . In some embodiments, the first and third portions 36 , 38 can support at least ½ of the weight of box 12 as it is being lowered into place on first and second surfaces 40 . In some embodiments, the first and third portions 36 , 38 can support at least ⅓ of the weight of the box 12 as it is being lowered into place on both the first and second surfaces 40 and the fourth and fifth surfaces 44 . In some embodiments, the first and third portions 36 , 38 can support at least ½ of the weight of box 12 as it is being lowered into place on both the first and second surfaces 40 and the fourth and fifth surfaces 44 . Other ranges of weight support are also possible.
[0038] Because the first and second portions 36 are relatively thick compared to both third portion 38 and the thin ledge comprising surface 42 , and because first and second surfaces 40 are positioned near corners of the box 12 already on the ground, the weight of other box 12 is easily supported by the two contact points or areas near the corners of the boxes 12 . If the weight of the other box 12 were to be lowered onto the surface 42 , the ledge comprising surface 42 may likely break or fracture. Similarly, the third portion 38 may break or fracture. Thus, providing relatively thick first and second portions 36 , along with recessed receiving areas 40 near the corners of the box 12 , can facilitate assembly of the two boxes 12 without undesired stress or fracture.
[0039] Additionally, and with reference to FIGS. 8 and 10 , sealing pads 48 or other similar devices can be used to facilitate assembly of the boxes 12 and/or form a seal between the boxes 12 . For example, a sealing pad 48 can be placed and/or attached onto first and second portions 36 or first and second surfaces 40 . The sealing pads 48 can be used to cushion and/or absorb the contact between the first and second portions 36 while one box 12 is being lowered and pivoted about another box 12 . The sealing pad 48 can remain, in a compressed state, between the two boxes after they have been assembled, as shown in FIG. 10 .
[0040] With continued reference to FIGS. 9 and 10 , by using the first and second portions 36 and surfaces 40 to create initial contact and pivot points between boxes 12 , an area (e.g. gap) between the third portion 38 and surface 42 can be created and/or used. Similarly, by using sealing pads 48 , an area (e.g. gap) between the third portion 38 and surface 42 can be created and/or used. For example, and as illustrated in FIG. 10 , a gap 50 can be created between the third portion 38 and surface 42 . Prior to assembly of the boxes, a sealant 52 (e.g. a type of adhesive, or any other type of sealant), such as shown in FIG. 6 , can be spread across surface 42 . When the boxes are assembled, and pivoted into place on top of first and second surface 40 and sealing pads 48 , the sealant can be pressed and fill at least part of the gap 50 shown in FIG. 10 , thereby facilitating a strong, generally leak-free attachment between the two boxes. In some embodiments, the gap 50 can be bordered at least in part by the sealing pads 48 .
[0041] While the sealant 52 can be used in gap 50 , it is understood that sealant could be used elsewhere. For example, sealant could be used between the angled surfaces 32 a and 34 a along the walls 18 , 20 , and 16 of the boxes 12 , and/or between the angled surfaces 36 a and 44 . In some embodiments, no sealant can be used, and gap 50 can remain open. In some embodiments, no sealant can be used, and gap 50 does not exist. Rather, the third portion 32 can contact (e.g. but not press with significant force) against the surface 42 when the boxes 12 are assembled.
[0042] In yet other embodiments, sealing pads 48 can be placed elsewhere, or not used at all. For example, in some embodiments, no sealing pads 48 can be used. Instead, the first and second portions 36 can directly contact the first and second surfaces 44 . In other embodiments, sealing pads 48 can be used on the other two corners (e.g. the bottom two corners) of the boxes in addition to or alternatively from using sealing pads 48 as shown in FIG. 10 .
[0043] In yet other embodiments, the first, second, and third surfaces 40 and 42 can all generally have the same elevation (i.e. can be coplanar). Thus, in such an embodiment, the gap 50 can be significantly larger than that shown in FIG. 10 . Other sizes, shapes, and configurations for the gap 50 other than that shown are also possible.
[0044] As described above, the assembly 10 allows the boxes to be placed together and/or sealed without sliding the boxes along the ground. This advantageously inhibits the accumulation of dirt, debris, or other matter which may cause premature deterioration or inefficient use of the culvert.
[0045] Additionally, the boxes 12 can be pivoted about two points or areas which are stable, and can fully support the load of a concrete box 12 . This advantageously permits the boxes 12 to be assembled without undesired stress and/or fracture. This arrangement also advantageously allows the boxes to be sealed together, and/or formed tightly together, simply by lowering one box down next to another and allowing gravity to pivot one box into another. Such ease of assembly reduces the effort involved in assembling a large culvert.
[0046] Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above. | A box culvert assembly and method of forming a box culvert assembly is provided. The boxes forming the assembly comprise portions configured to allow pivoted assembly of one box into another, while reducing the likelihood of high stress or fracture. The box assembly further allows for a generally tight seal between the boxes. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 11/047,080, filed Jan. 31, 2005, now abandoned.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
The present invention generally relates to tools such as scrapers for removing residual material from cans, buckets or similar containers, and also generally relates to trowels for spreading materials on a surface.
The use of scrapers and trowels to remove various materials such as adhesives, grouts, cements, plaster, resin, stucco, paint and the like from cans, buckets or other containers is well known in the prior art. Examples of such scrapping tools are shown for example in U.S. Pat. Nos. 4,355,432; 4,627,128; 4,987,635; and 5,875,515. When using such scrapping tools to apply a material, some material is removed from the container with the tool, then the material is deposited upon the surface to which the material is to be applied such as a surface to be tiled. The user must then put the scrapping tool away and pick up a different tool such as a trowel which is then used to spread the material on the surface. This process of switching from one tool to another then back again can be time consuming and tedious. A tool which functioned to improve the efficiency of this process would be desirable.
SUMMARY OF THE INVENTION
The present invention is a combination squeegee (i.e., a scraper) and hand trowel tool. The tool can be conveniently used to first remove a material from a can, bucket or other material container and then used to spread the material evenly on a surface or substrate. The tool has a substantially flat blade having a continuous arcuate curved edge portion substantially conforming to a portion of an interior wall of a container for efficiently removing residual material from the interior wall of containers such as cans or buckets and a separate notched edge portion (preferably with indentations or serrations) for evenly spreading the material on a surface. The invention further contemplates a method of using the tool to remove material from a can, bucket or container and applying the material to a surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a combination squeegee and hand trowel constructed in accordance with the present invention.
FIG. 2 is a cross-sectional view of the combination squeegee and hand trowel of FIG. 1 taken along line 2 - 2 thereof.
FIG. 3 is a cross-sectional view of the combination squeegee and hand trowel of FIG. 1 taken along line 3 - 3 thereof.
FIG. 4 is a plan view of another embodiment of a combination squeegee and hand trowel constructed in accordance with the present invention.
FIG. 5 is a plan view of another embodiment of a combination squeegee and hand trowel constructed in accordance with the present invention.
FIG. 6 is a plan view of another embodiment of a combination squeegee and hand trowel constructed in accordance with the present invention.
FIG. 7 is a perspective view yet another embodiment of a combination squeegee and hand trowel constructed in accordance with the present invention.
FIG. 8 is a side cross-sectional view showing the use of the tool of FIG. 1 for removing material from an interior wall of a container.
FIG. 9 is a top plan view illustrating a curved edge portion of the combination squeegee and hand trowel disposed substantially adjacent an interior wall of a container.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIGS. 1-3 , shown therein is a combination squeegee and hand trowel 10 constructed in accordance with the present invention. The combination squeegee and hand trowel 10 (hereinafter also referred to as tool) is provided with a substantially flat blade 12 having an upper surface 14 and a lower surface 16 . A handle 18 is connected to the flat blade 12 so as to extend upwardly from the upper surface 14 of the blade 12 so that a person can grasp the handle 18 . The handle 18 can be releaseably or non-releaseably connected to the blade 12 of the tool 10 .
As shown in FIG. 1 , the blade 12 has a semi-circular configuration (i.e. the shape of a half-circle) and has a curved edge 20 and a notched edge 22 . The curved edge 20 is a continuous arc which extends from a first end 24 of the notched edge 22 to a second end 26 of the notched edge 22 . That is, the blade 12 is provided with a continuous arcuate curved edge 20 and the curved edge 20 of the blade 12 is sized to substantially correspond to a portion of a curved interior sidewall of the container for which the blade 12 is used to remove material from the interior sidewall of the container as will be described in more detail hereinafter.
The notched edge 22 includes a plurality of notches 28 , only a portion of which are specifically indicated by a reference numeral. The configuration of the notched edge 22 can vary widely and will depend, to a large extent, on what the tool 10 is to be used for. For example, the notched edge 22 is shown in FIG. 2 as being crenelate, a desired configuration when using the tool 10 to apply an adhesive to a surface, such as when laying tile.
The blade 12 has a length 30 and a width 32 which extends perpendicularly from a center point 33 of the notched edge 22 to the curved edge 20 . The length 30 and width 32 of the blade 12 will vary depending on the size of the container with which the blade 12 is used to scrape material from the sidewall of the container. That is, the blade 12 is provided with a sufficient length 30 and a sufficient width 32 so that the curved edge 20 of the blade 12 can be disposed substantially adjacent a portion of the curved interior surface or wall of the container whereby a material on the sidewall can be removed by the tool 10 . For example, when using the tool 10 to remove material from the sidewall of a conventional five gallon bucket, desirable results have been obtained wherein the blade 12 of the tool 10 is provided with a length of about 10.25 inches and a width of about 6.75 inches.
As previously stated, the curved edge 30 of the blade 12 has a continuous curvature which conforms to or compliments the curvature of an inner surface of a side wall of a container with which the tool 10 is anticipated to be used. That is, the curved edge 30 of the blade 12 is void of any straight line segments. Thus, the particular size of the blade 12 of the tool 10 will be determined based upon the size of the container with which the tool 10 is to be used. Further, the material removed from the container can be tile adhesives, grouts, stucco, plaster, or other bonding materials as well as paints which are used in construction. Such containers are well known in the art. Thus, no further discussion concerning the size of such containers or the nature of such containers is deemed necessary.
As noted above, the handle 18 of the tool 10 is sized to permit a person to grip the handle so that the tool 10 can be used to scrape material from the inner surface of the sidewall of the container. Thus, the handle 18 has a length 34 , a width 36 and a height 38 . The length 34 , width 36 and height 38 of the handle 18 can vary widely depending on the size of the blade 12 . For example, desirable results have been obtained wherein the length 34 of the handle 18 is about 6.75 inches, the width 36 is about 1 inch and the height 38 is about 1.5 inches.
To enhance removal of material from the interior surface of the sidewall of the container, the curved edge 20 of the blade 12 is desirably beveled substantially as shown. The degree of beveling of the curved edge 20 of the blade 12 can vary widely. However, desirable results have been achieved wherein the curved edge 20 of the blade 12 has a bevel height 40 of about 0.125 inch and a bevel width 42 of about 0.25 inch.
As previously noted, the notched edge 22 of the blade 12 is provided with a plurality of notches 28 . Each notch 28 has a notch width 44 . The notched edge 22 of the blade 12 shown in FIGS. 1-3 has a crenelate shape. The distance between the notches 28 of the notched edge 22 can vary widely depending on the intended use of the tool 10 , as can the width of the notches 28 . For example, the notches 28 can be provided with a notched width 40 of about 0.25 inches.
Referring now to FIGS. 4-6 , shown therein are three additional embodiments of a tool constructed in accordance with the present invention wherein the notched edges of the tools have alternate notch patterns. Shown in FIG. 4 is a tool 10 a having a flat blade 12 a . The blade 12 a has a handle 18 a connected to an upper surface 14 a of the blade 12 a such that the handle 18 a extends upwardly therefrom. The blade 12 a has a semi-circular configuration, and as such has a curved edge 20 a and a notched edge 22 a . The curved edge 20 a is a continuous arc which extends from a first end 24 of the notched edge 22 a to a second end 26 a of the notched edge 22 a . Thus, with exception of the configuration of the notched edge 22 a , the blade 12 a of the tool 10 a is similar in construction and functioned to the blade 12 of the tool 10 hereinbefore described with reference to FIGS. 1-3 . That is, the notched edge 22 a of the blade 12 a of the tool 10 a has a serrated or “toothed” pattern rather than the notched pattern of the blade 12 of the tool 10 .
Referring now to FIG. 5 , shown therein is a tool 10 b constructed in accordance with the present invention. The tool 10 b is provided with a flat blade 12 b having a handle 18 b connected to an upper surface 14 b of the blade 12 b such that the handle 18 b extends upwardly therefrom. The blade 12 b has a semi-circular configuration and as such has a curved edge 20 b and a notched edge 22 b . The curved edge 20 b is a continuous arc which extends from a first end 24 b of the notched edge 22 b to a second end 26 b of the notched edge 22 b . Thus, with exception of the configuration of the notched edge 22 b , the blade 12 b of the tool 10 b is similar in construction and function to the blade 12 of the tool 10 hereinbefore described with reference to FIGS. 1-3 . That is, the notched edge 22 b of the blade 12 b of the tool 10 b has a crenelate or scalloped pattern which is “curved” or “wavy”.
Referring now to FIG. 6 , shown therein is a tool 10 c constructed in accordance with the present invention. The tool 10 c has a flat blade 12 c . The blade 12 c has a handle 18 c connected to an upper surface 14 c of the blade 12 c such that the handle 18 c extends upwardly therefrom. The blade 12 c has a semi-circular configuration and as such has a curved edge 20 c and a notched edge 22 c . The curved edge 20 c is a continuous arc which extends from a first end 24 c of the notched edge 22 c to a second end 26 c of the notched edge 22 c . Thus, with exception of the configuration of the notched edge 22 c , the blade 12 c of the tool 10 c is similar in construction and function to the blade 12 of the tool 10 hereinbefore described with reference to FIGS. 1-3 . That is, the notched edge 22 c of the blade 12 c of the tool 10 c has a pattern wherein smaller notches 28 c alternate with larger notches 28 cc.
While certain patterns for the notched edge of the tools hereinbefore described have been shown, it will be readily apparent to those skilled in the art that other notch patterns can be employed in the construction of the notched edge of the tool of the present invention.
As noted before, the handle 18 of the tool 10 may be releaseably connected, i.e. detachable, from the blade 12 . Shown in FIG. 7 is a tool 10 d which includes a blade 12 d , a handle 18 d and a connector assembly 47 for connecting the handle 18 d to the blade 12 d . The blade 12 d is provided with a curved edge 20 d and a notched edge 22 d . The blade 12 d of the tool 10 d may be the same as the blade of any other tool described herein. The tool 10 d differs from the tools 10 - 10 c described herein in that the handle 18 d is detachably connected to the blade 12 d.
The connector assembly 47 includes a female connector 48 and a male connector 49 . The female connector 48 is formed integrally with the blade 12 d so as to extend outwardly from an upper surface 14 d of the blade 12 d substantially as shown. The male connector 49 is formed on one end of the handle 18 d and is adapted to matingly engage the female connector 48 so that the handle 18 d can be connected to the blade 12 d.
Any suitable mechanism can be used as the connector assembly 47 . For example, the female connector 48 can include a housing having an opening therein with internally disposed threads and the male connector 49 can be a threaded portion on one end of the handle 18 which can be inserted within the housing for mating engagement with the threads in the housing of the female connector 48 substantially as shown. Thus, the handle 18 d can be operably connected or disconnected from the blade 12 d via the connector assembly 47 .
Any of the tools 10 - 10 d contemplated herein or alternate embodiments of them may be constructed of materials known to be used in the construction of trowels, squeegees, scrapers, or the like, including metals, polymers, plastics (including thermoplastics), rubber, wood, wood products, cardboard, or combinations thereof. The tools 10 - 10 d may be flexible or rigid. The tools described herein, such as tools 10 - 10 c , may be formed as an integral one piece construction molded from a thermoplastic material, although the tool 10 d is shown as constructed of separate materials such as a separate blade 12 d and a separate handle 18 d which are connected together via the connector assembly 47 hereinbefore described.
Referring now to FIGS. 8 and 9 , the manner of usage and operation of the combination squeegee and hand trowel of the present invention will now be described with reference to the tool 10 . Once a cylindrically shaped container 50 , such as a gallon bucket, a 5 gallon bucket or a 10 gallon bucket has been opened, the tool 10 is inserted into the container 50 to remove material therefrom. Once the container 50 has been substantially emptied the curved edge 20 of the tool 10 , which is arcuately shaped to substantially correspond to an arc configuration of a segment of an inner surface 52 of a sidewall 54 of the container 50 , is positioned adjacent the segment of the inner surface 52 of the sidewall 54 and the interior surface 52 of the sidewall 54 is scraped with the curved edge 20 of the tool 10 to remove residual material from the inner surface 52 of the sidewall 54 . The scraping motion utilizing the curved edge 20 of the tool 10 is repeated until substantially all the material has been removed from the inner surface 52 of the sidewall 54 of the container 50 . It should be noted that the tool 10 may also be used to remove residual amounts of material from the bottom of the container 50 or from beneath an interior rim of the container 50 . As such, removal of substantially all material within the container 50 can be effected utilizing the tool 10 (or any other tool of the present invention). Furthermore, the tools described herein can be utilized to spread or otherwise apply material removed from a container, such as the container 50 , to a surface or substrate in a manner appropriate for the material. That is, the notched edge 22 of the blade 12 of the tool 10 can be utilized to effectively spread material removed from the container 50 as required for a particular application.
The size of the container 50 can vary widely but the container 50 will typically be of a size used in various manners of construction and remodeling. Further, the size of the tool 10 and any other tools described herein, will vary and desirably be sized and configured to enhance removal of material from the interior surface 52 of the sidewalls 54 of the container 50 .
It is to be understood that the dimensional relationships of the materials from which the tools 10 - 10 d and the handles 18 and 18 d are fabricated, and the components of the tools 10 - 10 d of the invention such as the blades 12 - 12 d or the handles 18 and 18 d , can vary, as well as the configuration of the handles 18 and 18 d of the tools 10 - 10 d.
Therefore, the foregoing is considered as illustrative only of the tools 10 - 10 d of the present invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, the tools 10 - 10 d and their uses are not limited to the exact construction and operation shown and described, and all suitable modifications and equivalents of the tools 10 - 10 d described herein may be resorted to, and fall within the scope of the present invention. | The present invention is a combination squeegee (i.e., a scraper) and hand trowel tool. The tool can be conveniently used to first remove a material from a can, bucket or other material container and then used to spread the material evenly on a surface or substrate. The tool has a blade having a curved edge portion for removing material from cans or buckets and a separate notched edge portion (preferably with indentations or serrations) for evenly spreading the material on a surface. The invention further contemplates a method of using the tool to remove material from a can, bucket or container and applying the material to a surface. |
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FIELD OF THE INVENTION
The present invention relates to a method for hauling up especially casings or other objects placed within a cylindrical hole drilled in earth mass or rock. Also, the method may be used for inserting or pushing a pipe or other objects down into such a hole.
BACKGROUND OF THE INVENTION
Likewise, the invention relates to arrangements and improvements in drill rigs, generally comprising a derrick and a power source for rectilinear displacement of a working head or the like to and fro, e.g. a working head for connection of a drill string having a bit. Thus, the invention aims at utilizing such a prior art drill rig and assigns thereto extra equipment enabling the above-mentioned hauling, possibly insertion, of objects into the ground.
NO patent application No. 952813 deals with a method of piling in connection with drilled vertical or substantially vertical bore holes for receiving casings of the kind desired to be hauled up again and reused when the piling is finished. The present invention is not restricted to hauling up casings extending vertically in a driven down position, the invention also being associated with ashore drilling generally, and comprises hauling up casings in connection with deviation drilling.
As mentioned, NO patent application No. 952813 deals with a method of piling in connection to a preceding drilling operation carried out by means of a combined drilling/piling rig, and wherein, by means of a drilling means included as a working tool at the end of a drill string in a drilling rig, a vertical hole is drilled, and the piling can start from the bottom of this bore hole. A casing of the kind to be hauled up in accordance with the present invention, is releasably suspended from said drilling means by means of a reamer ring which, together with the casing, surrounds the bit, leaving a radial clearance, so that the casing is left standing on the lower end thereof at the bottom of the bore hole when the drill string is pulled up after terminated drilling.
When the piling is finished, it is desirable to have the casing hauled up for reuse. In accordance with the present invention, such casings are intended to be hauled up in an efficient way by means of a rational method, wherein the hauling device shares power source with the drilling machine in that respect that hauling device and drilling machine may use the same power source for reciprocating, rectilinear displacement movements. Downward insertion of drill string and hauling the same up are, thus, carried out through a common power source; this is also the case when lowering the catcher means of the hauling device in order to bring the former to grip and surround the upper end of the casing, and also upon hauling the same up, possibly followed by lowering the same into position. On the other hand, the rotation of the drill string/bit is based on the use of a separate power source, e.g. a hydraulic turning motor. In prior art technique, a separate rig or simlar machine has to be used for hauling up the casing.
From NO patent application No. 952813 it is previously known to dispose the drilling machine pivotally about a vertical axis at one vertical side of the drilling machine. Thus, the drilling machine may be swung laterally out of the vertical path from the upper end of the derrick down to the bottom of a predrilled hole. Such a pivotal capability is required in piling. Also, it is used a pipe narrower than the casing but surrounding the drill string. The annulus between said narrower pipe and the casing is made so narrow as possible in order to make more efficient the transport and removal of cuttings and to reduce the requirement for the air compressor's capacity. Said narrower pipe is brought to follow the drill string up and out of the bore hole, the casing--as mentioned--being left behind standing on the bore hole bottom.
SUMMARY OF THE INVENTION
According to the present invention, catcher means is disposed such that it has a first position, wherein it is widened in order to surround a casing lowered into the earth, around the upper end thereof, and a second position, wherein it is narrowed in order to secure a reliable grip around the upper end portion of the casing. In connection with elongated objects having a round cross-section and driven down into the earth, such a catcher means will have the form of a divided, substantially circular ring comprising interhinged ring parts and assigned an activation means, such as a hydraulic piston cylinder. The catcher means per se, which possibly may be made as a replacable device, is shaped and designed for adaption to the object to be lifted and hoisted up from its position downhole in the ground. Alternatively, the device may be used to urge e.g. a pipe down into a predrilled bore hole.
This catcher means is disposed on a first carriage adapted to the two guidances on the derrick of the drilling rig for the carriage of the drilling machine--in the following called the second carriage. First carriage will constitute bottom carriage and second carriage top carriage.
The most important feature of the method according to the present invention consists in that the first (bottom; lower) carriage with the hauling-up device is permanently coupled to a driven motion transferring mechanism adapted to effect rectilinear, reciprocating displacement movements of the hauling-up device in the derrick, the second (top; upper) carriage to which the drilling machine is coupled, in a first condition of the rig is coupled to the derrick, such that the first carriage with the hauling-up device alone can be displaced by means of the driven motion transferring mechanism during the hauling up of e.g. a casing, and that the second carriage, in a second condition of the rig is uncoupled from the derrick and, thereafter, is interconnected to the first carriage for common reciprocating displacement movements by means of the same motion transferring mechanism, which is driven by one single power source.
A drilling rig comprising a derrick having guidances for said upper (second) carriage carrying a drilling machine is, in accordance with the present invention, provided with said lower (first) carriage disposed below the upper carriage, guided in the guidances of the derrick and carrying said hauling-up device adapted for reciprocating displacement movements by means of said motion transferring mechanism and carrying said catcher means in the form of a grab, a clamp, a clip or similar claw or jaw means adapted to securely grasp e.g. a casing situated in a bore hole in the earth, in order to being able to haul the casing up and park it, the catcher means releasing the casing upon the parking thereof. According to the invention, said rig further distinguishes itself through exhibiting means for interconnecting the upper carriage and the lower carriage (when the upper carriage with the drilling machine has been uncoupled from the derrick) so that the drilling machine and the hauling-up device can be displaced to and fro jointly by means of the driven motion transferring mechanism, and means for interconnecting the upper carriage with the drilling machine and the derrick (thereby making the upper carriage stationary), simultaneously as the first-mentioned means uncouples the upper carriage from the lower carriage, which is connected to said driven motion transferring mechanism and which, in this condition, can be reciprocated alone, i.e. during the hauling-up operations.
Said interconnecting means may advantageously have the form of piston cylinders carried by the upper carriage carrying the drilling machine, and wherein each piston rod end portion is extendable beyond the end of the associated hydraulic cylinder, each cooperating with through-going locking holes, one locking hole in the derrick and one locking hole in the lower carriage carrying the hauling-up device. Each of double-acting plunger cylinders contain the real piston which constitutes a thickening on the plunger, each cylinder being assigned two ports alternately acting as inlet for the supply of hydraulic liquid to the respective cylinder chamber below/above the piston and as outlet/return port for hydraulic liquid from the outer and inner cylinder chamber, respectively.
The ports of the two plunger cylinders, each alternately acting as supply/return port, may, using hoses/pipelines, a hydraulic pump and a multiple-way valve, be coupled such that the port of one cylinder passing to the cylinder chamber for extending the plunger end portion is coupled to the other cylinder's port passing to the cylinder chamber for pulling in said plunger end portion, the other ports of the cylinders also being interconnected in such a way that extension of one plunger end portion into engagement with e.g. the locking hole in the derrick compulsorily causes withdrawal of the other plunger end portion which was in engagement with the locking hole of the lower carriage, and vice versa. Thus, such a compulsory guidance of the end portions of the two plungers makes sure that the upper carriage is not interconnected with the lower carriage for reciprocating movements therewith simultaneously as the upper carriage carrying the drilling machine is connected to the derrick.
In one embodiment, such driven motion transferring mechanism may consist of an endless chain passed around two turning sprockets, one at each of the two opposite transitions between the parallel portions of the chain. The drive source may e.g. consist of a hydraulic turning motor the outgoing shaft thereof carrying a sprocket meshing drivingly with the chain. Alternatively, the drive/transmission mechanism may consist of a combination of a hydraulic piston cylinder and a chain passed around sprockets with a view of achieving an increased force during the extension.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects, advantages and features of method and device according to the invention will appear from the following description with reference to accompanying drawings, wherein:
FIG. 1 shows in a perspective view a drilling rig where the carriage for the drilling machine is coupled to the lower carriage, as seen obliquely from ahead;
FIG. 2 shows the drilling rig in a position wherein the lower carriage with the hauling-up device is uncoupled from the upper carriage with the drilling machine, and where the latter is interconnected with the derrick in an upper position, the lower carriage with the hauling-up device taking a lower position;
FIG. 3 corresponds to FIG. 1, but it shows the upper and lower carriage in an interconnected condition and, moreover, illustrates a casing and a narrower, internal, concentric pipe which, together with the casing, is used during the drilling operations, without the bit;
FIG. 4 shows a perspective view of the drilling rig where the interconnected carriages for drilling machine and hauling-up device, respectively, occupy a lower position, in which the casing has been placed in a hole drilled in the ground;
FIG. 5 shows a perspective view of the drilling rig when the drilling machine has hauled said narrower inner pipe entirely up, the carriage for the drilling machine occupying the uppermost position, simultaneously as the drilling machine with the inner pipe is swung laterally about hinges having a vertical axis and positioned along one of the vertical side edge of the upper carriage , so that the lower carriage carrying the hauling-up device is uncoupled from the upper carriage which is coupled to the derrick and carries the drilling machine, and where the lower carriage carrying the hauling-up device can be moved downwards and upwards without said inner pipe interfering with the rectilinear movement path thereof;
FIG. 6 shows a perspective view on a somewhat larger scale, seen obliquely from below, where the displacing means, the catcher means and the lower carriage of the hauling-up device appear, the upper carriage with the drilling machine occupying the upper position, coupled to the derrick, and in a swung-in position in relation to FIG. 5;
FIG. 7 shows a perspective view of the drilling rig, seen obliquely from below, where the drilling machine has been swung laterally, out of the way, so that the upper carriage, which is coupled to the derrick, exhibits the two plunger cylinders serving as coupling means between the upper carriage and the derrick on the one hand and the upper carriage and the lower carriage on the other hand;
FIG. 8 shows a top plan view of the catcher means or clip of the hauling-up device in a closed gripping position;
FIG. 9 shows the same catcher means in an open position;
FIGS. 10 and 11 show horizontal sections in the area XI in FIG. 7, FIG. 10 showing how the two carriages are interconnected, the upper carriage compulsorily being uncoupled from the derrick, while FIG. 11 corresponding to the section plane XI shows how the upper carriage with the drilling machine is coupled to the derrick, simultaneously as the upper carriage compulsorily is uncoupled from the lower carriage.
DETAILED DESCRIPTION OF THE INVENTION
When drilling a hole in the ground in order to cast an underground tubular base or in order to effect piling from the bottom of the bore hole, a casing is disposed such that it follows the drilling machine in the downwardly directed movement thereof as the drilling proceeds, said casing being left standing on the bottom of the bore hole upon the conclusion of the latter, whereafter the drill string with the bit is pulled up. When the tubular base, the base pipe, has been placed in the bore hole, it is desired to withdraw the casing upwards for reuse. Now, the drilling machine's carriage (the upper carriage) which up to now has been coupled to the casing hauling-up device's carriage (the lower carriage), is coupled to the derrick, while the catcher means of the hauling-up device is brought to grip and surround the upper end portion of the casing, whereafter the casing is hauled up. If the previously mentioned inner pipe, which during drilling forms a narrow annulus with the casing, still is suspended from the chuck of the drilling machine (FIGS. 3 and 5), the drilling machine with the inner pipe is swung laterally aside, in order to prevent that the inner pipe shall interfere with the casing hauling-up operation.
In the drawings, reference numeral 10 generally denotes a drilling rig, the drive aggregate 12 thereof being rotatable 360° about a vertical axis 14. A derrick 16 is, through a turnable attachment frame 16', pivotally suspended from the drive aggregate 12 through a boom 17 about a horizontal axis 18, around which the derrick 16 can be pivoted by means of a hydraulic piston cylinder 20. The boom 17 can be moved in the vertical plane by means of a hydraulic piston cylinder 22. The derrick 16 together with the drilling machine 24 can be turned in relation to the attachment frame 16' by means of hydraulic piston cylinders 23, 23'.
Below, the derrick 16 is defined by a projecting plate 26 having a guiding hole 28 for a casing, not shown.
The drilling machine 24 is carried by an upper carriage 30, see FIGS. 2 and 10, U-shaped guide edge portions 30' thereof engaging displaceably around the derrick's 16 longitudinal guidance edges 32 which, for the purpose of guiding, likewise may have a horizontal U-shaped cross-section, in respect of a lower carriage 34 the vertical edges 34' thereof engaging displaceably into said U-shaped guidance edges 32'.
The lower carriage 34 carries a catcher means in the form of a clamp or clip, generally denoted at 36. The clip 36 which appears clearest from FIGS. 8 and 9 on a relatively large scale, has a fixed jaw 38 and a movable jaw 40 hinged thereto and pivotable about the vertical axis 42 of the hinge, a double-acting hydraulic piston cylinder 44 turning the movable jaw 40 between a closed catching position, FIG. 8, and a more or less open position of readiness/release position taken by the clip when it, from above, is threaded down onto the upper end portion of a casing, FIG. 9.
On the top of the derrick 16, a small winch 46 is disposed, the winch i.a. being used for easing a base pipe (a tubular base) down into the bore hole.
The lower carriage and, thus, the hauling-up device's catcher means in the form of the clip 36, are permanently attached to a driven motion transmission device which, in the embodiment shown, has the form of a driven endless chain 48, see e.g. FIG. 7, which has been placed around turning sprockets, not shown, and which is driven by a sprocket, not shown, in engagement with the chain 48 and carried by the outgoing shaft of a hydraulic motor, not shown. The turning sprockets, not shown, for the chain 48 are both rotatably suspended from the derrick, one turning sprocket in an uppermost position in the derrick 16, one turning sprocket at the lowermost end of the derrick, assigned thereto horizontal rotational axes, as well as being positioned such that the two longitudinal portions of the chain are substantially parallel to the derrick 16. The two ends 48' and 48" are attached to the lower carriage 34, at the upper and lower portions thereof, respectively.
As mentioned above, the upper carriage 30 is adapted to be coupled temporarily to the derrick 16, while the lower carriage 34 carrying the catcher means 36, by means of the chain 48, is displaced down within the bore hole, in order to fetch a casing used in a preceding operation, said casing now being hauled up for reuse. The clip 36 is eased off and brought to catch surroundingly around the casing's upper end portion, which projects up through the casing guidance 26, 28.
With the casing suspended from the clip 36, the chain 48 is activated for upward movement, thus pulling the casing up from its lowermost position within the bore hole. Alternatively, the lower carriage 34 carrying the catcher means 36 may be used to lower or urge a pipe down into a predrilled hole.
The upper carriage 30 is equipped with hinges 52 having a vertical axis along one vertical side edge 30'. The drilling machine 24 is hinged to the upper carriage 30 and can be turned between a normal position where it occupies a central position in front of the upper carriage, e.g. as shown in FIGS. 1-4, and a position swung laterally aside from the front side of the upper carriage and of the derrick, respectively, e.g. as shown in FIGS. 5 and 7.
In FIG. 5, a casing 54 is shown , the clip 36 keeping it firmly at the upper end portion thereof. From this figure, it appears that the two carriages 30, 34 are uncoupled from each other, the upper carriage 30 being coupled to the derrick 16, so that the lower carriage 34 carrying the clip 36 of the hauling-up device may effect the casing hauling-up operation. Likewise, the carriage 30 of the drilling machine may be coupled to the derrick in a normal position, i.e. without having been turned laterally aside, see e.g. FIG. 6. As previously mentioned, the upper and lower carriages have to be interconnected during drilling operations and, possibly, during piling operations, so that the upper carriage carrying the drilling machine is displaced downwardly and upwardly by means of the driven chain 48 permanently coupled to the lower carriage 34. In this way, one can carry out both hauling-up operations, drilling operations and insertion operations in underground bore holes with a common driven motion transmission mechanism.
The upper carriage 30 carrying the drilling machine 24 is coupled to the lower carriage 34 carrying the clip 36 of the hauling-up device when drilling operations are to be carried out and is coupled to the derrick 16 and uncoupled from the lower carriage 34 when hauling/up and downwardly directed insertion operations, respectively, are to be carried out. It should, without saying, be clear that the upper carriage 30 either must be coupled to the lower carriage or to the derrick 16. Thus, the upper carriage can under no circumstances be coupled both to the lower carriage and to the derrick.
A suitable device for effecting these interconnections, excluding the possibility of interconnecting the upper carriage, the lower carriage and the derrick simultaneously, appears from FIGS. 5, 7, 10 and 11.
The upper carriage 30 carries two double-acting plunger cylinders 56 and 58. Each of these plunger cylinders 56 and 58 has an internal piston carried by a piston rod 56', 58' extendable beyond the adjacent end face of the respective cylinder 56 and 58, respectively. These extendable piston rods 56', 58' may be brought into engagement with a locking hole 60 in the lower carriage 34 and with a locking hole 62 in the derrick 16, respectively.
Each of the two double-acting plunger cylinders 56 and 58 on the upper carriage 30 carrying the drilling machine, has two ports 64a, 64b and 66a, 66b, respectively, the various ports changing between constituting the inlet and the outlet. The hydraulic system comprises, besides hoses/pipelines coupled to the connecting branches surrounding the ports 64a, 64b, 66a and 66b, also a hydraulic pump assigned an operating means and a multi-way valve (not shown). Then, the connecting branch of the port 64a is coupled to the connecting branch of the port 66b, the connecting branch of the port 64b being coupled to the connecting branch of the port 66a. Such a cross coupling makes it impossible for the upper carriage 30 to be coupled to the lower carriage 34 and to the derrick 16 simultaneously. When a locking portion of the plunger, e.g. 56', from the position of FIG. 11, is pushed into the locking hole 60 of the lower carriage 34, as shown in FIG. 10, the locking portion 58' of the plunger associated therewith, simultaneously, because of the port's 64b interconnection to the port 66a, is compulsorily pulled out from the hole 62 of the derrick 16, the positions shown in FIG. 10 then being established.
When the locking portion 58', from the position in FIG. 10, is to be pushed into the locking hole 62 of the derrick 16, as shown in FIG. 11, hydraulic liquid is supplied to the port 66b, whereby hydraulic liquid simultaneously and compulsorily is supplied to the other plunger cylinder's 56 port 64a, effecting withdrawal of the locking portion 56' into the cylinder 56 and pulling the locking portion 56' out from the locking hole 60 of the lower carriage 34, so that the upper carriage 30 carrying the drilling machine 24 is locked to the derrick 16, simultaneously as the lower carriage 34 carrying the clip 36 of the hauling-up device is released from the upper carriage, whereby the positions shown in FIG. 11 for the upper and lower carriages are established. | The invention relates to an additional equipment for a drilling rig (10) in order to enable hauling-up and lowering, respectively, of a pipe in a borehole. On the derrick (16) of the drilling rig (10), a lower carriage (34) for a catcher means (36) of the hauling-up device is disposed. The carriage (34) is displaceable up and down along the derrick (16). An upper carriage (30) carrying a drilling machine (24) is also displaceable up and down along the derrick (16). The carriage (34) of the hauling-up device is permanently interconnected to a driven transmission mechanism (48) providing up and downward movements along the derrick (16). During the drilling operations, the two carriages (30, 34) are interconnected. During the hauling-up/lowering operations, the two carriages (30, 34) are uncoupled from each other, and, then, the carriage (30) of the drilling machine (24) is coupled to the derick (16). Thus, the same transmission mechanism (48) is used both during the drilling operations and during the hauling-up/lowering operations. |
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INCORPORATION BY REFERENCE
[0001] The present application incorporates by reference the entire disclosures of U.S. Pat. Nos. 6,003,606 (entitled “PULLER-THRUSTER DOWNHOLE TOOL”); 6,347,674 (“ELECTRICALLY SEQUENCED TRACTOR”); 6,241,031 (“ELECTRO-HYDRAULICALLY CONTROLLED TRACTOR”); 6,679,341 (“TRACTOR WITH IMPROVED VALVE SYSTEM”); 6,464,003 (“GRIPPER ASSEMBLY FOR DOWNHOLE TRACTORS”); and 6,715,559 (“GRIPPER ASSEMBLY FOR DOWNHOLE TRACTORS”). The present application also incorporates by reference the entire disclosures of U.S. Patent Application Publication Nos. 2004/0168828 (“TRACTOR WITH IMPROVED VALVE SYSTEM”); and 2005/0247488 (“ROLLER LINK TOGGLE GRIPPER AND DOWNHOLE TRACTOR”). The present application also incorporates by reference the entire disclosure of U.S. Provisional Patent Application No. 60/781,885, filed Mar. 13, 2006 (“EXPANDABLE RAMP GRIPPER”).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to tools for conducting operations within passages, and specifically to tools for borehole intervention and/or drilling.
[0004] 2. Description of the Related Art
[0005] U.S. Pat. No. 6,003,606, entitled “Puller-Thruster Downhole Tool,” discloses an innovative self-propelled tool or tractor for drilling, completion, stimulation, and intervention that pulls a drill string and simultaneously thrusts itself and its payload downhole and/or into a casing or borehole formation. The '606 patent discloses a tractor that includes one or more gripper assemblies (e.g., bladders or packerfeet) that grip onto an inner surface of a borehole or casing, and one or more propulsion assemblies that propel the tractor body forward when at least one of the gripper assemblies is gripping the borehole. A valve system directs a fluid (e.g., drilling mud, intervention fluid, hydraulic fluid) to and from the gripper assemblies and propulsion assemblies to power movement of the tractor.
[0006] The '606 patent discloses two basic types of tractor configurations—open loop and closed loop. The open loop system uses an externally provided fluid as a medium of hydraulic communication within the tractor. The open loop consists of a ground surface pump, tubing extending from the pump into a borehole, a tractor within the borehole and connected to the tubing, and an annulus between the exterior of the tractor and an inner surface of the borehole. The fluid is pumped down through the tubing to the tractor, used by the tractor to move and conduct other downhole operations, and then forced back up the borehole through the annulus. The tractor is powered by differential pressure—the difference of the pressure at the point of intake of fluid to the tractor and the pressure of fluid ejected from the tractor into the annulus. In the open loop system, a portion of the fluid is used to power the tractor's movement and another portion of the fluid flows through the tractor for various downhole purposes, such as hole cleaning, sand washing, acidizing, and lubricating of a drill bit (in drilling operations). Both portions of the fluid return to the ground surface through the annulus.
[0007] The '606 patent also discloses a closed loop configuration in which a hydraulic fluid is circulated through the gripper assemblies and propulsion assemblies to power the tractor's movement within the borehole. In particular, FIG. 19 of the '606 patent discloses a downhole motor that powers the recirculation of the hydraulic fluid.
[0008] The '606 patent further discloses, in FIG. 24, an embodiment in which an electrical line (referred to herein as an “E-line”) is provided within the coiled tubing. The E-line can be utilized to send electrical signals from the ground surface to the tractor to control the position of a start/stop valve that regulates the inflow of drilling fluid into the tractor's valve assembly, in an open loop system.
[0009] U.S. Pat. Nos. 6,347,674; 6,241,031; and 6,679,341, as well as U.S. Patent Application Publication No. 2004/0168828, disclose alternative valve systems and methods for directing fluid to and from a downhole tractor's gripper assemblies and propulsion assemblies for moving the tractor.
SUMMARY
[0010] In one aspect, a tool for moving within a passage is provided. The tool comprises an elongated body; a closed system for converting a circulating flow of a fluid into movement of the tool within the passage, and a pump-powering assembly configured to power the pump, the pump-powering assembly comprising one of a turbine and an E-line controlled motor. The closed system comprises a gripper assembly on the body, a barrel surrounding and engaged with the body, a piston longitudinally fixed with respect to the body, a valve assembly, and a pump configured to circulate the fluid through the closed system. The gripper assembly is configured to utilize fluid pressure to grip onto an inner surface of the passage. The barrel is longitudinally movable with respect to the body, and the gripper assembly is longitudinally fixed with respect to the barrel. The barrel and the body define an annular space therebetween, wherein one or more interfaces between the barrel and the body are sealed to substantially prevent escape of fluid from the annular space to an exterior of the barrel. The piston is positioned within the barrel and fluidly separates the annular space into aft and forward chambers of the barrel, wherein sizes of the aft and forward chambers of the barrel vary as the piston moves longitudinally within the barrel. The valve assembly is configured to direct fluid to and from (1) the gripper assembly and (2) the aft and forward chambers of the barrel to produce movement of the body within the passage.
[0011] For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0012] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic diagram of a conventional coiled tubing tractor system.
[0014] FIG. 2 is a schematic diagram of a turbine-powered motor for a closed loop system for powering a downhole tractor, according to an embodiment of the invention.
[0015] FIG. 3 is a more detailed schematic diagram of the closed loop system of FIG. 2 .
[0016] FIG. 4 is a schematic diagram of an E-line powered motor for a closed loop system for powering a downhole tractor, according to an embodiment of the invention.
[0017] FIG. 5 is a more detailed schematic diagram of the closed loop system of FIG. 4 .
[0018] FIG. 6 is a schematic diagram of a turbine-powered pump for a closed loop system for powering a downhole tractor, according to an embodiment of the invention.
[0019] FIG. 7 is a more detailed schematic diagram of the closed loop system of FIG. 6 .
[0020] FIG. 8 is a schematic diagram of a system in which a positive displacement motor powers a pump for a closed loop system for powering a downhole tractor, according to an embodiment of the invention.
[0021] FIG. 9 is a more detailed schematic diagram of the closed loop system of FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 illustrates a conventional coiled tubing tractor or tool for conducting downhole operations such as intervention and drilling. The illustrated system is an open loop configuration. The coiled tubing system 100 typically includes a power supply 102 for powering ground-level equipment, a tubing reel 104 , a tubing guide 106 , and a tubing injector 110 , which are well known in the art. The illustrated system includes a bottom hole drilling assembly 120 for drilling a borehole 132 with a drill bit 130 . However, other types of bottom hole assemblies 120 can alternatively be provided, such as those for intervention operations like hole cleaning, sand washing, acidizing, and the like. As known, coiled tubing 114 is inserted into the borehole 132 , and a fluid (e.g., drilling mud, intervention fluid) is typically pumped through the inner flow channel of the coiled tubing 114 towards the drill bit 130 located at the end of the drill string. Positioned between the drill bit 130 and the coiled tubing 114 is a tool or tractor 112 . The illustrated bottom hole assembly 120 includes a number of elements known to those skilled in the art, such as a downhole motor 122 and a Measurement While Drilling (MWD) system 124 . The tractor 112 is preferably connected to the coiled tubing 114 and the bottom hole assembly 120 by connectors 116 and 126 , respectively, as known in the art. In this system, the fluid is pumped through the inner flow channel of the coiled tubing 114 and through the tractor 112 to the drill bit 130 . The fluid and drilling debris return to the surface in the annulus defined between the exterior surface of the tractor 112 and the inner surface of the borehole 132 , and also defined between the exterior surface of coiled tubing 114 and the inner surface of the borehole 132 .
[0023] When operated, the tractor 112 is configured to move within the borehole 132 . This movement allows, for example, the tractor 112 to maintain a pre-selected force on the bottom hole assembly 120 such that the rate of movement or drilling can be controlled. The tractor 112 can be used to move various types of equipment through the borehole 132 . For example, it will be understood that the tractor 112 can be connected with or include, without limitation, a downhole motor (for rotating a drill bit), steering system, instrumentation sub (an instrumented package that controls various aspects of downhole operation, including shock vibration, weight on bit, torque at bit, rate of penetration, downhole motor rpm, and differential pressure across motor), Measurement While Drilling apparatus (an apparatus for measuring gyroscopic data such as azimuth, inclination, and measured depth), drill bit, mechanical and hydraulic disconnect for intervention, jetting tools, production logging tools (including apparatus for measuring and recording, without limitation, temperature, annulus pressure, and various flow rates), drilling logging tools (for measuring and recording, without limitation, resistivity measurements, magnetic resonance (MRI), sonic neutron density, density, fluid identification, and gamma ray measurements), perforation guns, casing collar locators, and torque limiting tools (for drilling).
[0024] A closed loop configuration has relevant differences from an open loop system that operates on differential pressure (the difference in pressure between the bore of the tractor and the exterior of the tractor). With an open system, a restriction in the system is required to produce a pressure difference (decrease) between the interior and exterior of the tractor. Typically, the restriction is an orifice such as a fixed diameter nozzle, and is not capable of being adjusted from the surface. For typical coiled tubing rig operations, the effective means of control is to control the surface pump output flow rate. However, the differential pressure available at the tractor is a quadratic (non-linear) function of the surface pump output flow rate. Thus, doubling the surface pump output flow rate will increase the differential pressure through an in-series fixed orifice by a factor of four. This makes power control of the tractor more difficult as normal operational changes can have non-linear impact on tractor power, requiring additional features to be incorporated into the open loop powered tractor to restrict the amount of pressure delivered to the gripper assemblies, for example. Further, this has a disadvantage in that the normal operating range of the surface pump output flow rate required for various operations may have to be restricted, thus reducing cleaning efficiency during the operation.
[0025] Described below are four embodiments of closed loop power systems for powering a tractor: (1) a turbine-powered motor, (2) an E-line powered motor, (3) a turbine-powered pump; and (4) a pump powered by a positive displacement motor. Any one of these configurations can be used for circulating a given tractor's closed system fluid (e.g., hydraulic fluid) through the tractor's valve system, gripper assemblies, and propulsion assemblies. The difference between these configurations is how power is delivered to the downhole pump that circulates the fluid.
[0000] Turbine-Powered Motor
[0026] FIG. 2 is a schematic illustration of a turbine-powered motor for circulating hydraulic fluid in a closed loop for powering a downhole tool or tractor, according to an embodiment of the present invention. In this configuration, a first fluid (typically drilling/intervention fluid) that is externally pumped into the coiled tubing usually at the ground surface flows through the tractor and passes through a turbine 150 on its way to the remaining bottom hole assembly (typically secured to the distal end of the tractor). The turbine 150 drives a generator 152 that produces electricity, as known in the art of turbine power generation. The electricity produced by the generator 152 powers an electric motor 154 that in turn powers a pump 156 . The pump 156 circulates a second fluid (typically hydraulic fluid) in a closed system loop 155 . Box 158 represents a valve system, gripper assemblies, and propulsion assemblies as known in the art. For example, the valve system, gripper assemblies, and propulsion assemblies can be substantially as shown and described in U.S. Pat. Nos. 6,003,606; 6,347,674; 6,241,031; and 6,679,341, as well as U.S. Patent Application Publication No. 2004/0168828. Also, the gripper assemblies can be substantially as shown and described in U.S. Pat. Nos. 6,464,003 and 6,715,559; U.S. Patent Application Publication No. 2005/0247488; and U.S. Provisional App. No. 60/781,885. The second fluid provides hydraulic force for operation of the gripper assemblies and propulsion assemblies, and in some cases the valves.
[0027] Commercially available turbine-generators are sold by Spring Electronics of Worcestershire, United Kingdom. One turbine-generator sold by Spring Electronics comprises a three-phase alternator, rectifier, and switch mode power supply producing about 70 Watts at 50 volts. Larger versions of turbine-generators are commercially available.
[0028] FIG. 3 is a more detailed schematic illustration of the closed loop system of FIG. 2 adapted for use with a variation of the Puller-Thruster Downhole Tool (also referred to as “Puller Thruster Assembly” or “PTA”) described in U.S. Pat. No. 6,003,606. As the first fluid is pumped through the turbine 150 , the turbine powers the motor 154 and in turn the pump 156 that circulates the second fluid through the illustrated valve assembly. The second fluid flows from a supply line 228 through a start/stop valve 160 (also known as an “idler valve”) into the valve system. A six-way control valve 162 shuttles back and forth to direct the fluid to and from an aft gripper assembly 180 (illustrated as a deflated packerfoot) and a forward gripper assembly 182 (illustrated as an inflated packerfoot), and also to and from an aft propulsion assembly 184 and a forward propulsion assembly 186 (each propulsion assembly comprising barrels and internal pistons, as taught in the '606 patent). Valves 164 and 166 (also known as “directional control valves”) control the shuttling and position of the six-way control valve 162 . Packerfeet valves 168 and 170 regulate the flow of fluid into the packerfeet 180 and 182 . A reverser valve 172 controls the direction of tractor movement (i.e., uphole or downhole). The operation of these valves is understood from the teachings of the aforementioned patents incorporated by reference. A sump 157 is preferably provided to store a reservoir of the second fluid. The circulating second fluid returns to the sump 157 via a return line 230 .
[0029] FIG. 3 shows an embodiment of a tool 200 (illustrated as a Puller-Thruster Assembly) positioned within a drilled hole 205 inside a rock formation 212 . The tool 200 includes an elongated body formed of central coaxial cylinders 207 . The aft gripper assembly 180 , aft propulsion assembly 184 , forward gripper assembly 182 , and forward propulsion assembly 186 are engaged on the central coaxial cylinders 207 . The aft propulsion assembly 184 includes annular pistons 218 secured to the cylinders 207 . Similarly, the forward propulsion assembly 186 includes annular pistons 220 secured to the cylinders 207 . The number of pistons can vary (e.g., up to 20 pistons) and depends on the desired thrust and pull loads.
[0030] The tool body defines an internal mud flow passage 224 inside the cylinders 207 . The aft end of the tool body has an inlet 201 connected to coiled tubing 114 via a coiled tubing connector 206 (connection can be threaded or snapped together). While FIG. 3 shows coiled tubing 114 , the tool 200 can also be used with rotary drill rigs instead (and the same is also true for the embodiments of FIGS. 4-9 ). The forward end of the tool body is connected to a bottom hole assembly (BHA) 204 . The illustrated tool includes a female coiled tubing connector 208 and stabilizers 210 . The valve control pack 214 is positioned between the forward and aft gripper assemblies and also between the forward and aft propulsion assemblies. Splines 216 can optionally be incorporated between the central coaxial cylinders 207 and the gripper assemblies to prevent the transmission of torque from the BHA 204 to the coiled tubing 114 .
[0031] In use, drilling/intervention fluid flows from the coiled tubing 114 into the inlet 201 of the tool body, and downhole (toward the bottom of the hole) through the mud flow passage 224 . The fluid flows through the turbine 150 , turning the motor 154 . The fluid continues through the passage 224 into the BHA 204 , exiting the BHA 204 through an outlet 203 . The inlet 201 and outlet 203 are also shown in relation to the turbine 150 on the bottom right hand side of FIG. 3 . The drilling/intervention fluid that exits via the outlet 203 then flows uphole to the ground surface through an annulus defined between the tool 200 and the drilled hole 205 .
[0032] The upper right hand side of FIG. 3 includes a cross-sectional view of the inflated packerfoot 182 , taken along line A-A. The illustrated packerfoot 182 includes three inflated sections. Three mud flow return paths 222 are defined between the three inflated sections of the packerfoot. These return paths 222 allow drilling fluid that exits via the outlet 203 to flow back uphole past the inflated packerfoot. It will be understood that the aft packerfoot 180 can be substantially identical to the forward packerfoot 182 . The illustrated packerfoot cross section shows the packerfoot inflated radially beyond the outside diameter 226 of the tool 200 .
[0033] An advantage of the system using a turbine-powered motor as illustrated is that the system is flow-based, meaning that the downhole tractor can be more easily controlled by the surface pump that pumps fluid down into the coiled tubing toward the turbine. With a flow-based system, any change in the surface pump output volume flow rate linearly changes the power available to the tractor. Since the surface pump output flow rate can be relatively easily adjusted dynamically during tractor operation, the resulting adjustment of the power to the tractor provides enhanced control over the tractor's speed and pulling force. This enhanced control is available over a substantial operating range of surface pump output flow rates. This is convenient for some types of operations. For example, during sand washing it is desirable to provide a maximum amount of fluid into the borehole while the tractor continues its forward movement, usually at near-maximum pulling capacity.
[0034] While the illustrated turbine-powered motor system disclosed in FIGS. 2 and 3 offers enhanced control over prior systems, one limitation of the system is a loss of efficiency. With each energy conversion, the overall machine efficiency is reduced. For example, the conversion from fluid flow of the drilling/intervention fluid in the coiled tubing into mechanical rotation of the turbine results in some energy loss. Similarly, the conversion of mechanical rotation of the turbine into electrical power from the generator also results in some energy loss.
[0035] Another limitation of the turbine-powered pump system is that the turbine requires relatively high flow rates to generate significant amounts of electrical power. For some tractor operations, such as delivering perforation guns, it may be desirable to limit the amount of flow that gets delivered to the bottom hole assembly, for environmental protection reasons. For these types of applications, a turbine-powered motor system may be less preferable than other embodiments disclosed herein.
[0000] E-Line Powered Motor
[0036] FIG. 4 is a schematic illustration of an E-line powered motor for circulating hydraulic fluid in a closed loop for powering a downhole tool or tractor, according to an embodiment of the present invention. In this configuration, an E-line 190 preferably extends from the tractor upward to a control box 191 , typically located at the ground surface. As used herein, “control box” is a broad term and incorporates a wide variety of controls, including controls in a very small housing and those including wireless features. The illustrated E-line 190 extends to the downhole electric motor 154 that in turn powers the pump 156 , it being understood that the motor 154 and pump 156 are preferably housed within or on the tractor. Compared to the embodiment of FIGS. 2 and 3 , this embodiment does not include a turbine. The control box 151 preferably includes at least a portion of an electronic control system adapted to send electrical control signals through the E-line 190 for powering and controlling the motor 154 . The pump 156 circulates a fluid (typically hydraulic fluid) in a closed system loop 155 . Box 158 represents a valve system, gripper assemblies, and propulsion assemblies as known in the art and preferably as described above.
[0037] In one embodiment, the E-line 190 is provided within coiled tubing that also delivers a fluid to the tractor in an open system loop. For example, in drilling operations it is typically desirable to deliver fluid to the drill bit to lubricate the bit and carry drill cuttings back up to the ground surface through the annulus between the borehole inner surface and the exterior of the tractor. In other operations, it may be desirable to deliver an intervention fluid to the bottom hole assembly (e.g., sand washing, acidizing, hole cleaning, etc.). The drilling or intervention fluid preferably passes through an internal passage of the tractor to the bottom hole assembly, and then flows up through the annulus.
[0038] In an alternative embodiment, the E-line 190 is provided within a wireline that does not include a lumen for the delivery of fluid. In other words, there is no coiled tubing. In this embodiment, the tractor is completely electrically powered and controlled. This configuration is useful for operations that do not require the delivery of fluid into the borehole, for example logging operations.
[0039] FIG. 5 is a more detailed schematic illustration of the closed loop system of FIG. 4 adapted for use with the variation of the Puller-Thruster Downhole Tool shown in FIG. 3 . The E-line 190 provides power and electrical control for the motor 154 , which in turn powers the pump 156 that circulates a fluid (typically hydraulic fluid) in a closed loop through the illustrated valve assembly. The E-line 190 extends along with the coiled tubing 114 for delivering drilling/intervention fluid to a BHA 204 . As noted below, other embodiments omit the coiled tubing 114 and only provide a wireline. In use, drilling/intervention fluid flows from the coiled tubing 114 into the inlet 201 of the tool body, and downhole (toward the bottom of the hole) through the mud flow passage 224 . The fluid flows into the BHA 204 and ultimately exits the BHA 204 through the outlet 203 . The drilling/intervention fluid that exits via the outlet 203 then flows uphole to the ground surface through an annulus defined between the tool 200 and the drilled hole 205 .
[0040] An advantage of an E-line powered motor as described herein is that the tractor's performance is independent of any fluid flow pumped down to the tractor from a ground surface pump. In the illustrated embodiment, the power to operate the tractor comes from surface electricity. Hence, the tractor is completely controllable with electrical power transmission and control equipment. The power can be delivered to the motor via an E-line or wireline, without using any coiled tubing. Advantageously, for operations that do not require an intervention or drilling fluid (e.g., logging), the tractor can be operated with wireline equipment alone. This makes the system easily transportable because the costs and time associated with assembly and disassembly of coiled tubing equipment are completely circumvented. Thus an advantage of the disclosed embodiment is the ability to be rapidly deployed.
[0041] The disclosed system is useful for a variety of operations. For example, the disclosed configuration is useful if multiple tractors are employed in series, as may be necessary to traverse a “washout” in the borehole. A washout is a portion of the borehole having a relatively larger diameter than the rest of the borehole. The washout diameter may be larger than the expansion capability of the tractor's gripper assemblies, making it impossible to grip the borehole wall within the washout. However, the washout can be traversed if two tractors are employed in series and both tractors employ a closed loop hydraulic fluid circuit powered by an E-line and electric motor as disclosed above. In particular, the first tractor's motor can be electrically powered until the first tractor encounters the washout, at which point its gripper assemblies are unable to contact the borehole wall. When this condition is detected, power to the first tractor's motor can be turned off and power to the second tractor's motor can be turned on. The second tractor will then move until it encounters the washout, at which point the second tractor can be turned off and the first tractor again turned on to resume movement in a portion of the borehole having a contactable hole diameter. It will be understood that the separation between the tractors typically controls the maximum length washout that can be traversed. Separate E-lines can be provided for each tractor. Alternatively, a single E-line and a downhole control system can be provided to control which tractor receives the electrical power. In some operations, it may be desirable to simultaneously power both tractors.
[0042] Even in embodiments in which the E-line is provided within coiled tubing, skilled artisans will recognize that the fluid delivery through the coiled tubing can be selectively provided or shut off (simply by turning on or off the surface pumps) depending upon the type of operation conducted by the tractor. For operations that require tractor movement but do not require fluid for other purposes (e.g., logging), tractor control becomes easier and less expensive due to the ability to shut off the fluid delivery through the coiled tubing.
[0043] Another advantage of the E-line powered motor system, compared to the turbine-powered motor system of FIGS. 2 and 3 , is that there is no efficiency loss associated with converting turbine rotation into electricity with a generator, or in converting a fluid flow into motor rotation. The motor is controlled entirely electrically. Still another advantage of the E-line powered motor system, compared to the turbine-powered motor system, is that it is possible to generate significant amounts of electrical power without any fluid input to the tractor, let alone an undesirably high rate of fluid input. As mentioned above, in certain tractor operations, such as delivering perforation guns, it is desirable to limit fluid flow to the bottom hole assembly. In these applications, an E-line powered motor system may be preferable.
[0044] While the illustrated E-line powered motor system may be more efficient in some cases than the turbine-powered motor system described above, the E-line system nonetheless still involves some energy losses associated with the transmission of electrical power through the E-line, as well as efficiency loses in the electric motor and the downhole pump.
[0045] In one embodiment, the control box 191 comprises a power supply, switches, connectors, displays (e.g., LED, other types of lights), a NEMA (National Electrical Manufacturers Association) box, and electrical wires. In this embodiment, the control box 191 is designed for simple on/off toggling for the delivery of power to the motor 154 . In addition, various types of power regulation devices may be included, such as a rheostat to adjust power to the tractor and hence tractor speed.
[0046] In another embodiment, in addition to using the E-line 190 to deliver power and control signals to the motor 154 , the control box 191 delivers power and control signals through the E-line 190 to other components of the tractor. The control box 191 can also receive signals from such other components and use the received signals to make control decisions. In this embodiment, the control box 191 preferably comprises a power supply, electrical switches, electrical connectors, power converters, a computer server or personal computer with CPU board, display panel, data storage capability, user interface (preferably graphical), software operating system, high speed mouse, and keyboard. Software for running the control box 191 can be custom-developed. Alternatively, the software can be a modification of a commercially available program (such as “Lab View” made by National Instruments of Austin, Tex.).
[0047] In this embodiment, the control box 191 can deliver electrical power and control signals through the E-line 190 to various instruments, tools, and apparatuses on the tractor. The control box 191 can also be configured to present and store data collected from such instruments, tools, and apparatuses. For example, for intervention and completion operations, the tractor can include logging tools (e.g., pressure sensors, flow rate sensors, and temperature sensors), casing collar collectors, and/or gyroscopic-based positioning instruments electrically connected to the control box 191 through the E-line 190 . As another example, for drilling operations, the tractor can include a Measurement While Drilling apparatus (e.g., for measuring inclination, azimuth, and depth), tension compression sub, instrumented downhole drilling motor, and/or Logging While Drilling apparatus (e.g., drilling logging tools for detecting resistivity, magnetic resonance (MRI), sonic, neutron density, density, fluid identification, gamma ray measurements) electrically connected to the control box 191 through the E-line 190 . Furthermore, sensors such as speedometers, temperature sensors, pressure sensors and the like can be included within the tractor and in electrical communication with the control box 191 through the E-line 190 .
[0000] Turbine-Powered Pump
[0048] FIG. 6 is a schematic illustration of a turbine-powered pump for circulating hydraulic fluid in a closed loop for powering a downhole tool or tractor, according to an embodiment of the present invention. In this configuration, a first fluid (typically drilling/intervention fluid) that is externally pumped into the coiled tubing at the ground surface flows through the tractor and passes through a turbine 150 on its way to the remaining bottom hole assembly (typically secured to the distal end of the tractor). The flow through the turbine 150 produces rotation of the turbine's output shaft, which drives the pump 156 through a gearbox 192 . The pump 156 circulates a second fluid (typically hydraulic fluid) in a closed system loop 155 . Box 158 represents a valve system, gripper assemblies, and propulsion assemblies as known in the art and preferably as described above.
[0049] FIG. 7 is a more detailed schematic illustration of the closed loop system of FIG. 6 adapted for use with the variation of the Puller-Thruster Downhole Tool shown in FIG. 3 . As the first fluid is pumped through the turbine 150 , the turbine output shaft rotates to power the pump 156 via the gearbox 192 (not shown), and the pump 156 in turn circulates the second fluid through the illustrated valve assembly. In use, drilling/intervention fluid flows from the coiled tubing 114 into the inlet 201 of the tool body, and downhole (toward the bottom of the hole) through the mud flow passage 224 . The fluid flows through the turbine 150 , powering the pump 156 . The fluid continues through the passage 224 into the BHA 204 , exiting the BHA 204 through the outlet 203 . The inlet 201 and outlet 203 are also shown in relation to the turbine 150 on the bottom right hand side of FIG. 7 . The drilling/intervention fluid that exits via the outlet 203 then flows uphole to the ground surface through an annulus defined between the tool 200 and the drilled hole 205 .
[0050] A relevant advantage of using a turbine-powered pump as illustrated is that the system is flow-based, as described above. In other words, the downhole tractor can be more easily controlled by the surface pump that pumps fluid down into the coiled tubing toward the turbine. With a flow-based system, any change in the surface pump output volume flow rate linearly changes the power available to the tractor. Since the surface pump output flow rate can be relatively easily adjusted dynamically during tractor operation, the resulting adjustment of the power to the tractor provides enhanced control over the tractor's speed and pulling force. This enhanced control is available over a substantial operating range of surface pump output flow rates.
[0051] Another relevant advantage of the turbine-powered pump system is that the downhole pump is desirably directly powered by the rotating output of the turbine/gearbox combination, without any intermediate steps (e.g., electrical power generation from the turbine output, and use of such electrical power to drive an electric motor that drives the pump). As explained above, the provision of such intermediate steps can introduce a risk of a loss of efficiency in converting the kinetic energy of the first fluid pumped into the turbine into power for driving the operation of the downhole pump. While the turbine-powered pump system still involves some efficiency losses associated with converting the first fluid's flow into mechanical rotation of the turbine, the disclosed turbine/gearbox combination advantageously provides a highly efficient conversion of the first fluid's kinetic energy.
[0000] Pump Powered by Positive Displacement Motor
[0052] FIG. 8 is a schematic illustration of a pump powered by a positive displacement motor (PDM) for circulating hydraulic fluid in a closed loop for powering a downhole tool or tractor, according to one embodiment of the present invention. In this configuration, a first fluid (typically drilling/intervention fluid) that is externally pumped into the coiled tubing typically at the ground surface flows through the tractor and passes through a positive displacement motor 250 (sometimes referred to as a “mud motor”) on its way to the remaining bottom hole assembly (typically secured to the distal end of the tractor). The flow through the positive displacement motor 250 produces rotation of the motor's output shaft 251 , which drives the pump 156 , typically through a gearbox 252 . The pump 156 circulates a second fluid (typically a different type of fluid than the first fluid, such as, for example, hydraulic fluid) in a closed system loop 155 . Box 158 represents a valve system, gripper assemblies, and propulsion assemblies as known in the art and preferably as described above.
[0053] Positive displacement motors are well known. A positive displacement motor typically comprises a stator that defines a fluid flow enclosure, a rotor that revolves within the stator, and an output shaft that rotates with the rotor. The rotor typically includes a plurality of lobes, i.e., curved or rounded projections that absorb the kinetic energy of fluid flowing through the stator, causing the rotor to revolve within the stator. Numerous suppliers sell positive displacement motors in a wide variety of sizes and performance capabilities. For example, Weatherford's (www.weatherford.com) “High Performance PDM” and a “MacDrill High Temperature PDM” are suitable, as is the “Navi-Drill Ultra Series” motors sold by Baker Hughes (www.bakerhughes.com). Positive displacement motors are also sold by numerous smaller suppliers, and are commercially available in small diameter sizes that produce significant torque at acceptable RPM levels.
[0054] FIG. 9 is a more detailed schematic illustration of the closed loop system of FIG. 8 adapted for use with the variation of the Puller-Thruster Downhole Tool shown in FIG. 3 . As the first fluid is pumped through the positive displacement motor 250 , the motor's output shaft 251 rotates to power the pump 156 via the gearbox 252 , and the pump 156 in turn circulates the second fluid through the illustrated valve assembly. In use, drilling/intervention fluid flows from the coiled tubing 114 into the inlet 201 of the tool body, and downhole (toward the bottom of the hole) through the mud flow passage 224 . The fluid flows through the positive displacement motor 250 , which drives the pump 156 through the gearbox 252 . The fluid continues through the passage 224 into the BHA 204 , exiting the BHA 204 through the outlet 203 . The inlet 201 and outlet 203 are also shown in relation to the positive displacement motor 250 on the bottom right hand side of FIG. 9 . The drilling/intervention fluid that exits via the outlet 203 then flows uphole to the ground surface through an annulus defined between the tool 200 and the drilled hole 205 .
[0055] A relevant advantage of using a pump 156 powered by a positive displacement motor 250 as illustrated is that the system is flow-based, as described above. In other words, the downhole tractor can be more easily controlled by the surface pump that pumps fluid down into the coiled tubing 114 toward the motor 250 . With a flow-based system, any change in the surface pump output volume flow rate linearly changes the power available to the tractor. Since the surface pump output flow rate can be relatively easily adjusted dynamically during tractor operation, the resulting adjustment of the power to the tractor provides enhanced control over the tractor's speed and pulling force. This enhanced control is available over a substantial operating range of surface pump output flow rates. The pump 156 powered by a positive displacement motor 250 also allows an operator to more quickly and easily shut off the tractor simply by stopping the pumping of the open system fluid down through the coiled tubing 114 to the motor 250 , or by reducing the fluid's flow rate to a level that is less than a level required to maintain operation of the pump 156 .
[0056] Another advantage of a positive displacement motor 250 is that several design aspects of the motor can be varied to allow some tuning of the expected operational torque and RPM delivered to the gearbox 252 . Design aspects that can be varied include the rotor pitch angle, the number of stages, and the number of lobes of the rotor. This makes it easier to optimize the range of operation of the pump 156 . Still another advantage is that positive displacement motors are a proven, reliable, and relatively inexpensive technology for utilizing the kinetic energy of a fluid.
[0057] Yet another advantage of this system is that the pump 156 can be directly powered by the rotating output shaft 251 of the motor/gearbox combination, without any intermediate steps (e.g., electrical power generation from the motor output, and use of such electrical power to drive an electric motor that drives the pump). The provision of such intermediate steps would introduce a risk of a loss of efficiency in converting the kinetic energy of the first fluid pumped through the positive displacement motor 250 into power for driving the operation of the pump 156 . The disclosed motor/gearbox combination advantageously provides a highly efficient conversion of the first fluid's kinetic energy.
[0058] Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above. | A tool for moving within a passage comprises an elongated body; a closed system for converting a circulating flow of a fluid into movement of the tool within the passage, and a pump-powering assembly configured to power the pump, the pump-powering assembly comprising one of a turbine and an E-line controlled motor. The closed system comprises a gripper assembly on the body, a barrel surrounding and engaged with the body, a piston longitudinally fixed with respect to the body, a valve assembly, and a pump configured to circulate the fluid through the closed system. The gripper assembly is configured to utilize fluid pressure to grip onto an inner surface of the passage. The barrel is longitudinally movable with respect to the body, and the gripper assembly is longitudinally fixed with respect to the barrel. The barrel and the body define an annular space therebetween, wherein one or more interfaces between the barrel and the body are sealed to substantially prevent escape of fluid from the annular space to an exterior of the barrel. The piston is positioned within the barrel and fluidly separates the annular space into aft and forward chambers of the barrel, wherein sizes of the aft and forward chambers of the barrel vary as the piston moves longitudinally within the barrel. The valve assembly is configured to direct fluid to and from (1) the gripper assembly and (2) the aft and forward chambers of the barrel to produce movement of the body within the passage. |
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RELATED APPLICATIONS
This application claims benefit of Prov. No. 60/190,484 filed Mar. 18, 2000.
The present application is related to U.S. patent application Ser. No. 08/893,008, filed Jul. 15, 1997.
TECHNICAL FIELD
This present invention relates to the field of anechoic chambers, and in particular to a modular anechoic panel system and method.
BACKGROUND OF THE INVENTION
The character and quality of noise emitted from manufactured products has become increasingly important to the function and marketability of such manufactured products. Product manufacturers, governments, and standard setting organizations often require consumer and industrial products and equipment to comply with increasingly stringent sound emission specification. Accordingly, a large number of consumer products and industrial equipment must now undergo sound emission testing.
Anechoic chambers, constructed using acoustical anechoic wedges are frequently employed in such sound emissions tests. According to previous techniques, an anechoic chamber consists of a shell constructed of material to provide structural stability and predictable transmission loss characteristics from the exterior of the anechoic chamber to the interior of the anechoic chamber and an array of sound-absorbing anechoic wedge devices (“anechoic wedges”) lining the shell's interior surfaces to eliminate interior reflected sound. Materials used in the construction of shells for anechoic chambers have included various materials, such as masonry, wood, and metal. Shell designs have included permanent shell structures, as well as semi-permanent shells constructed of modular interlocking structural panels. Anechoic chambers with anechoic wedges or other linings on all interior surfaces are typically referred to as “full” anechoic chambers while chambers having linings on only the walls and ceiling are referred to as “hemi” anechoic chambers. Anechoic chambers, both hemi and full, are used in the testing and or measurement of sound characteristics emitted by a specimen being tested or calibrated.
An anechoic chamber is a room that is used for precise acoustical measurements. Therefore, the room must be designed so that acoustically free field conditions exist. For practical measurements, the room also must be free of extraneous noise interferences. Anechoic chambers are widely used in the development of quieter products, including automotive and aircraft products and other products for use in transportation, communications, computers, security, and medical research.
An acoustical free field exists in a homogeneous, isotropic medium that is free of reflecting boundaries. In an ideal free field environment, the inverse square law would function perfectly, so that the sound pressure level generated by a spherically radiating sound source decreases approximately six decibels (6 dB) for each doubling of the distance from the source. A room or enclosure designed and constructed to provide such an environment is called an anechoic chamber.
Also usually an anechoic chamber must provide an environment with controlled sound pressure (L p ) free from excessive variations in temperature, pressure and humidity. Outdoors, local variations in these conditions, as well as wind and reflections from the ground, can significantly and unpredictably disturb the uniform radiation of sound waves. This means that a true acoustical free field is only likely to be encountered inside an anechoic chamber. For an ideal free field to exist with perfect inverse square law characteristics, the boundaries must have a sound absorption coefficient of unity at all angles of incidence.
Anechoic chambers are characterized by anechoic elements that are attached to the walls, ceiling and floor of the chamber. If the anechoic elements are attached to the walls and ceiling but not the floor of the chamber, the chamber is termed a hemi-anechoic chamber. Such chambers also are used for acoustical measurements. The anechoic elements may be attached so that they are essentially in contact with or spaced from the supporting walls, ceiling and floor, depending on what is considered to be the optimum design for the chamber based on its intended use.
An anechoic element is commonly defined as one that should have less than a 0.99 normal incidence sound absorption coefficient through the frequency range of interest. In such case, the lowest frequency in a continuously decreasing frequency sweep at which the sound absorption coefficient is 0.99 at normal incidence is defined as the cut-off frequency. Thus, in an anechoic chamber, 99% of the sound at or above the cut-off frequency is absorbed. For less than ideal conditions, different absorption coefficients may be established to define a cut-off frequency. Heretofore anechoic elements for anechoic chambers have commonly been designed in the shape of a wedge.
As already noted, a characteristic of a true free field is that the sound behaves in accordance with the inverse square law. In the manufacture of anechoic elements, those elements are tested in impedance tubes as a means for qualifying them for use in chambers simulating free field conditions. A fully anechoic chamber can also be defined as one whose deviations fall within a maximum of about 1-1.15 dB from the inverse square law characteristics, depending on frequency. According to currently accepted standards, semi-anechoic rooms or chambers, i.e., those with anechioic walls and ceilings but with acoustically reflective floors, e.g., floors made of concrete, asphalt, steel, or other metals or materials, can deviate from the inverse square law by a maximum of about 3 dB depending on frequency.
Because of the very high degree of sound absorption required in an anechoic chamber, conventional anechoic elements typically comprise sound absorptive material covered or contained by a cage or cover that is made of a wire cloth (mesh) or a perforated sheet metal. For many years anechoic elements typically embodied a wire mesh cage that typically was characterized by a 90-95% open area to allow maximum exposure of sound absorbing material to the sound waves.
A disadvantage with anechoic construction elements as explained above is that in highly industrial environments the wire mesh structure may not provide sufficient physical protection for the elements. The sound absorbing material can therefore become easily disfigured by unintentional impact that is quite foreseeable in a heavily industrial environment.
Another disadvantage of the conventional anechoic elements is potential medical hazards. The sound absorptive materials such as fiberglass, rockwool or foams can be highly erosive. Over a period of use such materials could erode into particulate matter floating in the air which could be inhaled into lungs.
A further disadvantage of the conventional anechoic elements and their wire mesh coverings is that in highly industrial applications, oil spills and dirt may rapidly accumulate on the sound absorbing materials. This may impede sound absorption performance of the material and additionally may impose a fire hazard. Cleaning the sound absorptive material is difficult and not efficient.
More recently, the wire mesh covering has been replaced by a perforated sheet metal, with the an open area provided by the perforations falling within a relatively wide range: usually the open area falls within the range of about 23% to about 52% of the entire area of the sheet metal covering.
The earliest practical design for sound absorbing units of the type used in making anechoic chambers was a wedge-shaped unit fabricated from or comprising fibrous glass. That geometry of anechoic wedges has been employed as the basis for anechoic chamber design and construction in the past. Examples of prior art anechoic elements and chambers made using such elements are provided by U.S. Pat. Nos. 2,980,198, 3,421,273, and 5,317,113, and the technical publications by L. L. Beranek et al, “The Designs And Construction of Anechoic Sound Chambers”, J. Acous. Soc. of America, Vol. 18, No. 1, pp.140-150, July 1946; and B. G. Watters, “Design of Wedges For Anechoic Chambers”, Noise Control, pp. 368-373, November 1958.
The cross-section of the conventional wedge shaped anechoic element consists of a square or rectangular base, with two opposite side surfaces of the element tapering to a line junction with one another. The length of the wedge unit. i.e., the distance measured from the line junction to the base, varies according to the low frequency cutoff desired in the chamber. The lower the low frequency cut-off, the longer the wedge unit or overall depth of treatment required to create an anechoic environment. Typically, a quarter wavelength of the desired low frequency cutoff approximates the overall depth of treatment that is required to create an anechoic environment in a test chamber. The depth of treatment is determined by the geometry of the anechoic wedge and the wall of the sound attenuating structure. Various combinations of wedge taper, size, and air gap (if any) between the anechoic element and the supporting wall structure may be required in order to achieve the proper depth of treatment for various low frequency cut-offs.
In addition to the shape of the anechoic wedge unit, both the flow resistance of that wedge unit and the sound absorbing material of which the wedge is constructed are critical to the performance of the wedge-shaped anechoic elements and the chamber that employs same.
There have been a number of changes in the design and construction of units used in the construction of anechoic wedge chambers. These changes have included changes in the sound absorbing materials, along with different protective coverings and support systems. Wedges fabricated from polyether or polyester open cell foams, e.g., polyurethane foams, or melamine, have been used for the wedge material. These have the advantage of light weight.
To increase sound absorbency in anechoic chambers, conventional industry practice has been to mount anechoic wedges having a wedge tip, wedge base, and air space elements in an array of alternating groupings of horizontal and vertical wedges over the entire interior surface of the anechoic chamber. Industry standards dictate that anechoic wedges should achieve greater than 90% sound absorption at the lowest frequency to be measured (the “cut-off frequency”). The shape, dimensions and composition of an anechoic wedge are governed by mathematical equations well known in the art. The size and dimensions of an anechoic chamber depend upon the size of the specimen to be tested and upon the frequency range to be measured. For example, small computer devices and equipment may only require an anechoic chamber the size of a medium-sized room, whereas large construction equipment and jet airplanes may require a chamber as large as an airplane hanger.
The anechoic chamber preferably should be capable of testing specimens at a broad spectrum of cutoff frequencies. The cut-off frequency similarly governs the chamber's dimensions. To achieve accurate low-frequency measurements, the measuring equipment should be located a sufficient distance from the equipment being tested and from the chamber's wall. ANSI standards specify that a measuring microphone be located no closer than one meter to the specimen and no closer than ¼ of the wavelength of the cut-off frequency to the tip of the anechoic wedge. Similarly, the necessary depth of an anechoic wedge is inversely proportional to the specified cutoff frequency. Like the anechoic chamber itself, is the specified cut-off frequency decreases, the wedge depth of a standard anechoic wedge must increase in proportion to the cut-off frequency's wave length in order to obtain sufficient low frequency sound absorption. Specifically, the wedge depth may be no less than ¼ of the wavelength of the cut-off frequency. Accordingly, as the cut-off frequency to be measured decreases, the necessary size and dimensions of the anechoic wedges and the anechoic chamber increase. As the specified cut-off frequency decreases, the wavelength of the cut-off frequency and the wedge depth and the size of the anechoic chamber increase proportionately. The increase in wedge depth can often be significant. For example, the industry standard cut-off frequency of 125 hertz would have a wavelength of 2.76 meters and require a wedge depth of 0.7 meters, whereas a lower cut-off frequency of 50 hertz would have a cut-off frequency of approximately 6.9 meters and require a wedge depth of approximately 1.72 meters.
This increase in required wedge depth has presented unique problems for the design of anechoic chambers. Increased wedge depth results in an exponential increase in both the volume and cost of sound absorptive material needed to construct the anechoic wedges.
Similarly, the increased size of the needed anechoic wedge also causes a corresponding increase in the necessary footprint for the anechoic chamber. Unfortunately, due to the low-rigidity of most sound absorptive materials, standard anechoic wedges exceeding a certain wedge depth may bend or break from their mounts under their own weight. At larger sizes, standard anechoic wedges also become extremely cumbersome, difficult to manipulate, and difficult to mount using conventional mounting systems
Also, given the increasing variety of products, industrial machinery, and equipment now being tested, anechoic chambers used to conduct such sound tests are exposed to more rigorous environments. Exposure to such rigorous environments frequently results in damage to and requires the replacement of the delicate sound-absorbing anechoic wedge tips used in such anechoic chambers.
Several techniques have been employed to strengthen and protect the anechoic wedges. One previous technique has been to enshroud the wedge tip and wedge base elements of the anechoic wedge with a wire cloth framework to provide structural support. Unfortunately, the overall size or cost of the wedge is not significantly affected and the direct introduction of such reflective material into the anechoic chamber may result in sound reflections which reduce the accuracy of the measurements. Another attempt at addressing this problem is demonstrated by the sound absorbing unit described in U.S. Pat. No. 5,317,113 in which perforated metal is used to shape, contain and protect the wedge material. Sound absorption may be sacrificed compared with a standard anechoic wedge. According to another previous technique, the wedge tip and wedge base are joined into an integral unit by an exterior housing. To form the air space element of the anechoic wedge, the housing containing the anechoic wedge base and tip is suspended or offset mounted approximately 3″ to 4″ inches away from the anechoic chamber's inner surface to create the air space important to the function of the anechoic wedge. Several methods are known in the art for mounting the wedge elements in this fashion, including the use of furring strips to offset mount housings containing a configuration of wedge base and wedge tips. Unfortunately, the use of frameworks and offset mounting of the anechoic wedges has turned out to be both costly and maintenance intensive. Typically, damaged wedges cannot be replaced without significant effort and expenses. Often, to replace a single wedge tip, an entire series of wedges must be removed from their mountings.
It is well known that in an anechoic chamber having wedges, the surface of the wedges need not be completely sound absorptive, and, indeed, if such complete absorption was possible, the wedge configuration itself would be unnecessary. Thus, the purpose of the wedges is to partially absorb and partially reflect the acoustic waves. Due to the steep wedge angles, reflected acoustic waves are trapped between adjacent wedges by a process of total internal reflection, such that any portion which is retro-reflected from the recess is highly attenuated. See. Warnaka, U.S. Pat. No. 4,477,505 (see FIG. 2 ), Pelonis, U.S. Pat. No. 5,141,073 (see FIG. 4 ), and U.S. Pat. No. 5,317,113, each of which is expressly incorporated herein by reference.
Thus, as long as the surface is only partially acoustically reflective, the elongated wedge will tend to absorb the sonic energy. A number of advantages are apparent from the use of a perforated sheet metal cover over the acoustically absorptive material in the wedge. These covered structures tend to have improved impact resistance, and indeed the acoustically absorptive material placed inside need not be self-supporting. The cover sheet, serves to retain the acoustically absorptive contents, and thus may prevent mineral wool or fiberglass fibers inside from becoming airborne. The perforated surface may also be cleaned, repainted or the like, since the acoustic properties of the surface are non-critical, likewise, under unusual circumstances, a further acoustically absorptive treatment may be applied for enhanced performance. The perforated steel also facilitates fire retardancy, even if the contents are somewhat flammable or contaminated with oil.
Thus, a need has arisen for an efficient anechoic wedge system for anechoic chambers that would employ traditional wedge materials while minimizing the overall size necessary for the wedge and room and providing sufficient protection to the anechoic wedge elements.
Similarly, it would be advantageous to provide a mounting system or method which would protect the anechoic wedge from damage and would permit ease of mounting, repairing and replacing of the anechoic wedges.
SUMMARY AND OBJECTS OF THE INVENTION
The modular anechioic panel system of the illustrative embodiment advantageously provides structural modular anechoic panels for the assembly of wall, roof and/or floor components of an anechoic chamber. Each modular anechoic panel is structurally self supporting and contains the acoustical wedge base and air space elements of an anechoic wedge. In the illustrative embodiment, an acoustically transparent interior shelf and a structural face plate retain the wedge base, air space, and transmission loss material in position within the modular anechoic panel's structural steel frame. H-joints permit numerous modular anechoic panels to connect to one another to form a shell such that each panel's face plate becomes a portion of the interior surface of the assembled anechoic chamber. Additionally, a wedge tip compression clip system allows selective mounting of the wedge tips flush to the surface of the face plates.
It has been found that the performance of the anechoic wedges may be improved by providing a configuration of the apertures of a perforated steel sheet facing having a high void ratio, without impairing the substantial mechanical performance of the wedges. In particular, while it is known that the acoustic reflectivity of the wedge surface is not a per se acoustic advantage, the structural integrity of the wedges and the manufacturability thereof is enhanced by providing a void ratio of less than 50%. Thus, traditional practical considerations compelled an acoustically inferior solution.
The present inventor has found, however, that the void ratio of the perforated sheet metal facing sheet may be increased to about 63% while maintaining structural integrity, other advantages of a perforated sheet covering, and manufacturability. Thus, the substantial acoustic reflectivity mandated by the design of Duda, U.S. Pat. No. 5,317,113, is overcome.
In fact, by providing an open mesh arrangement of the cover, acoustic reflectivity is held to low levels, over a broad range of frequencies, thus improving the performance of the wedges. Improvements in acoustic absorptivity, in turn, leads to a reduced need for wedge volume. Thus, for the sale interior volume, smaller external dimensions are required for an anechoic chamber. Further, reduced sheet metal weight leads to educed overall weight, leading to reduced transportation costs and raw material costs. Further, since the wedges must be mounted within the chamber, the mounting hardware is subject to less stress. Maintenance of the chamber, which might involve removal of the wedges, is also facilitated.
It is technical advantage that the incorporation of the anechoic wedge elements with each modular anechoic panel forming the anechoic chamber's structural shell permits the absorption of sound in an anechoic chamber having a reduced overall room footprint.
In addition, the illustrative embodiment provides a modular design that provides a level of protection to many elements of the acoustic wedge, and is cast efficient to manufacture, assemble, and maintain relative to previous techniques. Moreover, the compression clip system of the illustrative embodiment provides for ease of installation, maintenance, and repair of wedge tips, which are susceptible to exposure and damage. Should a wedge tip become unacceptably soiled or otherwise damaged it can be removed and replaced by hand and at far lessor cost than conventional means.
It is therefore an object of the invention to provide amodular wedge for an anechoic panel, comprising a unitary perforated metal sheet having greater than about 52% void area, formed in a wedge shape having a depth, and having therein an acoustically absorptive material, having an acoustic absorption of at least 90% at a cutoff frequency defined by a corresponding wavelength 4 times the depth. The sheet preferably has less than 80% void area, and more preferably a void area of about 63%.
It is a further object of the invention to provide a system and method for manufacture of anechoic chamber wedges which formed each wedge from a single sheet of perforated metal, bent to shape, and held in conformation by a set of rivets, said rivets passing through regular perforations in the perforated metal sheet.
The wedge is preferably packed with an acoustically absorptive material, such as acoustically absorptive fiberglass, and may be packed in layers to provide further control over absorption characteristics.
It is a further object of the invention to provide a substantially enclosed sound absorbing unit for an anechoic chamber, comprising a substantially flat panel member having a layer of sound absorptive material, and an anechoic wedge member disposed adjacent to said flat panel member, said anechoic wedge member configured having a base and four protruding walls, at least two of which are convergent, formed from a substantially sound transparent sheet having perforations formed therein, said perforations encompassing at least about 52% of the total area of the sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overhead plan view of an illustrative embodiment of an anechioic chamber employing the modular anechoic panel system.
FIG. 2 is an isometric view showing the method of joining a pair of modular anechioic panels and further highlighting the positioning of the anechoic wedge elements.
FIG. 3 depicts all isometric view of the anechoic wedge elements contained in a portion of the illustrative embodiment.
FIG. 4 is an isometric view of an illustrative embodiment of an assembled modular anechoic panel.
FIGS. 5 through 7 are isometric cut-away views revealing the internal construction and partitioning into zones and cells of an illustrative embodiment of a modular anechoic panel.
FIG. 8 is an isometric cut-away view showing the internal elements of an illustrative embodiment of a modular anechoic panel with the wedge tip compression clip system mounted upon tile face plate.
FIG. 9 is an isometric view illustrating the wedge tip compression clip system disposed upon the surface of the face plate.
FIGS. 10 and 11 are isometric and side cut-away views illustrating a three cell zone of a modular anechoic panel and showing the mounting of a set of wedge tips.
FIGS. 12 and 13 are side and longitudinal cut-away views showing the path of dissipated sound energy and the elements that make up a single cell of anechoic wedge in the illustrative embodiment of the modular anechoic panel.
FIGS. 14 A-G show, respectively, a series of perspective transformative steps of a planar sheet of perforated metal into a wedge-shaped shell;
FIGS. 15A and 15B shows, respectively, a perspective view of a wedge shell having notched corners and a detail of a corner notch;
FIGS. 15C, 15 D, 15 G, and 15 I show, respectively, perspective transformative stages of a bending operation to form a base of a wedge;
FIG. 15E shows an end view of a bending tool;
FIG. 15F shows a cross section view of FIG. 15D;
FIG. 15J shows a cross section view of FIG. 15G;
FIG. 15H shows a lip bending tool;
FIGS. 16A and 16B show, respectively, a perspective and side view of a wedge clip;
FIGS. 16C and 16E show an installation of a wedge in a pair of wedge clips;
FIG. 16D shows a detail side view of a wedge lip retained by a wedge clip;
FIGS. 17 A 1 , 17 A 2 , 17 B 1 , 17 B 2 , 17 C, 17 D 1 , 17 D 2 , 17 E 1 , 17 E 2 , 17 F, 17 G 1 , 17 G 2 , 17 G 3 , and 17 H show perspective views respectively of a series of transformative steps for converting a planar sheet of perforated metal into a wedge shell;
FIGS. 18A-18E show a front perspective view, and side view hinge details of a bending apparatus; and
FIGS. 19A and 19B show, respectively, a side view and perspective hinge detail, respectively, of the apparatus according to FIGS. 18A-18E.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An illustrative embodiment of the present invention and its advantages are better understood by reference to FIGS. 1 through 19.
FIG. 1 shows an anechoic chamber 20 constructed from an illustrative embodiment of modular anechoic panels 40 utilizing the modular anechoic panel system. The anechoic chamber 20 absorbs sound emissions 30 to create an essentially echo-free room 22 in which acoustically free field conditions exist. These echo-free conditions within the anechoic chamber 20 allow for precise acoustical measurements to be taken of the sound-pressure levels and frequency emissions from specimen 32 , such as equipment and products.
During product testing, a test specimen 32 may be positioned in the anechoic chamber 20 along with microphones 34 and other sound measurement instruments. To increase the accuracy of sound measurements, the testing instruments preferably measure only the direct sound emissions 30 of the test specimen 32 . Thus, the anechoic chamber 20 preferably reduces all reflected sound within the room 22 and filters extraneous noise from sources emanating from the exterior 23 of the anechoic chamber 20 . By reducing reflected and extraneous sound, the anechoic chamber 20 enhances the accuracy of the measurement and analysis of the sound emissions 30 actually generated by the test specimen 32 .
Preferably, as shown in greater detail in FIG. 2, an H-joint 51 interconnects successive pairs of modular anechoic panels 40 and 41 to form anechoic chamber 20 . To reduce sound leak-through. Z-shaped member 52 eliminates any direct sound path between the exterior 23 and the interior 24 of the anechoic chamber 20 . To form each H-joint 51 , spot welds 53 attach longitudinal beams 54 and 55 to Z-shaped member 52 . Sound leak-through may be further reduced through other well-known construction techniques such as the application of caulking to any mating surfaces.
In the modular anechoic panel system of the illustrative embodiment successive pairs of modular anechoic panels 40 and 41 join to form wall, roof, and floor sections and anechoic chamber 20 . Joinder of floor, roof, and/or wall sections may be accomplished through the application of techniques well known in the art to a person of ordinary skill. Accordingly, anechoic chambers 20 of various sizes may be assembled using selected quantities of modular anechoic panels 40 .
In the illustrative embodiment, a series of wedge tips 60 , 62 , and 64 mount to the interior surface 42 of each modular anechoic panel 40 . Compression clips 140 and 142 (shown in FIGS. 8 and 9) selectively retain wedge tips 60 , 62 , and 64 flush to interior surface 42 of modular anechoic panel 40 .
As further shown in FIG. 3, wedge tip 64 and the internal components of modular anechoic panel 40 constitute an anechoic wedge 70 . According to previous techniques, anechoic wedges are sound-absorptive acoustical devices for absorbing incident sound, thereby eliminating sound reflections. Anechoic wedge 70 creates a frequency specific, essentially sound reverberation free environment within anechoic chamber 20 .
Anechoic wedge 70 is composed of three critical elements necessary to achieve effective sound absorption: wedge tip 64 protruding perpendicular from the modular anechoic panel 40 toward the interior 24 of the anechoic chamber 20 , wedge base 72 and airspace 76 contained within modular anechoic panel 40 . According to previous techniques, wedge tips 60 , 62 , and 64 are constructed of a sound-absorptive material and have angular wedge-shaped bodies. The angular shape of wedge tip 64 provides the high surface area necessary for absorbing sound emissions 30 . Preferred sound absorptive materials used in the past to construct wedge tips 60 , 62 , and 64 include various low-rigidity materials such as fiberglass and foam. (While melamine is the foam material of choice, it is extremely costly on a volume basis). Wedge base 72 similarly may be constructed of any sound-absorptive material that has “blow through” (i.e., that allows sound to pass through it) and has a density higher than the material comprising the wedge tip 64 . Preferably, wedge base 72 is constructed of multiple layers of type- 703 fiberglass 74 . The wedge tip 64 , wedge base 72 and air space 76 configuration provides a density change over the length of the anechoic wedge 70 which assists in eliminating sound reflections. Accordingly, the elements of wedge base 72 and air space 76 are contained within modular anechoic panel 40 , as compared with previous techniques which disposed the wedge base and the air space elements within the interior surface of the anechoic chamber's shell, resulting in difficulty in assembly and repair.
FIGS. 4 through 7 detail the internal components and construction of an illustrative embodiment of the modular anechoic panel 40 . As shown in FIG. 4, modular anechoic panel 40 of the illustrative embodiment includes back wall 43 , side walls 44 , 45 , 46 , and 47 and face plate 49 . Back wall 43 and side walls 44 , 45 , 46 , and 47 preferably are formed from material having suitable structural integrity to provide rigidity, strength and durability, such as 16-gauge steel permanently joined. However, back wall 43 , and side walls 44 , 45 , 46 and 47 may alternatively be constructed of any rigid structural material. Face plate 49 is an acoustically transparent sheet having structural integrity, preferably 22-gauge perforated steel.
Perforations of face plate 49 permit sound emissions 30 from a specimen 32 within anechoic chamber 20 to pass substantially unimpeded into the modular anechoic panel 40 . Conventional mounting methods such as pop rivets mount face plate 49 to side walls 43 , 44 , 45 , and 46 and fix the position of the internal components of modular anechoic panel 40 .
A method of forming modular anechioic panel 40 is shown in more detail in FIGS. 5 through 8. Center partition 80 and fiberboard Lateral partitions 81 , 82 , 83 , 84 , 85 , and 86 partition the housing 50 (formed by the back wall 43 and side walls 44 , 45 , 46 , and 47 ) into eight 24″ by 24″ multiple zones 90 through 97 . Preferably each partition 80 through 86 is constructed from rigid fiberboard. In each zone 90 through 97 , a sheet of transmission loss material 110 , preferably a thick gypsum sheet, rests against and covers interior surface 58 of back wall 43 . Transmission loss material 110 may be fixed into position using connection techniques such as glue. Transmission loss material 110 assists in reducing sound from passing into anechioic chamber 20 from the exterior 23 . A wedge-base supporting member 111 retains the multiple fiberglass layers 74 of wedge base 72 in an elevated position from transmission loss material 110 to create air space 112 . In the illustrative embodiment, an acoustically transparent shelf 114 with supporting legs 116 and 118 , each preferably constructed of 22-gauge perforated steel to permit sound transmission, form the wedge-base supporting member 111 . The region bounded by the acoustically transparent shelf 114 and transmission loss material 110 forms air space 112 , which is critical to the sound-absorption function of anechoic wedge 70 . Though wedge-base supporting member 111 of the illustrative embodiment is disclosed as an acoustically transparent shelf 114 , alternate mounting and support methods may be employed.
As shown in FIGS. 6, 7 and 8 detailing the internal structure of modular anechoic panel 20 , cross members 120 and 122 preferably constructed of 1 A, rigid fiberglass rest vertically on acoustically transparent shelf 114 and further partition each zone 90 through 97 into rectangular cells 130 , 132 , 134 . The multiple fiberglass layers 74 of the wedge base 72 are then layered in each cell 130 , 132 , 134 . The multiple fiberglass layers 74 are preferably type- 703 fiberglass, however, other suitable acoustic dampening materials well known in the art may be employed.
As shown in FIGS. 7 and 8, upon assembly of the interior components of the modular anechoic panel 40 , face plate 49 may be fastened into place by means such as pop-riveting to lock the interior components into position. Final assembly includes mounting of a series of wedge tip compression clips 140 and 142 to face plate 49 , which may be accomplished by conventional mounting means such as pop rivets.
FIG. 9 illustrates an illustrative embodiment of the wedge tip compression clip system in further detail. The wedge tip compression clip system includes alternating pairs of compression clips 140 and 142 each having a base 144 and an angle bracket 146 . Compression clips 140 and 142 are preferably constructed of an acoustically transparent material, such as perforated steel, to minimize any chance of sound reflections. In the illustrative embodiment, clip base 144 of each compression clip 140 and 142 mount to face plate 49 by means of pop-rivets 149 .
As illustrated in FIGS. 10 and 11, wedge tips 60 , 62 , and 64 easily mount against the exterior surface 41 of the face plate 49 using compression clips 140 and 142 . Compression clips 140 and 142 are positioned to align wedge tips 60 , 62 and 64 with cells 130 , 132 and 134 . In the illustrative embodiment, wedge tips 60 , 62 and 64 preferably consist of a melamine material, which has a spongy elastomeric quality. Accordingly, wedge bottom 65 may be compressed to allow wedge tip 60 to be aligned and inserted between compression clips 140 and 142 . Upon release of wedge tip bottom 65 , angle brackets 146 will impinge upon wedge tip bottom 65 to hold wedge tip 60 in position. Each pair of compression clips 140 and 142 maintains three wedge tips 60 , 62 and 64 flush to the face plate 49 and in alignment with the underlying fiberglass layers 74 of acoustical dampening material 76 in each cell 130 , 132 , and 134 . With relative ease, a person may selectively insert and remove wedge tips 60 , 62 and 64 by compressing the bottom 65 of the selected wedge tip and either inserting it into or removing it into or removing it from a position between angle brackets 146 of compression clips 140 and 142 .
As revealed in FIGS. 2, 7 , 8 and 10 , the configuration of each cell 130 , 132 , 134 and wedge tip 60 , 62 and 64 of the fully assembled modular anechoic panel 40 constitutes an acoustic anechoic wedge 70 .
FIGS. 12 and 13 illustrate a single cell constituting the elements of an anechoic wedge 70 . In operation, sound emissions 30 from specimen 32 travel along path 150 , impacting wedge tip 64 and causing it to vibrate. The vibration energy continues to travel generally along path 150 through the sound-absorptive wedge tip 64 , thereby dissipating a portion of the energy. The energy continues through face plate 49 and into the interior of the modular anechoic panel 40 . As the energy from sound emissions 30 pass through the higher density multiple fiberglass layers 74 of wedge base 72 , the energy is further dissipated.
Finally, any remaining energy substantially dissipates in air space 76 before impacting the transmission loss material 110 . In similar fashion, transmission loss material 110 and airspace 76 sufficiently dampen any noise that attempts to enter the anechoic chamber 20 from the exterior 23 through the back wall 43 .
In the illustrative embodiment, each modular anechoic panel 20 constitutes a single 4′×8′×1′ structural member of a wall, ceiling or floor of an anechoic chamber 20 . Accordingly, the modular anechoic panel system allows anechoic chamber 20 to be selectively assembled or disassembled. Accordingly, anechoic chamber 20 need not be a permanent fixture and may selectively be broken down for easy storage.
According to one embodiment, a modular anechoic panel system (MAPS) hemi-anechoic chamber is provided having an interior noise level of less than about 22 dB. cutoff frequency of 150 Hz (ANSI S12.35. ISO 3745, or ISO 7779), having external dimensions of 24 ft. length, 24 ft. width, and 14 ft. height, with nominal internal working dimensions of 22 ft. 4 in. width, 22 ft. 4 in. length, and 12 ft. 4 in. height. The preferred design comprises:
1. Acoustical Panel System having a relatively thick panel for high transmission loss and good absorption characteristics, a modular design for ease of installation and future modifications, and flexibility of chamber sizing and performance ratings:
2. Anechoic Wedge System, having a sheet metal cover sheet having a void ratio of above about 52% and preferably 63%, having high acoustic absorption characteristics, versatile design allowing a broad range of performance criteria to be met, while providing an interior which is free or exposed fiber:
3. Access Door System, having high performance doors to match wall acoustic performance, and allowing a wide range of door sizes and configurations;
4. Ventilation System designed with high performance supply and exhaust silencers, which may be a self-contained system or connected to a passive host connected heating/ventilation air conditioning (HVAC) systems, and optionally including specialty filtration, fume extraction, or other types of equipment:
5. Electrical System, having multiple receptacles for access to power, e.g., 120VAC and 240VAC line power, inside the chamber, which meets various local electrical codes, e.g., NEC, BOCA, etc.; and
6. Lighting System, having ceiling mound, heavy duty, high output incandescent fixtures, with corner mounted secondary lighting fixtures including dimmer controlled incandescent lamps, and specialty lighting, such as “Test in Progress” and “Emergency Exit”.
The preferred anechoic chamber panel-wedge assemblies preferably comply with ASTM specification E-1050-90, having a normal incidence absorption coefficient of not less than 0.99 at 150 Hz.
The MAPS panels are preferably constructed of 16 gauge galvanized-bonderized, cold rolled steel outer surface and 22 gauge galvanized-bonderized, cold rolled steel inner surface. The sheets are perforated with {fraction (3/32)}″ holes on {fraction (3/16)}″ staggered centers providing a 23% open area. These panels are filled with five inches of acoustical glass fiber insulation, with a two inch air space and one inch of gypsum wallboard. Internal framing members are formed of 16 gauge galvanized-bonderized, cold rolled steel, spaced 24 inches apart. All welds ae spaced at 4-6″ intervals and ground smooth.
Wedge tips are 8″ wide by 24″ long by 12″ deep (150 Hz cutoff frequency), which are fastened to the inner wall surface in alternating 90 degree rotated groups of three, using compression clips affixed to the chamber walls. The wedge is constructed of sheet metal, 22 gauge galvanized-bonderized, cold rolled steel perforated with {fraction (5/32)} staggered, 0.156″ diameter holes on {fraction (3/16)} centers (accurate Perforating Company), having a 63% void area. The wedge is completely filled with absorptive material.
The wedge tips are fabricated by first precut into a rectangular sheet 210 of perforated metal sheet of appropriate size (FIG. 17 A 1 ), and placed onto a table 201 of a compound break, partially under a wedge form 202 (FIG. 17 A 2 ). The table 201 is then raised by pressing a pedal 200 (FIGS. 17 B 1 and 17 B 2 ), so that the perforated sheet 210 is between the table 201 and wedge form 202 . Metal shears 211 are then used to trim the edges 212 of the rear 213 (portion below the wedge form) to size. With rear template flaps 204 as guides (FIG. 17 C). The perforated sheet 210 is then folded in an acute angle, by flexing a joint 215 in the table 201 (FIGS. 17 D 1 and 17 D 2 ), and metal shears 211 are used to trim the edges 216 of the front portion 214 to size (FIG. 17 F), now sandwiched between the table 201 , table extension 203 , and wedge form 202 , using the template flaps 205 for guidance (FIG. 17 E 1 ). The front and rear flaps 217 are then folded toward each other (FIGS. 17 G 1 and 17 G 2 ), and connected together with ⅛″ pop rivets 218 (FIG. 17 G 3 ), and {fraction (1/10)}″ skirt rivets, which fit through respective perforations without drilling. The table 201 , 203 is then opened, allowing the formed perforated sheet metal wedge shell 220 to be removed from the wedge form 202 (FIG. 18 H).
These same operations are shown in FIGS. 14A-14G, separate from the forming apparatus.
In order to mount the wedge, the corners 221 are first notched, about 1″ from the edge, to form a bevel (FIGS. 15 A and 15 B). Using a sheet bending tool 222 , the front and back flaps 213 , 214 are placed between portions of the bending tool 222 , and inwardly bent at the notched bevel, to form a flat partial surface 223 (FIGS. 15 C and 15 D). The side flaps 224 are trimmed to about ½″, and bent outwardly at about a 135 degree angle, to form wings 225 (FIGS. 15G, 15 H, 15 I and 15 J). A wedge clip 230 , formed of 22 gauge, small hole perforated sheet, is formed as a bracket 22″ long (FIGS. 16 A and 16 B), and is mounted on the wall 231 (the MAPS panel) 24″ apart (FIG. 16 C). The spaced wedge clips 230 snap in and lock the side wings 225 of each wedge 220 in place, the pair of brackets 230 holding three wedges 220 in a row (FIGS. 16 D and 16 E). The acoustically absorptive filling, for example, acoustical glass fiber insulation, is stuffed in the wedge 220 shell prior to mounting, but after fabrication.
The compound break form shown in FIGS. 18 and 19, includes a foot-operated lift pedal 200 , for lifting the table 201 upward toward the wedge form 202 , as well as a hinged table extension 203 , which folds over the top of the wedge form 202 . The table 201 and table extension 203 each have hinged template portions 204 . 205 , which serve the dual purpose of providing a template for cutting the perforated sheet to size, and for folding the sides of the sheet inward.
Although an illustrative embodiment and its advantages have been described in detail above, they have been described as example and not as limitation. Various changes, substitutions and alterations can be made in the illustrative embodiment without departing from the breadth, scope, and spirit of the claims. | The modular anechoic panel system provides modular anechoic panel for construction of anechoic chambers particularly advantageous for use in sound testing and measurement. The modular anechoic panel incorporates into a single structural member the elements of structural support, transmission loss features, and the wedge base and air space elements of an anechoic wedge thus providing enhanced protection to elements of the anechoic wedge. The modular anechoic panel provides a durable structural member and, as assembled, form a structural shell of an anechoic chamber having a reduced footprint. Additionally, the modular anechoic panel provides a compression clip mounting system for conveniently mounting and replacing wedge tips, thus allowing for use of standard wedge tip materials and easy assembly, repair and replacement of damaged wedge tips. The wedge is preferably formed of perforate sheet metal having a void ratio of greater than 52%, and more preferably 63%, and is packed with sound absorptive material, such as fiberglass. |
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This application is a continuation-in-part of U.S. patent application Ser. No. 09/272,824, filed on Mar. 19, 1999, having the title “Support System for Vessels Such as Swimming Pools,” which was a continuation of U.S. patent application Ser. No. 08/858,637, now issued as U.S. Pat. No. 5,884,347, filed May 19, 1997, having the same title, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to vessels such as swimming pools and more particularly to strapless support systems for above-ground swimming pools and to buttresses for walls of the above-ground swimming pools.
BACKGROUND OF THE INVENTION
The popularity of swimming pools, particularly in residential areas, continues to increase. This increased popularity is based at least in part on the availability of aesthetically appealing above-ground pools, whose durability permits cost-effective purchasing by consumers. Above-ground pools additionally are particularly useful in areas where substantial excavation is either impermissible or undesirable. In densely-populated regions, for example, residential lawns may not be sufficiently large to accommodate the space required for in-ground pools. Moreover, in some cases they may be inadequate to accommodate the equipment necessary to excavate in-ground pools, even if space for such pools exists. Alternatively, above-ground pools may be preferable because of the decreased time typically needed for installation (and, if necessary, removal) or the lesser maintenance requirements and costs often associated with them.
Many substantially-permanent above-ground pools are generally either circular or oval in shape, with each type comprising multiple vertical walls and a frame. Because of their strength, galvanized steel or other compositions are usually chosen as materials from which the walls are made. Nonetheless, water pressure present at and near the bottoms of filled pools often requires the walls of above-ground pools to be braced for reliable performance. This bracing requirement is particularly pertinent in connection with oval pools, whose elongated side walls are especially vulnerable to collapse from the outward pressure exerted by the water contained therein.
As a consequence of this vulnerability, existing oval above-ground pools are constructed with braces supporting the lower sections of their side walls. Each brace includes three pieces, denominated an “upright” portion, an “angled” portion, and a “connecting” portion. FIG. 1 illustrates such braces 10 of above-ground pool 14 , whose generally oval shape requires use of multiple vertical side walls 18 . As shown in FIG. 1, upright portion 22 extends upward from bottom 26 of side wall 18 , with connecting portion 28 being either at ground level or buried underground. An end of each of upright portion 22 and angled portion 30 connects to a respective end of connecting portion 28 , while the other end 34 of angled portion 30 attaches to upright portion 22 . The resulting structure resembles the outline of a right triangle, with angled portion 30 constituting the hypotenuse.
FIG. 1 details the protruding nature of braces 10 . Such braces 10 frequently extend outward several feet from side walls 18 on both sides of pool 14 , increasing the surface area of the lawn required for installing the pool. This increased surface area can cause difficulties in installing pools in areas subject to covenants or zoning regulations, as insufficient land may remain post-installation to meet setback and other legal or contractual requirements. Braces 10 may also inhibit lawn maintenance adjacent pool 14 and, to some, may detract from the aesthetic appeal of the pool itself. The three-piece structure of each brace 10 additionally increases its associated manufacturing and installing cost, while supporting less than the entire vertical height of a side wall 18 .
Furthermore, the nature of above-ground pools requires support straps that extend a substantial horizontal distance beneath the pool. Such straps render it difficult to construct a pool having a “deep” end because the straps run the substantial horizontal length of the pool and prevent the liner forming the bottom of the pool from filling a hole that has a depth extending below the straps. Removing the straps changes pressure allocations. It is thus desirable to provide a pool that alleviates the need for straps extending a substantial distance below the pool and that alleviates the protruding braces shown in FIG. 1, while providing support for a deep pool or a pool having a deep end. It is also desirable to provide such a pool that keeps the pool removable, i.e., that does not require a concrete fill and that is easy to assemble.
SUMMARY OF THE INVENTION
The present invention, by contrast, provides a support system intended to resolve these issues. Particularly suited for vessels such as elongated above-ground pools, the support system includes a set of, typically, one-piece buttresses adapted to support the entire vertical height of one or each of a series of side walls. The flared design of the buttress, furthermore, matches the support it provides the side wall to the outward water pressure present along its height for enhanced reliability, permitting use of fewer buttresses than the number of existing braces that would otherwise be necessary. The one-piece design of the buttress further eliminates some of the manufacturing and installation costs associated with existing braces, while its sleek appearance is more likely to please discerning observers.
The diminished footprint of the innovative buttress additionally reduces the surface area required for its corresponding pool. Setback and similar requirements thus pose fewer problems than with existing pools, permitting pools incorporating the present invention to be located in smaller (especially narrower) lawns. Consequently, more residential customers in densely-populated areas are able to situate these pools in the lawn space available to them, increasing the market for the pools beyond that existing today. Abolishing the open areas between the angled portions of current braces and the ground additionally avoids many of the difficulties associated with providing lawn care in those areas. Additionally, residential and other customers are able to enjoy pools having deep ends because of a feature that makes it possible to provide an area of the pool that is deeper than a standard installation provides.
In some embodiments of the invention, each buttress is a unitary structure whose height approximates that of the side wall or walls of its associated pool. At least one surface of the buttress contacts the side wall along substantially its entire height, supporting the height of the wall continuously against the outward pressure exerted when the pool is filled with water. Because the buttress defined by these embodiments flares along its height it assumes, in side elevational view, the general form of a truncated, solid triangle. Embodiments of the buttress further comprise notched sections to retain the bottom rim of the pool—and therefore help retain the side walls—in place.
Additionally included in some support systems of the present invention may be elongated cross-members spanning the width of the pool. Often called “omegas” because of their cross-sectional appearance, the cross-members, when present, are buried so that only their upper surfaces are above the ground. Buttresses on each side of the pool may be bolted or otherwise attached to the upper surfaces to retain them in position relative to the ground. Protruding from the upper surface of a cross-member adjacent its ends are one or more tabs, which in use fit into slots in the bottom rim of the pool to maintain its position. The buttresses, side walls, bottom rim, and cross-members thus can interact to preserve the position and structure of the pool relative to the ground. Alternatively, the buttresses may extend below ground level and be bolted, interlocked, or otherwise connected or fitted to the cross-members.
A further option that may be included in some embodiments of the invention is a support system that alleviates the straps that extend below the pool. This feature may accompany the pool system or may be sold as a separate kit. It permits above-ground pool owners to have a deeper pool than is conventionally available.
It is therefore an object of the present invention to provide a system for supporting a vessel designed to be filled with water or similar fluid.
It is also an object of the present invention to provide a system including one or more buttresses for supporting the side wall or walls of an above-ground swimming pool.
It is a further object of the present invention to provide a system in which a buttress supports a wall of a pool substantially continuously along the height of the wall.
It is another object of the present invention to provide a system for supporting pool walls in which the supporting structures extend only minimally beyond the exteriors of the walls.
It is an additional object of the present invention to provide a system, including one or more buttresses, for supporting a vessel such as an above-ground pool, in which the buttresses comprise notched sections to retain the bottom rim of the pool in position.
It is yet another object of the present invention to provide a system for supporting an above-ground swimming pool in which buttresses, side walls, the bottom rim, and cross-members interact to maintain the position and structure of the pool relative to the ground.
It is also an object of this invention to provide a system for supporting an above-ground swimming pool that enables a deep pool or a pool having a deep end, while still maintaining the position and structure of the pool relative to the ground.
It is still a further object of this invention to provide a substantially strapless support system that uses plates and beams that support the pool relative to the ground, while incorporating buttresses that extend only minimally beyond the exterior of the walls.
Other objects, features, and advantages of the present invention will be apparent with reference to the drawings and remainder of the text of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an oval pool having an existing set of braces.
FIG. 2 is a perspective view of an oval pool utilizing a support system of the present invention.
FIG. 3 is a side elevational view of a portion of the pool and of a buttress of the support system of FIG. 2 .
FIG. 4 is a top plan view of the buttress of FIG. 3 .
FIG. 5 is a side elevational view of the buttress of FIG. 3 together with a surface of a cross-member of the support system of the present invention.
FIG. 6 is a perspective view of a portion of the cross-member of FIG. 5 .
FIG. 7 is a (nominally) front elevational view of the buttress of FIG. 3 together with portions of the cross-member of FIG. 5 and the bottom rim of the pool of FIG. 2 .
FIG. 8 is a perspective view of an alternative buttress of the present invention.
FIGS. 9A-C are (nominally) front elevational views of yet alternative buttresses and cross-members for use as support systems of the present invention.
FIG. 10 is a perspective view of a portion of a strapless support system of the present invention.
FIG. 11 is an exploded perspective view of the strapless support system of FIG. 10 .
FIGS. 12A-B are top plan views of oval pools having a strapless support system of FIG. 10 installed at or near opposing sides of the pools.
DETAILED DESCRIPTION
FIGS. 2-5 and 7 illustrate buttresses 38 of the present invention. As shown in FIG. 2, buttresses 38 may be used in connection with pool 14 ′ instead of braces 10 . Doing so can diminish significantly the surface area required for installation of pool 14 ′, permitting pool 14 ′ to be positioned in areas inadequate for placement of pool 14 . As noted earlier, setback and similar requirements additionally pose fewer problems for pool 14 ′ because of its smaller overall size.
FIGS. 2 and 3 detail typical locations of buttresses 38 in connection with pool 14 ′. Illustrated in FIG. 2 is a set of buttresses 38 spaced along side 42 of (generally) oval pool 14 ′. Although not shown in FIG. 2, a similar set of buttresses 38 may be spaced along opposite side 46 of pool 14 ′. Because pool 14 ′ is oval, sides 42 and 46 are elongated relative to ends 50 and 54 and subject to greater stresses caused by the pressure of water W within the pool 14 ′.
This pressure within pool 14 ′ additionally is greatest at bottom 26 of side wall 18 (adjacent ground G) and decreases toward the corresponding top 58 of the wall 18 . To support the entirety of height H of side wall 18 , the above-ground height of buttresses 38 may be substantially similar or identical to height H and, as shown in FIG. 3, most or all of their surfaces 62 A and 62 B (see FIGS. 4 and 7) may contact the side wall 18 . To match more closely the support provided side wall 18 to the pressure of water W as a function of height H, buttresses 38 additionally may be flared in depth as illustrated in FIGS. 2 and 3. Such flaring results in buttress 38 having its minimum depth D 1 at its top 66 and its maximum depth D 2 at its bottom 70 (also adjacent ground G), with the depth increasing substantially continuously between top 66 and bottom 70 . Buttress 38 thus resembles, in the side elevational view shown in FIG. 3, a right triangle.
Unlike brace 10 , however, buttress 38 of FIG. 3 has solid sides 74 A and 74 B, a solid face 78 , and is truncated at top 66 . Surfaces 62 A and 62 B, moreover, function as flanges of buttress 38 . The result is a unitary structure for buttress 38 that both provides greater and more uniform and continuous support for side wall 18 and has a sleeker profile than braces 10 . Furthermore, for some embodiments of buttress 38 , maximum depth D 2 does not exceed ten inches, an amount significantly less than the distance (typically thirty-six inches) from pool 14 that braces 10 protrude. Other dimensions of an exemplary buttress 38 include height between approximately forty-two and sixty inches, width of approximately four inches, and a minimum depth D 1 of approximately two to four inches. Buttress 38 is usually made of metal such as galvanized steel but may be manufactured of other materials when necessary or appropriate. The face 78 , sides 74 A and 74 B, and surfaces 62 A and 62 B of buttress 38 additionally need not be integrally formed, although so forming them may avoid reducing the strength of the overall structure. Surfaces 62 A and 62 B also need not necessarily be formed at substantially right angles to respective sides 74 A and 74 B as shown in FIG. 4 .
FIG. 5 illustrates notched section 82 of buttress 38 . In use, buttress 38 may be connected (by bolts or other suitable means) to a cross-member 86 spanning the width of pool 14 ′. Such a cross-member 86 is shown in FIG. 6 and is buried in ground G so that only upper surface 90 is visible, and it is to this surface 90 that buttress 38 connects. Attaching buttress 38 to cross-member 86 in this manner thus retains the buttress 38 in position relative to ground G. Once buttress 38 is positioned, rim 94 (see FIG. 7) may be fitted into section 82 to assist in fixing its placement relative to the ground G. Slots of rim 94 additionally may receive tabs 98 protruding from upper surface 90 of cross-member 86 to complete its positioning. Side wall 18 may then be fitted into rim 94 in conventional fashion to retain it in place. Those skilled in the art will thus recognize that buttresses 38 , side wall 18 , rim 94 , and cross-members 86 of the present invention may be designed if desired to interact appropriately to preserve the position and structure of pool 14 ′ relative to the ground G.
Shown in FIG. 8 is an alternative buttress 38 ′. Unlike corresponding components of buttress 38 , face 78 ′ of buttress 38 ′ is curved, and surfaces 62 A′ and 62 B′ are formed at acute angles to respective sides 74 A′ and 74 B′. Buttress 38 ′ additionally extends beyond notched section 82 ′ to terminate at lower edge 102 , which in use is buried underground.
FIGS. 9A-C detail alternate cross-members 106 A-C. Like upper surface 90 of cross-member 86 , upper surfaces 110 of cross-members 106 A-C are at or near the level of ground G. Similar to buttress 38 ′, furthermore, buttresses 114 A-C extend so that lower edges 118 A-C are buried underground. In the buttress 114 A of FIG. 9A, lower edges 118 A are bent to form flanges 122 , which include apertures in which bolts 126 or other fasteners may be placed. Horizontal sections 130 additionally include apertures for receiving bolts 126 , thereby permitting buttress 114 A to be fastened to cross-member 106 A. By connecting buttress 114 A to horizontal sections 130 rather than vertical sections 134 of cross-member 106 A, bolts 126 are subjected to reduced shear stresses. Optionally excavating ground G to pour a concrete or other base C beneath horizontal section 130 may enhance the ability of buttress 114 A to support a pool.
Cross-members 106 B and 106 C instead may include slots 138 or recessed segments 142 for receiving pins or tabs 146 of buttresses 114 B or 114 C. Such slots 138 or recesses formed by segments 142 effectively retain buttresses 114 B or 114 C in position relative to respective cross-members 106 B or 106 C by engaging, or interlocking with, tabs 146 below ground G. Although lower edge 118 B is flanged and lower edge 118 C is not, such edges 118 B-C may be interchanged as necessary or desired. In any case, the result is a relatively secure positioning of a buttress 38 ′, 114 A, 114 B, or 114 C vis{grave over (-a)}-vis a cross-member 106 A, 106 B, or 106 C by connecting them underground.
FIGS. 10-12 illustrate strapless support system 210 of the present invention. This system alleviates the use of at least one pair of straps that extend a substantial length underneath the water-containing portion of traditional above-ground pools. The system allows a deeper excavation area, but still provides support for the walls using a system of buttresses, cross-members, vertical beams, and a plates that support the walls against the pressure of the water in the pool.
If the system is sold as an expandable kit, intended to expand the size of an already-installed pool, it is possible to provide different sized kits for different sized pools. Such kits permit the pool to be deeper on just one side, i.e., a “deep end,” or they may provide for a deeper pool in general.
As shown in FIG. 10, buttress 38 may be used in connection with alternate cross-members 212 , plates 220 , 224 , and 226 , and vertical beam 222 . Similar to cross-member 86 , alternate cross-member 212 is adapted to cooperate with buttress 38 and pool rim 94 . More particularly, it may cooperate in any of the ways previously described. For example, alternate cross-member may cooperate with buttress 38 as illustrated and described in reference to FIGS. 9A-C or it may have a tab protruding from its horizontal upper surface 218 that may be received by slots of rim 94 in order to serve as a guide for the placement of rim 94 , as discussed above.
Alternate cross-member 212 , however, is also adapted to cooperate with vertical beam 222 and with plates 220 , 224 , and 226 . In a preferred embodiment, each of two alternate cross-members 212 , two associated vertical beams 222 , and two buttresses 38 , are supported by three plates 220 , 224 , and 226 . However, it may be possible to achieve similar support effects using only two of the plates, i.e., using plate 220 and only one of plates 224 and 226 located anywhere along cross-member 212 . The assembly is supported in the ground G by block 240 , which is typically a concrete block, but may be made from any suitable material. Block 240 acts as a support to keep system 210 level in the ground G and to provide a means for suitable weight distribution. Any suitable support means may serve this purpose.
FIG. 11 details the location of alternate cross-member 212 in connection with the additional support system elements including buttress 38 , vertical beam 222 and plates 220 , 224 , and 226 . Cross member 212 may be any length that provides appropriate support for the system. A particularly suitable length for an alternate cross-member is about four feet. Buttress 38 (or 38 ′ as shown in FIG. 8) is connected at or near the first end 214 of alternate cross-member 212 by means similar to those described above and has the features described above.
Vertical beam 222 has a channel 246 , resembling a U-shaped channel, which in use cooperates with channel 244 of alternate cross-member 212 . Vertical beam 222 is of a length and depth appropriate to provide support for the system, and preferably has a length of about twelve inches so that it appropriately stabilizes the system in the ground. Vertical beam 222 is usually made of metal such as galvanized steel but may be manufactured of other materials when necessary or appropriate. It is connected at or near the second end 216 of alternate cross-member 212 (by bolts, screws, or nuts, or other suitable means, non-limiting examples including truss head machine screws and hex nuts) and is substantially perpendicular to the longitudinal axis of alternate cross-member 212 .
Plates 220 , 224 , and 226 function to support and secure system 210 in place. They provide correct structural support for the system, i.e., ensure that the buttresses 38 are placed at correct distances from one another. Plates 220 , 224 , and 226 also provide lateral support. They are usually made of metal such as galvanized steel, but may be manufactured from any suitable material. Plates 220 , 224 , and 226 may have various dimensions, exemplary dimensions including a range from about forty three inches to about forty seven inches. Plates 220 , 224 , and 226 may each have a flange 252 to facilitate connecting the plate to the system. Flange 252 may also act as a further support by “grabbing” ground G and alleviating any slippage that may occur when system 210 is in place. Plates 220 , 224 , and 226 may also have grooves 254 which prevent buckling that may occur if a flat plate is used, providing further structural support.
Front plate 220 also secures system 210 in ground G, as shown in FIG. 10 . It also acts to “grab” into ground G, which is one of the aspects of system 210 that allows the removal of the traditional straps. Front plate 220 is connected to vertical beam 222 using suitable connecting means, such as those described above. Front plate 220 will be at an angle that is substantially perpendicular to cross-member 212 . Plates 224 and 226 are connected to the horizontal upper surface 218 of alternate cross-member 212 at or near first and second ends 214 and 216 , respectively, using suitable connecting means. As noted, although the three plates 220 , 224 , and 226 provide the preferred support, the invention may be practiced using less than the three plates 220 , 224 , and 226 . For example it may be possible to retain only front plate 220 for support. The system 210 is shown as additionally supported by block 240 and angle brace 242 .
FIG. 11 also illustrates optional inserts 250 and 248 , which may be made of Styrofoam or other relatively pliable or pressure absorbing material, which may optionally be inserted into channel 244 of alternate cross-member 212 and channel 246 of vertical beam 222 . Inserts 250 and 248 help prevent system 210 from sinking into ground G by providing a surface for ground G to abut. They essentially act as space-fillers to keep the dirt from entering channels 244 and 246 . An optional angle brace 242 may be attached to alternate cross-member 212 to stabilize alternate cross-member on block 240 . Angle brace 242 holds alternate cross-member 212 (and thus strapless support system 210 ) in place. Although angle brace 242 is particularly useful, any type of support or stabilization technique may be used to secure cross-member 212 on block 240 .
FIGS. 12A-B illustrate top plan views of the strapless support system 210 of this invention assembled and in place in the bottom of two types of pools. FIG. 12A shows the invention in connection with a relatively small pool, for example a fifteen by twenty-four foot pool. In this embodiment, system 210 completely replaces the conventional straps 402 (that are shown in FIG. 12 B), with plates 220 (not shown), 224 , and 226 and alternate cross-members 212 . An expandable liner (not shown) is used with system 210 to line the pool and to provide a deep or deeper pool than would conventionally be available. FIG. 12B shows the system 210 located at or near opposing sides of the pool, replacing one set of straps in order to create a deep pool or a pool having a deep end. It may also be possible to completely replace straps 402 using one or more system 210 on a larger sized pool.
In order to deepen a pool or to provide a deep end, a preferred embodiment of the strapless support system 210 is assembled according to FIG. 10 . Block 240 is placed in a trench in the ground G. The trench should correspond to the appropriate dimensions of the system components.
As detailed in FIG. 11, vertical beam 222 is attached to the second end 216 of alternate cross-member 212 and the buttress 38 is attached to the first end 214 of cross member 212 . Front plate 220 is attached to vertical beam 222 . Second and third plates 224 and 226 are attached to the top surface 218 of the alternate cross-member 212 at or near the first and second ends 214 and 216 , respectively. Inserts 250 and 248 are then inserted into the channels 244 and 246 of the alternate cross-member 212 and vertical beam 222 . An angle brace 242 or other form of support is installed on either the alternate cross member 212 at or near the first end 214 or on the block 240 to provide stability. The completed assembly may then be placed in the trench on block 240 and at least partially buried underground. The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. | Support systems for vessels such as above-ground swimming pools are disclosed. Each system may include one or more buttresses adapted to support substantially the entire vertical height of the side wall or each of a series of side walls of the pool. A strapless support system to provide a pool having a deep end is also disclosed. The buttresses, which flare along their lengths, closely match the support they provide each side wall to the outward water pressure present along its height for enhanced reliability. The diminished space required for installation of the disclosed buttresses reduces the surface area required for their associated pool. |
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for determining the draw down characteristics of a well. More particularly, the invention relates to a technique wherein both static and dynamic water table levels are measured by means of an absolute pressure transducer immersed in the bore hole, independent of any casing or tubing structure, and a direct reading measuring circuit located at the surface is used to derive the draw down of the well. The draw down data is then used in conjunction with water pressure and water flow data to provide a monitoring system for water wells.
One of the tests that is paramount to determining the productivity of a water well is measuring the influx of water to the well during pumping. The influx is directly indicative of the ability of the surrounding soil formation to give up the water it contains. Poor water producing formations may contain a plentiful reservoir of water but yield it at rates which render wells located therein of low productivity. While the water well industry has long been aware of the importance of draw down as a key factor indicating the quality of a well, the methods for measuring it have remained largely manual. Two other factors which are well known as being required to evaluate the influx of a well are the discharge pressure and volume of flow of the water being produced. As a result of the relative difficulty of having a measuremment of well draw down quickly and easily available, there is a tendency to overlook the importance of having frequent measurements of the parameter. A number of foreign countries have rigid requirements calling for measurements of a water well's productivity upon completion of drilling. In addition to the importance of having the influx characteristics of a well known for evaluating the production quality, the three factors mentioned above are also invaluable for making rapid and accurate diagnosis of fault symptoms, and for planning of preventive maintenance of the well and its facilities.
The basic method for measuring the draw down of a well involves an operator lowering an electrical contact on a plumb bob and measuring the length thereof when contact with the water is made. As the water level changes, the operator must try to follow the change with the plumb bob. Obviously, this is very difficult to do and yields only approximations if the level is changing rapidly.
Other representative methods and devices for measuring draw down have been used in the past, however, most prior art techniques lack automaticity, or accuracy or involve multistep processes and calculations. Typical prior art approaches are found in U.S. Pat. Nos. 3,321,965 to C. R. Johnson et al; 3,780,574 to Miller; and 3,737,728 to Fitzpatrick. Many of the prior art approaches to measurements of draw down are derived from oil well drilling and measuring techniques, which are not entirely applicable to the water well industry. For the most part this is due to the fact that oil well operations generally are carried out in structural environments wherein pressures encountered in the well bore are due to geological conditions. In direct contrast, the water well environment is one in which gravity is the predominant factor, hence the measurement of draw down is done under conditions wherein the depth of a column of water is directly and linearly related to the hydrostatic pressures encountered at that depth.
SUMMARY OF THE INVENTION
Therefore it is a primary object of the present invention to provide an improved method and apparatus for measuring the draw down of water wells. The basic method comprises making a pair of in situ measurements of hydrostatic pressure heads representing the static and dynamic water table levels, and determining the draw down directly in feet from these two measurements. An extension of the basic method comprises combining the draw down measurement with water pressure and volume measurements made at the discharge port of the pumping system to yield a set of data which uniquely describes the well's character and production capability. The apparatus for carrying out the method provides for automatically performing the draw down and other measurements in a simple and efficient manner. Use is made of three pressure transducers positioned at key locations within the system to yield all of the required data in accurate, unambiguous form.
It is an object of this invention to provide a method and apparatus for measuring the draw down characteristics of a water well whereby the measuring process may be carried out continuously without the need for operator intervention, and whereby the resulting measurement provides a direct quantitative reading of the draw down in feet.
It is a further object of the present invention to provide a method and apparatus for monitoring the characteristics of a water well whereby a time history of the well is compiled as a diagnostic aid, or as an aid in scheduling production rates or maintenance intervals.
It is yet a further object of the present invention to provide apparatus for automatically monitoring water well characteristics at a site remote from the well itself.
It is still a further object of the present invention to provide apparatus for accurately and automatically measuring the water level, either static or dynamic, in a well independent of the existence of a well casing, a drill pipe, or other installed equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects and advantages of the invention will become apparent to those skilled in the art as the description proceeds with reference to the accompanying drawings wherein:
FIG. 1 is a schematic diagram of the water well monitoring system; and
FIG. 2 is a schematic diagram showing the circuitry of the draw down measuring unit of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 there is shown a schematic diagram of the water well monitoring system according to the present invention. A well is indicated generally at 10 having a casing 12 inserted into ground strata 14, and water intake tubing 16 inserted into a bore hole 17. The lower end of tubing 16 is fitted with a filter assembly 18 for guarding against the ingestion of unwanted particulate debris into the water flow. The upper end of tubing 16 is connected to an intake port 20 of a pump 22, which discharges the water produced via a discharge port 24 into a venturi section 26, and thereafter into the water distribution system via an output port 28. With the exception of the venturi 26, all of the elements described are well known and are found in virtually all water wells. It should be noted that the use of a casing, while desirable in many circumstances, is not necessarily used in water wells, and in any event plays no intrinsic part in the present invention.
Two levels of the strata 14 are of particular importance to the method of the invention. A horizontal plane indicated by a line 30 defines the upper limit of the local water table under static conditions. A second line 32 designates the location of the water table under dynamic conditions wherein the pumping system is deriving water from the well. This is referred to hereinafter as the dynamic level 32. The difference between the two levels is designated as the draw down 34, a key parameter of a well system, knowledge of which is essential for characterizing the producing capabilities of the well. To accurately and automatically monitor these two levels, a simple and portable measuring unit has been devised. A pressure transducer 36 is suspended in the bore hole by means of a flexible electrical cable 38. The upper end of the cable 38 is connected to a draw down measuring unit 40. A detailed description of the measuring unit 40 will be provided below in connection with FIG. 2. An output of the measuring unit 40 is routed via a line 42 to a first input of a signal processor and recorder 44.
A water discharge pressure and water flow measuring subsystem of the present invention, shown as the group of elements within the block 45, performs the required measurements of water pressure and water flow at the discharge end of the pumping system. Associated with the venturi 26 in the discharge section of the water path are a pair of pressure transducers 46 and 48. The transducer 46 is positioned at the inlet of venturi 26 and provides a measure of the water discharge pressure at the output of the pump 22. The transducer 48 is positioned at the throat of the venturi 26 to provide a water pressure measurement at that location. The output of transducer 46 is routed via a line 50 to an amplifier 52, and thereafter via a first output of amplifier 52 via a line 54 to a second input of the signal processor 44. The output of the transducer 48 is routed via a line 56 to a first input of an amplifier 58. A second input to the amplifier 58 is routed via a line 60 from a second output of the amplifier 52. An output from amplifier 58 is routed to a square root taking circuit 62, and thereafter to a third input of the signal processor 44. As is well known, the pressure drop across the inlet and throat sections of a venturi is proportional to the square of the flow through it. Hence, lines 60 and 56 which carry signals representing the inlet pressures and throat pressures respectively are routed to difference amplifier 58, whose output then represents the pressure difference at the two locations. Circuit 62, whose output contains the square root of the pressure differences thus provides a measure of the water flow being produced by the well.
Functionally, the water discharge pressure and water flow measuring subsystem 45 provides its two outputs to the signal processor 44, where the draw down data is also availble. These three parameters, all of which are represented by properly scaled voltages quantitatively defining their respective variables, are then recorded and further processed to provide the desired quantitative description of the well. Included within the further processing may be means for coding and impressing the three parameters, along with station identification, date and time, onto a data transmission channel -- phone lines, RF or land line telemetry circuits, or the like -- for routing to a central office facility.
Referring now to FIG. 2 there is shown a schematic diagram of the circuitry of the draw down measuring unit 40. Briefly, a battery 110 is applied to a voltage regulating module 112, and the regulated output voltage therefrom is used to energize the piezoresistive pressure transducer 36. The output of the pressure transducer 36 is read out by a digital voltmeter 114. A second battery 116 is used to energize the digital voltmeter 114, and is further applied to a regulated, compensating network 118, whose output voltage is inserted into the transducer/voltmeter circuit to modify the voltmeter reading. A charging and switching network 120 provides for charging the batteries 110 and 116 when the measuring unit 40 is not in operation.
A line 122 connects a positive terminal of the 12 volt battery 110 to a first movable pole 124A of a four-pole-double-throw switch 124. For ease of description the switch 124 is shown as four electrically independent sections designated as 124A-124D, each lettered element corresponding to a movable pole portion of the respective independent section. All sections of the switch 124 are operated in unison, and are shown in the ON (measuring unit 40 operating) position. A line 126 further routes the positive battery voltage from an ON fixed contact associated with movable pole 124A to an input terminal 128-8 of a voltage regulator chip 128. The voltage regulator chip 128 is equivalent to the commercially available type designated as RCA 723, and provides at its output terminal 128-1, a highly regulated voltage which is adjustable by means of an external resistor network as is well known and conventional. The regulated, adjusted output voltage from 128-1 is routed via a line 38A to a first input node 36A of the pressure transducer 36. The pressure transducer 36, which is of the piezo-resistive bridge type, may be of a type equivalent to a unit available from C&J Enterprises of Tarzana, Calif. as device CJSG-3101. A line 130 connects a negative terminal of the battery 110 to a movable pole 124B, and thereafter via an associated ON fixed contact and a line 132 to a plurality of circuit locations. Hereinafter the line 132 will be referred to as the unit common 132. A first connection of unit common 132 is routed via a line 38B to a second input node 36B of the pressure transducer 36. The lines 38A and 38B, are part of a multiconductor cable which is used to lower the pressure transducer 36 into the well bore during actual measuring operations. The multiconductor cable had been shown more simply in FIG. 1 as the cable 38. Completing the interconnection of the voltage regulating chip 128, there is shown a resistor 134 connected between terminals 128-3 and 128-4; a jumper 136 connecting terminals 128-7 and 128-8; a jumper 138 connecting terminals 128-6 and 128-10; a resistor 140 connected between terminals 128-10 and 128-1; a capacitor 142 connected between terminals 128-2 and 128-9; and a line 144 connecting terminal 128-5 to unit common 132. A resistive voltage divider network consisting of a fixed resistor 146, a potentiometer 148 and a fixed resistor 150 are connected in series between the terminal 128-1 and the unit common 132. The wiper of potentiometer 148 is connected to the terminal 128-2. In operation, the potentiometer establishes the precise voltage produced by the voltage regulator 128 at its output terminal 128-1, as is also conventional.
An output of pressure transducer 36 is routed via a node 36C and a line 38C to a first signal input terminal of the digital voltmeter 114. The digital voltmeter 114 may be of a type equivalent to a Weston Model 1220 device adapted to provide a remote output, either in analog or digital form, via the output line 42. A second output of pressure trannsducer 36 is routed via a node 36D and a line 38D to the compensating network 118, as will be further described below. The lines 38C and 38d complete the interconnection of pressure transducer 36 with the measuring unit 40 via the cable 38 of FIG. 1. As the pressure transducer 36 is of the bridge type, the output voltage representative of the pressure being sensed is available between the nodes 36C and 36D. Were it not for the compensating technique, to be described below in connection with the compensating network 118, the node 36D would normally be connected directly to a second signal input terminal of the digital voltmeter 114.
A 12 volt battery 116, which consists of two series - aiding - connected 6batteries 116A and 116B with their junction point accessible to the external circuit, provides the power to energize the digital voltmeter and also to energize the compensating network 118. A line 152 connects a positive terminal of the battery 116A to a movable pole 124C and thereafter via an associated ON fixed contact and a line 154 to a resistor 156. The other end of resistor 156 is connected to a node 118A of the network 118.
A line 158 connects a negative terminal of the battery 116B to a movable pole 124D and thereafter via an associated ON fixed contact and a line 160 to a resistor 162. The other end of resistor 162 is connected to a node 118B of network 118. A zener diode 164 has its cathode connected to the node 118A and its anode connected to an anode of a diode 166. A cathode of the diode 166 is connected to the node 118B. Thus, there will exist across the nodes 118A and 118B a regulated voltage substantially determined by the reverse conduction of zener diode 164 and by the value of the dropping resistors 156 and 162. A resistive voltage divider network consisting of a fixed resistor 168, a potentiometer 170 and a fixed resistor 172, all of which are connected in series, is connected across the nodes 118A and 118B. A wiper 170of the potentiometer 170 provides the output of the voltage divider network via a line 174 and the line 38D to the node 36D of the pressure transducer 36. A line 176 connects a negative terminal of the battery 116A to a positive terminal of the battery 116B and further to a first power input and a second signal input terminal of the digital voltmeter 114. A further extension of the line 154 connects the positive voltage of battery 116A to a second power input of the digital voltmeter 114 via a series connected dropping diode 178. Thus it is seen that the digital voltmeter is powered by the 6V battery 116A. A pair of capacitors 180A and 180B are connected in parallel with each other with 170A end of the combination connected to the wiper 170of potentiometer 170, and the other end of the combination connected to the line 176. As shown, the capacitors 180A-180B are polarized types and have their oppositely polarized terminals connected so as to produce a bipolar resulting capacitance.
Effectively, the combination of the battery 116 and the compensating network 118 produces a bipolar, floating, precisely adjustable voltage which is inserted in series with the output voltage of the pressure sensor 36 and digital voltmeter 114. The voltage, hereinafter referred to as the compensating voltage, is available between the lines 174 and 176. By adjustment of the potentiometer 170, the voltage on line 174 can be made positive or negative in precisely adjustable increments around zero volts. When inserted into the transducer/voltmeter circuit the compensating voltage may be used, as described below, to translate the voltmeter reading higher or lower to achieve operationally desirable modifications of the hydrostatic pressure readings.
The charging and switching network 120 provides for turning the measuring unit 40 ON and OFF and further for placing the 12 v batteries 110 and 116 in parallel and applying an external source for periodic recharging in the OFF condition. Typically the external source may consist of any convenient automobile electrical system, or the like, thereby permitting extended operations of the measuring unit 40 at remote field sites when required. Operating the switch 124 to the OFF position deenergizes the measuring unit 40 and places the batteries 110 and 116 in parallel. A line 182 is connected to an OFF fixed contact associated with movable pole 124A carrying the positive terminal of battery 110; and is also connected to an OFF fixed contact associated with movable pole 124C carrying the positive terminal of battery 116. The line 182 is routed via a series-connected protective diode 186 to the positive terminal (+) of the charging source connection. A line 184 is connected to an OFF fixed cotact associated with movable pole 124B carrying the negative terminal of battery 110; and is further connected to an OFF fixed contact associated with movable pole 124D carrying the negative terminal of battery 116. The line 184 is routed directly to the negative terminal (-) of the charging source connection.
Functionally, the major features of the measuring unit 40 are as follows. The pressure transducer (alternately pressure sensor) 36, which basically is required to produce two hydrostatic pressure measurements, the difference of which constitutes the desired draw down measurement, is energized by a precisely controllable, stable voltage. By proper combination of the voltage applied to the pressure transducer 36 and the intrinsic sensitivity of the pressure transducer 36, an output scale factor is obtained which is then read out on the digital voltmeter. The pressure sensor cited as an illustrative implementation, the CJSG-3101 device, was made to produce a scale factor of one millivolt change in output for each 0.433 psi change in pressure sensed, when resistors 146, 148 and 150 having respective ohmic values of 2.2k, 5k and 2.2k were used. The potentiometer 148 is adjusted to precisely compensate for the length of interconnecting cable in use, and similar circuit variables. It should be noted that the above scale factor produces a digital voltmeter reading which corresponds directly to feet of water head, and therefore the draw down measurement per se requires no further data reduction. For example -- a first measurement taken on a properly calibrated system under conditions wherein no water was being removed from the well might produce a reading of 127.6 on the digital voltmeter. Disregarding for the moment the secondary effects of ambient atmospheric pressure and well site altitude, this reading indicates that the pressure sensor is 127.6 feet below the surface of the water. After starting up the well pumping system and establishing the water removal at some desired rate, a second reading of 107.6 might be noted. The draw down would be immediately known to be the difference of the two readings -- 20 feet. Further, the other mentioned secondary effects would have no effect on the accuracy of the resultant drawn down measurement using this technique as they would have made the same contribution to both readings, and would therefore be washed out by the subtraction process.
While the secondary effects indicated above are negligible for measurements of draw down by the subtractive technique, it is often of value to perform certain well measurements with reference to either absolute pressure levels, or predetermined pressure levels. The use of the compensating voltage circuitry described previously allows the measuring unit 40 to accomplish these desired absolute measurements. By adjusting the compensating voltage with the aid of predetermined calibration tables of the potentiometer 170, which may be a ten turn device, the base line readings of the voltmeter may be to reflect hydrostatic pressure heads referenced to a standard, or predetermined, barometric pressure or site elevation. Also, a time series of readings of draw down may be desired all to a common barometric base so as not to mask the effects of small, long term shifts in the static water table level. An additional technique wherein the compensating voltage provides an enhanced operational capability involves setting the compensating voltage such that the voltmeter reads zero under zero well water withdrawing conditions. Thereafter, under pumping conditions, a draw down reading directly in feet would be indicated on the digital voltmeter.
Although the invention has been described in terms of selected preferred embodiments, the invention should not be deemed limited thereto, since other embodiments and modifications will readily occur to one skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention. | A method and apparatus for measuring the draw down of a water well by making in situ measurements of the static and dynamic water table levels. A well bore located pressure sensor provides the hydrostatic pressures to a surface located electronic measuring unit which provides a draw down measurement directly in terms of feet of water. An extension of the method provides for combining the measured draw down parameter with water discharge pressure and water flow measurements to derive a set of data which uniquely characterizes the production capability of the well. The apparatus performs all measurements automatically and has provisions for producing a time history of the well parameters, and telemetering to a central station for monitoring and processing. |
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FIELD OF THE INVENTION
[0001] The present invention relates to collapsible warning signs which can be used either in or near a roadway to advise motorists as to caution conditions.
DESCRIPTION OF THE RELATED ART
[0002] Over the years, different types of sign systems have been proposed for warning motorists of unusual caution conditions. Such conditions typically arise infrequently or only during certain parts of a work day. Accordingly, it is preferred that the sign systems be relatively light weight and subject to easy storage configurations. For example, roadway signs have been proposed utilizing flexible sign panels supported by framework which can be quickly and easily separated from the sign panel and collapsed for storage in a vehicle, for example. The framework for these types of sign systems originally included rigid metallic frame members but, increasingly, these are being replaced by frame members of epoxy rib construction. Such sign stands are typically employed on the side of the roadway or on the roadway edge so as to avoid unintentional contact with oncoming vehicles. If the roadway is reduced in size by traffic delineators such as cones or barricades, design systems may be employed adjacent to such delineator devices.
[0003] It is generally desirable that the sign systems be self supporting, yet light weight and portable. Initially, the framework was supported by a system of collapsible support legs which, when folded out, resemble a tripod or similar structure for engaging the ground. Recently, monolithic slabs have been proposed for supporting an upright framework member. The slabs may be made of crumb rubber or the like pliable, resilient material for example. The use of these types of sign bases has been noted, in some applications, to improve crash worthiness of the sign system.
[0004] Heretofore, temporary roadway warning signs have been employed largely by construction and repair crews that are deployed on or near a roadway surface. In the past, unusual, temporary caution conditions not associated with a construction event, such as school cross-walks, have been protected by human operators holding a warning sign. Even in construction areas, human operators are sometimes employed to manually present a caution sign to oncoming motorists. Increasingly, usage of in-street signing has been proposed for special events such as school crosswalks that are in use for only a small portion of the day. The Federal government and various State and local organizations have proposed their own Manual on Uniform Traffic Control Devices (MUTCD). For example, one such manual is published by the Federal Highway Administration of the U.S. Department of Transportation. States and local governmental bodies have been inspired to either adopt or produce their own manual, drawing inspiration from the work done by the Federal government. Accordingly, attention is now being given to enhancing pedestrian crosswalks using improved in-street signage. Uniform in-street pedestrian crossing signs or reduced sized in-street School Advance Warning signs have been proposed in the Federal Highway Administration MUTCD Section 7B09. Even if similar signs are employed remote from a roadway surface, advantages can be obtained from the use of in-street signage.
SUMMARY OF THE INVENTION
[0005] The present invention provides a novel and improved sign system. A first embodiment of a sign system, according to the present invention includes a flexible sign panel having a middle section and opposed free ends, along with a frame including first and second frame members pivotally joined together, with each frame member having opposed free ends. A mounting member defines a socket for receiving a first end of the first frame member, and at least one biasing tether connects the mounting member to at least one free end of the sign panel. The support members, the sign panel, the mounting member and the biasing tether cooperate such that, with the second support member engaging the middle section of the sign panel, the free ends of the sign panel are supported adjacent the first end of the first support member, and the second support member and the middle section of the sign panel are supported by the first support member at a point spaced from the first end of the first support member.
[0006] The biasing tether may comprise a pair of bias cords having opposed ends extending from the free end of sign panel, with a central portion of the cord engaging the mounting member. Alternatively, the biasing tether could comprise a web of elastic material engaging a center portion of the sign panel free end.
[0007] Preferably, the middle section of the sign panel is supported by the second support member which is located at approximately midway between ends of the sign panel, with opposed sign panel portions generally coextensive with one another, so that the free ends of the sign panel are positioned adjacent one another. Also, stiffeners are provided at the free ends of the sign panel.
[0008] In another embodiment, a sign system includes a flexible sign panel having a middle section and opposed free ends. A frame includes first and second frame members pivotally joined together, each frame member having opposed free ends, and a mounting member defining a socket receives a first end of the first frame member. At least one biasing tether connects the mounting member to at least one free end of the sign panel. The support members, the sign panel, the mounting member and the biasing tether cooperate such that, with the second support member engaging the middle section of the sign panel, the free ends of the sign panel are supported adjacent the first end of the first support member, and the second support member and the middle section of the sign panel are supported by the first support member at a point spaced from the first end of the first support member. Also included is a support base engaging the second end of the first support member, to engage the second end of the first support member, holding it in an upright position.
[0009] In another embodiment, a sign system includes a flexible sign panel having a middle section and opposed free ends, with stiffeners at the free ends and a frame including first and second frame members pivotally joined together, with each frame member having opposed free ends. The middle section of the sign panel is supported by the second support member and located at approximately midway between the ends of the sign panel, with opposed sign panel portions generally coextensive with one another, and with the free ends of the sign panel positioned adjacent one another. A mounting member defining a socket receives a first end of the first frame member, and at least one biasing tether connects the mounting member to at least one free end of the sign panel. The support members, the sign panel, the mounting member and the biasing tether cooperate such that, with the second support member engaging the middle section of the sign panel, the free ends of the sign panel are supported adjacent the first end of the first support member, and the second support member and the middle section of the sign panel are supported by the first support member at a point spaced from the first end of the first support member.
[0010] In a further embodiment, a sign system includes a flexible sign panel having a middle section and opposed free ends, along with a frame including upright and cross frame members pivotally joined together, each frame member having opposed free ends and at least one engagement member on the upright support member. At least one biasing tether connects the at least one engagement member to the sign panel. The support members, the sign panel, the at least one engagement member and the biasing tether cooperate such that, with the second support member engaging the middle section of the sign panel, the free ends of the sign panel are supported adjacent the second end of the first support member, and the second support member and the middle section of the sign panel are supported by the second support member at a point spaced from the first end of the first support member.
[0011] In another embodiment, a sign panel kit includes a flexible sign panel having a middle section and opposed free ends, a frame including first and second frame members pivotally joined together, each frame member having opposed free ends and a mounting member defining a socket for receiving a first end of the first frame member. At least one biasing tether connects the mounting member to at least one free end of the sign panel. The support members, the sign panel, the mounting member and the biasing tether cooperating such that, with the second support member engaging the middle section of the sign panel, the free ends of the sign panel are supported adjacent the first end of the first support member, and the second support member and the middle section of the sign panel are supported by the first support member at a point spaced from the first end of the first support member. Also included is a container for carrying the sign panel, mounting member, tether and base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings:
[0013] FIG. 1 is a front elevational view of a sign system illustrating the present invention;
[0014] FIG. 2 is a side elevational view thereof;
[0015] FIG. 3 is a perspective schematic view of the sign panel component thereof;
[0016] FIG. 4 is an exploded perspective view of the sign system;
[0017] FIG. 5 is a perspective view of a mounting component used in the sign system;
[0018] FIG. 6 is a bottom plan view thereof;
[0019] FIG. 7 is a top plan view thereof;
[0020] FIG. 8 is a front elevational view thereof;
[0021] FIG. 9 is a cross-sectional view taken along the line 9 - 9 of FIG. 8 ;
[0022] FIGS. 10-12 show a sequence of operations for engaging a sign panel rib with the mounting member;
[0023] FIG. 13 is a perspective view of kit components for a sign panel system;
[0024] FIG. 14 is a front elevational view of an alternative sign panel system;
[0025] FIG. 15 is a side elevational view thereof;
[0026] FIG. 16 is a front elevational view of an alternative mounting member arrangement;
[0027] FIG. 17 shows a portion of FIG. 16 , taken on an enlarged scale;
[0028] FIG. 18 is a cross-sectional view taken along the line 18 - 18 of FIG. 17 ;
[0029] FIG. 19 is a cross-sectional view taken along the line 19 - 19 of FIG. 16 ;
[0030] FIG. 20 is a cross-sectional view showing an alternative of the FIG. 19 arrangement;
[0031] FIG. 21 is a top plan view of the arrangement of FIG. 17 ;
[0032] FIG. 22 is a front elevational view of an alternative mounting component;
[0033] FIG. 23 is a cross-sectional view taken along the line 23 - 23 of FIG. 22 ;
[0034] FIG. 24 is a fragmentary cross-sectional view taken along the line 24 - 24 of FIG. 23 ;
[0035] FIG. 25 is a front elevational view of a further alternative embodiment of a mounting component;
[0036] FIG. 26 is a cross-sectional view taken along the line 26 - 26 of FIG. 25 ;
[0037] FIG. 27 and FIG. 28 are cross-sectional views similar to those of FIG. 26 , but showing stages of assembly of a sign system.
[0038] FIG. 29 is a fragmentary perspective view of an alternative assembly for attaching the sign panel; and
[0039] FIG. 30 is a fragmentary perspective view of another alternative assembly for attaching the sign panel.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] The invention disclosed herein is, of course, susceptible of embodiment of many different forms. Shown in the drawings and described herein below in detail are the preferred embodiments of the invention. It is to be understood, however, that the present disclosure is an exemplification of principles of the invention and does not limit the invention to the illustrated embodiments.
[0041] For ease of description, sign systems embodying the present invention are described herein below in their usual assembled position as shown in the accompanying drawings in terms such as front, rear, upper, lower, horizontal, longitudinal, etc., may be used herein with reference to this usual position. However, sign systems may be manufactured, transported, sold and or used in orientations other than that described and shown herein.
[0042] Referring now to the drawings, and initially to FIGS. 1-12 , a first embodiment of a sign system according to principals of the present invention is generally indicated at 10 . Included is a framework generally indicated at 12 (best seen in FIGS. 2 and 4 ) and a flexible web generally indicated at 14 (best seen in FIG. 3 ). Also included is a base schematically illustrated at 16 .
[0043] Referring to FIG. 3 , flexible web 14 has opposed free ends 20 , 22 and a mid-section 24 preferably located midway between the free ends. An opening 26 is formed in mid-section 24 and is generally preferred so as to facilitate assembly of the sign system. In the preferred embodiment, opening 26 is located at a halfway position between ends 20 , 22 and thus divides the flexible web into two panels 30 , 32 . In the preferred embodiment, stiffeners 34 , 36 are located at free ends 20 , 22 as indicated for example in FIG. 10 , stiffeners 34 , 36 preferably comprise a cylindrical dowels about which ends of flexible web 14 are wrapped and secured with stitching 38 . In the preferred embodiment, central portions of dowels 34 , 36 are exposed so as to facilitate wrapping tethers 42 about the dowels. As will be seen, tethers 42 serve as biased members and are preferably made of elastic material.
[0044] Referring now to FIGS. 2 and 4 , framework 12 includes an upright number 46 , and a cross member 48 joined together by a pivot pin 50 . Referring additionally to FIG. 11 , upright member 46 has an upper or first free end 54 and a second or lower free end 56 shown for example in FIG. 4 . As shown in the drawings, upright and cross members 46 , 48 are elongated and have generally rectangular cross-sections. In a preferred embodiment, upright and cross members 46 , 48 are preferably made of conventional epoxy rib material and thus are flexible so as to prolong their service light upon incidental contact with an outside source. Pivot pin 50 preferably comprises a hollow rivet, but could also comprise a screw fastener or a solid rivet, the ends of which are headed over, for example. Referring again to FIG. 4 , support base 16 is provided with a central aperture 60 for receiving the lower end 56 of upright 46 , as indicated in FIGS. 1 and 2 , for example. As indicated in FIG. 13 , cross member 48 is pivotable so as to become, lined with upright 46 for a compact storage position of minimal size. By simply rotating cross member 48 to the position indicated for example in FIG. 4 , framework 12 is placed in an operational mode, ready for assembly of the sign stand.
[0045] As shown for example in FIGS. 1 , 2 and 4 , a mounting member 66 is located at the top of the sign stand assembly. Referring now to FIGS. 5-9 , mounting member 66 is preferably made from a one-piece integral plastic molding. If desired, mounting member 66 could be made from several inter-cooperating parts or could be made from other materials such as wood or metal. Referring for example to FIGS. 8 and 9 , mounting member 66 includes a handle 68 joined to a body generally indicated at 70 by a stem 72 . Body 70 preferably forms a hollow socket having an interior hollow chamber 76 , shown for example in FIG. 5 . Included in body 70 are side walls 78 and front walls 80 . As can be seen for example in FIGS. 5 and 6 , recesses 84 are formed in front walls 80 and extend slightly into side walls 78 .
[0046] Referring to FIG. 8 , body 70 further includes an end wall 88 that extends between side walls 78 and is joined to one end of stem 72 . Referring to FIGS. 6 and 8 , end wall 88 includes a series of pads 92 which provide a convenient bearing surface for abutting engagement with the upper end 54 of upright member 46 , as will be seen with reference to FIGS. 11 and 12 .
[0047] As shown for example in FIG. 8 , front walls 80 do not extend to end wall 88 but rather, are abbreviated so as to form windows 96 , exposing the upper ends front walls 80 . The windows 96 extend to the hollow interior 76 of body 70 . Referring again to FIG. 5 , recesses 84 form a raised separator portion 102 separating the channels or recesses 84 from one another. In the preferred embodiment, separator 102 comprises the central portions of side walls 78 . As can be seen in FIG. 9 , recesses 84 are preferably continuous with windows 96 to allow for easy threading and assembly of the tether members, as will be described below. Referring to FIG. 9 , end wall 88 preferably defines a downwardly facing recess 106 defined by side wall 78 and locator walls 108 .
[0048] Referring now to FIGS. 9 and 10 , webs 42 are looped over front walls 80 and secured with stitching, as indicated in FIG. 10 . The inner portions of the loops surrounding the front walls 80 have edges received in recesses 84 (see FIGS. 5 and 9 ) so as to space the looped portion of the tethers from the center portion of the hollow interior of body 70 . With reference to FIG. 5 , recesses 84 gave two parts, a central part which in effect increases the width of the hollow interior of body 70 and the end portions which extend into side walls 78 which hold edges of the tethers 42 , captive. Thus, the enlarged width accommodates the thickness of the tethers while the end portions of recesses 84 hold the tether captive so as to press against the inner surface of front wall 80 . The tether loops shown in FIGS. 10-12 , for example, are exaggerated for drawing purposes, it being generally preferred that the inside portion of the tethered loops are held against or very close to front walls 80 , to avoid interference with the upright support member, as will now be described.
[0049] With reference to FIGS. 10-12 , and beginning with FIG. 10 , the upper portion of a flexible assembly 120 is shown in a relaxed, pre-installation stage. Referring additionally to FIG. 13 , flexible assembly 120 include the flexible web 14 (shown for example in FIG. 3 ) and mounting members 66 joined to the tethers 42 of the flexible web. Assembly of the sign system begins with inserting the lower end 56 of upright 46 through hole 26 of flexible web 14 ( FIG. 3 ). The upright 46 is inserted through opening 26 until cross member 48 contacts mid section 24 of the flexible panel. At this point of assembly, the upper end 54 of upright 46 is located between the upper free ends of the flexible panel. Referring to FIG. 11 , the handle portion 68 of mounting member 66 is then pulled in the direction of arrow 126 so as to raise mounting member 66 above the upper free end 54 of upright 46 . At this time, the upper end 54 of upright 46 is generally aligned with the hollow interior cavity 76 of body 70 referring to FIG. 12 , tension of tethers 42 is relaxed by lowering mounting member 66 in the direction of arrow 128 , so as to bring the upper end of upright 46 into the hollow interior of the mounting member 70 .
[0050] The mounting member is then lowered so as to bring the upper end 54 of upright 46 into recess 106 (see FIGS. 10 and 11 ), until the upper end of the upright is held captive by locator walls 108 . At this point, flexible tethers 42 preferably exert a predetermined downward biased force maintaining engagement of the mounting member and upright, so as to maintain the alignment illustrated for example in FIGS. 2 and 4 . Thereafter, the lower end of upright 46 is secured to a support so as to maintain the sign assembly in a generally upright position shown for example in FIG. 4 .
[0051] If desired, the orientation of the sign system can be quickly and easily attained by providing support base 16 so as to receive and engage upright 46 . If desired, the support base may be omitted and a ground socket or hole in a support surface may be provided for this purpose. As a further option, mounting member 66 provides convenient attachment to the side of a traffic standard, vehicle or building wall, for example. Since it is generally preferred that the sign panels 30 , 32 have a generally rectangular configuration, cross member 48 is made to have a width sufficient so as to maintain the rectangular configuration at the bottom of the sign panels, and stiffeners are provided at the upper ends of the sign panels, as described.
[0052] Referring now to FIG. 13 , a sign system kit is generally indicated at 130 , and includes, in addition to the sign system components described above, a carrying case 132 having a first compartment 134 for receiving framework 12 , a second compartment 136 for receiving flexible assembly 120 and a third compartment 138 for receiving support base 16 . In order to contribute to the portability of the sign system, it is generally preferred that the support base 16 be formed of a relatively light-weight material such as crumb rubber, solid rubber which is either machined, case, or molded, wood, fiberglass or other material as may be desirable. With the addition of a carrying strap 140 , the kit 130 can be easily transported from one location to another. It is generally preferred that case 132 is made of lightweight flexible material such as a cloth composition, which can be easily folded and stored while the sign system is being displayed.
[0053] Referring now to FIGS. 14 and 16 , an alternative arrangement of a sign system is illustrated. The framework 12 is inverted from the first embodiment shown in FIG. 112 and engagement members 142 are provided adjacent the lower end of upright 46 . The opposite or upper portion of upright 46 is preferably abbreviated so as to lie entirely within the fold of flexible web 146 . If desired, upright 46 can extend upwardly beyond flexible web 146 with the addition of central opening similar to the opening 26 illustrated in FIG. 3 . The lower ends of flexible web 146 are preferably provided with stiffeners 34 , 36 as described above.
[0054] If desired, the tethers 42 shown for example in FIG. 1 may be employed in an arrangement of FIG. 15 , if desired. However, FIGS. 14 and 15 show an alternative arrangement in which a centrally located elastic tether is replaced by a tether cord 150 having end portions secured adjacent the lateral edges of the free ends of flexible web 146 . By comparison of FIGS. 1 and 14 , it will be noticed that the indicia in FIG. 14 is inverted. If desired, the same flexible web can be provided for assembly according to both FIGS. 1 and 14 , with the indicia shown in FIG. 14 printed on the inner surface of the flexible web shown in FIG. 1 , for example. Thus, by choosing the relative orientation of framework 12 , the proper surfaces of the flexible web can be chosen so as to provide indicia for either arrangement of FIG. 1 or 14 .
[0055] If tether cord 150 is to be used in place of the central tether 42 , modifications to the mounting member 66 shown in FIGS. 1-12 , is generally preferred. Referring to FIGS. 16-18 , a mounting member 156 is generally identical to the mounting member 66 described above, except that body 70 is provided with an optional upper structure 158 shown in FIGS. 16-18 and 21 . With reference to FIG. 18 , end wall 162 is provided with a pair of recesses 164 , for receiving respective tether cords 150 .
[0056] With reference to FIG. 21 , recesses 164 can be provided with optional staggered tabs 166 that holds the tether cords captive, while allowing the tether cords to be threaded into the recesses 64 during the assembly of the sign system. As can be seen in FIGS. 16 and 17 , for example, the front wall windows described above with reference to FIGS. 1-12 have been omitted, as being unnecessary since the central tethers 42 are not employed. However, if desired, the windows and remaining construction of the mounting members 66 described above with reference to FIGS. 1-12 , can be included in mounting member 156 to accommodate mass production of the mounting member, as may be desired.
[0057] FIGS. 19 and 20 show alternative methods for securing the ends of tether cord 150 to the flexible web. As shown in FIG. 19 , the flexible web is looped about tether cord 150 and a lateral stiffener 170 and secured by stitching or other joinder 172 .
[0058] In FIG. 20 , material from the flexible web is looped over lateral stiffener 170 and secured at 172 . A rigid clip made of plastic or metal, for example, is indicated at 176 and provides engagement with tether cord 150 , as illustrated. Clip 176 is secured to lateral stiffener 170 by conventional fastening means 178 such as a ribbon or threaded fastener, for example. If desired, two clips 176 can be provided, one adjacent each end of lateral stiffener 170 , or a single clip 176 can be arranged so as to co-extend with the lateral stiffener and preferably the width of the flexible web.
[0059] Turning now to FIGS. 22-28 , two alternative arrangements of mounting members are shown. A first alternative embodiment generally indicated at 182 is shown in FIGS. 22-24 . Mounting member 182 is generally identical to mounting member 66 described above, except for being formed from three components, a body 186 and a pair of removable front walls 188 . Body 186 includes the features of mounting member 66 as described above, except for the absence of front walls 180 . With the arrangement of FIGS. 22-24 , mounting member 182 can accommodate a fully formed flexible web, shone for example in FIG. 3 . As mentioned above, the mounting member 66 requires the tethers 42 to be looped around the front walls 80 and secured in the manner illustrated, for example, in FIGS. 10-12 .
[0060] With the mounting member 182 , the tethers 42 can be completely formed during fabrication of the flexible web. With reference to FIG. 24 , side walls 78 are provided with a pair of dove tail channels formed by channel members 192 . Opposed ends of front walls 188 are provided with dove tail configurations 194 , as illustrated in FIG. 24 . Thus, the front walls 188 can be slid into dove tail channels of side walls 78 from above, and lowered until the front walls contact stop members 196 (see FIGS. 22 and 23 ), so as to prevent separation of the front walls from body 186 while loads are applied by tethers 42 . Thus, by simply inserting front walls 188 in the loops of tethers 42 and sliding the front walls into the position illustrated in FIG. 22 , construction of the flexible assembly 120 , shown for example in FIG. 13 , is completed, allowing all sewing or other construction of the flexible web to be completed off site, as may be desired.
[0061] Turning now to FIGS. 25-28 , an alternative embodiment of a mounting component is generally indicated at 204 . As with the preceding embodiment, mounting member 204 allows the flexible web to be completely constructed prior to assembly of the sign system. Referring to FIG. 27 , the looped ends of tether 42 are passed entirely through the interior of the body of mounting member 204 . The upper ends of tethers 42 are inserted through windows 208 and a cross member 210 . 210 is inserted through the loop. Thereafter, the cross member 210 is seated in pockets 214 formed in side walls 78 and thus held captive within the mounting member. In the preferred embodiment, recesses are formed in side wall 78 , similar to recesses 84 (see FIGS. 5-9 ), to keep the tether from interviewing with the upright member.
[0062] Referring now to FIGS. 29 and 30 , alternative arrangements are show for attaching the sign panel to an upright support, such as the upright member 46 shown in FIG. 2 . These alternative arrangements provide support for the upper ends of the sign panel or flexible web 14 , to prevent fluttering or other front-to-back movement of the upper end of web 14 when subjected to wind gusts or air turbulence from passing vehicles, causing the upper ends of web 14 to rock about upright member 46 .
[0063] Referring to FIG. 29 , a clip 230 is attached to upright member 46 , by a rivet or other conventional fastener. Preferably, clip 230 is free to rotate to a storage position overlying upright member, for compact storage, but could be fixedly mounted, if desired. As shown, clip 230 has a downwardly opening U-shape portion 232 shown in the deployed position in FIG. 29 . Clip 230 can be made of virtually any rigid material as may be desired, such as metal or plastic, for example. With reference to FIG. 2 , clip 230 is mounted at the upper portion of upright member 46 , adjacent laterally extending stiffener 34 . A complementary, interengaging clip 236 is attached to stiffener 34 (or, less preferably, the upper end of web 14 ) using conventional fasteners such as rivets, screws, adhesive or sewn attachment.
[0064] As shown, clip 236 has an upwardly opening U-shaped portion 238 , dimensioned for interengagement with portion 232 of clip 230 . As tether 42 is pulled in the upward direction of arrow 242 , clips 230 , 236 are brought into mating engagement, one with the other. Owing to the stiffness of the clips 230 , 236 , rocking of the upper portion of web 14 about upright member 46 is prevented. As shown in FIG. 29 , a clip arrangement is provided only for the front panel portion of web 14 . For a folded web, such as that illustrated in FIG. 2 for example, a similar pair of interengaging clips could be provided for the second, rear facing panel portion.
[0065] Referring now to FIG. 30 , and alternative arrangement for stabilizing the upper end of web 14 is shown utilizing a cross member 246 , rotatively secured to upright member 46 by a rivet 248 or other conventional fastener. A pivoting connection is preferred, so that the cross member is brought into overlying relationship with upright member 46 , for compact storage. Upon deployment of the sign stand assembly, the cross member 246 is rotated to the extended or working position illustrated in FIG. 30 . Cross member 246 is preferably made of rigid material, such as wood, plastic or epoxy or other material, reinforced with fiberglass strands, for example.
[0066] A pair of clips 252 is attached to the upper end of web 14 , preferably by securement to stiffener 34 . As indicated in FIG. 30 , clips 252 are spaced from one another, on either side of tether 42 . Clips 252 , made of rigid material, have upwardly opening U-shaped portions 254 , dimensioned to receive cross member 246 . The cross member 246 is located at the upper end of upright member 46 of FIG. 2 , adjacent cross member 34 . As the tether is pulled in an upward directions, clip portions 254 are brought into engagement with cross member 246 . Owing to the rigidity of cross member 246 and clips 252 , their interengagement prevents fluttering of the upper end of web 14 , that would otherwise cause it to rock about upright member 46 .
[0067] Several variations of the arrangement of FIG. 30 are possible. For example, although a cross member 246 of round cross-section is shown, the cross member could have an elongated cross sectional shape, such as the cross member 24 , employed at the lower end of the sign stand assembly. As a further variation, the two separate clips 252 could be replaced by a single clip, preferably with a central recess that would allow the clip to straddle upright member 46 .
[0068] The arrangements of FIGS. 29 and 30 are shown for tethered connections at the upper end of the sign stand assembly, such as that shown in FIGS. 1-4 . The same arrangements could, with simple inversion, be employed with an arrangement, such as that shown in FIGS. 14-15 , where a tethered connection is provided at the lower end of the sign stand assembly.
[0069] As indicated herein, a pair of sign panels are preferably provided as portions of a flexible web which, when folded, causes the sign panels to overly one another. If desired, a single sign panel could be employed, with end portions attached to opposed ends of the same support member, preferably, an upright member. One end of the sign panel would be secured to one end of the support member, and the other end of sign panel would be secured to the other end of the support member. Although both ends of the flexible web are secured to the support member, (an upright mast, for example), it is generally preferred that one of the securements to the support and/or the tethers themselves be made resiliently stretchable, using elastic cords or straps and/or spring bias members such as coil springs. The tethers can be homogenous throughout their length, or can be formed from a serial array of different components. Some of the components could be rigid and some of the components could be resilient, for example.
[0070] The foregoing description and the accompanying drawings are illustrative of the present invention. Still other variations and arrangements of parts are possible without departing from the spirit and scope of this invention. | A sign system is disclosed in which a flexible sign panel is supported by light weight frame numbers such as fiberglass ribs joined together with a pivot connection. A sign panel of flexible material has a center section disposed between a pair of opposed sign panel portions. The center portion of the sign panel engages a cross member with the sign panel portions being folded over on either side of an upright support member. Free ends of the sign panel member are secured with a stretchable elastic cord, ribbon or the like, to a mounting member having a socket for receiving one end of the vertical support member. By engaging the mounting member and stretching the elastic cords, the mounting member is disposed over one end of the vertical support and one released, engages the vertical support holding the sign panel portions in a display position. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an assembly type partition wall structure, and more particularly, to an assembly type partition wall structure utilizing a technique of interior space design in which a plurality of partition wall units are joined by connecting side by side successively to form a continuous wall panel so as to easily form a vertical partition of a three-dimensional spacing.
2. Description of the Prior Art
How to make a perfect space plotting has been a deeply concerned matter of human being. As our living environments, the earth, cities, parks, stages or stadiums, and building stories all belong to natural or artificial three-dimensional spaces, architectures have been doing their best efforts to work out a perfect design to make such spaces pleasant for people to live in. In order to improve a visual feeling of the living space, vertical partition wall structure in the building is considered to be the best way that it has been widely adopted in the building interior.
In early days, the primitive brick wall material is used to bond together with binders to support the structure. Afterwards, the C steel frame structure associated with hard board material is employed to form a light partition system, pour light concrete material, or use the metal troughs to construct an equivalent system.
However, the aforesaid partition wall structure are found to have the following disadvantages, namely:
1. Construction work has to rely on well-trained skillful workers to accomplish.
2. In the case of brick work, the brick must be stacked up one by one with the mortar intercalated there between tediously wasting time.
3. The utility ducts such as electricity, gas and water involved in the wall structure are difficult for regular maintenance.
All above mentioned structures have the common demerits of requiring long working time with technical difficulty. Above all, the light concrete system and mental trough system need high construction cost, and the metal trough system has a poor capability to resist fire.
SUMMARY OF THE INVENTION
For these defects noticeable on the prior art, an improvement is seriously required. It is the main object of the present invention to provide an assembly type partition wall structure, which is applicable to any figured space and easily fabricable with low cost for improving human life.
To achieve the above object, the present invention provides a partition wall unit including a quadrilateral main wall body having a L shaped first connecting plate linearly extended from the front end along two adjacent sides with a thickness half that of the main wall body, and another L shaped second connecting plate linearly extended from the front end along the other two adjacent sides with a thickness half that of the main wall body. Moreover, there are several horizontal ducts and several vertical ducts provided in the main wall body both ducts in communication with one another. There are tapped holes formed respectively on the first and second connecting plates. There are two layers of metallic net intercalated in the main wall body between the corners of aforesaid horizontal and vertical ducts. There are provided several supporting frames disposed longitudinally and transversely in the main wall body at the outer side of the two metallic nets. One side of the first connecting plate of a partition wall unit is just able to joint with corresponding side of the second connecting plate of another partition wall unit.
In the present invention, a continuous wall panel can be formed by jointing side by side the plurality of aforesaid partition wall units. At least one steel hoop is provided around the circumference of the partition wall unit assembly to fasten the partition wall units jointed side by side in the three-dimensional spacing. The steel hoop consists of a rim band secured to the bottom edge of the space, and the rim band is outwardly bent in vertical direction to form an assembly frame which being facing to the first and second connecting plates of each partition wall unit.
With this structure, a continuous wall panel is formed by jointing side by side the first and second connecting plates of the adjacent partition wall units, and by combining and fastening the circumferential edge of each partition wall unit of the continuous wall with the steel hoop in the three-dimensional space. A closed partition space can be formed easily, promptly and firmly in a short time with a reduced cost.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following specifications and inspection of the accompanying drawings.
FIG. 1 is a perspective view of the partition wall unit of the present invention.
FIG. 2 is a fractional view of the partition wall unit of the present invention.
FIG. 3 is another fractional view of the partition wall unit of the present invention.
FIG. 4 is an exploded view of the metallic net and its supporting frame of the present invention.
FIG. 5 is a schematic view showing assembling of the present invention.
FIG. 6 is a perspective view showing the steel hoop of the present invention.
FIG. 6A is a fractional enlarged view of the steel hoop of the present invention.
FIG. 7 is a cross sectional view of two jointed partition wall unit.
FIG. 8 is a cross sectional view showing the structural relation between the partition wall unit and the steel hoop.
FIG. 9 and FIG. 10 are fractional cross sectional vies showing the partition wall unit is secured to the steel hoop by bolts and joint members.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now a preferred embodiment of the present invention will be described in detail with reference to the subjoined drawings.
Referring to FIGS. 1 , 2 , 3 , 5 and 8 , the present invention vertically divides the three-dimensional space with a plurality of partition wall units 1 and connects them side by side to form a continuous wall panel, and at least a steel hoop 2 is used to secure the continuous wall panel around its circumferential edge. Furthermore, a hoop bar 3 is filled into the gap between the steel hoop 2 and the partition wall units 1 .
As show in FIG. 1 through FIG. 4 , the partition all unit is composed of a main wall body 11 figured into a quadrilateral concrete structure, a L shaped first connecting plate 111 with a thickness half as that of the main wall body 11 is extended from its front end linearly along two adjacent sides; and another L shaped second connecting plate 112 with a thickness half as that of the main wall body 11 is extended from its front end linearly along other two adjacent sides. A first bond face 1111 and a second bond face 1121 are respectively formed in the inner sides of the first and second connecting plates 1111 and 1121 , wherein the two bond faces 1111 and 1121 are bonded together with their corresponding ends. There are several horizontal ducts 113 and vertical ducts 114 in communication one another are provided in the main wall body 11 . A tapped hole 4 is provided respectively on the first and second connecting plates 111 and 112 . There are two layers of metallic net 12 intercalated in the main wall body 11 between two corners of aforesaid horizontal and vertical ducts 113 and 114 . There are provided several supporting frames 13 , which being made of metal material approximately in C shape, disposed longitudinally and transversely in the main wall body 11 at the outer side of the two metallic nets 12 . One side of the first connecting plate 111 of a partition wall unit 1 is just able to joint with corresponding side of the second connecting plate 112 of another partition wall unit 1 .
As shown in FIGS. 5 , 6 and 6 A, the steel hoop 2 has a rim band 21 which can be secured to any one of the bottom, top and side of the space. The rim band 21 has a width slightly less than ½ that of the main wall body 11 , and several through holes 211 are provided on the rim band 21 . Furthermore, the rim band 21 is outwardly bent in vertical direction to from an assembly frame 22 which being facing to the first bond face 1111 of the first connecting plate 111 and the second bond face 1121 of the second connecting plate 112 , and several through holes 221 are provided on the assembly frame 22 each of them is aligned to the corresponding tapped hole 4 as shown in FIGS. 3 and 7 .
As shown in FIGS. 5 and 8 , the hoop bar 3 is made of concrete to be filled into the steel hoop 2 between its rim band 21 and assembly frame 22 , and an outer side of the hoop bar 3 is firmly secured to the main wall body 11 of the partition wall unit 1 . Besides, there are provided several tapped holes on the hoop bar 3 respectively aligning to the through holes 221 on the assembly frame 22 of the steel hoop 2 and the tapped holes 4 respectively formed on the first and second connecting plate 111 and 112 of each partition wall unit 1 .
As shown in FIGS. 1 , 2 , 6 A and 8 , each tapped hole 4 consists of an outer hole 41 and its coaxial smaller inner hole 42 , wherein the through hole 221 of the steel hoop 2 is aligned to the inner hole 42 . The inner hole 42 is configurated approximately into an elliptical shape so as to let a bolt member 5 pass through the tapped hole 4 and its corresponding through hole 221 with some allowance to adjust the position of the bolt member 5 such that the partition wall unit 1 , the steel hoop 2 , and the hoop bar 3 can be combined with a relevant tightness.
Referring again to FIG. 2 through FIG. 5 , FIGS. 6A , 7 , 9 and 10 , when in assembling, at first the steel hoop 2 is settled either on the bottom, top or side of the three-dimensional space with its rim band 21 leaning against the side of the space, and nail a joint member 6 (steel nail for example) through the through hole 211 on the rim band 21 .
Next, combining side by side the first bond face 1111 of the first connecting plate 111 and the second bond face 1121 of the second connecting plate 112 of the main wall body 11 selected from any two partition wall unit 1 . The structure is secured using the bolt members 5 to screw through the tapped holes 4 provided on the first and second connecting plates 111 and 112 so as to form a continuous wall panel combining the multiple numbers of partition wall units 1 . Afterwards, bonding the first bond face 1111 of the outer end first connecting plate 111 of the last partition wall unit 1 (or the second bond face 1121 of the second connecting plate 112 ) to the rear side of the assembly frame 22 of the steel hoop 2 set in the three dimensional space, and installing the hoop bar 3 in the steel hoop 2 between its rim band 21 and assembly frame 22 , and finally securing tightly the side of the continuous wall panel formed of partition wall units 1 with the steel hoop 2 and the hoop bar 3 using the bolt members 5 to screw into the tapped holes 4 on the first and second connecting plate 111 , 112 to pass through the through holes 221 provided on the assembly frame 22 of the steel hoop 2 and the tapped holes 4 of the hoop bar 3 thereby closing the entire three-dimensional space with a continuous wall panel formed of a plurality of partition wall units 1 mutually combined side by side.
The mission of utility power, gas and water supply to the building can be performed by the horizontal and vertical ducts 113 and 114 communicatively run in the continuous wall panel without any difficulty in maintenance when necessary.
It emerges from the description of the above example that the invention has several noteworthy advantages, in particular:
1. The partition wall units 1 can be easily assembled at the working site without the need of skilled workmen, so the cost is low.
2. The assembly work of the present invention is much easier and time and cost saving compared with the conventional partition work.
3. The utility power, gas and water supply can be performed by the horizontal and vertical ducts communicatively run in the continuous wall. No special installation is required which may have to break the wall surface.
4. The present invention is well applicable to industrious utilization because of its novelty, versatility and progressiveness.
Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. Various alternations and modifications will no doubt become apparent to those skilled in the art after reading the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alternations and modifications as fall within the true spirit and scope of the invention. | An assembly type wall structure is disclosed. The assembly type wall structure may be used as a vertical wall in an interior space and includes a plurality of wall units. Each wall units together to form a wall and may connect this wall with the corresponding ceiling, walls and floor of the interior space. Hence, the assembly type wall structure may be used as a vertical wall in an interior space and has the advantages of fast and simple implementation. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/244,958 filed Sep. 16, 2002 which in turn is a continuation in part of U.S. patent application Ser. No. 09/609,971 filed Jul. 3, 2000 and which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a system for use as transit boarding platform structures. In particular the present invention provides panels to replace pre-cast concrete panels or cast-in-place concrete panels typically used for transit boarding platforms. In a preferred embodiment, the panels of the present invention are formed of reinforced polymer composite materials and incorporate a non-slip walking surface for improved wear and slip resistance.
BACKGROUND OF THE INVENTION
[0003] Conventional concrete and wooden transit platforms have a durability problem due to degradation by environmental chemicals such as, salt, urea, acid rain, oils and greases as well as stray electrical currents. This necessitates regular maintenance and periodic replacement of the platforms at considerable cost to transit authorities. Replacement is further complicated with trains going by the platform every few minutes. Steel and concrete are also susceptible to corrosive elements, such as water, salt water and agents present in the environment such as acid rain, road salts, chemicals, oxygen and the like. Environmental exposure of concrete structures leads to pitting and spalling in concrete and thereby results in severe cracking and a significant decrease in strength in the concrete structure. Steel is likewise susceptible to corrosion, such as rust, by chemical attack. The rusting of steel weakens the steel, transferring tensile load to the concrete, thereby cracking the structure. The rusting of steel in stand alone applications requires ongoing maintenance, and after a period of time corrosion can result in failure of the structure. The planned life of steel structures is likewise reduced by rust. Wood, like concrete and steel, is also susceptible to environmental attack, especially rot from weather and termites. In such environments, wood encounters a drastic reduction in strength which compromises the integrity of the structure. Moreover, wood undergoes accelerated deterioration in structures in marine environments.
[0004] Concrete transit platforms are typically constructed with the concrete poured in situ as well as using some preformed components pre-cast into structural components such as supports and transported to the site of the construction. Constructing such concrete structures in situ requires hauling building materials and heavy equipment and pouring and casting the components on site. This process of construction involves a long construction time and is generally costly, time consuming, subject to delay due to weather and environmental conditions and the requirement not to disrupt the schedule of trains unduly.
[0005] On the other hand, pre-cast concrete structural components are extremely heavy and bulky. Therefore, they are also typically costly and difficult to transport to the site of construction due in part to their bulkiness and heavy weight. Although construction time is shortened as compared to poured in situ, extensive time, with resulting delays, is still a factor. Construction with such pre-cast forms is particularly difficult, if not impossible, in areas with difficult access or where the working area is severely restricted due to adjoining tracks, buildings or platforms. There is a need for a light weight structure to facilitate installation in areas which have difficult access and working area. In addition a lightweight structure could eliminate the costly concrete foundations and steel support systems necessary to support conventional concrete platforms.
[0006] There have been solutions proposed for preventing deterioration of steel and concrete bridge and roadway decks. For example U.S. Pat. No. 5,901,396 discloses the use of an aluminum bridge deck to provide light weight and durability. In addressing the limitations of existing concrete, wood and steel structures, some fiber reinforced polymer composite materials have been explored for use in constructing parts of bridges including foot traffic bridges, piers, and decks and hulls of some small vessels. Fiber reinforced polymers have been investigated for incorporation into foot bridges and some other structural uses such as houses, catwalks, and skyscraper towers. These composite materials have been utilized in conjunction with, and as an alternative to, steel, wood or concrete due to their high strength, light weight and highly corrosion resistant properties. However, construction of load bearing applications built with polymer matrix composite materials have not been widely implemented due to extremely high costs of materials, high assembly costs and uncertain performance, including doubts about long term durability and maintenance. As cost is significant in the public transit industry, such materials have not been considered feasible alternatives for many load bearing traffic designs. For example, high performance composites made with relatively expensive carbon fibers have frequently been eliminated by cost considerations.
[0007] U.S. Pat. No. 5,794,402 is directed to a polymer matrix composite modular load bearing deck as a part of a modular structural section for a highway bridge deck. The load bearing deck is formed from a plurality of sandwich panels, each panel having a flat upper surface, a lower surface and a core. The core includes a plurality of trapezoidal, substantially hollow, elongated core members positioned between the upper surface and the lower surface. Each core member has side walls positioned generally adjacent to a side wall of an adjacent core member and are joined together by fasteners, such as bolts and screws, or by adhesives. The assembly time required to fasten the deck together renders the cost prohibitive and impractical for use in a transit platform.
[0008] In public transit facilities, such as subway stations and railway stations, there is also a requirement for pedestrians to be able to safely navigate the platform. There is a need for pedestrians to get good traction on the platform to prevent slips and falls in particular on outdoor platforms that can be subject to wind, rain and snow conditions. In addition it is important for pedestrians to be able to detect the location of platform edges so that the pedestrian does not accidentally walk off the edge of the platform. The need for making platform edges detectable is of course particularly acute in attempting to make such facilities accessible and safe for blind or visually impaired persons.
[0009] In the 1980's a series of studies were undertaken in the United States to improve the design of buildings and transportation facilities to improve the mobility of the visually impaired. These studies culminated in recommendations on making potential hazards detectable to the visually impaired either by use of the long cane or underfoot.
[0010] Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities set the requirements for the use of detectable warnings on inter alia transit platforms to warn visually impaired persons of hazards. The Guidelines require that detectable warnings shall consist of raised truncated domes of prescribed diameter, height and center-to-center spacing and shall contrast visually with adjoining surfaces. Detectable warnings used on interior surfaces are required to differ from adjoining surfaces in resiliency or sound-on-cane contact. Various tactile tiles having raised truncated domes in compliance with the ADA Guidelines or the equivalent have been developed such as those shown in U.S. Pat. No. 4,715,743 and U.S. Pat. No. 5,303,669. Other tactile surfaces have been proposed such as the rubber on concrete composite tile illustrated in Netherlands Patent 8600855.
[0011] U.S. Pat. No. 5,303,669 describes a detectable tactile tile that is intended to be installed in concrete or the like. The tiles are illustrated as square with depending flanges projecting downward from the edge of the tile. The flanges have holes through them to assist in anchoring the tile in freshly poured concrete. The holes in the flanges around the perimeter of the tiles permit air to flow out from under the tiles when they are pressed into the concrete. However it is virtually impossible to remove all of the air and there is typically an air space between the bottom surface of the tile and the top of the cured concrete. When baggage carts, money carts with small wheels or heavy mechanical equipment either for cleaning, snow removal etc. passes over the tiles, there may be a tendency for the tiles to crack under the weight of the equipment, due to the air space between tiles and the concrete surface.
[0012] U.S. Pat. No. 5,775,835 provides a tactile tile for embedment in fresh concrete on a platform or walking surface. By anchoring the tiles with the concrete through holes in depending flanges the need for adhesives or mechanical fasteners which are labor intensive to install are eliminated or reduced. The bottom surface of the tile is provided with a series of projections. As the tile is being pushed into the concrete the projections assist in having the concrete flow underneath the tile and as the concrete cures and shrinks slightly the projections remain in contact with the cured surface of the concrete so that the tile is fully supported across its surface. During snow removal or cleaning, the tile will then support the weight of any heavy mechanical equipment and eliminate cracking of the tiles and their necessary replacement. As the fresh concrete cures, an air space forms between the bottom surface and the surface of the cured concrete. This air space prevents the load from equipment moved over the tiles from being transferred to the platform surface resulting in potential damage to the tiles. By incorporating the projections into the bottom surface the loads can be transferred to the platform or walkway surface through the conical standoffs. However the airspace between the concrete surface and the bottom surface is not eliminated resulting in a hollow sound when struck by the cane of a visually impaired person. This distinct sound-on-cane contact between the tiles and the adjoining concrete surface permits the tiles to be used indoors in compliance with the ADA Guidelines. Where the tiles are bonded by an adhesive or mechanically fastened directly to the concrete surface it may not be possible to get a distinctive sound-on-cane contact with a hard material of manufacture such as ceramic, glass reinforced thermosetting resin or vitrified polymer composite and softer resilient rubber or vinyl tiles must be used. In addition use of the projections increases the surface area of the tile that is in contact with the cured concrete which helps resist movement due to thermal expansion etc.
[0013] In conventional systems there is also a problem with drainage. Corrosive elements can penetrate past poorly installed or worn sealant joints leading to the deterioration of the steel support structure and concrete foundation.
SUMMARY OF THE INVENTION
[0014] It is an object of the invention to provide a transit boarding platform structures to replace pre-cast concrete panels or cast-in-place concrete panels typically used for transit boarding platforms.
[0015] It is a further object of the invention to provide transit platform panel formed of reinforced polymer composite materials and incorporating a detectable warning surface in accordance with Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities.
[0016] Thus in accordance with the present invention there is provided a transit platform panel comprising a base portion formed from a reinforced composite polymer. The base portion has a top deck and a bottom plate, a first end, a second end, a first side and second side. One or both of the first and second ends is adjacent the edge of the platform. Between the top deck and bottom plate are a series of internal support members. Where the panel comprises the width of the platform the support members are both longitudinal and cross members. In other applications only cross support members are required. The top deck is adapted to have a detectable surface along the first and/or second ends that are adjacent the edge of the platform. Where the panel is the width of the platform, the top deck has a central section and opposite end sections. Detectable warning tiles are mounted to the top surfaces of the end sections. In this application the top surface of the central section has a slip resistant surface. In the preferred embodiment the slip resistant surface consists of a non-slip walking surface coating applied to the top deck. The slip resistant coating should be resistant to the effects of ultraviolet radiation, temperature changes and corrosive elements such as acids, alkalis, salts, phosphates, organic chemicals and solvents such as mineral spirits, gasoline etc. It should also preferably be sufficiently hard to protect against abrasion, chipping, scratching or marring.
[0017] Positive drainage, where required, may provided by the top deck being symmetrical about the mid-point line tapering from the mid-point to the ends of the panel to facilitate runoff of any precipitation and prevent standing pools of water. Positive drainage can further be provided by the interface between adjacent panels utilizing a ship lap configuration with a drainage channel beneath the joint between adjacent panels.
[0018] In another embodiment the present invention provides a transit boarding platform panel for use along the edge of an existing transit platform adjacent a track. The panel comprises a molded base portion formed from a reinforced composite polymer. The base portion has a top deck and bottom plate, a first side intended to be adjacent a track at an edge of the transit platform, a second side opposite said first side and intended to be adjacent the existing transit platform, first end and second side, and between the top deck and bottom plate a series of internal support members. The top deck, bottom plate, first and second sides, first end, second end and series of internal support members are preferably molded at the same time to form an integral unit. The top deck has a detectable warning surface consisting of raised truncated domes detectable by the visually impaired in accordance with Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities. The first side of the panel has a first vertical wall section extending from the top deck and having a top edge and a base. A horizontal flange having inner and outer edges extends inwardly from the base of the first vertical wall section. A second vertical wall section depends from the inner edge of the flange and connects to an outer edge of the bottom plate of the panel. Means to protect the panel from damage are located along the second vertical wall section.
[0019] Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order that the invention may be more clearly understood, the preferred embodiments will now be described in detail by way of example, with reference to the accompanying drawings, in which:
[0021] FIG. 1 is a perspective view of one embodiment of a transit boarding platform panel according to the present invention.
[0022] FIG. 2 is a top plan view of the transit boarding platform panel of FIG. 1 showing the position of the internal longitudinal and cross support members in dotted lines.
[0023] FIG. 3 is a schematic cross section of the transit boarding platform panel of FIG. 2 through line 3 - 3 .
[0024] FIG. 4 is an enlarged cross section of the transit boarding platform panel of FIG. 2 along line 4 - 4 and showing adjacent panels.
[0025] FIG. 5 is an enlarged view of one end of the transit boarding platform panel of FIGS. 2 and 3 showing the means of connection to an underlying support.
[0026] FIG. 6 is an enlarged view of the means of connection to an underlying support shown in FIG. 5 .
[0027] FIG. 7 is an enlarged view in cross section of a top corner of the transit boarding platform panel of FIG. 2 ; and
[0028] FIG. 8 is an enlarged view in cross section of part of the top surface of the transit boarding platform panel of FIG. 2 showing the interface between the detectable tactile surface and the granite wearing surface in the preferred embodiment.
[0029] FIG. 9 is a top plan view of another embodiment of a transit boarding platform panel according to the present invention.
[0030] FIG. 10 is an enlarged schematic cross section of the transit boarding platform panel of FIG. 9 through line 10 - 10 .
[0031] FIG. 11 is a schematic cross section of the transit boarding platform panel of FIG. 9 through line 11 - 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring to FIGS. 1 to 4 a preferred embodiment of transit boarding platform panel according to the present invention is generally indicated at 1 . In the preferred embodiment illustrated the panel 1 comprises a base portion 2 formed from a reinforced composite polymer. The base portion 2 has top deck 3 and bottom plate 4 , a first end 5 , a second end 6 , a first side 7 and second side 8 . Between the top deck 3 and bottom plate 4 are a series of internal longitudinal and cross support members 9 and 10 respectively.
[0033] The top deck 3 has a central section 11 and end sections 12 and 13 . Detectable warning tiles 14 are mounted to the top surfaces 15 and 16 of end sections 12 and 13 . The top surface 17 of the central section 11 has a slip resistant coating 18 applied to it. In the preferred embodiment the slip resistant coating 18 consists of a non-slip monolithic walking surface. The slip resistant coating should be resistant to the effects of ultraviolet radiation, temperature changes and corrosive elements such as acids, alkalis, salts, phosphates, organic chemicals and solvents such as mineral spirits, gasoline etc. It should also preferably be sufficiently hard to protect against abrasion, chipping, scratching or marring. A suitable coating is the Diamond Tek™ coating system from Engineered Plastics Inc. of Buffalo, N.Y. The Diamond Tek™ coating can be sprayed on to the top deck 3 of the panel 1 and then fusion bonded. The coating 18 has a depth of about 0.1875 inches.
[0034] The detectable warning tiles 14 are similar to the tiles described in U.S. Pat. No. 5,303,669. The tiles, shown in FIGS. 1, 2 , 5 , 7 and 8 , have a horizontal portion 50 adapted to overlie the top surfaces 15 and 16 of the end sections 12 and 13 of the top deck 3 of panel 1 up to the first and second ends 5 and 6 , and rear and front edges 51 and 52 respectively, the “front” edge being the one remote from the ends 5 and 6 of panel 1 .
[0035] The surface of the horizontal portion 50 has plurality of rows of spaced buttons 53 projecting upwardly therefrom, thereby providing a distinctively textured surface relative to the texture of the surface of the platform. As can be seen in FIGS. 1 and 2 , the buttons preferably are circular. Buttons in adjacent rows are offset from each other by one-half of the centerline spacing distance. The buttons 53 have generally flat upper surfaces which have texturing means thereon for creating a palpably rough surface texture. The texturing means in the preferred embodiment is provided by rows of semi-spherical raised dimples arranged in a grid pattern.
[0036] The areas between buttons preferably also have texturing means consisting of a plurality of rows of spaced dimples projecting upwardly therefrom, to provide slip resistance in those areas (e.g. for women in high heels and to improve maneuverability of wheelchairs).
[0037] Each tile preferably is the entire width of the panel to avoid the need for joints between tiles. The tiles preferably are bonded to the top surface of the end section by the use of a suitable adhesive, such as “Bostic Ultra-Set” (trademark) urethane adhesive. However, for added security, the tiles can also be mechanically fastened to the top deck.
[0038] To reduce the possibility of tripping, the height of the buttons in one or more rows adjacent the front edge 52 is reduced in height and diameter relative to the height and diameter of buttons in subsequent rows, so that there is a gradual increase in height and diameter. Thus in the preferred embodiment the buttons in the first row adjacent the front edge 52 are only about one-third as high as the other buttons and the buttons in the second row are only about two-thirds as high as the other buttons. Similarly the buttons in the first row have a diameter about 12% less than the other buttons and the buttons in the second row have a diameter about 3% less than the rest of the buttons.
[0039] The tiles 14 preferably have an integral depending flange 55 , best seen in FIGS. 5 and 7 , adapted to overlie the first and second ends 5 and 6 of the panel and thereby facilitate holding the tile in place. Preferably, an adhesive such as “Bostik Ultra-Set” (trademark) urethane adhesive is used to secure the flange 55 to the ends 5 and 6 . The adhesive may be augmented by or replaced by mechanical fastening means. To facilitate a smooth mounting of the tiles the first and seconds 5 and 6 have their top portion 20 offset from the remaining height 21 of the ends 5 , 6 , the thickness of the depending flange 55 of the tiles 14 . The top portion 20 is the length of the depending flange 55 .
[0040] The tiles can be made of vinyl, rubber, urethane, ceramic or cast composite materials or the like. The edging tile is preferably made entirely of yellow thermoset glass-reinforced plastic composite material having the textured surface pattern as described. In addition, a micro-thin film may be applied to the upper surface if desired, to provide enhanced abrasion resistance characteristics. Because the entire tile preferably is brightly colored, it serves to visually alert sighted and visually impaired pedestrians of the vicinity of the subway platform edge. The textured surface provides a tactile signal as well, which is particularly important for the visually impaired. The buttons can be felt through most if not all footwear, and can also be readily detected by a “white cane” of the type frequently used by the blind or visually impaired. Certain types of conventional canes can detect the buttons very readily, while types may pass between the buttons and can readily detect the dimples in the areas between buttons. It is therefore preferable to have these dimples in the areas between buttons, and not just on the surface of the buttons themselves.
[0041] As an alternative to a single bright color, a scheme of alternating contrasting colors could be used to create a distinctive pattern, if desired.
[0042] It will be appreciated that a wide range of dimensions may be suitable for the edging tile and for the buttons. However, in the embodiment of the tile shown in the Figures, for example, key dimensions are as follows:
Forward to rear dimension: 24.00 inches Tile width: 47.75 inches Tile thickness: 0.100 inches Button diameter (base): .325 inches Button diameter (top): 0.875 inches Button height (excluding dimples): 0.200 inches Button height (first row from front): 0.066 inches Button height (second row 0.132 inches Spacing of buttons in the same row: 2.800 inches (centerline to centerline): Spacing of rows (centerline to 1.400 inches centerline):
[0043] It will be appreciated that the dimensions can be varied widely subject to the ADA Guidelines, as desired to suit the particular application.
[0044] As best shown in FIGS. 5 and 8 , the top surface 17 of the central section 11 is recessed from the top surfaces 15 , 16 of end sections 12 and 13 so that the top surface 56 of the tile 14 adjacent its front edge 51 will be flush with the top surface 19 of coating 18 . As an alternative to applying the slip resistant coating in the preferred embodiment, the top surface 17 can be flush with the top surface 56 of tiles 14 and a slip resistant surface integrated into the top deck using a grid work of raised dimples etc. Alternatively the surface 17 of the central section 11 of the top deck can be finished with a vinyl, rubber, urethane, ceramic or cast composite materials or the like to provide the desired slip resistance. The minimum friction value established by the ADA guidelines is 0.6 for accessible routes. The preferred embodiment of the present invention exhibits both wet and dry coefficients of friction close to 1.00 exceeding the minimums required. In addition use of the Diamond Tek coating system resulted in abrasion values well above granite floor tiles.
[0045] The panel 1 of the preferred embodiment shown in the drawings has nominal dimensions of 15 feet long by about 4 feet in width. The base section 2 has a nominal thickness of between 8 inches at the first and second ends 5 , 6 and 10 inches along the mid point line 22 of the panel. The top deck 3 is typically symmetrical about the mid-point line tapering from the mid-point to the ends 5 , 6 to facilitate runoff of any precipitation and prevent standing pools of water. The weight of the preferred embodiment is about 480 lbs., about one-tenth the weight of standard precast concrete panels currently in use. The panels of the present invention were tested for vibration and load to test the ability of the panel to withstand the uplifting forces caused by passing rail traffic and the load bearing characteristics of the panel. Vibration tests on the preferred embodiment indicated vibration amplitudes below the human threshold of perception and comparable to results for precast concrete platforms.
[0046] With reference to FIG. 4 , the interface between adjacent panels 1 utilizes a ship lap configuration. The first side 7 of base section 2 has a top section 42 having a first vertical wall section 23 extending from the top deck 3 . A horizontal flange 24 extends outwardly from the base 25 of the vertical wall section 23 . A second vertical wall section 26 extends upwards from the exterior edge 27 of flange 25 . Extending outwardly from the top 29 of the second vertical wall section 26 is a second flange 30 . This effectively creates a drainage channel 28 beneath the joint between adjacent panels. The bottom section 43 of side 7 has third vertical wall section 31 that depends from the outer edge 32 of the second flange 30 and connects to the edge 33 of bottom plate 4 .
[0047] The other side 8 of the base section 2 has a top section 40 having a first vertical wall section 34 extending from the top deck 3 . A horizontal flange 35 extends inwardly from the base 36 of the vertical wall section 34 . The bottom section 41 of side 8 has a second vertical wall section 37 depends from the inner edge 38 of the flange 35 and connects to the edge 39 of bottom plate 4 . As can be seen in FIG. 4 , the top section 40 of second side 8 of one panel overlays the bottom section 43 of side 7 of the adjacent panel. The joint 44 between adjacent panels is sealed preferably with a urethane sealant to prevent moisture from getting between the panels and possibly corroding the support structure. The drainage channel 28 will collect and direct to the edge of the platform any moisture that does manage to penetrate the sealant or if the sealant is damaged by weather or environmental conditions. As shown in FIG. 5 one or more drip holes 45 can be provided in the bottom plate 4 to eliminate any moisture or condensation from within the base section 2 .
[0048] The panel 1 can be attached to support columns, generally indicated at 46 , provided to support the platform. The support columns 46 typically comprise a concrete footing 47 on which a metal I-beam 48 is mounted. The I-beams 48 are usually arranged to support adjacent panels along the length of the platform. To facilitate connection to the I-beam 48 , panel 1 is provided with Z clip mounting brackets 49 . A metal channel 57 is bonded to the inside 58 of bottom plate 4 . Additional support haunches can be provided in the bottom plate if required. The Z clip bracket 49 is connected to channel 57 by machine screws 59 that go into threaded holes 60 in the channel 57 . The Z clips 49 , channel 57 and screws 59 are preferably stainless steel to resist corrosion. Testing of the panel indicated that the connection clips can withstand a 6000 lb uplift force with minimal 0.01 and 0.03 inches permanent deformation of the clip connection. This is more than adequate to withstand the uplift forces generated by high speed trains.
[0049] The base section 2 including the internal longitudinal and cross support members 9 , 10 are formed of a polymer matrix composite comprising reinforcing fibers and a polymer resin to provide light weight and durability. Suitable reinforcing fibers include glass fibers, including but not limited to E-glass and S-glass, as well as carbon, metal, high modulus organic fibers (e.g., aromatic polyamides, polybenzamidazoles, and aromatic polyimides), and other organic fibers (e.g., polyethylene and nylon). Blends and hybrids of the various fibers can be used. Other suitable composite materials could be utilized including whiskers and fibers such as boron, aluminum silicate and basalt.
[0050] The resin material in the base section 2 is preferably a thermosetting resin, and more preferably a vinyl ester resin. The term “thermosetting” as used herein refers to resins which irreversibly solidify or “set” when completely cured. Useful thermosetting resins include unsaturated polyester resins, phenolic resins, vinyl ester resins, polyurethanes, and the like, and mixtures and blends thereof. The thermosetting resins useful in the present invention may be used alone or mixed with other thermosetting or thermoplastic resins. Exemplary other thermosetting resins include epoxies. Exemplary thermoplastic resins include polyvinylacetate, styrene-butadiene copolymers, polymethylmethacrylate, polystyrene, cellulose acetatebutyrate, saturated polyesters, urethane-extended saturated polyesters, methacrylate copolymers and the like.
[0051] Polymer matrix composites can, through the selective mixing and orientation of fibers, resins and material forms, be tailored to provide mechanical properties as needed. These polymer matrix composite materials possess high specific strength, high specific stiffness and excellent corrosion resistance. Polymer matrix composite materials, such as a fiber reinforced polymer formed of E-glass and a vinylester resin have exceptionally high strength, good electrical resistivity, weather and corrosion-resistance, low thermal conductivity, and low flammability.
[0052] The panels of FIGS. 1 to 8 can be fabricated by hand lay-up or other suitable methods including resin transfer molding (RTM), vacuum curing and filament winding, automated layup methods and other methods known to one of skill in the art of composite fabrication and are therefore not described in detail herein. Pultrusion fabrication is not an option where the top deck of the panel is formed with a taper from its midpoint as shown in the Figures.
[0053] A preferred method of making the panels of the present invention involves the use of vacuum assisted resin transfer injection. The process in general involves first laying down a plurality of glass sheets in a mould. The mould is typically a maximum of 4 to 5 feet wide and up to 15 to 20 feet long. Glass wrapped blocks of foam are then placed on top of the glass sheets. The space between the wrapped foam blocks forms the internal longitudinal and horizontal support members and the space to the edge of the mould forms the side and end walls of the panel. The top surface of the foam blocks are shaped to provide the taper over the length of the panels. If required tubes can be inserted into the mould to form raceways for electrical, plumbing or heating elements that may be desired to run along the platform. In addition if there are obstructions such as lamp posts on the platform, these can accommodated in the moulding process by framing around the space for the obstruction. Glass sheets are then placed on top of the foam blocks and the lid of the mould closed. A vacuum is applied to the mould to assist as the resin is injected into the mould. After the panel is removed from the mould, the area provided for any obstructions can be cut out in the panel and the foam is not exposed The result is a one piece panel fully completed in about one hour. This is substantial less time than to form the panel using pultrusions that are individually fastened together with bolts, screws or adhesives.
[0054] The panels of the present invention solve the problem of durability and premature breakdown of concrete and wood platforms due to degradation by environmental chemicals such as, salt, urea, acid rain, oil, greases as well as stray electrical currents. The light weight of the panels facilitates ease of installation in areas which have difficult access and work windows. The panels of the present invention also solve the problem of dealing with heavy concrete platforms (ten times heavier than the present invention) which necessitate the use of costly foundations and steel support systems. These benefits apply to both new and retrofit construction requirements. The panels of the present invention also solve a problem caused by joint expansion and degradation of seal integrity between panels with the provision of positive drainage channels. The drainage channels eliminate corrosive elements penetrating the joint past poorly installed or worn sealant joints which leads to the deterioration of the steel and or concrete structure and foundation. Reduced maintenance and long life cycles are achieved.
[0055] Typically the panels of the present invention sit on the grade and don't require the delay required for concrete to cure before they are ready to use. In addition, because the panels are formed to accommodate the detectable tiles there is not need to grind the deck to accommodate them as in the case of poured in place concrete platforms. The light weight of the panels also enables them to be used on elevated platforms typically using existing structural supports. Assembly of a typical platform installation using the panels of the present invention is completed within a few days as opposed to a number of weeks using other methods.
[0056] FIGS. 9 to 11 , illustrate another embodiment of a panel for use with a transit platform according the present invention is generally indicated at 100 . The panel 100 is suitable for use with the retrofit of an existing platform 98 as opposed to the replacement of the entire platform. The panel 100 is designed to fit along the edges 99 of the existing platform 98 adjacent the track (not shown). In the preferred embodiment illustrated the panel 100 is formed from a reinforced composite polymer comprising reinforcing fibers and a polymer resin to provide light weight and durability. The panel 100 has top deck 103 and bottom plate 104 , a first end 105 , a second end 106 , a first side 107 and second side 108 . Between the top deck 103 and bottom plate 104 are a series of internal cross support members 109 .
[0057] The top deck 103 has detectable warning tiles 110 mounted to or formed integrally with the top surface 111 of the top deck 103 .
[0058] The detectable warning tiles 111 are similar to the tiles described in previously. The surface 112 of the tiles 110 has plurality of rows of spaced buttons 113 projecting upwardly there from, thereby providing a distinctively textured surface relative to the texture of the surface of the platform. As can be seen in FIGS. 9 and 10 , the buttons preferably are circular. Buttons in adjacent rows are offset from each other by one-half of the centerline spacing distance. The buttons 113 have generally flat upper surfaces which have texturing means thereon for creating a palpably rough surface texture. The texturing means in the preferred embodiment is provided by rows of semi-spherical raised dimples arranged in a grid pattern.
[0059] The areas between buttons preferably also have texturing means consisting of a plurality of rows of spaced dimples projecting upwardly there from, to provide slip resistance in those areas (e.g. for women in high heels and to improve maneuverability of wheelchairs).
[0060] To reduce the possibility of tripping, the height of the buttons in one or more rows adjacent the side 107 of panel 100 is reduced in height and diameter relative to the height and diameter of buttons in subsequent rows, so that there is a gradual increase in height and diameter. Thus in the preferred embodiment the buttons in the first row adjacent the side 107 of panel 100 are only about one-third as high as the other buttons and the buttons in the second row are only about two-thirds as high as the other buttons. Similarly the buttons in the first row have a diameter about 12% less than the other buttons and the buttons in the second row have a diameter about 3% less than the rest of the buttons.
[0061] The side 108 of the panel 100 adjacent the track, in the embodiment shown, is adapted to receive means to protect the panel 100 from damage. In the embodiment shown, side 108 of panel 100 has a first vertical wall section 116 extending from the top deck 103 . A horizontal flange 117 extends inwardly from the base 118 of the vertical wall section 116 . A second vertical wall section 119 depends from the inner edge 120 of the flange 117 and connects to the edge 121 of bottom plate 104 . The means to protect the panel 100 comprises a plurality of bumpers 122 fastened to the second wall section 119 . Bumpers 122 are of sufficient thickness that they extend past the base 118 of the first vertical wall section 116 and in the preferred embodiment is a single bumper the length of the panel and formed of polypropylene. The bumpers 122 are fastened to the panel 100 by means of bolts 123 that thread into plates 124 embedded in panel 100 .
[0062] The side 107 of panel 107 , in the embodiment shown, is adapted to provide a visual and sound contrast to the top deck 103 of panel 100 that is preferably made of yellow thermoset glass-reinforced plastic composite material. In the embodiment shown a black granite strip 125 is integrated with the panel 100 to provide a visual and cane-on-contact sound contrast to both panel 100 and the surrounding platform surface 126 A which is typically poured in place concrete or pavers.
[0063] As noted earlier panel 100 is typically utilized in a retrofit application to an existing platform. To install the panel 100 , leveling bolts 126 are fastened to the bottom plate 104 by threading into reinforcing plates 127 formed into panel 100 . The leveling bolts 126 are used to level the panel 100 on the surface 128 of the existing platform 98 on which the panel is being installed. Threaded rods 129 are inserted through tubes 130 in the panel 100 and screwed into the existing platform 98 . To provide additional stability and support a grout bed 131 can be placed on the existing platform surface beneath the bottom plate 104 . Alternatively two of the rods 129 can be inserted through holes in the granite strip 125 to fasten the second end 107 of panel 100 to the platform.
[0064] At the end 107 of the panel 100 remote from the edge 99 of the platform 98 , the space between the panel 100 and the platform is filled with material to prevent moisture from penetrating the seam. In the embodiment shown a premolded joint filler 132 is inserted into the joint 133 . A closed cell foam backer rod 134 is inserted next and then topped off with a self leveling urethane sealant 135 .
[0065] A cap 136 is bonded with a structural adhesive over the rods 129 .
[0066] It will be appreciated that a wide range of dimensions may be suitable for the panel 100 . The panel 100 of the preferred embodiment shown in the drawings has nominal dimensions of 10 feet long by about 2 feet 4 inches in width. The panel has a nominal thickness of 6.5 inches and the panel plus leveling blots have a nominal height of 8 inches. The weight of the preferred embodiment is substantially less than the weight of standard precast concrete panels currently in use. Accordingly they can be used on elevated platforms typically using existing structural supports. Assembly of a typical platform installation using the panels of the present invention is completed within a few days as opposed to a number of weeks using other methods. The panels of the present invention were tested for vibration and load to test the ability of the panel to withstand the uplifting forces caused by passing rail traffic and the load bearing characteristics of the panel. Vibration tests on the preferred embodiment indicated vibration amplitudes below the human threshold of perception and comparable to results for precast concrete platforms.
[0067] Having illustrated and described a preferred embodiment of the invention and certain possible modifications thereto, it should be apparent to those of ordinary skill in the art that the invention permits of further modification in arrangement and detail. Variations in design are possible due to the flexibility and relative low cost of tooling used in the manufacturing process. Panel size, length, width, thickness, color, ribbing and surface profiles can be modified to suit specific project requirements. Drainage details can be modified to suit specific project requirements. Additional benefits of the present invention are the improved ability for the system to incorporate heat tracing systems for cold climates and electrical raceways for lighting and communication systems which can be integral to the panel. All such modifications are covered by the scope of the invention. | The present invention relates to a transit boarding platform panel for use along the edge of an existing transit platform adjacent a track. The panel comprises a molded base portion formed from a reinforced composite polymer. The base portion has a top deck and bottom plate, a first side intended to be adjacent a track at an edge of the transit platform, a second side opposite said first side and intended to be adjacent the existing transit platform, first end and second side, and between the top deck and bottom plate a series of internal support members. The top deck, bottom plate, first and second sides, first end, second end and series of internal support members are preferably molded at the same time to form an integral unit. The top deck has a detectable warning surface consisting of raised truncated domes detectable by the visually impaired in accordance with Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities. The first side of the panel has a first vertical wall section extending from the top deck and having a top edge and a base. A horizontal flange having inner and outer edges extends inwardly from the base of the first vertical wall section. A second vertical wall section depends from the inner edge of the flange and connects to an outer edge of the bottom plate of the panel. Apparatus to protect the panel from damage are located along the second vertical wall section. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for completing, providing sand control and/or fracturing a subterranean well in a single trip, and more particularly, to the use of one or more perforating gun assemblies positioned within a screen assembly to permit perforation of a well and formation while fluid in the well bore is pressured to an predetermined condition, such as an overbalanced condition, and proppant is subsequently placed in the well without removal of the assemblies.
2. Description of Related Art
Production of unconsolidated materials, e.g. sand and other fines, from subterranean formations into wells is problematic. Left unabated, continued production of such unconsolidated materials can result in erosion of production equipment, well plugging, and/or reduced or complete loss of fluid production from a well. Thus, it is conventional practice to control the production of unconsolidated materials into many subterranean wells. Where the subterranean formation is composed of relatively hard, consolidated material and fracturing operations are performed so as to enhance fluid communication with the well, conventional practice is to control the flow of proppant that is utilized in the fracturing operations back into the well thereby ensuring that the fractures remained propped open.
In accordance with the most commonly practiced technique, “gravel packing”, a tubular liner is positioned in the well bore and a proppant gravel is placed in the annulus between the liner and the well bore. Gravel is commonly mixed with the fluid, such as a liquid or foam, to form a slurry which is pumped through a work string and a crossover tool into the annulus between the well bore and the liner. The slurry flows down the annulus to the bottom of the well bore or to a sump packer in the well bore. Some of the fluid of the slurry flows through the apertures in the liner into the open bottom end of a wash pipe situated within the liner and returns to the surface through the crossover tool and the annulus between the work string and the well casing. The bulk of the slurry fluid flows into the subterranean zone through perforations in the well bore. Gravel is thus deposited in the annulus and against the subterranean zone. The liner has slots or other apertures in its walls which are smaller in size than the gravel particles, thereby permitting formation fluids to flow through the slots while preventing entry of any unconsolidated materials. Gravel packing operations are typically performed at pressures below the formation fracture gradient, and the primary design considerations are placement of proppant inside perforation tunnels and in the annulus between the well bore and liner. The small apertures may be provided by a screen encircling the outer circumference of the liner tube, in which case the openings in the tube may be larger than the gravel particles. As a result of improved technology, gravel packs have become quite effective in excluding sand from oil and gas production. In addition to this function, the gravel also assists in supporting the walls of uncased wells and preventing caving of loose material against the liner. Despite the effectiveness of gravel packs once they are properly placed and operating, the procedure often results in undesirable completion skins or damage to the walls of the well bore which reduce the flow of formation fluids into a well.
In accordance with a relatively recent technique of completing well bores while practicing sand control termed “frac packing”, the unconsolidated formation is fractured and propping material is deposited in the fracture. Typically, a completion fluid of sufficient density for pressure control is first placed in a cased well, the cased well is perforated adjacent the subterranean zone or formation of interest. The perforating equipment is then removed from the well and a separate trip is required to place sand control equipment in the well adjacent the perforations. A fracturing fluid having proppant material incorporated therein is pumped, with the sand control equipment in place, at a sufficiently high pressure to propagate a fracture into the subterranean formation. The proppant materials within the fracturing fluid are deposited in the resulting fracture(s). While several variations of this process are practiced, the steps set forth above are employed to complete a given frac pack operation. However, significant costs are incurred with the material, equipment and time necessary to perform this series of operations.
The problems associated with conventional frac packing operations have spawned significant interest in reducing fluid costs, in developing simplified equipment and methods for minimizing the number of trips necessary to deploy equipment in the well and in eliminating the use of a rig at the surface of the earth. Methods and apparatus have been recently developed that allow perforating operations and screen placement to be performed in a single trip. U.S. Pat. No. 5,722,490 discloses a method of completing and hydraulically fracturing a well wherein a tubing conveyed perforating gun assembly is attached below a gravel pack screen. The perforating gun assembly is lowered to a depth opposite a productive zone and activated. The perforating gun assembly may be designed to be released from the tubing and fall to the bottom of the well after firing. The tubing string is then lowered to place the gravel pack screen opposite at least one of the perforations formed. Hydraulic fracturing operations are subsequently performed. However, this method still requires intervention with a rig to perform operations for positioning, perforating, setting of packer(s), etc. that are necessary to accomplish the method. Accordingly, a need still exists for a cost effective method for providing the stimulation benefits of a frac pack method together with sand control without necessarily requiring the use of a rig at the surface of the earth.
Methods have also recently been developed for exerting extreme pressures on a subterranean formation instantaneously with perforating the well casing so as to clean the perforation tunnels that are formed and to generate near-wellbore fractures to connect with existing natural fractures in the formation. U.S. Pat. No. 5,131,472 discloses such a method and provides for non-mechanical sand control by use of resin coated sand. However, a need exists for performing an overbalanced perforating operation while utilizing mechanical means and methods to provide for increased sand control, decreased time and costs and increased safety.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, one characterization of the present invention may comprise a process for completing a well is provided which comprises positioning at least one explosive charge juxtaposed to a screen that is positioned in a well and detonating the at least one explosive charge.
In another characterization of the present invention, a process is provided for completing a subterranean well which comprises securing at least one explosive charge radially juxtaposed to a screen, positioning the screen and the at least one explosive charge in a subterranean well adjacent a subterranean formation, and detonating the at least one explosive charge thereby perforating the subterranean formation.
In yet another characterization of the present invention, a one trip well process is provided for fracturing a subterranean formation and for completing a well penetrating the formation. The one trip process comprises pressuring fluid present in a subterranean well to an predetermined condition and forming perforations in the well while a screen assembly is present in the well adjacent a subterranean formation, the fluid causing said formation to fracture.
In still another characterization of the present invention, a one trip well process for fracturing a subterranean formation and for completing a well penetrating the formation is provided. The process comprises pressuring fluid present in a subterranean well to an overbalanced condition and forming perforations in the well, said fluid causing said formation to fracture. A slurry of gravel is injected into an annulus defined between the well and the screen assembly thereby packing the perforations with the gravel and forming a gravel pack in the annulus.
In a still further characterization of the present invention, a one trip process for completing a well is provided which comprises securing at least one perforating gun assembly in a juxtaposed relationship to a screen assembly, positioning the at least one perforating gun assembly and the screen assembly in a well adjacent a subterranean formation, and pressurizing fluid in the well to an overbalanced condition thereby detonating the at least one perforating gun assembly so as to form perforations in the subterranean formation. The pressured fluid fractures the formation via the perforations.
In a still further characterization of the present invention, a well completion assembly is provided which comprises a screen assembly having at least one aperture, at least one perforating gun assembly having at least one explosive charge, and a pressure activated firing assembly connected to the at least one perforating gun assembly. The at least one perforating gun assembly is positioned within the aperture and secured to the screen assembly such that each of said at least one explosive charge is aimed through said at least one aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a partial cross sectional view of one embodiment of the assembly of the present invention;
FIG. 1A is a cross sectional view of a pressure firing head assembly that may be utilized in conjunction with the assembly and process of the present invention that is illustrated in FIG. 1 ;
FIG. 2 is a partially cutaway view of one embodiment of a screen assembly used in the assembly and process of the present invention;
FIG. 2A is a partially cutaway view of the embodiment of a screen assembly illustrated in FIG. 2 which has been rotated to illustrate apertures in the perforating charge carrier;
FIG. 2B is a cross sectional view of the embodiment of a screen assembly taken along line 2 B— 2 B in FIG. 2 ;
FIG. 3 is a partially cutaway view of another embodiment of a screen assembly used in the assembly and process of the present invention;
FIG. 3A is a partially cutaway view of the embodiment of a screen assembly illustrated in FIG. 3 which has been rotated to illustrate apertures in the perforating charge carrier;
FIG. 3B is a cross sectional view of the embodiment of a screen assembly taken along line 3 B— 3 B in FIG. 3 ;
FIG. 4 is a partial cross sectioned, perspective view of one embodiment of the assembly of the present invention as positioned adjacent a subterranean formation of interest;
FIG. 5 is a partial cross sectioned, perspective view of another embodiment of the assembly of the present invention as positioned adjacent a subterranean formation of interest;
FIG. 6 is a partial cross sectioned, perspective view of yet another embodiment of the assembly of the present invention as positioned adjacent a subterranean formation of interest;
FIG. 7 is a cross sectional view taken through a screen assembly utilized in conjunction with the assembly and process of the present invention wherein two perforating charge carriers are positioned within the screen assembly;
FIG. 8 is a cross sectional view taken through a screen assembly utilized in conjunction with the assembly and process of the present invention wherein three perforating charge carriers are positioned within the screen assembly;
FIG. 9 is a cross sectional view taken through another embodiment of a screen assembly utilized in conjunction with the assembly and process of the present invention wherein at least one perforating gun assembly is positioned within a housing that is secured to a half pipe configured screen assembly; and
FIG. 10 is a cross sectional view taken through a further embodiment of a screen assembly utilized in conjunction with the assembly and process of the present invention wherein at least one perforating gun assembly is positioned outside of and secured to a screen assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the assembly of the present invention is illustrated generally as 10 in FIG. 1 . Assembly 10 is comprised of a perforating gun assembly 20 and a firing assembly 40 secured to each other and positioned within a screen assembly 50 that is secured to the end of a tubular 90 . Perforating gun assembly, as illustrated, is comprised of a sub 24 , a perforating charge carrier 26 and a bull plug 28 . One end of the perforating charge carrier 26 is attached to sub 24 by any suitable means, such as by screw threads 25 . A pair of O-rings 33 provide a fluid tight seal between carrier 26 and sub 24 . The other end of perforating charge carrier 26 is attached to bull plug 28 by any means, such as screw threads 27 and O-rings 29 which provide a fluid tight seal therebetween. Charge carrier 26 and perforating charge tube 30 are generally tubular. Perforating charge tube 30 is designed to be aligned as positioned inside perforating charge carrier 26 so that the large ends 38 of charges 34 are adjacent scallops 32 formed in the exterior of perforating charge carrier 26 . As illustrated, openings 31 in the wall of charge tube 30 are positioned generally linear along axis of the tube. Although charges 34 are preferably lined charges, any other equivalent charge, explosive or bullet known to those skilled in the art as useful in perforating casing and/or a subterranean formation may be utilized in the assembly and process of the present invention. The charge, explosive or bullet may be designed to produce any suitably configured perforation or hole in the casing and/or subterranean formation, such as round, oblong, linear, etc. A detonating cord 35 is connected to the firing assembly 40 above sub 24 , to the small end 35 of each perforating charge 34 , and to an aluminum or rubber closure 39 in bull plug 28 . Where another gun assembly 20 is threaded onto the perforating charge carrier 26 in lieu of bull plug 28 , reference numeral 39 would refer to a booster transfer as will be evident to a skilled artisan.
Any suitable detonating system known to those skilled in the art may be used in the assembly and process of the present invention. The detonating system may be electrical or mechanical, may be used in conjunction with a timer, and may be initiated by fluid pressure (gas or liquid), electrical current, and/or any other suitable means, such as electromagnetic or acoustic signals as will be evident to a skilled artisan. An example of a detonating system suitable for use with the assembly of the present invention is illustrated in FIG. 1A. A vent 42 is provided in one end of vent housing 41 while the other end of vent housing is secured to a firing head 70 by any suitable means, such as by screw threads 71 and O-rings 72 to provide a fluid tight seal there between. A piston 43 is positioned within housing 41 and is releasably secured therein by means of shear pins 44 . O-rings 45 provide a fluid tight seal between piston 43 and housing 41 . An annular chamber 46 between piston 43 and the interior wall of housing 41 is filled with air. A firing pin 47 is connected to and extends downward from the bottom of piston 43 . A percussion firing assembly 81 is retained within firing head 70 by the pin end of housing 41 . Sub 24 is attached to firing head 70 by any suitable means, such as by screw threads 84 and O-rings 85 to provide a fluid tight seal there-between. An ignition transfer 83 at the top of sub 24 is in contact with detonating cord 35 passing through the perforating charge carrier 26 , as described above.
As illustrated in FIG. 1 , a screen assembly 50 has one end thereof secured to an end plug 51 while the other end thereof is secured to a length of tubular 90 , such as a section of blank pipe which may be attached to a packer assembly or designed for a screen assembly. Tubular 90 typically has a length of about 60 to 90 feet. In accordance with the present invention, screen assembly 50 is comprised of a pipe 52 having apertures 53 therethrough. A generally tubular screen 56 is positioned about the pipe so as to cover apertures 53 and the ends of screen 56 are secured to pipe 52 by any suitable means, such as by welds. Screen 56 may be any conventional screen employed for sand control, as will be readily evident to a skilled artisan. For example, screen 56 may be a conventional wire wrapped screen such as illustrated in FIGS. 3 , 3 A and 3 B and commercially available from the Johnson Screens, a Weatherford Company, under the trademark SuperWeld® or a sintered laminate such as is illustrated in FIGS. 2 , 2 A and 2 B and commercially available from Johnson Screens under the trademark Excelflo™.
In accordance with the present invention, firing assembly 40 and perforating gun assembly 20 are positioned within and axially offset to one side of the interior of screen assembly 50 and tubular 90 and secured thereto in a manner described below. The screen assembly is provided with an aperture or opening which is configured to encompass scallops 32 that are formed in the exterior of perforating charge carrier 26 . Specifically, as illustrated in FIGS. 2A and 3A , the aperture in screen assembly 50 is formed of an aperture 54 in perforated pipe 52 and an aperture 57 in screen 56 that is configured substantially similar to but is slightly larger than aperture 54 . As illustrated in FIGS. 2B and 3B , pipe 52 is secured to perforating charge carrier 26 at or near the edges 55 of aperture 54 in pipe 52 by any suitable means, such as welds 59 , so as to form a seal between pipe 52 and perforating charge carrier 26 that is sufficient to prevent proppant entry. In a similar manner, screen 56 is secured to pipe 52 at or near the edges 58 of aperture 57 in screen 56 by any suitable means, such as welds 60 , so as to form a seal between screen 56 and pipe 52 that is sufficient to prevent proppant entry. Although charge carrier 26 and charge(s) 34 are illustrated in FIGS. 2B and 3B as being within screen assembly 50 , it will be evident to a skilled artisan that aperture 54 may be sized such that both charge carrier and charges 34 protrude outwardly from screen assembly.
Referring to FIG. 4 , a subterranean well 100 is illustrated as comprising a well bore 101 , casing 102 and cement sheath 104 . Well bore 101 is drilled from the surface of the earth in a conventional manner so as to penetrate at least one subterranean formation or zone of interest 108 . A generally tubular casing string 102 is then positioned within well bore 101 and secured therein by means of a cement sheath 104 that is placed in the annulus between the casing string and the well bore in accordance with any conventional technique as will be evident to a skilled artisan. To complete well 100 in accordance with one embodiment of the present invention, assembly 10 of the present invention, blank pipe 112 , isolation plug 114 , closing sleeve 116 and packer 118 are assembled on tubing string 90 at desired spacing prior to or while tubing string 90 is run into well 100 . Tubing string 90 is then lowered into well 100 and snapped into a sump packer 119 which may be previously run into well 100 and set to isolate production of fluid from subterranean formation or zone 108 from that portion of the well below sump packer 119 . Other than assembly 10 , the component parts assembled on tubing string 90 are conventionally available. For example, a suitable isolation plug is commercially available from Halliburton Energy Services, Inc. of Dallas, Tex. under the trade name designation PX, RX or NX plug and a suitable closing sleeve is commercially available from Halliburton Energy Services, Inc. under the trade name designation MCS closing sleeve or from Weatherford International, Inc. of Houston, Tex. under the trade name designation Frac Sleeve. The packer utilized in accordance with the present invention will vary with the exact method employed, and as such, may be permanent or retrievable, may be wireline deployed or tubing conveyed, and may have a seal bore or be run with tubing as will be evident to a skilled artisan. Examples of a wireline deployed, retrievable packer is that commercially available from Halliburton Energy Services, Inc. under the trademark Versa-Trieve®, of a tubing deployed, retrievable packer is that commercially available from Halliburton Energy Services, Inc. under the trade name designation Perma Latch, of a high temperature, high pressure version of either a wireline or tubing deployed, retrievable packer is that commercially available from Halliburton Energy Services, Inc. under the trade name designation HTHP, and of a tubing deployed, retrievable packer is that commercially available from Halliburton Energy Services, Inc. under the trade name designation RH.
As positioned within well 100 , closing sleeve 116 is preferably placed in the open position. Wireline or coiled tubing may be used to open closing sleeve 116 , if necessary such as in a high angle well. Once tubing string 90 is located at the desired position within well 100 , i.e. such that assembly 10 is adjacent formation or zone 108 , packer 118 is set either by hydraulic or mechanical means depending upon the packer employed as will be evident to a skilled artisan thereby effectively isolating formation or zone 108 . At this point, the rig at the surface can be moved off location or may remain on location if appropriate for the completion operations. A coiled tubing unit and hydraulic fracturing equipment are moved on location. Hydraulic fracturing fluid is then pumped down tubing string 90 and is communicated via the opened sleeve 116 into the annulus defined between tubing string 90 and casing 102 and between packers 118 and 119 . This fracturing fluid may be any fluid deemed to have the proppant carrying properties as dictated by the subterranean formation of interest and completion method employed. Suitable carrier fluids include gels, for example hydroxyethylcellulose or crosslinked polymers. Water will be sufficient for certain applications, such as a high rate water pack in which the primary emphasis is packing perforations and the annulus without fracturing the formation. The fracturing fluid is also communicated via port 42 to piston 43 in firing assembly 40 . Pressure on the fracturing fluid is increased to a pressure that is significantly greater than the formation pressure until pins 44 shear causing firing pin 47 to strike percussion firing assembly 81 in firing head 70 . The ignition of percussion firing assembly 81 causes a secondary detonation in ignition transfer 83 which in turn ignites detonating cord 35 . Ignition of cord 35 detonates each perforating charge 34 which blasts through each adjacent scallop 32 in perforating charge carrier 30 and creates a perforation 122 which extends or penetrates through casing 102 and cement 104 and into subterranean formation or zone 108 . Pins 44 are designed to shear at an predetermined pressure, e.g. a pressure greater than the fracturing pressure of the subterranean formation or zone 108 of interest. In this manner, immediately upon detonation of perforating charge(s) 34 , the formation will be subjected to an condition that is in excess of the formation fracture gradient thereby fracturing the formation. Perforation(s) 122 will be surged with high pressure and fluid present in the annulus 120 will be injected into the formation or zone 108 at a high rate and pressure. Since perforation(s) 122 immediately upon creation thereof, the formation 108 is not allowed sufficient time to heal itself thereby increasing the efficiency and effectiveness of the fracturing process.
Once a pressure drop is noted at the surface indicating that the perforating charge(s) have fired and fluid has been injected into the formation, a frac pack operation is then performed via tubing string 90 . Fluid is pumped via string 90 at a pressure in excess of the fracture gradient of formation or zone 108 . Preferably, a “tip screen-out” technique is employed wherein a high concentration of proppant is pumped in the fracturing fluid near the end of the treatment. As proppant may be left in the tubing string 90 , coiled tubing may be run Into the well to wash proppant out of the tubing and casing and to pull the isolation plug 114 from the well. The coil tubing may then be used to close sleeve 116 and the well may be pressure tested, production tested or placed on production.
An alternative embodiment of the process of the present invention is illustrated in FIG. 5 in which a bridge plug 130 , for example a cast iron bridge plug commercially available from Alpha Oil Tools of Fort Worth, Tex. under the trade name designation A-1 Bridge Plug or B-1 Bridge Plug, is set in casing 102 below the subterranean formation or zone of interest 108 . The assembly 10 of the present invention is then lowered into well 100 by any suitable means, such as wireline, slick line or coiled tubing, and placed upon bridge plug 130 . Assembly 10 is secured to a blank pipe 112 and a centralizer 132 , for example a bow type centralizer, is secured to the outer surface of blank pipe 112 by any suitable means, such as by welds. A vent screen 113 is secured to the upper portion of blank pipe 112 . As previously discussed the lower end of the screen assembly 10 is closed to fluid flow while the upper end of blank pipe 112 or vent screen 113 is closed to fluid flow by means of bull plug or retrievable fishing neck 115 . If a retrievable fishing neck is employed, the neck is releasably secured to the upper end of blank pipe 112 or vent screen 113 by any suitable means, such as by shear pins. A tubing string 134 is positioned with well 100 and a packer 135 is hydraulically or mechanically set as will be evident to a skilled artisan to effectively isolating formation or zone 118 . Thereafter, hydraulic fracturing fluid is pumped down tubing string 134 and is communicated via blank pipe 112 and port 42 to piston 43 in firing assembly 40 . Pressure on the fracturing fluid is increased to an predetermined condition until pins 44 shear causing firing pin 47 to strike percussion detonator 81 in firing head 70 . The ignition of percussion detonator 81 causes a secondary detonation in ignition transfer 83 which in turn ignites detonating cord 35 . Ignition of cord 35 detonates each perforating charge 34 which blasts through each adjacent scallop 32 in perforating charge carrier 30 and creates a perforation 122 which extends or penetrates through casing 102 and cement 104 and into subterranean formation or zone 108 . Pins 44 are designed to shear at an predetermined pressure, e.g. a pressure greater than the fracturing pressure of the subterranean formation or zone 118 of interest. in this manner, once perforating charge(s) 34 detonate, the formation will be subjected to an pressure that is in excess of the formation fracture gradient. Perforation(s) 122 will be surged with high pressure and fluid present in the annulus 120 will be injected into the formation or zone 108 at a high rate and pressure.
Once a pressure drop is noted at the surface indicating that the perforating charge(s) have fired and fluid has been injected into the formation, a frac pack operation is then performed via tubing string 134 . Fluid is pumped via string 134 at a pressure in excess of the fracture gradient of formation or zone 108 . Preferably, a “tip screen-out” technique is employed wherein a high concentration of proppant is pumped in the fracturing fluid near the end of the treatment. As proppant may be left in the tubing string 134 and in well 100 above the top of the vented screen 113 , coiled tubing may be run into the well to wash proppant out of the tubing string 134 and well 100 to the location of vented screen 113 . The removed proppant is then circulated with the wash fluid to the surface of the earth. The coiled tubing is removed and the well may be pressure tested, production tested or placed on production. As placed on production, fluid flows from formation 108 through the proppant pack present in perforations 108 and annulus 120 and into assembly 10 through screen assembly through screen assembly 50 . Produced fluid then flows through blank pipe 112 , outwardly through vented screen 113 and to the surface through tubing string 134 . Alternatively, where a retrievable fishing neck is employed as 115 , wireline, slick line or coiled tubing may be lowered through tubing string 134 prior to placing the well on production, secured to fishing neck 115 and raised to release fishing neck 115 from vented screen 113 or blank pipe 112 . Once the fishing neck is retrieved from well 100 , the well is placed on production and fluid is produced from the formation into assembly 10 and through the top of vented screen 113 of blank pipe 112 prior to entry into tubing string 134 . As illustrated in FIG. 6 , assembly 10 may be used in the upper and/or lower zone of a multiple well completion process in a similar manner to that described above with respect to FIG. 4 as long as the perforating charges in the upper assembly 10 ′ are oriented to fire away from tubing string 140 so as not penetrate such string upon detonation.
The embodiments of the assembly and process of the present invention set forth above describe a combined perforating, fracturing and/or sand control tool that can be run into a subterranean well in a single trip and does not require that the tool be moved during operation. In accordance with the present invention, the perforating gun assembly 20 is not “dropped” during operation nor does the screen assembly 50 have to be “spaced out” across the subterranean zone of interest after perforating and prior to pumping fluid containing proppant. In this manner, pumping operations can be commenced immediately after perforating and sand control operations thereby eliminating the need for heavy completion fluid for pressure control in the well.
The following examples demonstrate the practice and utility of the present invention, but are not to be construed as limiting the scope thereof.
EXAMPLE 1
A well is drilled in the Gulf of Mexico, U.S.A. to 15,000 feet and is cased with 7″ OD, 32.0 lb/ft casing. A casing cleanup and fluid displacement is performed to displace the drilling mud and cement from the casing, and to prepare it for completion operations. A bit and scraper/gauge run, with casing brushes, is used to ensure the integrity of the casing, and to clean the casing walls.
The formation of interest has an equivalent pore pressure of 16.5 ppg. In this straight hole, that equates to a bottom hole pressure of 12,870 psi. Based upon experience in the field, it is anticipated that the formation fracture gradient is 17.9 ppg, which is equivalent to about 14,000 psi. The mud in the casing is displaced with the relatively inexpensive calcium chloride completion fluid of 11.6 ppg density. This fluid exerts an equivalent pressure on bottom of 9048 psi.
The workstring is pulled from the well, and electric line is utilized to run a cast iron bridge plug to the desired depth near the bottom of the well, and within a few feet of the desired location of the bottom perforation. The centralized, dual firing head assembly of the present invention is made up with a bull plug on bottom, 60 feet of blank pipe above the assembly, a frac port within the blank pipe section (run in the open position), and a frac pack packer near the top of the blank pipe. This assembly is then run in the hole via electric line, and lightly tags the bridge plug. The assembly is picked up to get on depth and ready to perforate. Alternatively, a work string could be utilized to run the assembly in the well as will be evident to a skilled artisan.
The packer is set and electric line is pulled out of the hole. The production tubing assembly, with the seal assembly, is run and stung into the packer. The tubing is landed in the tubing hanger and the tree is nippled up. A tree saver assembly is utilized to protect the tree during frac packing operations, and the well is prepared for pumping operations.
A frac boat is mobilized to pump the frac pack, and upon its arrival on location, a high pressure flexible hose is lifted up to the rig and surface equipment, including a high pressure manifold assembly, is rigged up to the well. The boat is utilized to initiate blending of a gelled carrier fluid, and prepare the equipment for injecting proppant. The boat is set up to circulate the gelled fluid against pressure, and is ready to pump the fracture treatment immediately upon determination that the casing has been perforated.
The firing heads are set to fire at a pressure in excess of the fracture gradient of the formation of interest. In this case, with 11.6 ppg fluid in the hole and a 17.9 ppg frac gradient, it is determined that a differential pressure 1000 psi over fracture gradient is satisfactory. Accordingly, the guns are set to fire at a pressure of 15,000 psi. The pressure applied to the 11.6 ppg fluid to exert this pressure on the firing heads is 5914 psi at the surface.
While the boat is circulating fluid, a choke is gradually closed on the loop to increase the circulating pressure to greater than 5914 psi. A choke between the loop and the workstring is gradually opened as the pressure on the workstring is raised to 5914 psi. As soon as a pressure drop is observed, indicating that the guns have fired, the choke to the worksting is opened fully, and the fracture treatment is pumped as planned without allowing the pressure to drop below the formation fracture gradient. Additional pumps on the boat are then utilized to bring the injection rate up to the desired rate for the fracture treatment. The injection rate is stabilized by the time the gel pre-pad reached the formation.
The fracture treatment is terminated with a pumping schedule intended to induce a screenout via the tip-screenout method. This method results in proppant being left in the wellbore. Pressure is bled off abruptly to allow fractures in the formation to close and flow some of the proppant back to the wellbore in order to assure a good annular pack. Coiled tubing is utilized to wash proppant out of the tubing, and to close the frac sleeve in the blank pipe assembly. Alternately, electric line is used to close the sleeve after the proppant is washed form the well. After the frac sleeve is closed, coiled tubing and electric line are pulled out of the hole and the tree saver is removed from the wellhead. The well is flow tested and then put on production.
EXAMPLE 2
A well is drilled in a similar fashion to that described in Example at the same locale and to approximately the same depth. In this example, a vented screen is employed in the blank pipe above the assembly and the tubing string is run with a single packer above the screen assembly. The screen assembly is not connected to the tubing string or packer assembly. The tubing below the packer consists of a joint of tubing, a landing nipple, another joint of tubing, and a muleshoe.
The well can be completed in accordance with the process set forth in Example 1 and tree nippled up prior to perforating and pumping a gravel pack or frac pack. A tree saver will be used to protect the tree during pumping operations.
As in Example 1, pumping operations are configured such that upon determining that the guns have fired, pumping operations are continued until tip screenout. Coiled tubing is mobilized to wash proppant out of the well down to the top of the vented screen. After cleaning out the tubing/wellbore and rigging down the coiled tubing and the tree saver, the well is first tested and then brought online.
As will be evident to a skilled artisan, the methods of Examples 1 and 2 can be applied in cases where the tree is not nippled up prior to perforating. In these cases, it will be necessary to provide some mechanism to prevent the well from flowing during completion operations. The options may include running a flapper valve assembly in the packer extension to isolate the lower interval, setting a plug in the blank pipe, or killing the well with heavy weight completion fluid. Since the latter is one of the reasons for the development of this tool and process, it should be used only after it is determined that the other options are not feasible under the completion scenario.
Although assembly 10 of the present invention has been illustrated in FIGS. 1-6 as containing only perforating gun assembly having one set or row of spaced apart perforating charges which are aligned in a generally linear pattern, it is within the scope of the present invention as illustrated in FIGS. 7 and 8 to use multiple perforating gun assemblies having aligned perforating charges which are arranged in parallel within screen assembly 50 . This parallel gun configuration may be employed where rotationally spaced perforations in a well and surrounding formation are desired for a specific subterranean completion application and where space within screen assembly 50 permits placement of multiple gun assemblies.
Further, although the screen assembly 50 that is utilized in the assembly of the present invention has been illustrated in FIGS. 1-8 as being a pipe which has a generally annular cross sectional configuration, it is within the scope of the present invention to utilized other screen configurations, such as a trough or half pipe as is illustrated in FIG. 9 . In this embodiment, the longitudinal edges of screen assembly 50 are secured to one side of an elongated housing 64 by any suitable means, for example by welds. In this embodiment, one or more perforating gun assemblies 20 are positioned within and secured to the housing 64 by any suitable means. Each charge 34 in said perforating gun assembly 20 is aimed to penetrate through charge carrier 26 and housing 64 . Although illustrated in FIG. 9 as having a generally triangular cross sectional configuration, housing 64 may have any cross sectional configuration, for example rectangular or oblong, that can be sized to be positioned within a cased or open hole well bore as will be evident to a skilled artisan. Those portion(s) of housing 64 directly in front of perforating charges 34 may be provided with scallops to assist in penetration of housing 64 upon detonation as will be evident to a skilled artisan. In addition, it is within the scope of the present invention that housing 64 could serve as a carrier for the perforating charges 34 of the perforating gun assemblies positioned therein. In this manner, charge carriers 26 may be eliminated. When housing 64 functions as a carrier for perforating charges 34 , housing 64 will have sufficient thickness to provide the structural integrity necessary for operation of the assembly and process of the present invention.
It is also within the scope of the present invention to position one or more perforating gun assemblies 20 on the outside of screen assembly 50 as illustrated in FIG. 10 and to secure each perforating gun assembly 20 to the screen 56 by means of at least one spacer or standoff 66 . Each spacer or standoff 66 is secured to screen assembly 50 and perforating gun assembly 20 by any suitable means, for example by welds. In this embodiment, the charges 34 may be assembled with any phasing that does not affect the screen assembly 50 . To ensure that the screen assembly 50 is not damaged upon detonation of the perforating gun assemblies during the process of the present invention, it is within the scope of the present invention to secure a shield (not illustrated) along that portion of screen assembly 50 that is closest to perforating gun assembly 20 . The exact construction, configuration and assembly of a shield will be evident to a skilled artisan.
Further, multiple assemblies 10 of the present invention may be employed where the formation or zone of interest is of a sufficient thickness so as to require a larger length of perforations than can be formed using one assembly for proper completion. Where more than one assembly is employed in this embodiment of the present invention, the assemblies are arranged in series with adjacent assemblies mechanically and ballistically connected by means of a sub and booster transfer, respectively, as will be readily apparent to a skilled artisan.
The assembly and process of the present invention has been described and illustrated herein as being applied to a well bore having casing positioned therein. It will be evident to a skilled artisan that the assembly and process of the present invention is equally applicable to open hole applications, i.e. in subterranean well bores that are not cased. When utilized in an open hole, the assembly of the present invention is deployed as depicted in FIGS. 4 and 5 or in FIG. 6 , detonation of the charges initiates fracturing of the subterranean zone of interest and the screen assembly 50 functions to prevent flow back of proppant into the production string.
While the foregoing preferred embodiments of the invention have been described and shown, it is understood that the alternatives and modifications, such as those suggested and others, may be made thereto and fall within the scope of the invention. | A process and assembly for completing and providing sand control in a subterranean well and/or fracturing and preventing proppant flowback in a subterranean formation in a single trip. One or more perforating gun assemblies are juxtaposed and secured to one or more screen assemblies. Once positioned in a well adjacent a subterranean formation of interest, the explosive charges in each perforating gun assembly are detonated so as to penetrate the well and formation thereby initiating fracturing. The penetrations and the annulus defined between the well and screen assembly are then packed with gravel. Well fluid may be pressurized to in excess of the formation pressure prior to detonation of the explosive charges so as to enhance formation fracturing. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/030,961, filed Feb. 23, 2008, which is hereby incorporated by referenced herein in it entirety, including but not limited to, those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced provisional application is inconsistent with this application, this application supercedes said above-referenced provisional application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to toilet bowl cleaning apparatus and methods, and more particularly, to an apparatus mountable within a toilet bowl and methods that clean deposits in toilet bowls with each flush of the toilet.
[0005] 2. Description of the Prior Art
[0006] Potassium phosphate is formed by the reaction of potassium, phosphoric acid and carbon dioxide. Since urine and fecal matter typically contain all three compounds, it is common for calculus deposits to be formed in toilets and toilet drain pipes containing a combination of potassium phosphate and organic compounds eliminated by the body. As the organic compounds decay, the calculus deposits give off a characteristic foul odor that is present in poorly maintained rest rooms. Because urine and fecal calculus deposits do not readily dissolve in water, their removal is a challenge for janitorial staffs.
[0007] After calcium, potassium and phosphorus are the most abundant elements found in the human body. Calcium, potassium and phosphorus are, respectively, the first, second and third most common elements found in the human body. The presence of potassium is essential for the regulation of the acid-base balance and water balance in the blood and the body tissues, for the synthesis of proteins from amino acids, for carbohydrate metabolism, for the building of muscle tissue, for normal body growth, and for the proper functioning of nerve cells, in the brain and throughout the body. With the proliferation of soft drinks, such as colas, which contain both phosphoric acid and carbon dioxide, these two ingredients are found in urine and fecal matter in increasing concentrations.
[0008] In order to counteract the foul odor of decomposing urine and fecal matter, deodorant blocks are commonly placed inside toilets and urinals. For many years, deodorant blocks containing paradichlorobenzene and/or naphthalene were used to counteract odors in rest rooms. However, during the last several decades, it has been observed that exposure to the former chemical is responsible for numerous health problems, including kidney and liver disease. Consequently, the use of paradichlorobenzene—particularly around children—has been prohibited in certain jurisdictions. Naphthalene has compiled a record of even greater toxicity than paradichlorobenzene. Other, less toxic aromatic compounds are now being used to combat foul odors in rest rooms.
[0009] One current device involves the use of drop tabs in a toilet tank. Unfortunately, all cleaning chemicals in the tabs quickly dissipate in the water and are flushed down the drain, so there is little, if any, long term cleaning effect. Another device used for toilet bowl cleaning clips over the side of the bowl so that a small amount of the water released into the bowl runs over the cleaning compound. This device is only marginally effective because of very limited contact with the bowl water. Another device connects to the back of the toilet bowl by suction. Again, there is limited contact with the water released into the bowl for cleaning.
[0010] What is needed is an apparatus that is installable within the toilet bowl in a position to come into contact with substantially all of the fresh water released into the bowl. Further, what is needed is a device that releases a water-soluble compound into substantially all of the fresh water coming into a toilet bowl so as to effectively clean the bowl. Also needed is a device to not only release a refreshing aroma that counteracts urine and fecal matter odors, but also dispense a controlled amount of chemical compound that interferes with the formation of urine and fecal matter calculus deposits in toilet bowls and toilet drain pipes.
SUMMARY OF THE INVENTION
[0011] A toilet bowl cleaning unit disposed to intercept an intermittent flow of water from each flush of water from a water line to a toilet bowl comprises a mounting device for installation in the flow of water, and a water-soluble compound positioned on the mounting device to intercept a substantial portion of the water as it is flushed from the water line to the toilet bowl, said water-soluble compound thereby being released into the toiled bowl with the water from each flush to inhibit formation of mineral deposits on the surfaces of the toilet bowl and/or drainage pipes.
[0012] A method for cleaning a toilet bowl comprises providing an intermittent flow of water from a water line to a toilet bowl with each flush of the toilet bowl, and providing a water-soluble compound to intercept a substantial portion of the flow of water, said water-soluble compound thereby being released into the toilet bowl with the water from each flush to inhibit formation of mineral deposits on the surfaces of the toilet bowl and/or drainage pipes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an isometric front side view of the toilet bowl cleaner unit that installs under the rim of a toilet bowl;
[0014] FIG. 2 is an isometric back side view of the toilet bowl cleaner unit;
[0015] FIG. 3 is a close-up isometric view of one of the six grills that houses one or more bleach packets;
[0016] FIG. 4 is a close-up isometric view of the joint structure at the center of the toilet bowl cleaner unit; and
[0017] FIG. 5 is a side elevational view of a polymer cloth packet containing a bleach in solid granular form;
[0018] FIG. 6 is an end view of the polymer cloth packet of FIG. 5 ;
[0019] FIG. 7 is an isometric view of a block of bleach in solid block form, the block shaped to fit behind a grill cover; and
[0020] FIG. 8 is a cross-sectional side view of a toilet having an elongated bowl in which the toilet bowl cleaner unit has been installed.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention relates to a toilet bowl cleaner unit that intercepts the flow of water into a toilet bowl with each flush to provide a water soluble cleaning agent for cleaning the toilet bowl.
[0022] In one illustrative embodiment, a cleaner unit is provided that installs under the rim of a toilet bowl. The unit includes a generally linear, resilient mounting strip having a front side and a back side, which can bent into a horseshoe shape for installation beneath the rim of a toilet bowl. When the mounting strip is bent to conform to the shape of the toilet bowl, energy is stored in the mounting strip. This stored energy confers a “memory” to the mounting strip, which attempts to return the mounting strip to its original linear conformation. The stored energy exerts a radial force against the toilet bowl that holds the mounting strip in place within the toilet bowl in the horseshoe configuration.
[0023] The memory of the plastic hoop may be enhanced by incorporating structural fibers in the plastic. Structural fibers can be made of glass, graphite, boron nitride, boron carbide, and other similar materials that have excellent memory characteristics up to the point of fracture. As a practical matter, glass fibers are the most common and least expensive structural fibers available. In addition, they can be made transparent. Thus, if it is desired that the mounting strip match the color of a white toilet bowl, transparent glass fibers in a resilient polymer plastic containing titanium dioxide pigment is likely the most cost effective combination. Multiple supply modules snap onto the resilient mounting strip and contain a water-soluble compound for removing urine and fecal matter deposits from the toilet bowl.
[0024] In a first illustrative embodiment, a bleach supply module includes one or more grill covers that snap onto the resilient mounting strip, each grill cover containing at least one water-permeable polymer cloth package containing bleach granules. The polymer cloth is made from mildew resistant fibers made from a polymer such as nylon, polypropylene, polyethylene, or other similar polymers, which are equivalent for the application.
[0025] The bleach also works as a deodorant, since the foul smelling deposits are removed and a smell of chlorine and/or other cleaning chemicals is predominant. Optionally, the bleach compound may include a fragrance to further deodorize and provide a pleasing smell. Further, the mounting strip might optionally include a deodorant bar incorporating a sublimable aromatic material suspended on a resilient clip, which is unitary with the mounting strip and projects from the back side thereof. As the resilient clip is longer than the bar is thick, it acts as a standoff to space the deodorant bar away from the side of the toilet bowl so that a greater surface area of the deodorant bar is exposed to air in the toilet bowl. The deodorant bar continually dispenses an odor-counteracting aroma.
[0026] With each flush of the toilet, the bleach granules within the cloth packets are partially dissolved, thereby dispensing a controlled amount of the chemical compound, which interferes with the formation of urine and fecal matter calculus deposits that form within the toilet bowl. The bleach granules and deodorant bar are designed to last for generally about 30 to 90 days, depending on the amount of usage. At the end of this period, the unit is removed, discarded, and replaced with a fresh unit.
[0027] The mounting strip may incorporate a hook and loop at opposite ends thereof so that the entire cleaner unit having expended the bleach supplies and, optionally the deodorant supplies, may be discarded as a hoop that fits within canister-type garbage containers. As a means of reducing manufacturing cost of the item, the hoop may be made in two equal-length pieces, which lock together to form a single linear piece. The mounting strip may incorporate a gentle curve along its length so that when it is bent into a horseshoe configuration, the lower edge of the mounting strip is angled slightly toward the toilet bowl, thereby making the installation thereof less conspicuous.
[0028] The invention will now be described with reference to the included drawing figures. It is to be understood that the drawings are not necessarily drawn to scale, and that they are intended to be merely illustrative.
[0029] Referring now to FIGS. 1 and 2 , the cleaner unit 100 includes a generally linear, resilient mounting strip 101 having a front side 102 F and a back side 102 B, which can be bent into a horseshoe shape for installation beneath the rim of a toilet bowl. When the mounting strip 101 , which may be made of injection-molded polymer plastic, is bent to conform to the shape of the toilet bowl, energy is stored in the mounting strip 101 . This stored energy, which is provided by the stretching of molecular bonds and attractions, confers a “memory” to the mounting strip which attempts to return the mounting strip 101 to its original linear conformation. The stored energy exerts a radial force against the toilet bowl that holds the mounting strip 101 in place within the toilet bowl in the horseshoe configuration.
[0030] As polymer plastic compounds typically tend to flow under pressure and stress at a rate that is a function of temperature, the memory of the resilient mounting strip may be made more permanent by incorporating structural fibers in the polymer plastic to form a composite matrix. Structural fibers can be made of glass, graphite, boron nitride, boron carbide, and other similar materials, which have excellent memory characteristics up to the point of fracture. As a practical matter, glass fibers are the most common and least expensive structural fibers available. In addition, they can be made transparent. Thus, if it is desired that the mounting strip match the color of a white toilet bowl, transparent glass fibers in a resilient polymer plastic containing titanium dioxide pigment is likely the most cost effective combination. The mounting strip 101 may incorporate a gentle curve along its length so that when it is bent into a horseshoe configuration, the lower edge 103 of the mounting strip 101 is angled slightly toward the toilet bowl, thereby making the installation thereof less conspicuous.
[0031] Referring now to FIGS. 1 , 2 , and 3 multiple grill covers 201 -A, 201 -B, 201 -C, 201 -D, 201 -E and 201 -F ( 201 , generally) snap onto the resilient mounting strip 101 . Each grill cover 201 holds a supply of a bleach in either granular or block form. Some types of bleach that are effective for this application are, without limitation, hydrogen peroxide (H 2 O 2 ), TCIC (trichloroisocyanuric acid), SDIC (sodium dichloroisocyanurate), calcium hypochlorite, chlorine dioxide, didecyl dimethyl ammonium chloride, decyl dimethyl octyl ammonium chloride, and alkyl(C12-16) dimethylbenzylammonium chloride. Granular bleach may be contained within at least one water-permeable polymer cloth packages (shown in drawing FIGS. 5 and 6 ). Alternatively, solid bleach may be molded in block form in a shape that fits within the grill cover 201 (shown in FIG. 7 ). Installation finger tabs 107 A and 107 B enable an installer to hold the ends of the mounting strip 101 after it is bent into a horseshoe shape and more easily position it beneath the rim of a toilet bowl.
[0032] It will be noted, particularly in FIG. 3 , that each grill cover 201 has an upper retention tab 301 in the center of the top edge of the grill cover 201 , which snaps into an upper retention slot 104 along the upper edge of mounting strip 101 . There is also a bottom retention tab located in the center of the bottom edge of the grill cover 201 . Though the lower retention tab is not visible, its function is identical to that of the upper retention tab 301 . The bottom edge of the mounting strip 101 also has a plurality of lower retention slots (also not shown), which are analogous in function to the upper retention slops 104 . It will also be noted that each grill cover 201 has an alignment aperture 302 at each corner thereof. Alignment pegs 202 , which are even more visible in the enlarged view of FIG. 4 , slide into those alignment apertures 302 , thereby allowing the mounting strip 101 to flex. The grill covers 201 are also designed to flex so that they assume the curvature of the toilet bowl in which the cleaner unit 100 is installed. Even when the mounting strip 101 is bent into a horseshoe configuration, the upper retention tab 301 and the lower retention tab maintain the grill cover 201 secured to the mounting strip 101 , and the alignment pegs 201 , in combination with the alignment apertures 302 , maintain proper alignment of the grill cover 201 with the mounting strip 101 . Optionally, a fragrance may be added to the bleach compound If desired.
[0033] Also, as an alternate embodiment, a deodorant bar 203 incorporating a sublimable aromatic material is suspended at each end of the mounting strip 101 on a resilient clip 204 A or 204 B that is unitary with the mounting strip 101 and projects from the back side thereof. As the resilient clips 204 A and 204 B are longer than the bars 202 are thick, they act as a standoffs to space the deodorant bars 203 away from the side of the toilet bowl so that a greater surface area of the deodorant bar 203 is exposed to air in the toilet bowl.
[0034] Referring now to FIG. 4 , as a means of reducing manufacturing cost of the item, the mounting strip 101 may be made in two equal-length pieces 101 A and 101 B, which lock together to form a single mounting strip 101 . An upper barbed tab 401 U on piece 101 B passes through an upper retention slot 402 U and snaps over an upper retention shelf 403 U on piece 101 A, and a lower barbed tab 401 L passes through a lower retention slot 402 L and snaps over a lower retention shelf 403 L on piece 101 A.
[0035] Likewise, an upper barbed tab 404 U on piece 101 A passes through an upper retention slot 405 U and snaps over an upper retention shelf 406 U on piece 101 A, and a lower barbed tab 404 L passes through a lower retention slot 405 L and snaps over a lower retention shelf 406 L on piece 101 A. In order to joint the two equal-length pieces 101 A and 101 B, they are joined in a folded configuration so that the back side 102 B of each piece 101 A or 101 B makes about a right angle with the other piece. They are then unfolded to a straight configuration and the barbed tabs 401 U, 401 L, 404 U, and 404 L virtually simultaneously snap over their respective retention shelves 403 U, 403 L, 406 U, and 406 L. The deodorant bars 203 continually dispense an odor-counteracting aroma.
[0036] With each flush of the toilet, the bleach inside the grill covers 201 —whether in granular or block form—is partially dissolved, thereby dispensing a controlled amount of the chemical compound, which interferes with the formation of hard water deposits and urine calculus deposits that would otherwise form within the toilet bowl. The weak acid supplies behind the cover grills 201 and the deodorant bars 203 are designed to last for about 30 days. At the end of this period, the unit is removed, discarded, and replaced with a fresh unit. The mounting strip 101 may incorporate a hook 105 and loop 106 at opposite ends thereof so that an entire multi-function cleaner and deodorizer unit 100 having expended bleach and deodorant supplies may be discarded as a hoop that fits within canister-type garbage containers.
[0037] Referring now to FIGS. 5 and 6 , bleach granules are enclosed in a water-permeable polymer cloth package 500 . At least one such package 500 is installed beneath each cover grill 201 . The polymer cloth is made from mildew resistant fibers made from a polymer such as nylon, polypropylene, polyethylene, acrylic, acetate, polyester, or other similar polymers or copolymers which are equivalent for the application. The cloth can be sewn or heat seamed at line 501 to form the package 500 . One end of the package 500 can remain unseamed or unsewn while filling. After filling the end can be seamed or sewn.
[0038] Referring now to FIG. 7 , a block of solid bleach 700 , molded to fit beneath a cover grill 201 , is shown.
[0039] Referring now to FIG. 8 , the cleaner unit 100 is shown installed beneath the rim 801 of bowl 802 of a toilet 800 . Because this is a cross-sectional view, only one half of the unit 100 is visible. The loop 106 on piece 101 B is visible in this view, as are barbed hooks 404 U and 404 L, installation finger tab 107 A, and a single cover grill 201 -D.
[0040] In addition to the embodiments of the invention that have been shown and described, it will be obvious to those having ordinary skill in the art that changes may be made thereto without departing from the scope and spirit of the invention as claimed. For example, other cleaning agents besides bleach may be used in connection with the cleaning device described herein. Examples of other cleaning agents are, without limitation, as follow: sulfamic acid, sodium hypochlorite (NaClO), sodium perborate, sodium percarbonate, benzoyl peroxide, bromates, peracetic acid, tetrasodium (EDTA), sodium dodecylbenzenesulfonate, and sodium dichloroisocyanurate. | A toilet bowl cleaning unit disposed to intercept an intermittent flow of water from each flush of the water from a water line to a toilet bowl comprising a mounting device for installation in the flow of water, and a water-soluble compound positioned on the mounting device to intercept a substantial portion of the water as it is flushed from the water line to the toilet bowl, said water-soluble compound thereby being released into the toiled bowl with the water from each flush to inhibit formation of mineral deposits on the surfaces of the toilet bowl and/or drainage pipes. A method for cleaning a toilet bowl, comprising providing an intermittent flow of water from a water line to a toilet bowl with each flush of the toilet bowl, and providing a water-soluble compound to intercept a substantial portion of the flow of water, said water-soluble compound thereby being released into the toilet bowl with the water from each flush to inhibit formation of mineral deposits on the surfaces of the toilet bowl and/or drainage pipes. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
In the field of hydrocarbon exploration and recovery, holes (wellbores, boreholes) are drilled deep into the crust of the earth to access deposits of fluid hydrocarbons. The degree of fluidity and the makeup of deposits varies, it is desirable to have the ability to control flow from different deposits into the wellbore. Flow control devices are varied in nature and in their particular construction but all must be actuatable from a remote location, such as a surface location, to be of use to a well operator. One common configuration for remote actuation of a downhole device such as a flow control device is a pair of hydraulic control lines. One of the lines is employed to force the flow control device to an open position while the other is employed to force the device to a closed position. While such systems work well for their intended purpose, it is axiomatic that a number of flow control devices each having a pair of hydraulic control lines is problematic with respect to the number of control lines that would ultimately need to reach the location intended for remote control (e.g. surface). All such control lines would need to extend through a borehole that in most instances is 9⅝ inches in diameter. Large numbers of control lines in such a small diameter borehole take up space where space is at a premium. This is not an advantageous situation.
While the art has proposed several remedies for this issue, each is complex, adds cost, adds potential for malfunction and is overall not a panacea. The art is therefore still in need of a configuration and operative modality for flow control valves that reduces the number of necessary hydraulic control lines while maximizing the number of devices controllable thereby and while maintaining simplicity and cost efficiency of design.
SUMMARY
Disclosed herein is a control system for a plurality of devices including a plurality of devices in at least one group. A first control line is in operable communication with the plurality of devices. A second control line in operable communication with the at least one group. A step-advance mechanism is in operable communication with each of the plurality of the devices, each mechanism being distinct from each other mechanism within the group of devices.
Further disclosed herein is a method for reducing the number of control lines needed to control a plurality of downhole devices including supplying a first control line in operable communication with a plurality of devices, the plurality of devices including at least one group of devices and supplying a second control line in operable communication with the at least one group. The method further includes moving the at least one group of devices to a selected position with a step-advance mechanism.
Further disclosed herein is a method for controlling a plurality of devices with two control lines including configuring each device with a distinct step-advance mechanism and alternating pressurization in the control lines to sequentially position the three devices so that following fourteen steps, all possible configurations of the devices have been achieved.
Yet further disclosed herein is a system controlling nine devices with four control lines. The system includes a first control line in operable communication with all nine devices, a second control line in operable communication with a group of three of the devices, a third control line in operable communication with a second group of three of the devices, a fourth control line in operable communication with a third group of three of the devices and each of the nine devices having a step-advance mechanism, and wherein the step-advance mechanisms are distinct within groups.
Yet further disclosed herein is a method for independently controlling a plurality of groups of devices including supplying a number of control lines equal to the number of groups of devices plus 1 control line.
Yet further disclosed herein is a system for controlling a plurality of devices with a reduced number of control lines. The system includes a plurality of devices represented by one or more groups of devices, a number of control lines equal to the number of groups of devices plus one control line.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a schematic illustration of a flow control valve actuation configuration utilizing four control lines and actuating nine flow control devices;
FIG. 2 is a representative schematic view of a J-slot and bearing sleeve laid flat;
FIG. 3 is a schematic view of a J-slot and bearing sleeve arrangement for a first control device in a group;
FIG. 4 is a schematic view of a J-slot and bearing sleeve arrangement for a second control device in a group;
FIG. 5 is a schematic view of a J-slot and bearing sleeve arrangement for a third control device in a group; and
FIG. 6 is a representation of the collective movements of the flow control devices in a nine valve on four line setup.
DETAILED DESCRIPTION
Referring to FIG. 1 , a system is illustrated that provides for remote control of nine individual flow control devices using only four hydraulic control lines. The configuration and operational functionality is facilitated by grouping of flow control devices and through the incorporation of a step-advance mechanism, which may comprise a J-slot and optionally a bearing sleeve in each flow control device. The illustrations and most of this specification are directed to a three device per group arrangement. It is to be understood however that groups of two devices or four devices are also possible and contemplated as within the scope of the invention. In the specifically illustrated embodiment(s) groupings of flow control devices include groups 12 , 14 and 16 . Each group includes three flow control devices 18 , 20 , 22 ; 24 , 26 , 28 ; and 30 , 32 , 34 , each device having two positions, those being closed and open, open and choked or choked and closed. This provides a total number of distinct configurations of two to the third power or eight (2 3 =8). This is represented for clarity in the following table:
Position
Sleeves
1
2
3
4
5
6
7
8
1
O
C
O
C
O
C
O
C
2
O
O
C
C
O
O
C
C
3
O
O
O
O
C
C
C
C
Where O = Open and
C = Closed
Two hydraulic control lines are employed for each group of devices 12 , 14 and 16 as one line is required to actuate the devices to the home position and one line is required to actuate the devices to the second position. For group 12 , these lines are line 36 and line 38 . The reader will note that line 38 is a home line (home position for purposes of this disclosure is the open position of the devices; it will be appreciated however that home could be any predetermined position to which the device will return when actuated in one direction). Home line 38 is shared by all devices in groups 12 , 14 and 16 as illustrated. When line 38 is pressured-up then, all devices of group 12 are actuated and move to the home position. Line 38 and individual lines for groups 14 and 16 , i.e., lines 40 and 42 are not shared between groups but are shared among devices within each group. More specifically, line 38 is shared among devices 18 , 20 and 22 ; line 40 is shared among devices 24 , 26 and 28 ; and line 42 is shared among devices 30 , 32 and 34 . Each of lines 38 , 40 and 42 are “home” actuating lines. Line 36 is common to all devices and actuates to the second (open, choked or closed) position. Each of lines 38 , 40 and 42 independently actuate only the single group with which they are associated.
At this point it is clear that all devices can be moved to the position by line 36 pressure. It is also clear that group 12 devices may all be actuated to the home position by line 38 ; group 14 devices may all be actuated to the home position by line 40 ; and group 16 devices may all be actuated to the home position by line 42 .
If it would be sufficient for a particular application to have each device of each group of devices in the same position (i.e., either open or closed; open or choked; closed or choked), then the system so far described is useful in that nine devices are operable by four control lines.
Since it is not often sufficient in the downhole environment to have a group of devices, for example devices 18 , 20 and 22 , all open or all closed or all choked, but rather is often the case that they would be in different positions, further capability in the groups is desirable. To provide the greater variability of positioning among individual devices of each group of devices 12 , 14 or 16 , each device 18 , 20 , 22 , 24 , 26 , 28 , 30 , 32 and 34 is constructed with a step-advance mechanism comprising such as a J-slot and optionally a bearing sleeve.
Referring to FIG. 2 , a J-slot sleeve 46 has been illustrated cut and laid flat for clarity. One of ordinary skill in the art is familiar with J-slot sleeves, their purpose being to guide a pin during reciprocal movement into advancing slots. In the illustration, a number of slot sections 48 and slot sections 50 are shown. The “J-sections” 52 between each slot section pair 48 / 50 are configured to allow a pin 54 to advance in the J-slot sleeve 46 in only one direction. It will be noted that each slot section 48 is the same length in the figure and each slot section 50 is the same length in the figure. In such configuration, there is no specifically controlled movement of the attached device. It is possible in this invention to use J-slots having different slot section lengths to specifically control movement but this relies on the load holding capability of the pin 54 . In higher load situations, which are anticipated for the devices hereof, a bearing sleeve 60 is employed along with the J-slot sleeve 46 , together making up the step-advance mechanism. The purpose of the bearing sleeve 60 is to create a specific control of motion of the attached device and hold the load thereof. Thus bearing lug 62 is appreciably larger in dimension, and therefore strength, than pin 54 . The bearing sleeve 60 is of a stepped configuration allowing for specific position limiting of the bearing lug 62 .
In this disclosure, an object is to operate multiple flow control devices with few control lines. In the illustrations, which follow, the individual flow control devices utilize only two positions: open and closed, closed and choked or choked and open. The FIG. 2 illustration allows for more variability than that illustrated in the balance of the drawings hereof. Upon exposure to more of this disclosure one skilled in the art will appreciate that more variables could be introduced to the concept hereof by lengthening the circumferential step-advance mechanism path. This is done for example by adding more J-steps (each comprised of slot section 48 / 50 and J-section 52 ) to the sleeve. In such a system, it is possible to add more variability regarding positioning and still allow for sufficient stepping to account for all combinations of possible positions. More or fewer J-slot steps is also relevant to groups of devices containing more of fewer devices. For example, other groups of devices are contemplated herein and include for example two or four devices. In a two device group, the step-advance mechanism would have four total positions yielding four steps of the device (three home positions and three second positions). In a four device group the step-advance mechanism would have thirty positions to account for all combinations of device positions. Alternatively, one or more of the devices could have no step-advance mechanism at all while others in the same group would have a step-advance mechanism. By so configuring the system, more devices are available without requiring an unwieldy number of step-advance mechanism positions. It is to be understood that the number of devices operable by the concept hereof is limited only by the number of control lines allowed. Twenty one devices or more can be controlled, for example. Essentially, the concept hereof is mathematically described as number of control lines equal (number of devices/number of devices per group plus 1).
FIG. 2 illustrates bearing lug 62 in a position away from home (or open) and stopped from further motion by stop 64 of bearing sleeve 60 . A stop such as this is illustrated more schematically in FIGS. 3-5 and is referred to here for the clarity offered by the more detailed drawing. As noted above, the FIG. 2 bearing sleeve provides for variable actuation of a single sleeve. This must be taken into account when considering the following figures and disclosure. Providing this variability in a control line reducing system as set forth herein increases complexity and would require significantly more J-steps to represent each possible interaction. While possible, the number of system pressure-up steps will at some point become unwieldy and outweigh the benefit-ratio of the concept.
Referring to FIGS. 3-5 , schematic illustrations of the J-slot sleeve and bearing sleeve are shown. FIG. 3 relates to device 18 for a one group system; devices 18 and 24 for a two group system; and devices 18 , 24 and 30 for a three group system. FIG. 4 relates similarly to device 20 ; to devices 20 and 26 ; or to devices 20 , 26 and 32 . FIG. 5 relates to device 22 ; to devices 22 and 28 ; or to devices 22 , 28 and 34 . As is now apparent, each device of a group of devices is constructed with a unique bearing sleeve. Because of this, pressuring up on control line 36 may have differing actuation of the three devices in each group. Moving through the various positions of the J-slot sleeve, each group of three devices can be moved through every possible combination of positions.
Still referring to FIGS. 3-5 , the J-slot sleeve representation is of a continuous J-slot with end 56 adjoining end 58 when in tubular configuration. As stated above, the J-slot sleeve portion of this arrangement operates to advance the pin 54 shown in FIG. 2 thereby also advancing the bearing lug 62 shown in FIG. 2 . In FIG. 3 one should appreciate that bearing lug 62 (shown in FIG. 2 ) cannot move leftwardly in the figure at position 12 , 8 and 4 but can so move at position 10 , 6 , 2 and 14 , with position 13 , 11 , 9 , 7 , 5 , 3 and 1 being rightwardly of the figure and unimpeded. These latter positions are the home positions, have in this example being open. The operation of the J-slot and bearing sleeves in FIG. 3 is the same in FIGS. 4 and 5 with stops at distinct positions. The stops in FIG. 4 are at positions 10 , 8 and 2 and for FIG. 5 at positions 6 , 4 and 2 . In each case the stops prevent closure of the associated device when pressure is exerted on line 36 while allowing such closure when stops are not positioned.
In each of the J-slot configurations, fourteen positions are shown. This comports with the two positions to the third power statement made earlier as each valve is stepped back and forth between a home position and a second position. This means that the valves are at the home condition at positions 1 , 3 , 5 , 7 , 9 , 11 and 13 and at second positions, which are dictated by the stops of FIGS. 3-5 for positions, 2 , 4 , 6 , 8 , 10 , 12 and 14 . One will appreciate this and its cyclic implications for combinations of device position in the table below:
Positions
Sleeves
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1, 4&7
H
C
H
O
H
C
H
O
H
C
H
O
H
C
2, 5&8
H
O
H
C
H
C
H
O
H
O
H
C
H
C
3, 6&9
H
O
H
O
H
O
H
C
H
C
H
C
H
C
Positions:
H = Home Position (= Open),
C = Closed,
O = Open
Referring to FIG. 6 , the foregoing tabular operation is illustrated more graphically. A nine valve (device) system is illustrated however it should be understood that this same figure could represent a three or six device configuration identically. The graphical representations each include three broken lines 70 , 72 and 74 . Line 70 represents the home position; line 72 the stopped position and line 74 the closed position. The three graphical representations are specifically aligned from top to bottom to provide an indication of the distinctions of actuation among the three devices in each group. These three graphical representations also relate directly to FIGS. 3-5 . The top most graphical representation 76 relates to FIG. 3 ; the representation 78 to FIG. 4 and the representation 80 to FIG. 5 .
By stepping through all fourteen positions of the illustrated embodiments, each possible combination of binary movement for the three valves in each group is achievable and this control for flow in the well is achieved for three valves with only two control lines; for six valves with only three control lines and for nine valves with only four control lines. As noted above: number of control lines equals (number of devices divided by number of devices per group) plus 1. The system as described significantly reduces the problem of overcrowding of the wellbore with control lines. Moreover, since this system uses only two positions for each valve, no graduated fluid pressure in the control line is necessary. This facilitates non-surface located hydraulic initiators and therefore additional benefit to the art in the form of reduced well head crowding since the lines need not exit the wellbore at all.
In one embodiment utilizing the above-disclosed concept, a surface control system having predictable and controllable volume and/or pressure capability is provided. This provides for automatic compensation of fluid volumes and/or pressures as the devices age. Furthermore, the control system may be operable remotely. The control system may in one embodiment include a programmable logic system.
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 control system for a plurality of devices including a plurality of devices in at least one group. A first control line is in operable communication with the plurality of devices. A second control line in operable communication with the at least one group. A step-advance mechanism is in operable communication with each of the plurality of the devices, each mechanism being distinct from each other mechanism within the group of devices. Further disclosed herein is a method for reducing the number of control lines needed to control a plurality of downhole devices including supplying a first control line in operable communication with a plurality of devices including at least one group of devices and supplying a second control line in operable communication with the at least one group. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of Invention
The invention is directed to pressure relief devices for compensating for pressure changes within sealed or isolated zones of an annulus of an oil or gas wellbore.
2. Description of Art
Sealing or isolating zones or areas of an annulus of wellbores is well known in the art. In general, one or more wellbore barriers such as packers or bridge plugs are disposed with in a wellbore above and below a “zone” or area of the wellbore in which production, or other wellbore intervention operations are performed. In some instances, the isolated zone is not being produced or intervention operations are not being performed, however, tubing, e.g., an inner casing, is disposed through this zone so that oil or gas production or other downhole operations can be performed below the isolated zone. In these instances, the fluid trapped or sealed in this isolated zone can expand or contract depending on the temperature of the fluid trapped in the isolated zone. When the temperature increases, such as during production from other zones within in the wellbore, the fluid expands and can cause damage to the inner casing of the wellbore, the outer casing of the wellbore, other components within the wellbore, or the formation itself. When the temperature decreases, such as when fluid is pumped or injected into the wellbore, the fluid contracts and can cause damage to the inner casing of the wellbore, the outer casing of the wellbore, other components within the wellbore, or the formation itself.
SUMMARY OF INVENTION
In situations where wells are designed with multiple barriers, such as packers, bridge plugs and the like, in the annular space, fluid becomes trapped in the space between these barriers. If the temperature of this trapped fluid increases, such as during production from the well, pressure within this isolated annular space increases. If the temperature of this trapped fluid decreases, such as during injection of fluids into the well, pressure within this isolated annular space decreases. In some situations, these pressure changes can be substantial and may cause failure of critical well components, including damage to the formation itself.
The pressure relief devices disclosed herein facilitate compensation of the pressure within the isolated wellbore annulus. Broadly, the pressure relief devices disclosed herein comprise a tubular member having a housing disposed on an outer wall surface of the tubular member. The housing includes a housing chamber and one or more ports disposed through the housing. An expandable member is disposed within the housing chamber. An interior portion of the expandable member is in fluid communication with the one or more ports. An outer wall surface of the expandable member isolates the remaining volume of the housing chamber to provide a sealed chamber. The sealed chamber can be maintained at atmospheric pressure or at a charged pressure.
The pressure relief devices can be disposed on a tubular string and located within a wellbore. As pressure in an environment located outside the pressure relief device, referred to herein as an “outside environment,” such as within an isolated wellbore annulus, increases such as due to an increase in temperature within the outside environment, the resultant increase in pressure is distributed through the port and into the interior of the expandable member causing expansion of the expandable member. As pressure within the outside environment decreases, such as due to a decrease in temperature within that environment, the resultant decrease in pressure is compensated by pressure moving from the interior of the expandable member, through the port, and into the outside environment. As a result, the likelihood that the change in pressure within the outside environment will cause damage to the wellbore or the tubing disposed within the wellbore or any other wellbore component within the outside environment is decreased.
During expansion of the expandable member due to the increased pressure within the outside environment exerting force on the hydrostatic side of the expandable member, the volume of the interior of the expandable member is increased and the volume of the sealed chamber becomes decreased. Decreasing the volume of the sealed chamber energizes the fluid or gas contained in the sealed chamber. Conversely, when the hydrostatic pressure is decreased, the compressed fluid or gas in the sealed chamber exerts a force on the sealed side of the expandable member to force the expandable member back until equilibrium of pressure on both sides of the expandable member is established, or until the expandable member can no longer move, such as due to all of the fluid within the interior of the expandable member being forced out by the pressure of the fluid within the sealed chamber. In other words, the atmospheric pressure or gas pressure within the sealed chamber acts as a return mechanism for the piston.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 comprises a cross-sectional view of one specific embodiment of a pressure relief device disclosed herein having an expandable member, FIG. 1 showing the expandable member in a contracted position.
FIG. 2 comprises a cross-sectional view of the pressure relief device of FIG. 1 showing the expandable member in a expanded position.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
Referring now to FIGS. 1-2 , one specific embodiment of a pressure relief device 10 is shown. This embodiment of pressure relief device 10 comprises tubular member 20 having outer wall surface 22 and inner wall surface 24 defining bore 26 having axis 28 . Disposed on outer wall surface 22 is housing 30 .
Housing 30 comprises upper end 31 and lower end 32 , and inner wall surface 33 for connecting housing 30 to outer wall surface 22 of tubular member 20 . Housing 30 also comprises housing chamber 34 and outer wall surface 35 . One or more ports 36 are disposed through one or both of upper and lower ends 31 , 32 . As shown in FIGS. 1-2 , housing 30 comprises four ports 36 . Ports 36 are in fluid communication with an environment outside of pressure relief device 10 and, as discussed in greater detail below, with an interior of an expandable member.
In the embodiment of FIGS. 1-2 , each of ports 36 comprise filter 38 disposed within ports 36 to restrict flow of certain sized particles through ports 36 . Filter 38 may be a foam or meshed material formed by a polymer, ceramic, or metal. Alternatively, filter 38 can be glass or sintered metallic beads or other aggregate materials.
Expandable member 40 is disposed within housing chamber 34 . Expandable member 40 comprises upper end 41 , lower end 42 , interior 44 defined by inner wall surface 45 , and outer wall surface 46 . Interior 44 is in fluid communication with each of ports 36 so that inner wall surface 45 of expandable member 40 which defines interior 44 is referred to herein as the hydrostatic side of expandable member 40 . Outer wall surface 46 of expandable member 40 is also referred to herein as the sealed side of expandable member 40 because sealed chamber 50 is defined by outer wall surface 46 of expandable member 40 and upper end 31 , lower end 32 , and inner wall surface 33 of housing 30 . Thus, sealed chamber 50 comprises a portion of housing chamber 34 .
Expandable member 40 can be formed out of any material known or desired that permits expansion of expandable member 40 . Suitable materials include elastomers such as rubbers, ethylene-propylene terpolymers (EDPM), and the like.
In one particular embodiment, sealed chamber 50 comprises a pressure disposed therein. The pressure within sealed chamber can be atmospheric pressure or can be a charged pressure. A charged pressure means that a fluid such as nitrogen or some other gas or fluid is pumped into sealed chamber 50 to a desired pressure. For example the pressure within sealed chamber 50 can be charged to the operational pressure of pressure relief device 10 . Operational pressure is defined herein as the pressure anticipated at the location within the wellbore where pressure relief device 10 will be disposed. As noted above, the charged pressure within sealed chamber 50 can be established using air, nitrogen, or any other gas or fluid desired or necessary to provide the desired pressure within sealed chamber 50 . The charged pressure can be established by pumping the gas or other fluid through charge port 39 . Charge port 39 can include a one-way check valve 18 or other device known in the art to facilitate injection of the gas or other fluid so that the charged pressure remains within sealed chamber 50 .
In the embodiment of FIGS. 1-2 , anti-extrusion devices 60 are disposed along outer wall surface 22 of tubular member at upper and lower ends 41 , 42 of expandable member 40 so as to prevent expandable member 40 from extruding upward and downward. In embodiments comprising anti-extrusion devices 60 , ports 36 pass through anti-extrusion devices 60 so that interior 44 of expandable member 40 is in fluid communication with the environment outside of pressure relief device 10 . Anti-extrusion devices 60 can comprise rings or other devices secured to outer wall surface 22 of tubular member 20 .
In one specific operation of pressure relief device 10 , pressure relief device 10 , disposed in the contracted position (shown in FIG. 1 ), is placed in a work string such as production string or other string of tubing (not shown) and run-into a cased wellbore (not shown). Pressure relief device 10 is then disposed within the cased wellbore at a location where the annulus of the wellbore is isolated from other parts of the wellbore. The isolation of the wellbore can be established by any method or device known in the art such as by use of one or more wellbore barriers such as packers, bridge plugs, valves, wellheads, the bottom of the wellbore, and the like. In so doing, interior 44 of expandable member 40 is placed in fluid communication with the isolated wellbore annulus through ports 36 . In the event that the fluid contained within the isolated wellbore annulus expands, or the pressure within the isolated wellbore annulus increases, such as due to production operations being performed through the work string, the increased pressure enters interior 44 of expandable member 40 and exerts a force on inner wall surface 45 causing expansion of expandable member 40 toward the expanded position (shown in FIG. 2 ). Expansion of expandable member 40 causes the volume of sealed chamber 50 to decrease. As a result, the atmospheric pressure or gas pressure within sealed chamber 50 becomes compressed or “energized.” In addition, in certain embodiments, a portion of outer wall surface 35 of housing 30 inflects inwardly as shown in FIG. 2 due to hydrostatic pressure also acting on outer wall surface 35 .
Expandable member 40 continues to expand within sealed chamber 50 until the pressure on both inner wall surface 45 and outer wall surface 46 reach equilibrium, or until expandable member 40 can no longer expand due to the size of sealed chamber 50 . In so doing, the pressure being exerted on the inner wall of the casing, or the inner wall of the formation, or the outer wall surface of the work string, is spread out and lessened, which decreases the likelihood of failure of any of the casing, the formation, or the work string, or any other wellbore component disposed in the isolated wellbore annulus.
Thereafter, if the pressure within the isolated wellbore annulus decreases, such as due to a temperature decrease due to cessation of production operations through the work string, the compressed atmospheric pressure or compressed fluid pressure within sealed chamber 50 exerts a force against outer wall surface 46 of expandable member 40 that is greater than the hydrostatic pressure within interior 44 , i.e., the hydrostatic pressure acting on inner wall surface 45 . Accordingly, expandable member 40 contracts from the expanded position ( FIG. 2 ) toward the contracted position ( FIG. 1 ) causing the volume in interior 44 to decrease and the volume of sealed chamber 50 to increase. Expandable member 40 continues to move toward the contracted position, reducing the volume of interior 44 and increasing the volume of sealed chamber 50 , until the pressure acting on inner wall surface 45 and outer wall surface 46 reach equilibrium, or until the volume within interior 44 can no longer decrease. Thereafter, expandable member 40 is in a position such that it can again expand in response to a pressure increase within the isolated wellbore annulus.
In another particular embodiment, one or more ports 36 is disposed only through lower end 32 . Location of the one or more port 36 through lower end 32 facilitates retaining gas within housing chamber 34 in the event that expandable member 40 fails. For example, in an embodiment in which sealed chamber 50 contains a gas, such as nitrogen, in the event that expandable member 40 fails, the gas will not be allowed to flow out of housing chamber 34 . Instead, it would be trapped above any fluid that previously flowed through the one or more ports 36 into interior 44 of expandable member 40 . Thus, failure of expandable member 40 will not result in loss of the gas from housing chamber 34 .
It is to be understood that the invention 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. For example, the sealed chamber of the pressure relief devices are not required to be charged with a gas or other fluid before use. Instead, sealed chamber may be an atmospheric chamber such that no charging of the sealed chamber required. In addition, the pressure relief devices disclosed herein can be used in circumstances in which the pressure within the wellbore annulus increases or decreases. Moreover, of the use of “upper” and “lower” in describing the embodiments is not intended to limit the direction of the pressure relief devices when in operation. In other words, the pressure relief devices are not required to be disposed in a wellbore where the “upper” structures are toward the top of the wellbore and the “lower” structures are toward the bottom of the wellbore. Accordingly, the use of “upper” and “lower” herein is not intended to limit the orientation of the pressure relief devices within a wellbore. Moreover, a rupture disk or other device can be disposed within the port(s) so that fluid is not permitted to flow through the port(s) until the pressure relief device is located within the well at the desired depth. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | Downhole tools comprise a housing chamber with an expandable member disposed therein. An interior of the expandable member is in fluid communication with an outside environment so that hydrostatic pressure can act on an inner wall surface of the expandable member. The outer wall surface of the expandable member partially defines a sealed chamber within the housing chamber such that expansion of the expandable member due to an increase in hydrostatic pressure causes the volume within the sealed chamber to decrease, thereby energizing the sealed chamber. Thus, an increase in hydrostatic pressure within an outside environment is compensated. Further, when the hydrostatic pressure within the outside environment decreases, the energized sealed chamber causes contraction of the expandable member, thereby compensating for the decrease in hydrostatic pressure. |
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to a downhole gauge package integrated into a delivery and communications cable. More particularly, the present invention relates to a downhole gauge package integrated into a communications cable requiring no assembly and having a single uniform outer diameter.
[0002] Downhole sensor gauges are used throughout the petroleum drilling and recovery industry to measure and report various downhole conditions. Gauges that record and measure temperature, pressure, and other types of information are deployed to a location of interest downhole for either long or short-term emplacement. Particularly, one form of long-term emplacement involves the installation of a gauge below a packer to report a condition below the packer back to a remote location. Packers are frequently installed in petroleum industry wellbores to isolate one zone or region from another, adjacent zone or region. Particularly, packers can be used in petroleum production to isolate the annulus between a string of production tubing and a cased borehole to prevent the unwanted escape of production fluids.
[0003] Packers typically perform their functions by expanding an elastomeric packer element to fill any gaps between the production tube and the cased borehole. The packer element can be expanded by “inflating” the element with pressurized fluid or by activating the flexible element by axially compressing it between two pistons. Irrespective of construction or the deployment method used, the packer effectively creates a fluid seal between the production tubing and the remainder of the borehole.
[0004] However, while a production zone is isolated by a packer, downhole condition measurements are still necessary to determine the status of the isolated zone. While gauges (e.g. temperature sensors and pressure transducers) can be deployed to the production zone through the bore of production tubing running through the packer, it is not preferred. Sensors that run through the production tubing bore can restrict the flow of production fluids or can interfere with the operation of production equipment located at the distal end of the production tubing. Furthermore, various pieces of equipment, for example downhole safety valves, require an unobstructed bore to be effective or to be in compliance with regulations.
[0005] To accommodate sensor gauges, packer designs have formerly been produced that allow a conduit to pass through the production tubing-casing annulus and bypass the packer element. These former designs typically involve a port through the body of the packer through which a constant diameter communications conduit can pass. Seals inside the port seal with the outer profile of the communications conduit and therefore prevent fluids from escaping from or invading into the production zone. Because of the design of the seals, the communications conduit has to be of a substantially consistent outer profile. Irregularities in the outer profile of the communications conduit can prevent a proper seal with the packer, thereby compromising the packer's function to isolate upper and lower borehole zones.
[0006] Former downhole gauge systems required the passage of the conduit through the port of the packer assembly followed by the attachment and connection of the gauge device to the distal end of the communications conduit once the packer was traversed. This was necessary because either the gauge assembly or the connection means between the conduit and the gauge typically had an outer profile that was larger than the communications conduit itself. The larger profiled gauge or connection means was unable to pass through the communications port designed to hydraulically seal against the smaller, more consistent communications conduit. Therefore, the communications conduit and the gauge assembly were typically delivered to the field location separately. Any functional checks that needed to be made on the gauge had to be performed prior to its final mating with the communications conduit and at the field location. As a result there was no way to test the integrity of the final conduit/gauge communications interface until after the gauge was installed below the packer, when a repair or replacement operation would be very costly.
SUMMARY OF THE INVENTION
[0007] The invention comprises a sensor gauge assembly to measure and communicate conditions from a downhole zone to a remote location through a downhole assembly. The sensor gauge may include a main body having an outer profile, a sensor package, and a connection to the communications conduit. The communications conduit may include a second outer profile and is configured to transmit communications data from the sensor package to the remote location. The connection to the communications conduit may include a third outer profile and the first, second, and third outer profiles are substantially the same.
[0008] The invention also comprises a sensor gauge assembly to measure and communicate conditions from a downhole zone to a remote location through a downhole assembly. The sensor gauge assembly may include a main body having a first outer diameter, a sensor package, and a connection to the communications conduit. The communications conduit may include a second outer diameter and is configured to transmit communications data from the sensor package to the remote location. The connection to the communications conduit has a third outer diameter and the first and third outer diameters are smaller than the second diameter.
[0009] The invention also comprises a communications system to measure and transmit data from a zone of interest below a packer to a surface location. The communications system preferably includes a communications conduit extending from the remote location to the zone of interest through a communications port of the packer. Preferably, a lower portion of the communications conduit has a substantially consistent outer gauge diameter wherein the lower portion is configured to be sealingly engages with the communications port. The communications system preferably includes a sensor gauge connected to a distal end of the communications conduit by a seamless connection wherein the seamless connection and the sensor gauge preferably have concentric outer diameters equal to the outer gauge diameter.
[0010] The invention also comprises a method to communicate with a zone of interest below a downhole assembly. The method preferably includes deploying a sensor gauge upon a distal end of a communications conduit to the downhole assembly. The method preferably includes engaging the sensor gauge and the distal end of the communications conduit through a communications port of the downhole assembly. The method preferably includes engaging the communications conduit with hydraulic seals within the communications port to prevent leakage of fluids from the zone of interest. The method preferably includes suspending the sensor gauge below the downhole assembly wherein the sensor gauge is configured to measure conditions of the zone of interest. The method preferably includes communicating the conditions of the zone of interest from the sensor gauge to a remote location through the communications conduit. Preferably, the distal end of the communications conduit and the sensor gauge have a uniform and continuous outer diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic cross-sectional view of a sensor gauge assembly in accordance with an embodiment of the present invention.
[0012] FIG. 2 is a schematic cross-sectional view of a sensor gauge assembly of FIG. 1 engaged through a downhole packer assembly.
[0013] FIG. 3 is a schematic cross-sectional view of the sensor gauge assembly of FIG. 1 installed in a testing station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to FIG. 1 , a sensor gauge 100 in accordance with the present invention is shown. Sensor gauge 100 is deployed at the end of a communications conduit 102 and includes a main body 104 and a stinger head 1 06 . Sensor gauge 100 may be any type of gauge used to measure wellbore parameters, such as temperature, pressure, flow, vibration, fluid differentiation, chemical properties, among others. Communications conduit 102 can be constructed as an armored cable assembly or can be any type or design of communications conduit known to one skilled in the art, including, but not limited to a hydraulic conduit, fiber-optic conduit, pneumatic conduit, electrical conduit, or the like.
[0015] Stinger head 106 preferably includes a sensor port 108 and a stinger profile 110 . Main body 104 can include any electronics or signal processing devices (not shown) and is shown having a cavity 112 through which a communications conductor 114 extends from the rear of main body 104 into communications conduit 102 . A coil 116 of conductor wire 114 is preferably contained within cavity 112 to accommodate any displacement of or tension on conductor 114 relative to communications conduit 102 . In addition to sensor port 108 , stinger head 106 is shown having optional seal glands 118 to facilitate pressure testing of sensor gauge assembly 100 prior to deployment. Stinger profile 110 of stinger head 106 is preferably constructed to align and guide sensor gauge 100 through a clearance port in a packer or other downhole device. Sensor port 108 allows sensors contained within main body 104 to communicate with fluids coming into contact with stinger head 106 .
[0016] Readings from sensor gauge assembly 100 through sensor port 108 are reported back either to electronics (not shown) in main body 104 or to a remote location at the end of communications conductor 114 . If main body 104 contains sensor electronics to process the signals read from sensor port 108 , conductor 114 can be used to transmit the processed signals from main body 104 to a remote location. For example, sensor electronics inside main body 104 can contain digital processors, so that communications conductor 114 extending from main body 104 to remote location through conduit 102 is a digital data path. While the term “conductor” is used, it is important that any communications mechanism, hydraulic, electrical, and optical, etc. may be employed for communications conductor 114 without departing from the spirit of the present invention.
[0017] Main body 104 of sensor gauge assembly 100 is preferably connected to communications conduit 102 at 120 through a seamless welded connection. Once sensor gauge assembly 100 is welded (or similarly attached through brazing, soldering, etc.) to communications conduit 102 , the weld area 120 is ground down so that the transition between conduit 102 and main body 104 is geometrically insubstantial. As main body 104 is preferably constructed to have the same outer profile as that of communications conduit 102 , the connection therebetween at weld area 120 is preferably made with the same profile. Once welded, the communications conduit 102 and sensor gauge assembly 100 can have a single uniform outer profile from a remote location all the way to the main body 104 . Alternatively, to reduce costs, outer profile of communications conduit 102 can be uniform only along a length necessary to engage sensor gauge 100 through a piece of downhole equipment, for example, a packer.
[0018] The primary benefit of having a uniform outer profile along communications conduit 102 through main body 104 of sensor gauge 100 is that simple, standard, off-the-shelf seal mechanisms can be used to isolate sensor gauge 100 and conduit 102 from a piece of downhole equipment. For example, in a packer, a simple o-ring seal is sufficient to ensure a tight seal between the packer and the sensor gauge assembly 100 or communications conduit 102 (such as an o-ring disposed on seal gland 118 ).
[0019] Referring briefly to FIG. 2 , a packer assembly 150 having a clearance bore 152 and a sensor gauge bore 154 therethrough is shown located in a cased wellbore 200 . Packer 150 functions to isolate a lower zone 202 from an upper zone 204 through the actuation of packer elements 156 , 158 and anchors 160 . With elements 156 , 158 and anchors 160 actuated, any hydraulic communication between lower zone 202 and an upper zone (i.e. 204 ) or remote location must pass through bore 152 . A string of tubing (not shown) typically connects bore 152 to the surface, allowing zone 204 to be isolated completely. Such isolation prevents fluids flowing from production zones like lower zone 202 from being contaminated by fluids in upper zones 204 .
[0020] Packer 150 also includes a sensor gauge bore 154 through which a sensor gauge assembly 100 at the distal end of a communications conduit 102 can pass. Because conduit 102 and main body 104 of assembly 100 are preferably constructed having a consistent outer diameter profile, o-ring seals (not visible) are all that are needed to seal sensor gauge assembly 100 with packer 150 to keep zones 202 and 204 isolated. While any size can be used for sensor gauge assembly, a standard 0.25 inch (6.35 mm) outside diameter geometry is preferred. The sensor assembly 100 is delivered to the downhole location at the distal end of communications conduit 102 and is “stripped” through port 154 of packer until a length 162 of conduit 102 and sensor assembly 100 protrudes below packer 150 into lower zone 202 . In this position, sensor port 108 of gauge assembly 100 is exposed to fluids in zone 202 and can report any information measured there back to a remote location.
[0021] Referring briefly to FIG. 3 , a test station assembly 180 for sensor gauge assembly 100 is shown. Sensor test station 180 is shown having a simple cylindrical test body 182 , a hydraulic port 184 , and a seal gland 186 . Elastomeric seals 188 , 190 help isolate communications conduit 102 and sensor gauge 100 from the atmosphere so that weld area interface 120 can be tested for hydraulic integrity. To perform the test, hydraulic pressure is applied to port 184 while sensor gauge 100 is plugged into a monitoring unit (not shown). As pressure to port 184 is increased, that pressure acts upon weld area 120 and the monitoring unit can detect any rupture or leak. Furthermore, if sensor gauge 100 includes a pressure gauge, a pressure cap 192 can be located upon the distal end of test body 182 so that pressure can be increased in a test volume 194 through a second hydraulic port 196 . Isolating the stinger head 110 of sensor gauge 100 allows different pressures to be applied to weld area 120 and sensor port 108 to test and certify sensor gauge 100 at a broad range of operating pressures.
[0022] Formerly, sensor gauges were delivered to the rigsite in components and either assembled downhole or immediately before being run downhole. Using the former systems, the cable and sensor included a connector mechanism that was of considerably larger diameter than the cable and sensor assembly to be connected. Therefore, if a 0.25 inch (6.35 mm) conduit were connected to a 0.25 inch (6.35 mm) sensor gauge, the connection means would prevent the assembly from passing through a 0.25 inch (6.35 mm) port. Furthermore, as the connection between gauge and conduit was often made after the conduit was run down hole, there was no way to test the integrity of the connection prior to deployment. The assembly could be put together and tested prior to deployment, but was still disassembled prior to installation. Using the apparatuses and methods of the present invention, a communications conduit and attached sensor gauge can be stripped through a seal bore designed to accommodate 0.25 inch (6.35 mm) diameter conduits.
[0023] Furthermore, the present invention enables a unitary communications conduit and sensor gauge manufacturable to a high degree of tolerance. Particularly, geometric dimensioning and tolerancing (GD&T) standards for cylindricity (radial deviations along a cylindrical feature) as high as ±0.005 inches (±0.127 mm) are feasible. Additionally, using the apparatus and methods of the present invention, any deficiencies of the prior art are addressed and corrected. A cable/sensor assembly can be constructed and tested in a controlled environment and shipped to the rigsite ready to deploy on a large drum. Once at the rigsite, the integrity of the sensor/cable connection can be quickly and easily tested immediately prior to installation.
[0024] Numerous embodiments and alternatives thereof have been disclosed. While the above disclosure includes the best mode belief in carrying out the invention as contemplated by the inventors, not all possible alternatives have been disclosed. For that reason, the scope and limitation of the present invention is not to be restricted to the above disclosure, but is instead to be defined and construed by the appended claims. | The present invention includes a communications system to measure and transmit date from a zone of interest below a downhole assembly to a remote location. The communications system preferably includes a sensor gauge engaged through a communications port of the downhole assembly upon a communications cable whereby the communications cable and sensor gauge have substantially the same outer profile diameter. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] The present invention relates generally to downhole circulation subs. More particularly, this invention relates to the use of an electric motor to drive a downhole circulation sub.
[0004] Retrieval of oil and other hydrocarbons from below ground typically includes drilling a borehole, also known as a wellbore, in the Earth. As drilling technology has advanced, these boreholes may be drilled off of vertical, sometimes even sideways or horizontal. In this way, an operator can reach a formation that contains the desired substance. Thus, the terms “upper” and “lower”, or “above” and “below” as used herein are made with respect to a position in the borehole, and may not necessarily reflect whether two elements are above or below each other in an absolute sense. FIG. 1 includes rock formation 100 surrounding a borehole 110 . Borehole 100 is formed by the cutting action of drill bit 125 attached to rotating drill string 120 . Drill string 120 also includes a circulating sub 170 .
[0005] A variety of drill bits 125 are known, but a common feature is that each contains ports or nozzles on its face to direct drilling mud 130 (also known as drilling fluid) flowing through drill string 120 . The drilling mud 130 exits the drill bit as shown by arrows 160 . This mud not only cools the face of the drill bit, but also carries to the surface a substantial amount of shavings and cuttings 140 that result from the drilling action. These cuttings are carried up to the surface from downhole along an area between the drillstring and the borehole wall known as the annulus 150 . At the surface, the drilling mud is then cleaned, filtered and recycled for repeated use.
[0006] One problem occurs when the ports or nozzles on the face of the drill bit 125 become blocked or otherwise impeded from spraying drilling mud out the face of the drill bit 160 . This prevents or substantially slows the flow of mud to the surface, resulting in the rock cuttings falling to the bottom of the wellbore. It also results in a pressure build-up in the mud contained in the drill string. The increase in pressure can damage equipment uphole such as pumps. To minimize this problem, it is known to provide a circulating sub 170 that provides an alternate route 165 for drilling mud flow when the mud is unable to exit drill bit 160 properly.
[0007] Referring to FIG. 2, a known circulating sub 200 is called a ball-drop circulating sub. It includes a cylindrical valve sleeve 210 having holes or ports 220 . At its lower end is a lip 230 that reduces the inner diameter of the cylindrical valve sleeve 210 . The circulating sub housing surrounds valve sleeve 210 and also includes ports 225 . Shoulder 260 is positioned for abutment against the lower portion of valve sleeve 210 , as explained below. Between valve sleeve 210 and drill string 120 are o-rings 240 - 242 and a shear pin 250 . Ball 270 is shown falling in mid-travel from the surface before lodging in area formed by lip 230 .
[0008] During normal operation (i.e., when mud is properly flowing 160 through the drill bit 125 ), drilling mud 130 flows through the center of circulating sub 200 as shown by arrows 280 . However, upon a blockage in the flow of mud, a ball 270 is shot from the surface down to ball-drop circulating sub 200 . Ball 270 lodges against lip 230 , preventing the flow of mud 130 along flow path 280 . Pressure built up in the mud column exerts itself against ball 270 and causes shear pin 250 to break. Valve sleeve 210 drops down until stopped by shoulder 260 . This aligns ports or holes 220 and 225 . Drilling mud 130 then escapes circulating sub 200 and follows mud path 165 (shown in FIG. 1) to the surface. This lifts the rock cuttings above the circulating sub 200 to the surface. However, the ball-drop circulating subs have a number of problems. For example, because the ball 270 originates at the surface, it can take up to thirty minutes from the time the mud flow stops through a drill bit to the time the circulating sub redirects the flow. In addition, this design is a one-time actuation and cannot be reset. Other circulating subs having various problems, such as U.S. Pat. No. 5,465,787, are also presently known.
SUMMARY OF THE INVENTION
[0009] A preferred embodiment of the present invention features a downhole circulation sub having an electric motor associated with a valve poppet. The valve poppet moves from a first position to a second position in response to force from the electric motor, causing drilling fluid flowing through the circulation sub to switch its path of travel from a first route generally downhole to a second route generally uphole. In its second position, the valve sleeve may engage a valve plug. Further, the valve poppet may be placed back in its first position by operation of the electric motor. The circulation sub is designed so that this movement of the valve sleeve from its first to its second position, and back again, may be carried out repeatedly.
[0010] Another aspect to the invention is a method of redirecting the flow of drilling fluid in a circulation sub. This aspect of the invention includes actuating an electric motor to apply force to a connected valve sleeve, moving the valve sleeve from a first position inside a housing to a second position by actuation of the electric motor, preventing by movement of the valve sleeve to the second position the flow of fluid past a lower end of the circulation sub, and directing by the movement of the valve sleeve to the second position the flow of fluid through ports positioned between die valve sleeve and an annulus. The first position is typically an upper position with respect to a wellbore, and the second position is a lower position.
[0011] Thus, the present invention comprises a combination of features and advantages which enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
[0013] [0013]FIG. 1 illustrates the typical flow of drilling fluid in a borehole.
[0014] [0014]FIG. 2 depicts the operation of a ball drop circulating sub.
[0015] [0015]FIG. 3A and 3B is a cut-away view of the preferred embodiment of the invention.
[0016] [0016]FIG. 4A is a cut-away view of the valve sleeve of the preferred embodiment in a closed position.
[0017] [0017]FIG. 4B is taken along line A-A of FIG. 4A.
[0018] [0018]FIG. 5 is a cut-away view of the valve sleeve of the preferred embodiment in an open position.
[0019] [0019]FIG. 6 is a cut-away diagram of a second embodiment of the invention.
[0020] [0020]FIG. 7 is a block diagram of a third embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] [0021]FIGS. 3A and 3B generally show the operation of the preferred embodiment. A fluid circulating sub 300 according to the preferred embodiment is attached to drill string or other housing 320 . The circulating sub 300 includes a DC motor 310 with associated downhole circulating sub electronics 308 , the DC motor 310 being mechanically coupled to rotate threaded screw 330 in either direction. Nut 340 terminates in piston 335 . Nut 340 threadably affixes to screw 330 , and moves laterally as shown by arrow 345 upon the rotation of the screw by motor 310 . Chamber 350 terminates at its narrow end at piston 335 and at its wide end at piston 360 . Piston 360 connects to connecting rod 365 . Also shove in FIG. 3A are mud passage 305 around the perimeter of the circulating sub, oil compensation spring 355 , oil compensation piston 357 , and fail-safe spring 367 .
[0022] [0022]FIG. 3B also illustrates drillstring 320 and connecting rod 365 . Additionally shown are valve sleeve 370 , also known as a valve poppet, formed to sealably engage valve seat 375 . Valve seat 375 , also called a valve plug, may be mounted by use of a screw, for example, and includes an o-ring 378 to form a seal with valve sleeve 270 . Holes 380 and 381 for mud flow 390 into the center of the circulating sub are formed in the upper portion of valve sleeve 370 . Holes 382 and 383 in valve sleeve 370 correspond to holes 384 and 385 in the housing and provide an alternate route for the drilling mud when the circulating sub is open and activated. The housing is a circulating sub housing that engages with the valve sleeve, but may be any appropriate housing such as a section of the drill string. In addition, many of the advantages of the preferred embodiment may still be obtained even where the valve poppet is not exactly like the configuration shown. The valve poppet can therefore be any of a variety of configurations.
[0023] During operation, downhole circulating sub electronics 308 receive power from the surface. To facilitate power delivery, the system may be preferably part of a coiled tubing drillstring equipped with electric wiring. Alternatively, the system may be part of a slim-hole jointed drill pipe string, for example, or may be any other structure suitable to deliver power downhole. Real-time data communications from the surface are also sent to the downhole circulating sub electronics. In response, the electronics 308 control the operation of electric motor 310 . Electric motor 310 is preferably a DC motor, although this is not crucial to the invention. The electric actuation motor 310 is reversible and may turn screw 330 in either direction to repeatedly open and close the circulating sub 300 . As such, the circulating sub disclosed herein has a longer life span than circulating subs known in the prior art. It also does not require replacement when the drillstring is “tripped”, or removed from the well bore. It is therefore more economical than circulating subs known in the prior art.
[0024] As electric motor 310 turns screw 330 , the nut 340 moves laterally 345 by force of threaded screw 330 . This moves piston 335 within chamber 350 . Chamber 350 includes both a smaller cross-sectional end for piston 335 and a larger cross-sectional end for piston 360 . As screw 330 is actuated (i.e., moves from left to right in FIG. 3B), it applies force to clean hydraulic fluid filling chamber 350 . This fluid transmits the force from piston 335 to piston 360 . What results is a hydraulic intensifier requiring less torque from, and thus less instantaneous current for, DC motor 310 . As force is applied to piston 360 , connecting rod 365 moves laterally in opposition to fail-safe spring 367 . In case of power failure, fail-safe spring returns the connecting rod 365 , and hence the circulating sub, to its unactuated and closed position.
[0025] Surrounding chamber 350 is an oil compression spring to resist the collapsing force from the drilling mud under high pressure and traveling through passage 305 . Oil compensation piston 357 accounts for the expansion and contraction of the hydraulic fluid due to temperature variations.
[0026] When valve sleeve is in its unactuated position as shown in FIG. 3B, drilling mud flows through holes 380 and 381 and follows mud path 390 past valve seat 375 and down to a drill bit, where it exits and travels up to the surface. The movement of connecting rod 365 from left to right opens the circulating sub by movement of valve sleeve 370 .
[0027] When this occurs, valve sleeve 370 covers and seals with valve seat 375 by, for example, o-ring seal 378 . This movement of the valve sleeve aligns holes 383 and 385 , and holes 382 and 384 , respectively, to provide an alternate mud flow path to the annulus. This alternate mud flow path bypasses the downhole drill bit and provides direct access to the annulus for the drilling fluid. It would now be apparent to the artisan of ordinary skill that the valve plug need not necessarily engage within the valve sleeve exactly as shown, but rather that other appropriate geometries and structures could be used, so long as the valve sleeve engages to prevent flow of drilling fluid past the circulation sub.
[0028] [0028]FIG. 4A includes a connecting rod 365 that connects to sliding sleeve valve 370 . Sleeve valve 370 resides in nozzle sub 420 and lower sub 320 . Valve body 470 includes a bypass chamber 410 and wire channel 520 , as well as containing plug valve 275 . Sleeve valve 370 prevents the flow of mud into the bypass chamber 410 and forces the flow of drilling mud 390 past valve plug 375 toward a downhole assembly. Wires in wire channel 520 supply power downhole. Thus, like FIG. 3, FIG. 4A depicts the valve assembly in a closed position. FIG. 4B is taken along line A-A of FIG. 4A.
[0029] [0029]FIG. 5 shows the valve assembly in an open position. Connecting rod 365 attaches to sliding sleeve valve 370 . A seal between these two components is made by o-ring seal 378 . As can be seen, mud flow is prevented from going past valve plug 375 and instead is directed to bypass chamber 410 and out replaceable nozzles 430 . These nozzles 430 are angularly mounted with the centerline, creating a spiraling fluid stream that is effective to lift and transport cuttings out of the borehole for hole cleaning purposes. Further, because all bore fluid flow is cut off from the lower port of the bottomhole assembly, all of the drilling mud is forced to circulate to the annular region between the drillstring and the borehole wall. This results in the cuttings in the borehole above the circulating sub being circulated to the surface (where they can be cleaned from the drilling fluid) prior to the tripping or removal of the drill string from the borehole.
[0030] [0030]FIG. 6 illustrates a second embodiment of the invention. This circulating sub 600 includes an electric motor 610 attached to a lead screw 630 . The lead screw 630 attaches to a valve sleeve 670 . Hence, this embodiment does not use hydraulic force amplification. Instead, this embodiment uses direct mechanical actuation involving the advancing and retracting of a lead screw 630 by the electric motor 610 , the lead screw opening and closing the valve sleeve 670 .
[0031] [0031]FIG. 7 illustrates a third embodiment of this invention that does not include a connecting rod to associate the electric motor to the valve sleeve. An assembly inside a housing 720 includes an electric motor 710 associated with a valve poppet 770 . A translation means 730 applies from the electric motor 710 to the valve poppet 770 . Thus, a non-mechanical linkage, such as a hydraulic arrangement, may be used as the translation means 730 to open and close the downhole valve poppet 770 by operation of the electric motor 710 .
[0032] While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | A preferred novel circulating sub includes an electric motor, hydraulic intensifier, connecting rod, valve sleeve, valve plug, and angled nozzles. Upon activation of the circulating sub the electric motor drives the valve sleeve over the valve plug, causing a flow of drilling fluid to exit the angled nozzles. Upon deactivation of the circulating sub, the electric motor removes the valve sleeve from the valve plug, allowing the flow of drilling fluid to once again flow to the drill bit. Because the electric motor is reversible, the circulating sub can be repeatedly activated and deactivated. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a lathe, and more specifically, to a two-dimensional sheet or foil that converts into a three-dimensional lathe for installing natural and artificial stones and other suitable uses in the roofing and construction industry.
[0003] 2. Prior Art
[0004] Generally, metal wire lathe is used for many building applications. One such application is under natural or artificial stone architectures where it acts as a reinforcement for concrete mixture used to adhere such stones to a vertical wall, facade or structure. The metal lathe provides pockets/spaces wherein concrete mixture when applied results in extra strength and reinforcement needed to withstand the weight load of stones in vertical or near-vertical architectures.
[0005] However, such metal lathe has significant bulk and thickness resulting in cumbersome and relatively expensive handling before it is delivered to the job site. Current metal lathes are available in forms that are essentially three dimensional, bulky and unwieldy to handle and transport. Therefore, there is a need for a more efficient lathe in the art that can reduce the bulk of the lathe so it is more easily transportable and easier to handle, before being installed.
SUMMARY OF THE INVENTION
[0006] One object of the present invention is to provide a lathe for application in the building/construction industry that stretches from a two-dimensional flat structure into a three-dimensional form just prior to affixing it on a wall or similar substrate, to allow for normal roll forms for easier and cheaper transportation. Yet another object of the present invention is to provide a lathe with slits of different designs, lengths, widths and spacings in order to have a predetermined pattern and pockets/openings depending on the density and type of cross-slit pattern.
[0007] Accordingly, a lathe for use in building construction is provided, the lathe comprising a foil having a length, width and thickness, and one or more slits that extend throughout the foil, wherein the slits allow the foil to stretch to form openings when the foil is extended in a lengthwise or widthwise direction.
[0008] The foil can have substantially parallel rows of slits in a horizontal direction, and alternate rows of slits in the same location with respect to a vertical direction. The adjacent rows can have slits that are in a fully or partially staggered arrangement. The foil can have substantially parallel rows of slits, each row having a slit in a horizontal direction followed by a slit in a vertical direction. The foil can comprise a metal foil.
[0009] The metal foil can have substantially parallel rows of slits in a diagonal direction. The angle of the diagonal slits can be approximately forty five degrees, or approximately one hundred thirty five degrees. The lathe can comprise a plastic laminate composite material.
[0010] The metal foil can have rows of slits in a diagonal direction, and adjacent rows of slits in a cross diagonal direction. The slits in the diagonal direction can be at an approximately forty five degree angle, and the slits in the cross diagonal direction can be at an approximately one hundred thirty five degree angle.
[0011] Further provided is a method of applying a lathe for building construction, the method comprising stretching a foil having one or more slits that extend throughout the foil, wherein the slits allow the foil to stretch to form openings when the foil is extended in a lengthwise or widthwise direction, and affixing the foil to a substrate.
[0012] The above and other features of the invention, including various novel details of construction and combinations of parts, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular device embodying the invention is shown by way of illustration only and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0014] FIG. 1 illustrates a top view of a lathe in two-dimensional form in accordance with a first embodiment of the present invention;
[0015] FIG. 2 illustrates a top view of a lathe in two-dimensional form in accordance with a second embodiment of the present invention;
[0016] FIG. 3 illustrates a top view of a lathe in two-dimensional form in accordance with a third embodiment of the present invention; and
[0017] FIG. 4 illustrates a top view of a lathe in two-dimensional form in accordance with a fourth embodiment of the present invention; and
[0018] FIG. 5 illustrates a top view of the lathe of FIG. 1 in three-dimensional form once stretched out.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Although this invention is applicable to numerous and various types of applications for the building/construction industry, it has been found particularly useful in the environment of reinforcements for concrete mixtures used to adhere natural or artificial stone architectures to a vertical wall or structure. Therefore, without limiting the applicability of the invention to the above, the invention will be described in such environment.
[0020] With reference now to the drawings, the lathe of the present invention will be described. FIG. 1 illustrates one embodiment of a lathe 100 of the present invention. The lathe 100 comprises a foil having cross-slits. For purposes of illustration, a sample of the lathe 100 is shown in the figure, but is not illustrative of the length, width or thickness of the lathe 100 that may be used for application. In FIG. 1 , a top view of a lathe comprised of foil is provided with its total number of slits in one direction. Although the shape of the lathe 100 is shown as rectangular, it should be understood that the lathe can come in other shapes and is not limited to the shape as shown.
[0021] The foil can have several substantially parallel rows of slits 101 and 103 along a direction 102 of the lathe 100 . For purposes of illustration, seven parallel rows are shown along a direction 102 in FIG. 1 . The slits 101 and 103 extend completely through the thickness of the lathe 100 . The slits 101 and 103 are arranged such that alternate rows have slits 101 in substantially the same location with respect to a vertical direction A. In other words, each row has slits 101 that are fully or partially staggered.
[0022] In another embodiment of the present invention, as shown in FIG. 2 , adjacent slits 201 are formed in a perpendicular direction in substantially parallel rows. Accordingly, in row 1 , for example, a horizontal slit 201 is followed by a vertical slit 203 , which is subsequently followed by another horizontal slit 201 , and so on. In row 2 , the slits are arranged identical to row 1 , except that the vertical slit 203 is below the horizontal slit 201 of row 1 , and the horizontal slit 203 is below the vertical slit 203 of row 1 . Alternate parallel rows are identical, similar to FIG. 1 . Therefore, rows I and 3 have slits in identical fashion along a horizontal direction 202 , and rows 2 and 4 have slits in identical fashion along a horizontal direction 202 .
[0023] FIG. 3 shows another embodiment of the present invention in which the slits 301 and 303 are all arranged at an angle. This could be a diagonal arrangement with approximately a forty five degree angle, but the angle can be anywhere between 0 to 90 degrees. These parallel rows can also be arranged so that the slits 301 and 303 are in a cross diagonal arrangement. Alternate rows have slits in substantially the same location with respect to the direction A. In other words, each row has slits 301 and 303 that are fully or partially staggered.
[0024] FIG. 4 shows another embodiment of the present invention in which the slits 401 and 403 are arranged in a cross-diagonal arrangement in substantially parallel rows. Specifically, alternate parallel rows having slits in a diagonal direction, and adjacent parallel rows have slits in a cross-diagonal direction. For purposes of the figure, rows 1 and 3 have slits 401 at approximately a 45 degree angle with respect to the horizontal direction 402 , and rows 2 and 4 have slits 403 at approximately an 135 degree angle with respect to the horizontal direction 402 . Of course, the angle of the slits 401 can range from zero to ninety degrees in rows 1 and 3 , and the angle of the slits 403 can range from ninety to one hundred eighty degrees in rows 2 and 4 , but is preferably at an approximately 45 degree and 135 degree angle, respectively. Alternate parallel rows have slits in substantially the same location with respect to the direction A. In other words, rows 1 and 3 have slits 401 in the same location vertically (direction A), and rows 2 and 4 have slits 403 in the same location vertically.
[0025] In all of the four embodiments described above, the slits are formed in the foil so that the slits extend through the thickness of the foil. Further, the lathe can be of any length, width or thickness, and the number of rows and length or width shown is just a sample, but can obviously be modified according to the use it is intended for. Some natural or artificial stones, depending on size, would need a smaller or greater length, width or thickness, and the present invention includes such variations to suit end-use applications. Further, the lathe can be manufactured to any shape, and is not limited to a rectangular or square shape as shown in the figures.
[0026] The lathe can be of any material, such as metal, plastic, laminate, reinforced hybrid composites or a combination thereof. A metal lathe can be made of different metals, such as steel, stainless, steel, alloy, copper, zinc, and other metals known to one of ordinary skill in the art. Further, the lathe can be a plastic (polymeric) laminate composite, an extruded cast sheet or a film—reinforced or otherwise.
[0027] Now, a method of application of the lathe of the present invention as illustrated in FIGS. 1-4 will be described. The two-dimensional lathe shown in FIGS. 1-4 can be rolled into a roll for easy and inexpensive handle and transportation. When it is time to install or use the lathe, an on-site worker can simply remove the length needed from the roll, or simply take out a flat two-dimensional piece of lathe. Then, the worker can simply stretch out the two-dimensional lathe, opening up the slits in the foil, to convert it into a three-dimensional lathe for installing natural or artificial stones, or for other suitable uses. Thus, the worker can keep the lathe in two-dimensional form until just prior to affixing it on a wall or similar substrate.
[0028] FIG. 5 shows a three-dimensional lathe 500 , which corresponds to the two-dimensional lathe 100 of FIG. 1 once stretched out typically perpendicular or at an angle to the length of the slits. As seen in FIG. 5 , the lathe 500 stretches so that the foil 501 opens up and takes a three-dimensional shape. Slits 502 open up forming pockets/openings to take on the three-dimensional shape required before affixing the lathe 500 on a wall or similar substrate. The lathe can be tailored to have a predetermined pattern and pockets/openings depending on the density and type of cross-slit pattern (as shown in FIGS. 1-4 ), and the dimensions of the cuts and their density (i.e., number of cuts per unit area).
[0029] The lathe may be of any suitable length, width, thickness and stiffness as desired. It will be appreciated that the length and width of each foil may be as long and wide as desired subject to manufacturing constraints. Moreover, it will be appreciated that it is a feature of the present invention that different cross-slit patterns, dimensions of the cuts, their density, can be modified to achieve three-dimensional lathes with different patterns and size of the pockets/openings.
[0030] The present invention provides several advantages that solve the problems with prior art methods. It provides a two-dimensional lathe that can be provided in a flat two-dimensional structure, allowing normal roll forms for easier and cheaper transportation. Then at a job site, the two-dimensional lathe can be easily stretched to form into a three-dimensional form just prior to affixing it on a wall or similar substrate. The present invention provides a lathe that stretches due to the slits and allows the foil to be easily stretched to take on a three-dimensional shape.
[0031] The cross-slit patterns shown in FIGS. 1-4 can be used, and different modifications of these embodiments can be used (such as length and width of the cuts, spacing of the cuts, etc.) to achieve various patterns and sizes of the pockets/openings of the foil. Further, slight modifications can be made in the design of the embodiments shown in FIGS. 1-4 , as would be obvious to one of ordinary skill in the art, to achieve the desired lathe for the intended use.
[0032] The above description of the present invention is only the preferred embodiment of the invention. Embodiments may include any currently or hereafter-known versions of the elements described herein. Different types of metal may be used for the metal foil, and different lengths, widths, thickness and stiffness of the metal foil may be used, and different lengths, widths and spacing of the cuts may be used as well.
[0033] While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims. | A two-dimensional foil having slits that allow the foil to convert into a three-dimensional lathe by stretching out the lathe so that the slits form pockets or openings. The lathe is made of a foil that can have a plurality of individual slits formed in parallel spaced rows extending transversely from one end to the opposing end. The foil is expandable by extending the opposing ends of the foil in a lengthwise or widthwise direction, whereby the slits form an array of openings. The length, width, spacing, number of the cuts and the extent of staggering between the rows can be varied. The two-dimensional foil can be easily stored in the non-expandable position in a roll form, allowing inexpensive and easier handling and transportation. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/725,454, filed 20 Mar. 2007, claiming benefit thereof, the entire specification expressly incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to mechanical sleeves that protect fence posts, mailbox posts, or any structure that is embedded into the earth, from deterioration from environmental elements and mechanical abrasion such as weed cutting devices. The sleeve is designed to surround the post or other structure and drain water away from the structure, thereby reducing corrosion from metallic structures and reducing degradation from biological agents and attendant rotting.
[0003] While a preferred embodiment of the invention will be illustrated with respect to protecting wooden fence posts from attack by rotary string trimmers used in landscaping and ground maintenance operations it will be appreciated that the invention is not limited to this application, but has wider utility in connection with protecting any in-ground object which is subject to repeated attack by equipment which has the tendency of destroying the aesthetic appearance or the structural integrity of the object.
BACKGROUND OF THE INVENTION
[0004] Devices intended to protect fence posts or other structures that are embedded into the ground are well known. An example is found in U.S. Pat. No. 5,503,371, invented by Bies, fully incorporated herein by reference. Bies shows an article and method of maintaining wooden fence posts from attack by landscaping equipment in which the base of the post is encircled with a hard plastic cuff. The plastic cuff has a smoother surface than the post such that string cutters used in edging around the fence post create a smoother and cleaner cut of the vegetation with the cuff as a backing while protecting the post from attack by the tip of the string element.
[0005] U.S. Pat. No. 5,328,156 to Hoke, fully incorporated herein by reference, shows a generally “U” shaped self-adhering plastic extrusion that is firmly fitted to the bottom portion of a chain link or wooden fence without fasteners. Upstanding walls of the elongated plastic body are tapered towards the center having a neck for accepting the fence and a curved bottom to provide a channel on each side to rapidly drain off water. The tapered walls grip the fence in frictional engagement to hold the body member in place. The assembly includes short coupler members shaped to slide longitudinally in close frictional engagement over the outer surface of the body members where abutting ends are found. Couplers help secure the body members in place and cover the joint. A raised central ridge running along the length of the bottom positions the edge protector with respect to the bottom of the fence and holds the bottom of the fence elevated above drainage channels to protect the fence from moisture or termite damage.
[0006] U.S. Pat. No. 4,845,889 to Taylor, fully incorporated herein by reference, discloses a lawn trimmer shield for protecting trees, plants and the like against damage from being struck by the rotating string of a lawn trimmer/weed cutter. The shield comprises two wall sections of hollow substantially semi-cylindrical shape which are hingably connected via a hinge. Each of the wall sections has a chamfered ground engaging edge which facilitates trimming close to the ground adjacent the shield. Handles are provided for facilitating installation and removal of the shield. Spikes are provided proximate the ground engaging edge for securing the shield close to the ground when it is installed about a tree, plant or the like.
[0007] U.S. Pat. No. 4,349,989 to Snider, fully incorporated herein by reference, shows a fence guard for installation along a fence line for the purpose of preventing or retarding the growth of grass, weeds and other vegetation under and along a fence, which fence guard includes an elongated grass shield fitted along the straight runs of the fence line adjacent to the fence posts and extending outwardly from one or both sides of the fence line to cover the ground and grass along the fence. A swivel joint for attachment to the base of fence posts in the fence line at points where the fence changes direction; specially configured gate plates for mounting to the base of the gate posts installed in the fence and corner post plates provided at the base of each fence post in the fence line at points where a 90 degree directional turn is achieved, or where several fence lines meet, to match cooperating lengths of the grass shield.
[0008] U.S. Pat. No. 3,571,972 to Carter, fully incorporated herein by reference, shows a device for enveloping upright elements such as trees, posts and the like at ground level to inhibit the growth of vegetation. A collar is formed of flexible water resistant sheet material and a main opening is formed therein from which a main slit extends to the outer edge of the sheet of material, the main slit being for the purpose of facilitating envelopment of a tree trunk and the like. A plurality of radial inner slits are formed in the sheet and extend outwardly from the central opening to define a plurality of flexible fingers which are disposed against the tree trunk or post to inhibit plant growth. Preferably the sheet is of laminated construction and the inner slits are formed in such manner that the fingers formed in the two laminated sheets are disposed in staggered relationship and the main slits in the two sheets are disposed out of coincidence with each other.
DISCLOSURE OF THE INVENTION
[0009] Wood most often used for large fenced areas, horse and cattle farms, parks, golf courses and the like are typically soft, less expensive pressure treated pine poles six to eight feet in length. Fence contractors will generally install such posts using hydraulic post extractors to remove a weakened or broken post, or power augers for digging holes for a new fence. Pressure treated pine is a relatively soft wood and will not stand up under the abrasive action of the plastic or nylon string cutter. Nylon has a tensile strength of 22,000 PSI, an impact strength of 2.2 to 2.6 ft. lb./in and a compressive strength of 29,400 PSI. The wood fibers are eroded away by the abrasive action of the tip of the nylon string exposing the untreated substrate to rapid enabling attack from moisture and insects which enter the post at the erosion zone near the ground line. The sleeves of the present invention can be made of any hard plastic or thermo-setting resin such as polyvinylchloride having an ultraviolet stabilizer additive to prevent discoloration and deterioration over time from the ultraviolet rays of the sun. The resin should have a flexibility without cracking or breaking down to approximately 15 degree F. allowing for installation during cold weather conditions. Depending on costs, other high density plastics may be used such as HDPE (high density polyethylene) having a tensile strength of 34,800 PSI, impact of 0.4 to 4.0 ft. lb./in. and compression of 3,000 PSI; or acrylonitrile butadiene styrene (ABS) having a tensile strength of 7,000 PSI, impact of 2.0 to 6.0 ft. lb./in. and a compression strength of 12,500 PSI are just two examples of the plastic other than PVC which may be used for the sleeves. Posts having the sleeve installed will not need to be repainted near the ground line resulting in further cost savings in both labor and material. Posts are generally spray painted or brush painted with external enamel, usually white in the horse farm industry. Alternatively a creosote based material having a black, matt finish is applied to the fence post providing a protective covering. The sleeve, if installed prior to installation of the posts, or before extensive edging has occurred will protect wood from being removed by the abrasive action of the string cutter. However, even if installed after substantial erosion has occurred fence life will be increased and fence maintenance expenditures significantly reduced for the land owner.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 shows the brush guard as seen from the bottom, or ground contacting surface.
[0011] FIG. 2 shows the brush guard from the top, or visible side when the brush guard is installed on a post.
[0012] FIG. 3 shows the bottom side of the brush guard when viewed from a perpendicular perspective.
[0013] FIG. 4 is a blown up view of the section designated by the numeral 4 in FIG. 3 .
[0014] FIG. 5 is a cross-sectional view of FIG. 4 , corresponding to the section 5 - 5 of FIG. 4 .
[0015] FIG. 6 is a side view of the brush guard.
[0016] FIG. 7 shows the top of the brush guard, viewed perpendicularly.
[0017] FIG. 8 is a cross-sectional view of FIG. 7 , corresponding to the section 8 - 8 of FIG. 7 .
[0018] FIG. 9 is a detailed, enlarged cross-section as designated by the numeral 9 in FIG. 8 .
[0019] FIG. 10 is a one-piece embodiment of the invention.
[0020] FIG. 11 is a one-piece embodiment of the invention including spikes to secure the brush guard to the ground.
DETAILED DESCRIPTION OF THE FIGURES
[0021] FIG. 1 shows the invention from the ground facing side, or bottom. As can readily be seen the sleeve of the instant invention is split diagonally, enabling the sleeve to be assembled over a wooden post or other support. In FIG. 1 the sleeve is shown square, but it is understood that other configurations, such as rectangular, or round, are appropriate and largely determined by the shape of the support the sleeve protects. Snap detents ( 1 ) are provided on each of the two diagonal halves, which can be easily connected either before the post or other support is installed, or after the post has been secured to the ground. In this way, the invention can be utilized either with a new post, that has not been installed, or can later be added to posts that are already sunken into the ground or otherwise installed, such as supported on a concrete footer.
[0022] Flange, or vertical collar ( 2 ) extends vertically above horizontal supporting plate ( 3 ). The purpose of the vertical collar is to protect the post or other structure from string in a rotary trimmer, as well as to protect the portion of the post that contacts the ground from other environmental degradation. Additionally, the vertical flanges ( 2 ) can be used to secure the sleeve to the post by screws, adhesive, or other means known in the art. Connecting the supporting plates ( 3 ) and vertical flanges ( 2 ), is a curved portion ( 7 ) (best seen in FIG. 6 ), that is curved to eliminate stress concentration.
[0023] FIG. 2 shows the sleeve as viewed from the top half, that is seen when the sleeve is fixed to a ground support. Vertical flanges ( 2 ) protrude upwardly and surrounds the ground support. Horizontal plates ( 3 ) contact the ground. Rectangular sections ( 4 ) form part of detents that snap the two diagonal halves of the sleeve together, overlapping the two top halves of the sleeve. Elements ( 4 ) are best described in reference to FIGS. 5 and 6 .
[0024] FIG. 3 shows the underside of the sleeve, as viewed perpendicularly from the bottom.
[0025] FIG. 4 shows the detents ( 1 ) in greater detail. Each half has a rectangular extension designated by ( 4 ) that overlaps the other half of the trim guard. Studs ( 5 ) extend perpendicular from the rectangular extension and are in register with corresponding openings ( 6 ) in the supporting plate ( 3 ). When the two halves are assembled, the studs ( 5 ) are pressed through the corresponding openings. An interference fit between the studs ( 5 ) and the openings ( 6 ) establish a secure fastening of the two diagonal halves. As can be appreciated from FIG. 5 , the top of the studs ( 5 ) can be further provided with a flange that operates as a detent, that snaps over the opening when the two diagonal halves are pressed together.
[0026] Although the studs ( 5 ) and openings ( 6 ) are shown in vertical alignment, where the underlying fence post defines vertical, the studs ( 5 ) and openings ( 6 ) could equally be horizontal. In this embodiment, the studs would extend horizontally from the diagonal half, and a flange would extend vertically from the opposite diagonal half The studs ( 5 ) would then resiliently snap, in detent like fashion with an interference fit, through openings in the vertically extending flange of the opposite half of the trim guard.
[0027] FIG. 6 shows the invention in profile. Studs ( 5 ) are seen in their assembled position, protruding through opening ( 6 ). The overlapping portion of studs ( 5 ) snap over horizontal plate ( 3 ). All the sharp angles in the invention are rounded, to reduce strength concentration, and attendant failure at those sharp corners where stress failures are most common. As can be seen in FIG. 6 , the corners between the upright vertical flanges ( 2 ) and base ( 3 ) are well rounded, designated by ( 7 ).
[0028] FIG. 7 shows the invention as viewed perpendicularly from the top. Flange 4 is shown overlapping the two diagonal halves of the horizontal plate ( 3 ).
[0029] FIG. 8 shows the invention in cross-section, as designated in FIG. 7 . It is readily seen how the studs ( 5 ) connect the two halves.
[0030] FIG. 9 is an enlargement of the portion of FIG. 8 , designated by 9 . Small channels are seen in FIG. 9 that are intended for stress relief with thermal expansion, or other stress such as swelling of the post with moisture.
[0031] FIG. 10 shows another embodiment of the invention, that is one-piece in construction. In this embodiment, there are no diagonal halves or studs to connect the two halves. This embodiment is intended primarily for combination with a new post. Therefore it is not necessary to have two separate halves to surround the post. When a new post is driven or otherwise secured to the ground, the brush guard is slid over the top of the post, and the flange ( 2 ) is slid down the post until the horizontal plate ( 3 ) contacts the ground. Although primarily intended for new posts, it is understood that the one-piece embodiment of FIG. 10 is suitable for any application where the one-piece brush guard can be secured.
[0032] FIG. 11 shows the invention, including spikes that can be inserted through the horizontal plate ( 3 ) and driven into the ground. With this feature, the brush guard can be firmly attached to the ground, preventing the brush guard from riding up the post and allowing vegetative growth between the brush guard and ground.
[0033] Because the split embodiment of FIGS. 1-9 can be used with either a new or pre-existing post, this is the preferred embodiment of the invention. However, it is expressly understood that the one-piece embodiment of FIGS. 10 or 11 can be equally useful, and is intended to be within the scope of the claimed invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In the preferred embodiment, the trim guard of the instant invention is constructed of polyvinylchloride. However, any polymeric material with the necessary impact strength is suitable, for instance polyethylene, polybutylene, or polypropylene. Copolymers are also suitable, such as ABS copolymer. It must be remembered the trim guard is intended for outdoor use. Therefore, the material selected must possess the requisite thermal properties, i.e. it must not become overly brittle at cold winter temperatures and at the same time it must not become unnecessarily soft at higher summer temperatures. Polyvinylchloride plasticized with dioctylthalate or doctyladipate, and epoxidized soy bean oil, is commonly used in these temperature extremes. The material must also be resistant to radiant degradation, normally encountered when polymeric materials are exposed to sunlight. Any material selected absolutely must be impact resistant to mechanical abrasion, as when a string rotary trimmer cuts vegetation around the trim guard.
[0035] As can be appreciated from consideration of the structural configuration of the horizontal supporting plate, grass or other plants are prevented from growing anywhere near the post or other embedded support. Because the horizontal supporting plate rests directly on the ground, and is very thin, a rotary power or hand mower can pass over the horizontal support plate, thereby easily trimming plant growth that protrudes outside of the horizontal support structure. If the vertical collar fits tightly around the post, then all that is necessary to remove plant material from around the post is to simply mow over the horizontal support structure, thereby completely eliminating the added burden of using a rotary string cutter.
[0036] Metals usable to make the instant trim guard would include aluminum, steel, especially stainless steel, copper, brass, or alloys of these metals. Most important when using metals for the trim guard is to remember that the metals must be corrosion resistant, as they are intended for outdoor use. If metals are selected, it is critical to remember that the metal be similar to the post or other support encased. This will reduce the junction potential between dissimilar metals that encourages corrosion because anodic/cathodic action due to the junction of dissimilar metals. In this application, the trim guard is particularly suitable for high-voltage power line supporting structure, or metallic sign posts, etc.
[0037] Although the Figures show the device in a rectangular configuration, it must be understood that any shape is usable with the trim guard. Round trim guards, for round posts, half-round trim guards for half-round posts, are contemplated within the scope of the trim guard. In any of these embodiments, the trim guard is split in half and attached in the manner shown with the rectangular species. Most important is that the trim guard fit as closely as possible to the underlying post or support structure. In this fashion, weeds, grass or other vegetation is inhibited from growing between the trim guard and the post or other underlying structure.
[0038] It is also contemplated that adhesive or other material, such as a resiliently compressible material can provided between the trim guard and the post. This will act to further inhibit the growth of vegetation between the post and trim guard. In another embodiment of the instant invention, an herbicide is interposed between the trim guard and post, such as in an adhesive polymeric matrix, or other adhesive matrix. In yet another embodiment of the invention, a herbicide is included in the polymeric matrix of the weed guard itself, and is constantly dispersed by diffusion from the weed guard.
[0039] Biocides that inhibit bacterial growth are also within the scope of the invention. Such biocides are intended to diffuse into the underlying post, thereby inhibiting bacterial decomposition of the post. Bacterial decomposition is the usual mode of failure in wooden posts, particularly where the post is submerged into the soil. Bacteria from the ground invades the wood, and rots the wood. By diffusing the biocide into the post, rot is considerably slowed down.
[0040] Insecticides are also within the scope of the invention, impregnated in the plastic matrix of the vertical collar or interposed in a compressible matrix between the vertical collar and the embedded support.
[0041] When the instant invention is used with metallic support structures, corrosion inhibitors could also be incorporated. The corrosion inhibitors could be dispersed within a polymeric matrix of the surrounding sleeve, or they could be impregnated into an adhesive matrix that interposes between the sleeve and underlying supporting structure. Corrosion inhibitors, biocides, or herbicides or other additives that are impregnated into an interposed matrix could be reapplied, as the additive is depleted from the matrix. Conveniently, new additive in liquid form could be poured into the matrix and allowed to saturate the matrix for fresh dispersion. | A trim guard, that surrounds wooden posts sunken into the ground, as well as other embedded structures is disclosed. The trim guard protects the posts or support structures from mechanical abrasion from devices such as rotary weed trimmers. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority to Provisional Application U.S. Application No. 60/808,890 filed May 30, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to the extraction and recovery of subsurface hydrocarbon deposits by a process of microwave radiation and permeability enhancement of reservoir rocks due to fracturing by selective and rapid heating.
BACKGROUND OF THE INVENTION
[0003] Oil shale, tar sands, oil sands and subsurface media in specific areas contain useful hydrocarbons. For example, it has been reported that there are vast oil shale deposits in the United States, and in particular, in the States of Colorado, Utah and Wyoming; with over 1.5 trillion barrels of oil in the oil shale in these States. There have been many attempts to extract the hydrocarbons from these subsurface deposits.
[0004] Some of these applications involve removal of the subsurface media to above ground and the use of a retort to remove the oil. To avoid the step of excavating or mining, a number of in-situ processes have been proposed.
[0005] One such proposal employs relatively low microwave power supplied by a magnetron. The down hole microwave generator is disclosed in U.S. Pat. No. 4,193,448 issued Mar. 18, 1980 to Calhoun G. Jeambey, as inventor, and the use of this generator is disclosed in detail in U.S. Pat. No. 4,817,711 issued Apr. 4, 1989 to Calhoun G. Jeambey as inventor. The microwave generator is a mixer apparatus similar to those used in microwave ovens and is relatively ineffective for controlled heating and removing of hydrocarbons. The apparatus heats the easily reached hydrocarbons in the pores of the rock and will leave much of the hydrocarbon away from the bore hole untouched.
[0006] Although not designed for commercially recovering hydrocarbons from oil shale or other subterranean locations, a high power microwave system is disclosed in U.S. Pat. No. 5,299,887 issued Apr. 5, 1994 to Donald L. Ensley, one of the inventors herein. This system is disclosed for the removal of contaminant from a sub-surface soil matrix. It is taught in this patent that the application of high power microwave energy to chlorinated hydrocarbons contaminated (CHC) soil causes micro-fractionation of various soil aggregates, including clay and rock formations. This effect increases the local permeability and resulting diffusion rates for egress of both liquid and vapor phase CHC.
[0007] The teachings of the Ensley U.S. Pat. No. 5,299,887 patent were included in U.S. Pat. No. 6,012,520 by Andrew Yu and Peter Tsou as an alternative to use of high-pressure water jet drilling to create a high-permeability web in a hydrocarbon reservoir.
SUMMARY OF THE INVENTION
[0008] The present invention provides a new economical way of recovering oil contained in a rock formation, such as oil shale, by enhancing the permeability of the subterranean rock by selective and rapid heating. The basic concept taught by the co-inventor Ensley is built upon for efficient recovery of oil from oil shale and of oil from tar sands. Additionally, the residual oil from worked and/or abandoned oil wells may be recovered by the apparatus and method of this invention.
[0009] The method of extracting oil from oil shale, tar sands and oil sands includes the steps of drilling a bore hole into the media, encasing the hole with a casing and a fused quartz extension or well screen at the bottom of the casing, inserting a microwave carrier with a directional antenna at the bottom end into the uncased well and the fused quartz well screen, and radiating electromagnetic energy at microwave frequencies from the antenna into the media surrounding the antenna.
[0010] The apparatus includes a high power (½ megawatt or greater) microwave source which operates at 1 Gigahertz or higher frequency coupled through a waveguide or coaxial cable to a directional antenna in a well. The typical frequency for the microwave source is 2.45 Gigahertz. The apparatus further includes a circulator in the waveguide path near the output of the source to protect the source from reflected waves. The circulator directs any reflected waves to a dummy load. A casing, inside the drilled hole and containing the waveguide, provides a path for passage of vaporized water and vaporized or liquified hydrocarbons from the bottom of the well to the top for collection and management and recovery of the hydrocarbons. The fluids are either pumped or rise because of sufficient pressure created by the heating and vaporizing of water and hydrocarbons.
[0011] The apparatus may further include a rotator in the waveguide going into the well to permit rotation of the lower waveguide and antenna for selecting the direction of radiation from the antenna.
[0012] The apparatus and method of the present invention provide extraction of hydrocarbons from subsurface deposits, which include, but are not limited to, oil shale, tar sands, heavy oil, and residual oil from petroleum reservoirs by microwave (greater than 1 GHz frequency) radiation that vaporizes hydrocarbons or decreases hydrocarbon viscosity for removal by conventional pumping technologies.
[0013] Further, the intrinsic permeability of the host rock is increased by fracturing the rock as a result of rapid microwave heating of the in-situ fluids. The process of increasing the intrinsic permeability of the hydrocarbon reservoir rock enhances hydrocarbon removal efficiencies during microwave heating. A pressure bubble in permittivity space may be created that contains the migration of hydrocarbons from the source region to the extraction bore hole.
[0014] The apparatus and method of this invention provide an enhanced zone of intrinsic permeability surrounding bore holes that increases production rates for new or existing wells located in subsurface gas or petroleum reservoirs. A permeable skin region is created around the well bore that extends several meters radially from the well bore.
[0015] The apparatus and method provides a way to remove the hydrocarbons with minimal impact to the environment. A single bore hole is drilled to extract hydrocarbons leaving no waste, such as clay waste piles, which require additional disposal methods. Additionally, water requirements from limited water resources are minimized by use of this apparatus and method.
[0016] Further efficiencies are realized by capturing and employing some of the volatile vapor emissions as fuel to power the field portable microwave system; thus, limiting fuel supplies from other sources. Gas turbines may be easily employed in this way. The net result is an increase in the energy balance where judicious quantities of energy are used to economically produce portable forms of energy that have a minimal impact on the environment.
[0017] Further, the impact on groundwater resources is minimized or avoided by containing the hydrocarbon removal process to the vertical region of extraction while not disturbing upper or lower layers of water.
[0018] The system for extracting and recovering hydrocarbons from subsurface target formations may be a closed system downhole with pressure control to most effectively extract hydrocarbons from rock, such as oil shale. Oil shale typically contains 2% to 4% of water. If there is insufficient water in the target formation, water may be added through the encased bore hole.
[0019] The water in the target formation is superheated and causes fracturing of the rock. Further, the superheated water, from the target formation or added, causes the pressure to increase to push the liquified or volatized hydrocarbon to the surface. These hydrocarbons are collected in a tank and recovered.
[0020] The pressure created by the superheated water or steam may be controlled by controlling the microwave power applied to the antenna positioned in the target formation. Further, the frequency of the output of the microwave source may advantageously be 2.45 Gigahertz, which is the closest frequency to the resonance of water.
[0021] The above and other features, objects and advantages of this invention will become apparent from a consideration of the foregoing and the following description, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a diagrammatic illustration of a mobile microwave hydrocarbon recovery system, in accordance with this invention;
[0023] FIG. 2 is an enlarged view of the phase array antenna in the well, in accordance with this invention;
[0024] FIG. 3 is another view of the major components of the system, in accordance with this invention;
[0025] FIG. 4 is a cross-sectional view of the phase boundary from the energy radiated by the antenna, in accordance with this invention; and
[0026] FIG. 5 is a diagram illustrating the typical stratification in many target formations containing hydrocarbons and a pressure controlled system, in accordance with this invention.
[0027] FIG. 6 is a diagram illustrating the microwave power penetrating dry soil followed by saturated soil, in accordance with this invention;
[0028] FIG. 7 is a diagram illustrating the power intensity in the dry soil, in accordance with this invention; and
[0029] FIG. 8 is a diagram illustrating the power generation capacity of 4 MW and power efficiency rates ranging from 20 to 50 percent, in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The specific embodiments of the hydrocarbon recovery system are illustrated in the drawings and will be described in detail herein. FIG. 1 illustrates the major components of a mobile hydrocarbon recovery system. A 400 cycle turbine generator 1 , or some similar source, supplies electrical power for the system. The output of the generator 1 is applied to a transformer/filter unit 3 under the control of a control unit 2 . A crowbar electrical circuit 4 at the output of the transformer/filter unit 3 prevents an over voltage condition at the output of the transformer/filter unit 3 from damaging circuits coupled to its output. Once triggered, crowbars 4 depend on overload-limiting circuitry, and if that fails, the system is protected by a line fuse or circuit breaker (not shown).
[0031] A high power (½ megawatt or greater) microwave source 5 (klystron) provides electrical energy down a waveguide 6 . The source 5 may be a typical klystron with an efficiency between 40% and 50%. Preferably, the source is a sheet-beam klystron which has an efficiency close to 65%. The microwave energy travels through waveguide 6 , past an arc detector 7 , and through a circulator 8 , to a mode converter 9 . The mode converter 9 allows the microwave energy carried by waveguide 6 (which may be square or rectangular) to be carried by a water-cooled circular waveguide 10 or a coaxial cable (not shown). The microwave energy is directed downward into a specially designed well in a bore hole 14 via the water-cooled waveguide 10 . The microwave energy is applied to a radiating antenna 11 which is located at a selected depth in a target formation 18 .
[0032] The antenna 11 and water-cooled waveguide 10 or coaxial cable are located in a specially designed bore hole 14 drilled to the target formation 18 which contains hydrocarbons. Standard drilling techniques are used to drill the bore hole to desired depths and diameters. The bore hole 14 passes through various stratified layers of soil, rock and water as schematically represented in FIG. 5 . Selected layers, such as each layer of freely running water, are sealed off by concrete 31 or some other suitable seal to prevent contamination or other interference with the water or aquifers.
[0033] A casing 29 is placed inside the bore hole 14 and extends above the ground level and down into the hole 14 for nearly the entire depth of the hole.
[0034] A fused quartz well screen 12 extends from the bottom end of the casing 29 . This screen 12 is perforated before attachment or may be perforated while in the hole 14 .
[0035] The well screen 12 is located at the level of the target formation from which hydrocarbons are to be extracted.
[0036] Thus, in the hydrocarbon production zone, the radiating antenna 11 is contained in the perforated fused quartz well screen 12 or other low loss material. Preferably, the antenna 11 is a phase array antenna for directivity and control of the radiation pattern.
[0037] A circulator 8 , having a series of ferrite magnets, is included in the waveguide 6 path to shift the phase and to shunt any power reflected from the target formation into a water-cooled dummy load 13 , thereby protecting the klystron tube 5 .
[0038] A water-cooling system consisting of a heat exchanger 20 and a coolant storage container 21 provide cooling water for the dummy load 13 , circulator 8 , klystron tube 5 , waveguide 10 and antenna 11 . The heat exchange 20 may operate at 2 Megawatts.
[0039] Arc detectors 7 are strategically placed in the waveguide to detect potential arcing problems and to immediately shut down the system if there is an arcing problem. The arc detectors 7 are integrated into a central control system 22 that monitors, but not limited to, cooling water temperatures, off-gas temperatures, off-gas concentrations, and power conditions for the power supply and the klystron, and provides safety controls for the operation of the system.
[0040] Electromagnetic energy is radiated either horizontally or angled upward, in a sector along the length of the antenna from the radiating antenna 11 and induces a phase boundary 17 into the surrounding rock of the target formation as the water and hydrocarbons are liquified or vaporized. This heating effect occurs due to microwave energy that is directly absorbed by the water and hydrocarbons in the phase boundary area 17 . As subsurface water and hydrocarbon deposits in the phase boundary area liquify or vaporize, the phase boundary region expands resulting in a pressure gradient from the phase boundary to the encased well. Several atmospheres of pressure relative to the inside of the casing 29 and the bore hole 14 , where the pressures are closer to atmospheric, may occur as a result of heating. A pressure gradient develops and thereby forces hot vapor from the subsurface, through the annular space of the casing 29 , past an off-gas analyzer 15 , and diverted to a thermal condenser tank 16 or a distillation unit for capture and hydrocarbon component separation.
[0041] The pressure in the area of the phase boundary 17 may be monitored by a gauge 30 near the top of the casing 29 , which is closed at the top. See FIG. 5 . The pressure may be controlled by varying the rate of flow of the material from the well by employing a valve 32 between the encased well and the thermal condenser and contaminated tank 16 . The pressure may also be varied by varying the power level of the microwave source 5 .
[0042] As an alternative to or in addition to pressure in the well, a sump near the bottom of the well with piping to the exterior of the well (not shown) may be used to recover the hydrocarbons and other liquids or gases from the bottom of the well.
[0043] An important effect of microwave radiation of rocks containing hydrocarbons and/or water is macro-fracturing of the rock over the area within the phase boundary 17 . This effect significantly increases the intrinsic permeability of the rock, allowing the efficient egress of liquid and vapor from the phase boundary through the fractured rock and into the bore hole for collection.
[0044] The area within the phase boundary 17 is a preferential pathway for the migration of water and hydrocarbons (either in gas or liquid form) from the phase boundary 17 to the bore hole 14 and well screen 12 . Consequently, vapor loss to the surrounding target formation is minimal as are potential environmental effects on any surrounding groundwater.
[0045] FIG. 4 provides a generalization of the phase boundary 17 launched into a target formation 18 by the phase array antenna 11 . The phase boundary 17 is the location where microwave power is coupled with the water and hydrocarbons and are preferentially heated. As the water and hydrocarbons are vaporized or mobilized as a liquid resulting from microwave heating, the phase boundary advances into target formation 18 . Water and hydrocarbon vapors migrate to the surface under the pressure gradient induced by microwave heating. Alternatively, a supplemental vacuum system is employed, if necessary. Additionally, extraction by conventional pumping may be used.
[0046] Once the phase boundary 17 has reached the maximum radial extent, the antenna 11 and water-cooled waveguide 10 are rotated around their vertical axes resulting in the antenna slots pointing in a different direction for extraction in a new sector. Another phase boundary 17 is created in the area adjacent to the previously microwaved region 19 . The subtended angle of each sector is selected to most efficiently extract the desired hydrocarbons from the target formation. The smaller the angle the greater the energy in the sector. The angle may be 30° for most target formation. The process is continued until the majority of the region at a selected depth has been radiated in all directions. The antenna 11 is either raised or lowered in the bore hole 14 to another region in the target formation 18 and the process of launching phase boundaries in sequenced sectors is repeated. This process is continued until the distance of the phase boundary 17 from the antenna 11 results in diminishing hydrocarbon recovery rates which will dictate cessation of the process in that sector and eventually at the operating depth of the antenna and in the particular bore hole 14 .
[0047] At this point in the process, the antenna 11 and water-cooled waveguides 10 are removed from the bore hole 14 . A conventional oil recovery pump continues recovering liquid hydrocarbons until recovery rates cease. This process is repeated in additional bore holes spaced at approximately twice the electromagnetic propagation distance of the system.
[0048] Microwave heating has significant advantages over low frequency heating (generally less than 1.0 gigahertz) for the extraction of subsurface hydrocarbons. The imaginary part of the permittivity ε r ″ (the loss tangent) is a measure of how dissipative a medium is and gives the rate of attenuation to a propagating wave. In the lower RF frequency ranges, ε r ″ is dominated by ion conductivity. As rock is heated by a low frequency RF source, ions in groundwater will act as a charge carrier until approximately 100 degrees centigrade is achieved, depending on the system pressure, at which time the water will vaporize, terminating the charge carrier pathway. Further heating of the rock will rely on conduction that requires large energy inputs over substantial time periods to achieve desirable results. For example, kerogen locked in oil shale requires temperatures in the range of 450 to 500 degrees centigrade in order to liquify for removal. This requires an additional 350 to 400 degrees centigrade heating by conduction for RF frequency heating applications.
[0049] Conversely, microwave heating is caused by orientation polarization In a lossy material, the electromagnetic energy is turned into heat by friction due to displacing internal charges when the material is polarized in place with the alternating electric field of the propagating microwave. Most rocks and soils are composed of aluminum silicates, calcium carbonates, quartz, or similar mineral compositions that exhibit low loss tangents for propagating microwave energy while water and hydrocarbons exhibit higher loss tangents. As a result, microwave energy can effectively penetrate various types of rock and directly couple energy into water and hydrocarbons resulting in a hydrocarbon removal process that is both effective and requires substantially lower quantities of electric power.
[0050] This process can be illustrated by comparing heating rates between conduction and microwave heating. A sample of oil shale placed in an 1100 watt microwave oven and heated for 3 minutes reaches an interior temperature of 103 degrees centigrade at 4 cm from the surface of the rock. Repeating the experiment in an 11,000 watt conventional oven at 260 degrees centigrade requires 22 minutes to reach the same temperature in the interior of the oil shale sample. The experimental results show dielectric heating by microwave frequency heats the oil shale over seven times faster at one tenth of the power requirement compared to thermal conduction heating.
[0051] The physical process of efficiently heating subsurface hydrocarbon deposits is based on the concept of launching a phase boundary in the subsurface using directed microwave energy, thereby heating the hydrocarbon to temperatures where liquification or vaporization occurs. As hydrocarbons are removed, the remaining rock absorbs limited amounts of energy allowing the phase boundary to continue to migrate radially from the access well.
[0052] The key to the migration of a microwave induced phase boundary to significant radial distances is the permittivity of dry rock and soil no longer containing water or hydrocarbon. Power attenuation in the dry rock or soil between the phase boundary and the well, the region where all of the hydrocarbons and water have been removed by heating, controls the radial distance that the phase boundary can migrate. In order to test the permittivity of dry rock and soils, a specially designed resonant cavity with a vector network analyzer and newly developed software capable of making accurate measurements down to ε r ″/ε r ′<10 −5 were used to measure the permittivity on a variety of dry soil samples. Values of ε r ′, the real part of the permittivity, fall in the range of 2.6±0.1 and using very careful sample preparation, including temperature control, values for ε r ″, the imaginary part of the permittivity, showed repeatable minimum values as low as 0.006±0.001. It is believed the best asymptotic values produced to date lie near this limit.
[0053] Using these permittivity values with the microwave frequency (ƒ) and the speed of light (c), it is possible to calculate the attenuation loss in the region of dry soil or rock in the microwave subsurface region using the following equation.
ɛ ″ = 0.006
ɛ ′ = 2.6
f = 2.45 × 10 9 l / s
c = 2.997 × 10 8 m / s
α = 2 π f c [ ɛ ′ 2 ( 1 + ( ɛ ″ ɛ ′ ) 2 - 1 ) ]
α = 0.0955 l / m
Attenuation loss = 8.6855 d α
Attenuation loss ( α DB ) = 0.829 db / m
The power per unit area (P z ) flowing past the point z in the forward z-direction can be estimated using the following relationship:
P z =P 0 e −2az
where (P 0 ) is the power per unit area flowing past the point z=0, (α) is the attenuation coefficient, and (z) is the radial distance from the antenna. It is possible to estimate the skin depth, the distance at which the amplitude decreases to 1/e (≈37%) of its initial strength.
[0054] It is assumed that electromagnetic waves are incident on the soil sample that consists of 20 cm of dry soil and then wet soil. As shown in FIG. 6 , microwave power penetrates the dry soil with negligible losses until it reaches the wet soil where nearly all of the power is absorbed in the first 10 cm of the wet soil which is the active heating zone. The ability to couple energy into a narrow area has several advantages including the enhancement of the rock's intrinsic permeability and the generation of steam.
[0055] Once all of the water and hydrocarbons have been removed by microwave heating in the region between the antenna and the phase boundary, the power intensity can be calculated as a function of distance in the dry soil as illustrated in FIG. 7 .
[0056] Nearly 15 percent of the power being radiated by the antenna is still available to heat the water and oil at 10 meters. With 2 megawatts of power radiating from the subsurface antenna, approximately 30 kilowatts of power is available for heating at this distance.
[0057] Only the permittivity of dry soils comprised of aluminum silicates and quartz were measured in the laboratory, however, microwave heating of selected natural minerals were performed by McGill and Walkiewicz (1987) and are presented in the following table.
Chemical Temp, Time, Mineral composition ° C. min Albite NaAlSi 3 O 8 82 7. Arizonite Fe 2 O 3 •3TiO 2 290 10. Chalcocite Cu 2 S 746 7. Chalcopyrite CuFeS 2 920 1. Chromite FeCr 2 O 4 155 7. Cinnabar HgS 144 8. Galena PbS 956 7. Hematite Fe 2 O 3 182 7. Magnetite Fe 3 O 4 1,258 2.75 Marble CaCO 3 74 4.25 Molybdenite MoS 2 192 7. Orpiment As 2 S 3 92 4.5 Orthoclase KAlSi 3 O 8 67 7. Pyrite FeS 2 1,019 6.75 Pyrrhotite Fe 1 x S 886 1.75 Quartz SiO 2 79 7. Sphalerite ZnS 87 7. Tetrahedrite Cu 12 Sb 4 S 13 151 7. Zircon ZrSiC 4 52 7. a Maximum temperature obtained in the indicated time interval.
[0058] It is possible to estimate the adsorption of microwave energy by comparing the permittivity measurement with the results presented by McGill and Walkiewicz (1987). Aluminum silicates such as albite and orthoclase show only minor heating in a microwave field consistent with the low permittivity values measured by the resonant cavity with the vector network analyzer. Quartz also showed results that are consistent with the published data and the laboratory measurements. For oil reservoirs in limestone or marlstone, typical of oil shale deposits, marble while metamorphosed is a similar composition. Marble exhibits limited heating in a microwave field which is consistent with other geologic material.
[0059] The directionality of the microwave beam produced by the phase array antenna and the enhanced intrinsic permeability of the region between the phase boundary and the well allow for specific targeting of hydrocarbon rich zones. The ability to target these zones allows for the efficient heating of subsurface hydrocarbon deposits while minimizing heat loss to less desirable subsurface units. Subsurface zones containing groundwater can be avoided thereby minimizing environmental impacts.
[0060] Stripper wells, defined as oil wells producing less than 10 barrels of oil per day, are limited in production due to low permeable formations surrounding the well. Commonly, the effective radius of the stripper well is limited to the radius of the well itself (e.g. commonly a 6 inch diameter well). Hydrofracturing is commonly used in the gas and petroleum industry to increase the permeability of the formation surrounding the well. Fluid is injected under high pressure into the well to induce fracturing along existing weakness in the rock such as bedding planes or small fractures. Small ceramic balls or similar materials are also injected to keep the fracture open during the production phase of the well.
[0061] The microwave system has the advantage of fracturing the entire rock formation surrounding a stripper well up to a radial distance of 10 meters. This “skin” zone surrounding the stripper well will exhibit an intrinsic permeability at least four orders of magnitude greater than the surrounding formation. Because of the rapid heating by the high power microwave system, extensive fracturing of lithofied rock can be expected to further increase the intrinsic permeability. Instead of oil flowing to an effective well radius of 6 inches, microwaved wells have an effective radius of up to ten meters. Modeling studies suggest that oil production rates from microwaved enhanced wells increase by over an order of magnitude.
[0062] Vast oil shale and tar sand deposits located around the world contain more oil than proven reserves in conventional oil fields. Present technologies to extract oil from these resources involve surface retorts or innovative subsurface heaters presently being tested by Shell Oil in Colorado. Microwave heating provides an efficient and environmentally sound method for the extraction of oil from these deposits and has several significant advantages both in costs, timing, and environment impacts.
[0063] The extraction of oil, assuming the use of a power generation capacity of 4 MW and power efficiency rates ranging from 20 to 50 percent, is shown in FIG. 8 . Small losses will occur in the power supply and the waveguide, depending on depth. Klystron tubes proposed for the system are rated at a 65 percent efficiency. Therefore, for shallow extraction, less than 500 ft, the efficiency of the total system may be around 50 percent. Using the median value for specific heat of 1.3, the result is the production of approximately 300 barrels of kerogen per day from a single production well in the oil shale deposits. Similar production rates may be applicable to tar sand deposits.
[0064] Using the price of $60.00 per barrel of oil, with a 50 percent efficiency, and the most cost effective source of available power, the net result is that for every dollar spent on energy to power the microwave system an equivalent of approximately $6 of oil is extracted from the subsurface. This 6 to 1 ratio is double the ratio for current in-situ processes presently being tested in oil shale deposits. Further, the increased efficiency resulting from using some of the natural gas from a well to power the system is not included. In addition, oil will be produced almost immediately upon the application of microwave power to the subsurface instead of the three to four years required by other subsurface heating methods.
[0065] While the description above contains specificity, this should not be construed as limiting the scope of the invention; but merely as providing illustrations of the presently preferred embodiment of the invention. Although preferred embodiments and method for extracting subsurface hydrocarbons have been described above, the inventions are not limited to the specific embodiments, but rather the scope of the inventions are to be determined as claimed. | Hydrocarbons are extracted from a target formation, such as oil shale, tar sands, heavy oil and petroleum reservoirs, by apparatus and methods which cause fracturing of the containment rock and liquification or volatization of the hydrocarbons by microwave energy directed by a radiating antenna in the target formation. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation, under 35 U.S.C. §120, of copending international application No. PCT/EP2014/065884, filed Jul. 24, 2014, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. 10 2013 012 489.1, filed Jul. 26, 2013; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a door handle system for a vehicle door, in particular for a vehicle door that can be moved automatically by way of a door adjusting motor.
[0004] In the case of modern (motor) vehicles, in particular passenger motor vehicles, the aim is usually to reduce the consumption of energy and in the case of internal combustion engines that are conventionally used to reduce the consumption of fuel. In addition to improving the drive technology itself (for example internal combustion engines and electric motors), it is frequently desired to decrease the air resistance of the vehicle. For this purpose, in part a vehicle outer surface that is closed as completely as possible and is virtually smooth is styled for the vehicle.
[0005] However, in the case of a large proportion of vehicles, in order to open the vehicle doors, door handles are used that are arranged in such a manner that they protrude in a handhold-like manner from the vehicle surface or are arranged above a grip recess that is formed in the vehicle surface. Door handles of this type disrupt both the vehicle surface as well as the aesthetic appearance of the vehicle and in addition offer an increased air resistance—in particular in the case of an additional grip recess being used.
[0006] U.S. Pat. No. 7,108,301 B2 and its counterpart European patent application EP 1 402 138 A1 describe covering the grip recess flush with the door handle by means of a flap so that the grip recess is advantageously hidden in an aerodynamic manner. This flap is provided with a sensor by means of which it is possible to detect in the immediate vicinity of the door handle the presence of the hand of the vehicle user who wants to operate the door handle. In the case that the hand is in the proximity of the door handle, the flap is automatically folded into the grip recess and the door handle is consequently revealed.
SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide a door handle which overcomes the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and which provides for an improved door handle system for a vehicle.
[0008] With the foregoing and other objects in view there is provided, in accordance with the invention, a door handle system for a vehicle door, the door handle system comprising:
[0009] a door handle having a rear side;
[0010] at least one flap for reversibly closing off a grip recess formed in the vehicle door and set back with respect to an outer surface of the vehicle door relative to the rear side of said door handle;
[0011] an adjusting device configured to pivot said at least one flap between a closed position that covers said grip recess and an opened position that reveals said grip recess;
[0012] a distance sensor at least in part disposed on said at least one flap or on one of a plurality of said flaps; and
[0013] a control and evaluating unit configured:
with reference to a first measuring signal output by said distance sensor in the closed position, to conclude that a vehicle user is approaching said at least one flap; to control said adjusting device so as to adjust said at least one flap into the opened position when detecting that the vehicle user is approaching said at least one flap; and to determine with reference to a second measuring signal output by said distance sensor in the opened position whether said door handle is being gripped by the vehicle user.
[0017] In other words, the door handle system in accordance with the invention comprises a door handle and at least one flap for reversibly closing off a grip recess that is set back with respect to the surface of the vehicle door in relation to the rear of the door handle. When the door handle is actuated in the appropriate manner, the hand of the vehicle user regularly grips in this grip recess. Furthermore, the door handle system comprises an adjusting device by means of which it is possible to pivot the one or each flap between a closed position that covers the grip recess and an opened position that reveals the grip recess. In addition, the door handle system comprises a distance sensor (also: proximity sensor) that is arranged at least in part on the flap or on at least one of the flaps. In other words—if the distance sensor comprises multiple parts—at least the part of the distance sensor that is sensitive to proximity is arranged on the flap. Furthermore, the door handle system comprises a control and evaluating unit that is configured so as to conclude with reference to a first measuring signal that is output by the distance sensor in the closed position that the vehicle user is approaching the one or each flap. In addition, the control and evaluating unit is configured so as to control the adjusting device for adjusting the one or each flap into the opened position when the approach is detected. In addition, in accordance with the invention, the control and evaluating unit is configured so as to determine with reference to a second measuring signal that is output in the opened position by the distance sensor whether the door handle has been gripped by the vehicle user, preferably by the hand of the vehicle user. In other words, the control and evaluating unit is configured in a first measuring mode in which the measuring region of the distance sensor, in other words the volume of space that is monitored by means of the distance sensor, is aligned towards the outer side of the vehicle, so as to monitor the surrounding area of the one or each flap for an approach by the vehicle user. In a second measuring mode, the measured region of the same distance sensor is aligned in an opposing direction into the grip recess in order to be able to detect whether the door handle is being gripped by the vehicle user.
[0018] This is in particular advantageous for the case that the vehicle door is a vehicle door that can be automatically adjusted by means of a door adjusting motor, said vehicle door preferably being used in conjunction with a so-called keyless entry function (keyless entry/keyless go function). In the case of this function, the vehicle lock that is allocated to the respective vehicle door is by way of example unlocked if the person that is approaching is carrying the (radio) key that is associated with the vehicle. The control and evaluating unit is in particular configured for the purpose of interpreting a gripping of the door handle as being the vehicle user's wish to open the door and consequently to output a door opening command to the door adjusting motor so as to adjust the vehicle door into its open position. As a consequence, it becomes easier to handle the vehicle door and consequently the operating comfort increases.
[0019] Advantageously, owing to the fact that the desire to open the door is identified automatically, the door handle can be embodied in such a manner that it does not move with respect to the vehicle door. A conventional unlocking mechanism that is coupled to the door handle for the vehicle door can consequently be omitted.
[0020] Moreover, by virtue of using the one or each flap for covering the grip recess, it is advantageously rendered possible to embody the vehicle surface as smooth, in particular from an aerodynamic point of view.
[0021] It is preferred that the control and evaluating unit is in addition configured so as in the opened position to detect that the door handle is no longer being gripped and furthermore to adjust the one or each flap back into its closed position. Optionally, the control and evaluating unit is furthermore expediently configured for the purpose of monitoring the grip recess merely for a predetermined time (by way of example 2 to 15 seconds) after opening the one or each flap in order to establish whether the door handle is being gripped. If it is detected in this period that the door handle is not being gripped, the control and evaluating unit is expediently configured so as to control the adjusting device so as to close the one or each flap. As a consequence, it is prevented in a simple manner that in the case of falsely detecting the approach (by way of example if the vehicle user passes the vehicle door in close proximity to the one or each flap) the one or each flap remains in its opened position until further notice.
[0022] In a preferred embodiment, the distance sensor is embodied as a capacitive distance sensor. In this case, the one or each flap supports in particular in each case a sensor electrode of the capacitive distance sensor. By way of example, the sensor electrode is integrated into the respective flap. In one embodiment that is expedient in terms of production technology, the flap is embodied for this purpose as a synthetic material injection molded part in which the sensor electrode is injection molded with synthetic material as an electrically conductive insert part.
[0023] In an alternative embodiment, the one or each flap itself forms in each case a sensor electrode of the capacitive distance sensor. This is in particular advantageous in the case in which the surface of the flap that is facing towards the outer side of the vehicle is embodied from an electrically conductive, in particular metal, basic material (by way of example sheet metal). This electrically conductive outer layer (in particular an electrically conductive paint layer) of the flap only needs in this case to make contact with the corresponding connection of the distance sensor. Alternatively, however, it is possible within the scope of the invention for the flap to be produced from a sufficiently electrically conductive synthetic material, by way of example injection molded. Embodying the flap as a sensor electrode offers the advantage that on the one hand the installation space that is taken up by the flap and the sensor electrode is particularly small and on the other hand, the entire (outer) surface of the flap can be used for sensing, whereby in turn the range of the distance sensor is increased.
[0024] In one embodiment, the one or each flap is pivoted in the opened position against the wall of the grip recess. The flap lies by way of example flush in the wall of the grip recess in or on said grip recess.
[0025] In an alternative embodiment, in the opened position the one or each flap is pivoted onto the rear side of the door handle. In this case, the hand of the vehicle user lies directly on the one or each flap when gripping the door handle so that the distance with respect to the sensitive part of the distance sensor, preferably in other words with respect to the capacitive sensor electrode, is minimal. In the case of the capacitive distance sensor, the sensor capacitance of the sensor electrode is preferably maximal so that it is possible in a simple manner to detect that the door handle is being gripped.
[0026] Within the scope of the invention, it is fundamentally possible that the door handle covers the grip recess in part in a strip-like manner from only one side, in particular from the upper side. In this case, it is only possible when actuated in the appropriate manner—when viewed in the vehicle vertical direction—to grip the door handle from one side (for example from below). In a preferred embodiment, the door handle is however embodied in such a manner that said door handle spans the grip recess in a bridge-like manner—preferably in the vehicle longitudinal direction. The door handle can be consequently gripped (in accordance with a type of handhold) from two sides. In the case of this embodiment of the door handle, the grip recess is closed in the closed position expediently on two sides (for example from above and below) in each case by a flap.
[0027] In an alternative embodiment of the invention, two flaps are arranged in each case on a side of the door handle and in the opened position one of said flaps is pivoted against the wall of the grip recess and the respective other flap is pivoted to the rear side of the door handle. The advantage of this embodiment is in particular that the flaps comprise a smaller flap surface (in comparison to a flap that covers the grip recess alone) and consequently it is possible in the opened position in a particularly simple manner to fit said flaps flush into the wall of the grip recess and into the rear side of the door handle. As a consequence, a virtually smooth and homogenous curve of the wall of the grip recess and in particular of the door handle is achieved in an advantageous manner. As a consequence, it is possible for the vehicle user when gripping the door handle to experience the door handle as virtually smooth, in other words without any protruding edges of the pivoted flap and as a consequence, said door handle can convey a significant operating feeling. In addition, for the case that each flap comprises a sensitive part of the distance sensor, preferably a capacitive sensor electrode, a particularly high level of adjustability of the measuring regions that are allocated in each case to the closed position and the opened position is achieved.
[0028] For the case that the door handle system comprises only one sensor electrode, the control and evaluating unit is expediently configured for the purpose of performing a measurement with the aid of this sensor electrode with respect to ground. In other words, the sensor capacitance of the capacitive distance sensor is determined between the sensor electrode and an object that is connected to ground and is arranged in the surrounding area of the sensor electrode. Within the scope of the invention, it is however also feasible that the control and evaluating unit in each case performs a measurement with respect to ground by means of multiple sensor electrodes.
[0029] For the case that the door handle system comprises multiple flaps and multiple sensor electrodes that are arranged on these flaps, these sensor electrodes are however interconnected in a preferred embodiment at least in the opened position in each case in pairs as a transmitting electrode and as a receiving electrode. It is possible in a particularly precise manner in comparison to a distance sensor that performs a measurement with respect to ground to set the measuring region of the distance sensor, said measuring region being covered by means of the measuring field between the transmitting- and receiving electrode. The “measuring field” is by way of example an alternating field that is generated by an electrical alternating voltage that is applied to the transmitting- and receiving electrode. The transmitting- and receiving electrode consequently form a sensor capacitor.
[0030] In a simple embodiment, the sensor electrodes are also controlled in pairs as sensor- and receiving electrodes in the folded out state, in other words when the flaps are in the closed position. Alternatively, the sensor electrodes are controlled in the closed position so as to perform a measurement with respect to ground.
[0031] In particular in the case that the grip recess is covered in the closed position on the two sides of the door handle in each case by means of the two flaps, the sensor electrodes are expediently controlled in the opened position in such a manner that the sensor electrodes that are arranged in each case on a side of the door handle in pairs are used as associated transmitting- and receiving electrodes. As a consequence, it can be precisely detected by means of the respective electrode pairs whether the door handle is being gripped on each side of the door handle in the grip recess. As a consequence, the reliability of detecting that the door handle is being gripped is increased. In particular, it can be detected in a particularly simple manner whether only one foreign body is protruding from only one side of the door handle into the grip recess or that the door handle is being gripped on both sides.
[0032] Within the scope of the invention, it is furthermore feasible that in addition to each sensor electrode that is arranged in or on each flap, a sensor electrode (“grip electrode”) is arranged in the door handle itself. This or each additional grip electrode cooperates in the opened position with in each case a sensor electrode that is arranged on the flaps in accordance with the transmitter-receiver principle.
[0033] In a further optional embodiment, the one or each sensor electrode is segmented in the vehicle longitudinal direction so that it is possible to determine by means of the control and evaluating unit a movement direction of the vehicle user or at least the hand of said vehicle user. In this case, the control and evaluating unit is preferably configured so as in addition to identifying that the vehicle user is approaching the door handle approximately from the front (in other words approximately in the normal direction to the outer side of the door) to also identify a stroke over the one or each flap in the vehicle longitudinal direction and evaluate this stroke as different to the frontal approach. By way of example, the measuring signals that are output by the segments of the sensor electrode are evaluated in dependence upon time. If the changes in the sensor capacitances that are measured by means of the respective segments comprise at least one predetermined temporal offset, the control and evaluating unit concludes that a stroke over the segments has occurred in the longitudinal direction. Otherwise, the control and evaluating unit concludes that a frontal approach has occurred.
[0034] In particular, it is provided that a stroke over the one or each flap is to be interpreted in dependence upon the direction as a locking or unlocking command for the vehicle door, in particular for the central locking of the vehicle. In other words, the one or each flap is pivoted into the opened position in the case of a frontal approach to the door handle while the vehicle door is locked if the vehicle user strokes the one or each flap by way of example in the direction of the door lock of the respective vehicle door.
[0035] In a further embodiment, the control and evaluating unit is configured for the purpose of activating an illuminating device of the vehicle when detecting that the vehicle user is approaching the one or each flap. An illuminating device of this type is in particular the headlight of the vehicle, in particular circumstances it is the “parking” light or the “low beam” light. Alternatively however, the illuminating device can also be a light source that is arranged on the vehicle door or on the door handle and that when activated illuminates the area of the vehicle door or the grip recess.
[0036] In a further embodiment, the control and evaluating unit is configured so as when detecting that the vehicle user is approaching the one or each flap to control a window regulator that is allocated to an adjustable window pane of the vehicle door. This is in particular advantageous in the case of using so-called frameless vehicle doors, by way of example in the case of convertibles or coupes. In this case, namely when opening the vehicle door, the window pane is opened along a small part of its adjustment path with respect to its closed position so that the window pane cannot clamp in its window pane seal that is arranged on the fixed vehicle frame. The control and evaluating unit is expediently configured for the purpose of lowering the window pane of the vehicle door by this predetermined part of the adjustment path in addition to opening the one or each flap. In particular, in the case of a wire-actuated window regulator it can be provided alternatively to control the window regulator merely so as to tension the wire without lowering the window pane.
[0037] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0038] Although the invention is illustrated and described herein as embodied in a door handle system for a vehicle door, 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.
[0039] 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
[0040] FIG. 1 illustrates in a schematic side view a vehicle door having a door handle module;
[0041] FIG. 2 illustrates in a schematic sectional view the door handle system in a closed position, wherein the one grip recess that is arranged to the rear of the door handle is closed off by means of two flaps with respect to the vehicle outer side;
[0042] FIG. 3 illustrates in accordance with FIG. 2 the door handle system in an opened position, wherein the flaps are pivoted inwards so as to reveal the grip recess; and
[0043] FIGS. 4 to 10 illustrate in a view in accordance with FIG. 2 various exemplary embodiments of the door handle system in the closed position or in the opened position.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown an exemplary vehicle door 1 having a door handle system 2 that is arranged thereon. The vehicle door 1 is a frameless door that does not comprise a window frame that delimits the side window of the vehicle with respect to the upper side, the side window being arranged on the vehicle door 1 . A vehicle door 1 of this type is used by way of example in the case of convertibles or coupes. The door handle system 2 comprises a door handle 3 that is aligned in the vehicle longitudinal direction 4 and spans a grip recess 6 that is formed in the outer surface 5 of the vehicle door 1 .
[0045] In order on the one hand to embody the outer surface 5 of the vehicle door 1 as smooth and therefore to improve the aerodynamic characteristics of the vehicle, the grip recess 6 is closed off with respect to the outer side by means of two flaps 12 and 14 in a closed position 10 that is illustrated in FIG. 2 . The flap 12 is arranged above the door handle 3 in relation to the vehicle longitudinal direction 4 . The flap 14 is accordingly arranged below the door handle 3 . The door handle system 2 furthermore comprises an adjusting device by means of which the flaps 12 and 14 can be automatically adjusted between the closed position 10 that is illustrated in FIG. 2 and an opened position 16 that is illustrated in FIG. 3 . In each case, of the adjusting device, only the adjusting lever 18 that is allocated to the flap 12 or 14 is illustrated for purposes of clarity.
[0046] In an alternative embodiment, the door handle 3 and also the flaps 12 and 14 can also be arranged vertically on the vehicle door 1 . Such an arrangement of the door handle 3 (and the flaps 12 and 14 ) is in particular provided for the case that the vehicle door 1 is the tailgate of the vehicle.
[0047] In addition, the door handle system 2 comprises a capacitive distance sensor and also a control and evaluating unit that is not further illustrated. The control and evaluating unit is configured and provided for the purpose of detecting by means of the capacitive distance sensor the vehicle user approaching the door handle 3 and furthermore to control the adjusting device so as to adjust the flaps 12 and 14 from the closed position 10 into the opened position 16 . A capacitive sensor electrode 20 or 22 of the distance sensor is integrated in each case in each flap 12 or 14 . The sensor electrodes 20 and 22 cooperate together as a transmitting- and a receiving electrode so that in the closed position 10 , a roughly horseshoe-shaped measuring field 24 spreads out towards the outer side of the vehicle door 1 (cf. FIG. 2 ). The measuring region that is covered by the measuring field 24 is consequently in front of the door handle 3 . The measuring field 24 is generated as an electrical alternating field by means of applying an electrical alternating voltage to the sensor electrodes 20 and 22 . The sensor electrodes 20 and 22 consequently form a sensor capacitor whose sensor capacitance is detected by the control and evaluating unit.
[0048] FIG. 3 illustrates the arrangement of the flaps 12 and 14 in their opened position 16 . The flaps 12 and 14 are pivoted onto the inner side of the grip recess 6 , in other words against the wall 30 of the grip recess 6 . The alternating field (described as recess measuring field 31 ) that is generated in the opened position 16 between the electrodes 20 and 22 extends in the opened position 16 approximately in a linear manner between the electrodes 20 and 22 and consequently extends in a transverse manner over the interior space (of the grip recess 6 ) that is delimited by a wall 30 of the grip recess 6 . In the opened position 16 , in other words the measuring region that is covered by the recess measuring field 31 is located within the grip recess 6 and to the rear of the door handle 3 .
[0049] A guard electrode 32 is arranged in the door handle 3 , said guard electrode being connected to ground potential and configured and provided so as to shield the recess measuring field 31 in the opened position 16 with respect to influences from outside the grip recess 6 . The shielding electrode 32 also prevents the presence or a movement of the vehicle user being detected outside the grip recess 6 by the distance sensor (that comprises the sensor electrodes 20 and 22 ).
[0050] The control and evaluating unit of the door handle system 2 is configured so as within the scope of a door opening method when the vehicle door 1 is in the closed state to monitor the immediate surrounding area of the door handle 3 for an approaching person (in short, the vehicle user) by means of the sensor electrodes 20 and 22 arranged in the closed position 10 . If the vehicle user is located in the measuring field 24 , the sensor capacitance of the sensor electrodes 20 and 22 is altered. This change in the sensor capacitance is registered by means of the control and evaluating unit. In this case, the control and evaluating unit controls the adjusting device so as to open the flaps 12 and 14 into the opened position 16 so that the vehicle user can grip in the grip recess 6 and grip around the door handle 3 . In the opened position 16 of the flaps 12 and 14 , the control and evaluating unit monitors by means of the recess measuring field 31 whether the hand of the vehicle user is located in the grip recess 6 . A change in the sensor capacitance in the opened position 16 by a predetermined value is indicative of the door handle 3 being gripped by means of the hand of the vehicle user. The control and evaluating unit interprets such a change in the sensor capacitance as the vehicle user wishing to open the door and furthermore outputs a door opening signal to the door adjusting motor of the vehicle door 1 .
[0051] In order to prevent that the flaps 12 and 14 remain open in the case of the door handle 3 not being gripped for an undetermined period of time, the control and evaluating unit is configured so as to monitor the grip recess 6 after opening the flaps 12 and 14 only during a predetermined waiting time, by way of example during 10 seconds, for whether the door handle 3 has been gripped. If the waiting time expires without event, in other words without it being registered that the door handle 3 is being gripped, the control and evaluating unit controls the adjusting device so as to close the flaps 12 and 14 .
[0052] The case that the sensor capacitance (in the case of the flaps 12 and 14 being in the opened position 16 ) returns to its idle value (in the absence of the hand in the grip recess 6 ) is interpreted by the control and evaluating unit as an indication that the vehicle user has let go of the door handle 3 . In this case, the control and evaluating unit likewise controls the adjusting device so as to close the flaps 12 and 14 .
[0053] FIG. 4 and FIG. 5 illustrate an alternative exemplary embodiment of the door handle system 2 , wherein the sensor electrodes 20 and 22 are controlled in the closed position 10 in such a manner that a distance measurement can be performed with respect to ground by means of each sensor electrode 20 or 22 . This is indicated in FIG. 4 in an exemplary manner by means in each case of field lines 34 that extend from each sensor electrode 20 or 22 and are indicated by way of example in a linear manner. In this measuring mode, each sensor electrode 20 or 22 consequently forms a sensor capacitor with the nearest grounded object that is arranged in the surrounding area of the vehicle. In the opened position 16 , the sensor electrodes 20 and 22 are in turn controlled as transmitting- and receiving electrodes so that the distance sensor can be used according to the exemplary embodiment in accordance with FIGS. 2 and 3 (cf FIG. 5 ).
[0054] In accordance with a further alternative exemplary embodiment that is illustrated in FIG. 6 , in addition two further sensor electrodes (described as “grip electrodes 40 and 42 ”) are arranged in the door handle 3 . The distance sensor in this exemplary embodiment is configured so as in the opened position 16 to control the sensor electrode 20 and the grip electrode 40 and also the sensor electrode 22 and the grip electrode 42 in each case in pairs as transmitting- and receiving electrodes. As a consequence, in the opened position 16 , the sensor electrode 20 and the grip electrode 40 and also the sensor electrode 22 and the grip electrode 42 form in each case a sensor capacitor having a respective allocated recess measuring field 44 or 46 . It is possible by means of controlling the sensor electrodes 20 and 40 or 22 and 42 to separately detect that the grip recess 6 is being gripped on each side of the door handle 3 by means of the respective allocated electrode pair.
[0055] In a further exemplary embodiment in accordance with FIGS. 7 and 8 , the flaps 12 and 14 are hinged on the door handle 3 in such a manner that they can pivot so that the flaps 12 and 14 are folded in the opened position 16 onto the rear side of the door handle 3 . The flaps 12 and 14 form a part of the surface of the door handle 3 , said part of the surface of the door handle facing the grip recess 6 . The recess measuring field 31 of the sensor electrodes 20 and 22 extends in the illustrated exemplary embodiment in the opened position 16 approximately in a U-shape and thereby approximately parallel to the wall 30 of the grip recess 6 .
[0056] In a further alternative exemplary embodiment in accordance with FIGS. 9 and 10 , the grip recess 6 is closed in the closed position 10 on the two sides of the door handle 3 by means of in each case two flaps. In each case, one of the flaps (hereinunder described as the upper recess flap 50 and the lower recess flap 52 ) can be pivoted onto the grip recess 6 so that the upper and the lower recess flap 50 or 52 in the opened position 16 lie against the wall 30 of the grip recess 6 . The two other flaps are described hereinunder as the upper grip flap 54 and lower grip flap 56 and are pivoted in the opened position 16 onto the rear side of the door handle 3 (cf. FIG. 10 ). A sensor electrode of the distance sensor is arranged in each case on the recess flaps 50 and 52 and the grip flaps 54 and 56 .
[0057] As is illustrated in FIG. 9 , the sensor electrodes are controlled in the closed position 10 in such a manner that the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 form a common upper electrode. The sensor electrodes of the lower recess flap 52 and the lower grip flap 56 are controlled in a similar manner and consequently form a common lower electrode. The upper electrode and the lower electrode are controlled in a manner that can be compared to the exemplary embodiment in accordance with FIG. 2 as a transmitting- and receiving electrode and form the horseshoe-shaped measuring field 24 with respect to the outer side of the door handle 3 .
[0058] In the opened position 16 (cf. FIG. 10 ), the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 and also the sensor electrodes of the lower recess flap 52 and the lower grip flap 56 in contrast are controlled in pairs as transmitting- and receiving electrodes. Consequently, a measuring field 60 is formed between the sensor electrodes of the upper recess flap 50 and the upper grip flap 54 and a measuring field 62 is formed between the sensor electrodes of the lower recess flap 52 and the lower grip flap 56 . The control and evaluating unit can be configured in a manner comparable to the exemplary embodiment in accordance with FIG. 6 so as to detect that the door handle 3 is being gripped.
[0059] In an alternative (not further illustrated) exemplary embodiment, the control and evaluating unit is configured so as in the opened position 16 to control the sensor electrodes of the recess- and grip flaps 50 to 56 in an alternating manner. In a first step, the sensor electrodes are controlled in accordance with the exemplary embodiment in accordance with FIG. 10 . In a second step, in contrast the sensor electrodes of the recess flaps 50 and 52 are switched off. The sensor electrodes of the grip flaps 54 and 56 are then controlled as transmitting- and receiving electrodes. This second control corresponds essentially to the exemplary embodiment in accordance with FIG. 8 . It is possible by means of controlling the sensor electrodes in an alternating manner to detect in a particularly precise manner that the door handle 3 is being gripped on all sides and the reliability of the door handle system 1 is thereby increased.
[0060] The subject matter of the invention is not limited to the above-described exemplary embodiments. On the contrary, further exemplary embodiments of the invention can be derived by the person skilled in the art from the above description. In particular, the individual features of the invention that are described with reference to the various exemplary embodiments and their embodiment variants can also be combined with one another in other ways.
[0061] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
1 Vehicle door 2 Door handle system 3 Door handle 4 Vehicle longitudinal direction 5 Outer surface 6 Grip recess 10 Closed position 12 Flap 14 Flap 16 Opened position 18 Adjusting lever 20 Sensor electrode 22 Sensor electrode 24 Measuring field 30 Wall 31 Recess measuring field 32 Guard electrode 34 Field line 40 Grip electrode 42 Grip electrode 44 Recess measuring field 46 Recess measuring field 50 Upper recess flap 52 Lower recess flap 54 Upper grip flap 56 Lower grip flap 60 Measuring field 62 Measuring field | A door handle system for a vehicle door has a door handle and at least one flap for reversibly closing a grip recess set back to the rear of the door handle. An actuating device pivots the one or more flaps between a closed position that covers the handle recess and an open position that exposes the handle recess. A distance sensor is disposed on the flap. A control and evaluation unit uses a first measurement signal that is output by the distance sensor in the closed position, to deduce that a vehicle user is approaching so as to activate the actuation device to move the one or each flap into the open position. A second measurement signal that is output by the distance sensor in the open position indicates that the door handle is grasped by the vehicle user. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This nonprovisional application claims the benefit of, and priority from, U.S. provisional application 61/566,840 filed 5 Dec. 2011. The contents of such prior application and all patent documents referenced herein are hereby incorporated by reference in their entirety as if fully set forth herein.
TECHNICAL FIELD
The present disclosure relates generally to tents, and more specifically to a framed door panel structure including a swinging door which is attachable to a vestibule or door opening of a soft-walled tent.
BACKGROUND
The use of soft-walled tents for shelter is well known. Such structures have the benefits of light weight and portability which facilitates their use as mobile, temporary structures. In some instances, it may be necessary to use a tent for a prolonged period of time. In such circumstances, it may be desirable for the tent to exhibit characteristics of a more permanent structure to provide the user with a greater degree of comfort and security.
It is known to use a wooden or metal framework for the body of the tent. However, even in such framed structures, the entryway covering was typically a soft structure such as a flap or the like which did not mimic the action of a standard hinging door. Thus, a user did not have the perception of entering and leaving a permanent structure. It is also known to use solid wooden doors for operative connection to a tent frame. However, such structures are not highly portable due to substantial bulk and weight. Moreover, such structures may be relatively difficult to install in the field.
SUMMARY OF THE DISCLOSURE
The present disclosure provides advantages and alternatives over the prior art by providing a tent door panel assembly incorporating a pliable, soft material operatively connected to collapsible tubular frame to define an internal swinging door. The door panel of pliable material may be connected to the door opening or vestibule opening of the tent using well known attachment mechanisms. The collapsible tubular frame may be disassembled and reassembled for removal and portability.
In accordance with one exemplary aspect, the present disclosure provides a modular tent door panel adapted to be folded and unfolded for storage and shipment. The door panel includes a structural frame including a door skeleton defining a rotatable door adapted to rotate about a hinge line. The door skeleton includes a plurality of tube sections. One or more of the tube sections are multi-piece tube sections comprising multiple tube segments interconnected in releasable relation to one another along a length dimension such that the multi-piece tube sections have an enhanced length relative to the constituent tube segments. A pliable door skin panel is disposed in covering relation across one side of the door skeleton. The door skin panel is anchored in fixed relation to multiple tube segments forming a first outboard multi-piece tube section. The first outboard multi-piece tube section is positioned substantially parallel to the hinge line and outboard from the hinge line. The door skin panel is further anchored in fixed relation to multiple tube segments forming an inboard multi-piece tube section defining a free edge of the door oriented substantially parallel to the hinge line. A pliable side panel is anchored in fixed relation to multiple tube segments forming a second outboard multi-piece tube section. The second outboard multi-piece tube section is positioned substantially parallel to the hinge line and outboard from the free edge of the door when the door is in a closed position.
Other features and advantages of the disclosure will become apparent to those of skill in the art upon review of the following detailed description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the front surface (i.e. exterior) of a fully assembled exemplary modular tent door consistent with the present disclosure wherein fabric materials are disposed in attached covering relation to a collapsible frame;
FIG. 2 is schematic view illustrating the interior surface of the fully assembled exemplary modular tent door of FIG. 1 wherein fabric materials are disposed in attached relation to a collapsible frame;
FIG. 3 is a schematic view similar to FIG. 1 illustrating the front face of a fully assembled supporting frame consistent with the present disclosure wherein fabric materials have been removed to illustrate the underlying support structure;
FIG. 4 is a schematic view similar to FIG. 2 illustrating the interior of a fully assembled supporting frame consistent with the present disclosure wherein fabric materials have been removed to illustrate the underlying support structure;
FIG. 5 is a sectional view taken generally along line 5 - 5 in FIG. 1 illustrating an exemplary hinge construction for an exemplary modular tent door consistent with the present disclosure;
FIG. 6 is a sectional view taken generally along line 6 - 6 in FIG. 1 illustrating an exemplary overlapping door and jam arrangement for an exemplary modular tent door consistent with the present disclosure;
FIG. 7 is a sectional view taken generally along line 7 - 7 in FIG. 1 illustrating an exemplary Becket loop and weather seal flap arrangement for an exemplary modular tent door consistent with the present disclosure;
FIG. 8 is a sectional view taken generally along line 8 - 8 in FIG. 1 illustrating an exemplary door window for a modular tent door consistent with the present disclosure; and
FIG. 9 is a plan view illustrating fabric panels for use in an exemplary modular tent door consistent with the present disclosure.
Before the exemplary embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is in no way limited in its application or construction to the details and the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the disclosure is capable of other embodiments and of being practiced or being carried out in various ways.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the drawings wherein, to the extent possible, like elements are designated by like reference numerals in the various views. The figures illustrate various views of a modular tent door assembly 10 adapted for operative connection at the inner perimeter of a tent mouth opening or vestibule (not shown) as will be well known to those of skill in the art. The door assembly 10 include includes an outer covering 11 made up of panels of synthetic fabric or the like ( FIG. 9 ) disposed in overlying relation to a supporting door frame 12 ( FIGS. 3 and 4 ) as will be described further hereinafter. In this regard, the outer covering is preferably formed from a pliable polymeric fabric material including an insulation layer as will be described further hereinafter, although different materials may be used if desired.
As best seen through joint reference to FIGS. 1-4 , in the exemplary construction, the door frame 12 may be disposed across the surface of the door facing into the interior of the tent such that components of the door frame may be visible to an occupant in the tent. However, these components will typically be covered across the exterior so as to be substantially hidden from view at the exterior. By way of example only, and not limitation, the covering material may be affixed to the door frame by a multiplicity of rivets 14 extending through the covering material and into hollow tubes 16 of aluminum or other suitable tubular material forming the frame 12 .
By way of example only, and not limitation, one or more of the tubes 16 may be formed from multiple tube segments of relatively short length connected by use of joints having a structure generally as shown and described in U.S. Pat. No. 6,726,255, the contents of which are hereby incorporated by reference in their entirety. However other suitable connection structures which can be engaged and disengaged may likewise be used if desired. As will be appreciated, by using relatively short length tube segments which can be reversibly connected and disconnected, the frame 12 may be disassembled, while individual tube segments may remain attached in riveted relation to the outer covering 11 . Thus, when the frame 12 is disassembled, the door assembly 10 may be folded into a relatively compact structure without requiring complete disengagement of the covering from the tube segments.
A best seen in FIGS. 3-5 , the frame 12 is configured to correspond generally to a standard door frame as would exist in a permanent structure. In this regard, the frame 12 includes a rotatable door skeleton 20 of substantially rectangular configuration. In the exemplary construction, the rotatable door skeleton 20 includes a first inboard lateral tube section 22 made up of one or more tube segments and a second inboard lateral tube section 23 made up of one or more tube segments forming opposite sides of the door skeleton 20 . As will be readily understood, the first inboard lateral tube section 22 defines a free edge of the door skeleton 20 and the second inboard lateral tube section 23 defines a hinged edge of the door skeleton 20 as will be described further hereinafter. A top edge tube section 24 made up of one or more tube segments extends in crossing relation between the inboard lateral tube sections 22 , 23 to define the top of the door skeleton 20 . Likewise, a bottom edge tube section 26 made up of one or more tube segments extends in crossing relation between the inboard lateral tube sections 22 , 23 to define the bottom of the door skeleton 20 . A midline tube section 28 made up of one or more tube segments extends in crossing relation between the inboard lateral tube sections 22 , 23 to define an intermediate support.
As best seen in FIG. 2 , in the final construction a pair of removable top corner bolt connections 27 secures the inboard lateral tube sections 22 , 23 to the top edge tube section. By way of example only, and not limitation, the connections between the top edge tube section 24 and the inboard lateral tube sections 22 , 23 may be made by providing the top edge tube section 24 with a pair of short length ears (not shown) of tubing material which are matedly received in the corresponding inboard lateral tube sections 22 , 23 and are then held in place by the top corner bolt connections 27 . Of course, any other suitable connection technique as may be desired may likewise be used. A pair of removable bottom corner bolt connections 29 secures the inboard lateral tube sections 22 , 23 to the bottom edge tube section 26 . By way of example only, and not limitation, the connections between the bottom edge tube section 26 and the inboard lateral tube sections 22 , 23 may be made by inserting the ends of the bottom edge tube section 26 into cutouts in the corresponding inboard lateral tube sections and then securing the bottom corner bolt connections 29 in place. Of course, any other suitable connection technique as may be desired may likewise be used.
In the exemplary construction, a pattern of rivets 14 extends between a door skin panel 30 ( FIG. 9 ) and the first inboard lateral tube section 22 ( FIG. 6 ). Rivets 14 also extend between a door skin panel 30 and the top edge tube section 24 , the bottom edge tube section 26 and the midline tube section 28 . In this regard, the rivets 14 are disposed in spaced relation to one another at positions along the length dimension of the underlying tube sections. As best seen in FIG. 5 , in the exemplary construction the door skin panel 30 is not riveted to the second inboard lateral tube section 23 adjacent the door hinge line. Rather, an operative connection between the second inboard lateral tube section 23 and the door skin panel 30 is established by a hinge connection as will be described further hereinafter.
As shown, the frame 12 further includes a stationary rim joist disposed in adjacent outboard relation to the door skeleton 20 . In the exemplary construction, the stationary rim joist includes a first outboard lateral tube section 34 made up of one or more tube segments disposed in adjacent outboard relation to the first inboard lateral tube section 22 . The stationary rim joist further includes a second outboard lateral tube section 35 made up of one or more tube segments disposed in adjacent outboard relation to the second inboard lateral tube section 23 . As will be readily understood, the first outboard lateral tube section 34 defines a latching stop for the free edge of the door skeleton 20 and the second outboard lateral tube section 35 defines supporting anchor for the hinged edge of the door skeleton 20 . A header tube 38 made up of one or more tube segments is disposed in crossing relation above the outboard lateral tube sections 34 , 35 . A footer tube section 40 made up of one or more tube segments is disposed in crossing relation between the first and second outboard lateral tube sections 34 , 35 .
As best seen in FIG. 2 , in the final construction a pair of removable header bolt connections 42 secures the outboard lateral tube sections 34 , 35 to the header tube 38 . By way of example only, and not limitation, the connections between the header tube 38 and the outboard lateral tube sections 34 , 35 may be made by providing the header tube 38 with a pair of short length ears (not shown) of tubing material which are matedly received in the corresponding outboard lateral tube sections 34 , 35 and are then held in place by the header bolt connections 42 . Of course, any other suitable connection technique as may be desired may likewise be used. A pair of removable footer bolt connections 44 secures the outboard lateral tube sections 34 , 35 to the footer tube 40 . By way of example only, and not limitation, the connections between the footer tube 40 and the outboard lateral tube sections 34 , 35 may be made by inserting the ends of the footer tube 40 into cutouts in the corresponding outboard lateral tube sections 34 , 35 and then securing the footer bolt connections 44 in place. Of course, any other suitable connection technique as may be desired may likewise be used.
As best seen in FIGS. 3 and 4 , the frame 12 may further include a first vestibule leg pole 46 and a second vestibule leg pole 47 disposed on opposing lateral sides of the rotatable door 20 . A peaked vestibule A-frame 48 extends upwardly from the leg poles 46 , 47 . The vestibule leg poles 46 , 47 and the A-frame 48 may each be formed from an arrangement of hollow metal tubes as will be well known to those of skill in the art. As will be appreciated, the configuration of the vestibule leg poles 46 , 47 and the A-frame 48 may substantially correspond to the opening of a tent such that the leg poles 46 , 47 and the A-frame 48 may provide perimeter support when the door assembly 10 is installed. Of course, other perimeter geometries may be used depending on the configuration of the tent opening.
Referring now jointly to FIGS. 1 and 5 , it may be seen that in the exemplary construction a line of rivets 14 extends between a door skin panel 30 and the second outboard lateral tube section 35 . A pair of spring hinges 49 extends in connecting relation between the second inboard lateral tube section 23 and the second outboard lateral tube section 35 . Thus, an operative connection is established between the door skin panel 30 and the rotatable door skeleton along the hinge line defined by the spring hinges 49 . As will be appreciated through reference to FIG. 5 , in the exemplary arrangement the portion of the door skin panel overlying the spring hinges 49 forms a living hinge which flexes as the door 20 swings on its axis.
Referring jointly to FIGS. 1 and 6 , it can be seen that in the exemplary construction the first outboard lateral tube section 34 is secured to a fabric side panel 50 by a series of rivets 14 (only one shown) disposed in spaced relation along the length of the first outboard lateral tube section 34 . In this regard, the rivets 14 extend through the fabric side panel 50 along an inboard edge and into the underlying first outboard lateral tube section 34 . The fabric side panel 50 may be folded over onto itself and seamed to form a pocket adapted for receipt of the first vestibule leg pole 46 . In the exemplary construction, the outboard edge of the fabric side panel 50 may include a pattern of rivets secured to grommets 52 ( FIG. 2 ) adapted to provide a snap connection along one side of the tent opening.
As noted previously, the first outboard lateral tube section 34 defines a latching stop for the free edge of the hinge-mounted door skeleton 20 . Accordingly, in the final construction, when the rotatable door 20 is closed, the opposing surfaces of the door skin panel 30 and the first fabric side panel 50 will be in close overlapping relation ( FIG. 6 ). If desired, an optional handle 54 in the form of a strip of fabric or the like may be secured to the exterior of the door skin panel 30 to facilitate opening. According to the illustrated exemplary construction, the handle 54 may be mounted by rivets 14 to the underlying inboard lateral tube section 22 so as to promote stability. An optional latch 56 also may be provided to prevent unwanted opening of the rotatable door 20 .
In the exemplary construction, the portion of the door skin panel 30 extending outboard from the second outboard lateral tube section 35 may be folded over onto itself and seamed to form a pocket adapted for receipt of the second vestibule leg pole 47 . As best seen through joint reference to FIGS. 1 and 7 , the outboard edge of the door skin panel 30 may include a pattern of rivets 14 and may be seamed or otherwise secured to a loop support flap 58 supporting an arrangement of Becket loops 60 adapted to be joined in cinched relation to the perimeter of the tent vestibule opening in a manner as will be well known to those of skill in the art.
So as to promote a weather-tight covering at the location of the Becket loop attachments, a barrier flap 64 of PVC coated polyester fabric or the like extends outboard from the edge of door skin panel 30 adjacent the location of the Becket loops. As shown, the barrier flap 64 includes a flap connection element 66 along its free edge. By way of example only, the flap connection element may be one half of a hook and loop fabric connection such that the barrier flap may be folded over the Becket loops and be attached to a complementary element on the surface of the door skin panel 30 . An effective weather cover may thus be established.
As illustrated through joint reference to FIGS. 1 , 2 , and 9 , a vestibule header panel 70 of fabric or the like may be secured between the header tube 38 and the vestibule A-frame 48 . According to the illustrated exemplary construction, the vestibule header panel 70 may have a generally pyramidal shape with a first lateral edge 72 and a second lateral edge 74 converging to form a peak.
According to one exemplary practice, the vestibule header panel 70 may be secured along the header tube 38 by a multiplicity of rivets 14 as previously described in relation to other fabric panels. Heat welds 75 ( FIG. 1 ) may be used to join the lower edge of the vestibule header panel 70 to the adjacent upper edges of the door skin panel 30 and fabric side panel 50 . The vestibule header panel 70 may be may be folded over onto itself along the first lateral edge 72 and seamed to form a pocket adapted for receipt of a first A-frame leg 76 . In the illustrated exemplary construction, the outboard edge of the header panel adjacent to the first A-frame leg 76 may include a pattern of rivets 14 ( FIG. 1 ) secured to grommets 52 ( FIG. 2 ) adapted to provide a snap connection along one side of the tent opening. Thus, the grommets 52 disposed adjacent the first vestibule leg pole 46 and the grommets 52 disposed adjacent the first A-frame leg cooperatively form a substantially continuous connection along one half of a surrounding tent vestibule opening.
The vestibule header panel 70 may be may be folded over onto itself along the second lateral edge 74 and seamed to form a pocket adapted for receipt of a second A-frame leg 78 . In the exemplary construction, the outboard edge of the vestibule header panel 70 may be seamed or otherwise secured to a flap supporting a multiplicity of Becket loops 60 adapted to be joined in cinched relation to the perimeter of the tent vestibule opening in a manner as will be well known to those of skill in the art. The Becket loops 60 disposed adjacent the second vestibule leg pole 47 and the Becket loops 60 disposed adjacent the second A-frame leg 78 thus cooperatively form a substantially continuous cinched connection along one half of a surrounding tent vestibule opening.
According to the illustrated exemplary construction, the second lateral edge 74 of the vestibule header panel 70 may be seamed or otherwise secured to a barrier flap 80 ( FIG. 9 ) similar in construction to the barrier flap 64 such that substantially the same arrangement as illustrated in FIG. 7 is established with an arrangement of Becket loops 60 . So as to promote a weather-tight covering at the location of the Becket loop attachments, the barrier flap 80 of PVC coated polyester fabric or the like extends outboard from the edge of the vestibule header panel 70 adjacent the location of the Becket loops. The barrier flap 80 includes a flap connection element 81 along its free edge. By way of example only, the flap connection element 81 may be one half of a hook and loop fabric connection such that the barrier flap 80 may be folded over the Becket loops and be attached to a complementary element. An effective weather cover may thus be established.
As will be understood, the combination of Becket loop attachments forming a perimeter connection structure substantially along one half of the door assembly 10 and grommets forming a perimeter connection structure substantially along an opposing half of the door assembly 10 permits the door assembly to be free of perimeter zipper connections. The avoidance of zipper connections between the door assembly and a surrounding tent is believed to provide substantially improved reliability in harsh environments in which sand and/or rain main may degrade zipper performance over time.
As best illustrated through joint reference to FIGS. 1 , 2 and 8 , the door assembly 10 may include a window port 82 for seeing through the rotatable door 20 . By way of example only, and not limitation, the window port 82 may be formed at a cut-out 84 in the door skin panel 30 ( FIG. 9 ). A window pane 86 ( FIG. 8 ) may be secured in place in covering relation to the cut-out 84 . A window flap 88 may be secured by rivets 14 or other suitable connections to permit selective displacement of the window flap 88 relative to the pane 86 . According to the illustrated exemplary practice, the window flap 88 may be a folded fabric material having a distal edge supporting hook or loop connection material 92 adapted to engage a complementary hook or loop connection material 93 on the window pane 86 . Thus, the window flap 88 may be pulled in releasable covering relation over the window pane 86 . One or more straps 94 with hook or loop connection material 96 which is complementary to the hook or loop connection material 92 on the window flap 88 may be provided to hold the window flap in rolled-up stowed relation if continuous visibility is desired.
In accordance with an exemplary construction, the door skin panel 30 , the fabric side panel 50 , the vestibule header panel 70 and the window flap 88 may each have a multi-layer insulated construction. According to one exemplary construction, one or more of these structures may be formed from a polymeric outer fabric 98 of polyester, nylon, or the like with an outer surface coating of PVC or the like disposed in wrap-around relation to one or more layers of an insulating cellular foam 99 such as polyethylene foam or the like having a reflective coating of aluminum or the like on one or both sides oriented to face outwardly away from the interior of the tent. By way of example only, and not limitation, one such insulating cellular material is believed to be available under the trade name LOW-E® sold by Environmentally Safe Products, Inc. having a place of business in New Oxford, Pa. Such a construction is believed to provide substantial protection from intense outside heat, while also containing warmth within the tent when heaters are being used. Of course, virtually any other pliable fabric material may be used if desired.
As will be appreciated, a significant benefit of a modular tent door consistent with the present disclosure is the ability to disengage segments making up the individual frame support members from one another and to then fold the structure. By way of example only, and not limitation, each of the inboard lateral tube sections 22 , 23 and each of the outboard lateral tube sections 34 , 35 may be formed from multiple rectangular tube segments joined together in the manner as described in U.S. Pat. No. 6,726,255 (incorporated by reference). When these segments are disconnected from one another and the vestibule leg poles 46 , 47 are removed, the door skin panel 30 and the fabric side panel 50 may be folded while the individual tubular segments remain riveted to the fabric. Upon reuse, the tube segments are properly positioned and may be easily reconnected. Regardless of the actual geometry of the door panel assembly, the use of the collapsible frame facilitates permits relatively easy and rapid disassembly and compact packaging due to the pliable nature of the covering. Moreover, disassembly and reassembly may be carried out using only a single tightening tool such as a socket wrench or the like.
Of course, variations and modifications of the foregoing are within the scope of the present disclosure. All dimensions are merely exemplary. Thus, it is to be understood that the disclosure disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. | A tent door panel assembly incorporating a pliable, soft material operatively connected to collapsible tubular frame to define an internal swinging door. The door panel of pliable material may be connected to the door opening or vestibule opening of the tent using well known attachment mechanisms. The collapsible tubular frame may be disassembled and reassembled for removal and portability. |
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2011/001612, filed Mar. 31, 2012, which designated the United States and has been published as International Publication No. WO 2011/120692 and which claims the priority of German Patent Application, Serial No. 10 2010 013 725.1, filed Mar. 31, 2010, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to a method for producing a horizontal bore in the ground and a horizontal drilling device for use in such a method.
Horizontal drilling devices are used to introduce supply and disposal lines into the ground in trenchless construction or to exchange already installed old lines in a trenchless manner.
There are many different horizontal drilling devices. Common are horizontal drilling devices in which a drill head is initially advanced angled into the ground by means of a drill rod assembly and starting from a drill boom positioned above ground until the drill head has reached the desired drilling depth. Then, the drill head is redirected into the horizontal position in order to carry out the horizontal drilling. The target point of such a horizontal drilling can for example be located in a target excavation pit which is excavated for this particular purpose or in a basement room or it can also be located above ground i.e., like the starting point, so that the drill head after a defined drilling progress is redirected into a diagonally upwards pointing direction, to let the drill head reemerge above ground.
After the drill head has reached the target point, it is often replaced for a widening device for example a conical widening body, to widen the previously generated (pilot) bore by means of the drill boom when retracting the drill rod assembly. This may involve attaching a new line to be drawn into the widening device, to draw the new line into the ground simultaneous with the widening of the pilot bore.
Horizontal drilling devices are also used to replace old lines in the ground in a trenchless manner. For this, in a first step the drill rod assembly is pushed by the drill boom along the old line (and in particular through an old line) and after reaching a target point, which can be located in a maintenance shaft of the sewage system, the front end of the drill rod assembly is connected with a widening device by which the old line is cut or burst when retracting the drill rod assembly, wherein the fragments of the destroyed old line are radially displaced into the soil. At the same time, a new pipe can be drawn into the old pipe. Destroying the old pipe an displacing the fragments of the old pipe allows the new pipe to have an outer diameter which corresponds to the outer diameter of the old pipe or even exceeds this diameter.
As an alternative, an adapter can be connected to the front end of the drill rod assembly which adapter engages on the rear end of the old pipe and pulls the old pipe out of the ground when retracting the drill rod assembly. This allows avoiding that fragments of a destroyed old pipe remain in the ground which may otherwise cause damage to the new pipe due to sharp-edged brakeage edges and the pressure exerted by the surrounding soil.
Horizontal drilling devices usually have a linear drive with which the drill rod assembly can be advanced and retracted within the ground. Further, a rotational drive is usually provided with which the drill rod assembly (and with this the drill head and widening head connected thereto) can be rotated. The rotation of the drill head or the widening device allows improving the advance in the soil.
Further, most of the steerable horizontal drilling devices require a rotation of the drill head to steer the drill head into a desired drilling direction. The drill heads of such horizontal drilling devices have an asymmetrically formed (for example slanted) drill head front, which leads to a lateral deflection of the drill head during movement of the drill head through the soil. When the drill head is simultaneously rotatingly driven when being advanced in the soil, the asymmetric configuration of the drill head has no influence on the straight drilling course, because the lateral deflection evens out over a rotation. On the other hand, when the rotation of the drill head is stopped and the drill head is exclusively advanced by pushing—optionally supported by strokes of a stroke device which is integrated in the drill head or in the drill boom—the asymmetric configuration of the drill head leads to a (constant) lateral deflection. This achieves an arched drilling course and as a result a change of the drilling direction.
Horizontal drilling devices which are exclusively intended for replacing old pipes which are already installed in the ground often have no additional rotational drive.
Horizontal drilling devices in which the drill boom is intended for positioning above ground, often can only be used in non-urban areas because the horizontal drilling devices have to be positioned at a considerable distance to the region in which the bore or the new line is to be introduced into the ground or in which an already existing old pipe is to be exchanged, due to the drilling distance required to reach the desired drilling depth. Oftentimes, corresponding space requirements are not available in built-up areas. A further disadvantage of such horizontal drilling devices is that these drilling devices which are commonly configured as self-propelled drill boom, cause significant crop damage which has to be remedied by a corresponding financial effort.
Because of these disadvantages, the trenchless line construction in built-up areas is still largely limited to the trenchless replacement of old pipes because the old pipes always extend between subterranean hollow spaces (in particular supply shafts and basement rooms) which are already present and which can be used for the positioning of the horizontal drilling device. Excavation work and as a result, crop damage can thus mostly be prevented. For this, horizontal drilling devices have been developed which are configured so that they can be positioned in a supply shaft or sewage system. Because new supply lines often are not to be installed along existing supply routes these horizontal drilling devices are often not available for newly installing supply lines.
From IDE 196 33 934 A1 a horizontal drilling device is known which is configured for use in small excavation pits with a square cross section of about 70 cm×40 cm and a depth of about 1 m to 1.5 m. These horizontal drilling devices include a frame whose dimensions roughly correspond to the cross sectional dimensions of the excavation pit and are lowered into the excavation pit. A part of the frame protrudes over the upper edge of the excavation pit. In the section of the frame which is located inside the excavation pit a combined linear/rotary drive is provided via which a drill rod assembly which is composed of individual rod assembly sections is advanced into the soil. The rod assembly sections which are successively screwed to the rear end of the already drilled drill rod assembly are supplied to the linear/rotational drive via a rod assembly lift which transports the rod assembly sections from a rod assembly magazine which is arranged in the upper section of the frame which protrudes over the edge of the excavation pit, to the linear/rotational drive.
The horizontal drilling device known from DE 196 33 934 A1 enables introducing bores into the ground starting from any desired starting position. Because only a relatively small excavation pit is required for the positioning of the horizontal drilling device and the horizontal drilling device can also be transported easily owing to the compact design, its use is associated with relatively small crop damages.
A disadvantage of the horizontal drilling device known from DE 196 33 934 A1 is that for this horizontal drilling device an exact orientation of the excavation pit to be excavated is required because the direction in which the bore is initiated starting from the horizontal drilling device, is essentially perpendicular to the two narrow sides of the excavation pit. In addition, only two bores in opposite directions can be carried out based on one excavation pit, namely in the two directions which are perpendicular to the two narrow sides of the excavation pit. Drilling in the two directions requires lifting the entire horizontal drilling device out of the excavation pit, turning it by 180° about the vertical axis and then lowering it again into the excavation pit.
Proceeding from this state of the art, the invention is based on the object to provide an improved horizontal drilling device. Further, an improved method for introducing a bore into the ground was to be provided. In particular, a method and a corresponding horizontal drilling device was to be provided which, based on a relatively small excavation pit, allows flexibly introducing horizontal bores into the ground.
SUMMARY OF THE INVENTION
This object is solved by the subject matters of the independent claims. Advantageous refinements of the method according to the invention or the horizontal drilling device according to the invention are the subject matter of the respective dependent patent claims and result from the following description of the invention.
The idea on which the invention is based is to provide a horizontal drilling device which has a circular cross section and to insert the horizontal drilling device into an excavation pit which also has a circular cross section with preferably the same diameter. The preferably cylindrical shape of the excavation pit and the horizontal drilling device arranged therein allows rotating the horizontal drilling device in the excavation pit about the vertical axis and thus accurately orienting the horizontal drilling device in the desired drilling direction. A lifting of the horizontal drilling device out of the excavation pit is not required. There are thus no special demands on the orientation of the excavation pit in the ground owing to the circular cross section. Due to the fact that the excavation pit and the section of the horizontal drilling device which is located in the excavation pit each have a circular cross section with mostly identical diameter, the volume of the excavation pit to be excavated can be reduced to the required minimum. A cylindrical shape of the horizontal drilling device and the wall of the excavation pit surrounding the latter can be supported on a particularly large surface within the excavation pit independent of the respective rotative orientation of the horizontal drilling device in the excavation pit.
A method according to the invention for generating a horizontal bore in the ground has therefore the following steps:
a. generating an excavation pit with a circular cross section; b. lowering a horizontal drilling device into the excavation pit, wherein the horizontal drilling device at least partially has a circular cross section at least in the section in which the horizontal drilling device is arranged in the excavation pit after lowering into the excavation pit; c. generating the horizontal bore by using the ground drilling device.
The horizontal bore can be generated in any desired manner, i.e., in particular by advancing or retracting a drill rod assembly at which a drill head or a widening device can be arranged front side, wherein for example either a (pilot) bore is introduced into the ground, an existing old line is destroyed and/or replaced by a new line, or a new line is drawn into a bore.
It is noted that according to the invention “establishing” or “generating a horizontal bore in the ground” relates to all previously mentioned methods of the trenchless line rehabilitation and therefore not only to generating a (pilot) bore per se, but also to the widening of a bore, the drawing in of a new line into a bore and the bursting or pulling out of an old line.
A horizontal drilling device according to the invention, in particular for use in a method according to the invention, has at least one linear drive and a drill rod assembly which is drivable into or retractable out of the ground by the linear drive. According to the invention, a housing is also provided which largely or completely surrounds the linear drive and which, in at least the section in which it is arranged within an excavation pit (pit section) in the operating condition of the horizontal drilling device, i.e. when the linear drive pulls the drill rod assembly into the ground or retracts the drill rod assembly out of the ground, has at least in parts a circular section and is in particular configured cylindrical.
The housing of the horizontal drilling device is preferably dimensioned so that the latter defines the dimensions of the horizontal drilling device in at least the pit section. According to the invention, this means that the housing surrounds the remaining components of a horizontal drilling device such as in particular the linear drive and optionally a rotational drive and is intended for resting against a wall of an excavation pit in order to support the forces generated by the horizontal drilling device in the ground. Such a housing can for example be configured open or closed. An open housing can for example be formed by a scaffold or frame.
The method according to the invention allows in a simple manner to generate horizontal bores also out of excavation pits with very small dimensions and in particular out of such excavation pits within which no operating personnel can be present for operating the horizontal drilling device. In particular, the method according to the invention is useful for generating horizontal bores in the ground out of excavation pits which have a maximal diameter of about 85 cm and in particular about 60 cm but also smaller. A diameter of about 60 cm may resemble a good compromise because on one hand the size of the excavation pit is relatively small and as a result crop damages are limited, at the same time however, sufficient space remains within the housing of the horizontal drilling device for arranging a sufficiently powerful linear and/or rotational drive. At diameters of the excavation pit of greater than 85 cm the effort for producing an excavation pit with a circular cross section can become so great that the latter cannot be compensated by the advantages of the method according to the invention.
An excavation pit with a circular cross section cannot—or only with great effort—be produced by means of a conventional excavator or manually. This is in particularly true for small excavation pits with diameters of up to about 60 cm, which according to the invention are preferred. In a preferred embodiment of the method according to the invention, the excavation pit can be produced in that the surface seal (as far as present) such as for example tar or asphalt cover is drilled open with a crown drill and the underlying soil is sucked away with a conventional suction dredger. In this way cylindrical (more or less geometrically accurate) bores can be introduced into the ground.
Preferably, the housing forms a substantially closed sheath in the pit section of the horizontal drilling device according to the invention. This allows largely preventing the soil from falling into the interior of the housing and contaminating functional elements arranged there, such as in particular the linear and rotational drive etc. In addition, a substantially closed sheath can achieve a large support surface which allows increasing the stability of the horizontal drilling device in the excavation pit.
A “substantially closed sheath” means a sheath which covers a large part of the corresponding section of the housing and has in particular only recesses or openings which are required for the functioning of the drilling device. Such a recess or opening is for example required for the through-passage of the drill rod assembly.
In order to improve the positioning and support of the horizontal drilling device within the excavation pit, at least one support element can be provided which is drivable radially outward—past the outer circumference of the housing—in order to ensure a support of the horizontal drilling device against the wall which is as free of play as possible. The support element can thus be driven radially outward from a retracted position in which it is arranged within the dimensions defined by the housing, in order to securely position the horizontal drilling device in an excavation pit.
Particularly preferably, more than one support element and in particular at least two, four or five support elements are provided which are arranged spaced apart in defined, preferably even distribution relative to one another and can preferably be extended independent of one another. By individually extending multiple support elements, the horizontal drilling device can not only be securely supported in the excavation pit but also simultaneously oriented in its position (orientation of the longitudinal axis of the housing; corresponds in operating position to the vertical axis of the horizontal drilling device).
In a further preferred embodiment, the support element can have a support plate which forms a part of the sheath. On one hand this allows achieving that the horizontal drilling device forms a largely closed cylindrical sheath in the corresponding section, when the support element or the support elements are positioned in a retracted position; on the other hand, the support plate as section of the sheath has an arched shaped which is similar in its radius to the radius of the arch-shaped wall of the excavation pit so that an even and secure support can be achieved, when the support element is extended radially.
Further, a horizontal drilling device according to the invention can have a section (surface section) which is located above the excavation pit in operating condition. In this section of the horizontal drilling device, in particular the functional elements can be located which are intended to be accessible by operating personnel to operate the horizontal drilling device.
The surface section of the horizontal drilling device can further have a support device via which the horizontal drilling device is supported at the ground surface. Via the support device the horizontal drilling device can thus be suspensory supported within the excavation pit.
Particularly preferably, this support device can be configured adjustable to enable a height adjustment of the horizontal drilling device in the excavation pit. By this, a simple and flexible (because easily adjustable) height positioning of the horizontal drilling device according to the invention (or the pit section of the horizontal drilling device) within the excavation pit can be achieved. In addition it is avoided that an appropriate bottom of the excavation pit i.e., an even bottom which is oriented in the right angle relative to the horizontal direction, has to be provided. This allows reducing the effort for introducing the excavation pit.
Because the cylindrical excavation pit as well as the correspondingly dimensioned horizontal drilling device preferably have a small diameter, it may be required to successively supply the linear drive, which is located within the pit section of the horizontal drilling device, with rod assembly sections from the ground surface, which rod assembly sections are then interconnected to form the drill rod assembly. For this, the horizontal drilling device according to the invention can preferably be provided with a rod assembly lift which transports a rod assembly section of the drill rod assembly between the surface section and the pit section. This can occur in both directions i.e., during generating of a (pilot) bore, the rod assembly sections are transported one after another from the surface section to the linear drive within the pit section of the horizontal drilling device, while during retraction of the drill rod assembly from an already generated bore, for example when the latter is widened and/or a new line is drawn in, the individual rod assembly sections which are released from the drill rod assembly are transported by means of the rod assembly lift from the linear drive to the surface section where the rod assembly sections can be retrieved either by operating personnel or by an automated rod assembly transfer.
Further preferably, the rod assembly lift can have a rod assembly receiver in which a rod assembly section is laterally insertable. Such a rod assembly receiver enables a simple accessibility from the side by operating personnel and ensures a secure grip during the transport of the rod assembly section (along a vertically oriented rod assembly lift).
When rod assembly sections are used, which are configured at least partially hollow, a transfer of the rod assembly section from the rod assembly lift to the linear drive can preferably occur by means of a receiving mandrel which is arranged so that the rod assembly section can be directly attached by the rod assembly lift after reaching the target position of the rod assembly receiver.
The rod assembly sections preferably have a length which is shorter only as little as possible than the diameter of the housing in the pit section of the horizontal drilling device. By using rod assembly, sections which are as long as possible, the effort which is required for joining or releasing the individual rod assembly sections of the drill rod assembly can be reduced to a minimum. For reasons of space however, it may be necessary or useful to transport the relatively long rod assembly sections in the rod assembly lift in a vertical orientation. In this case, the receiving mandrel can be configured pivotal to enable the attachment of the rod assembly section which is transported by the rod assembly lift also in a substantially vertical orientation. After attachment of the rod assembly section the receiving mandrel can then be pivoted into a substantially horizontal orientation which corresponds to the direction of drilling.
BRIEF DESCRIPTION OF THE DRAWING
In the following, the invention is explained in more detail by way of an exemplary embodiment shown in the drawings.
In the drawings it is shown in:
FIG. 1 a horizontal drilling device according to the invention in a perspective view;
FIG. 2 the horizontal drilling device of FIG. 1 in a second perspective view;
FIG. 3 an enlarged section of the representation according to FIG. 2 ;
FIG. 4 the lower section of the horizontal drilling device according to FIGS. 1 to 3 in a perspective view;
FIG. 5 the representation according to FIG. 4 in another operating position of the horizontal drilling device;
FIG. 6 an isolated representation of the rotational drive of the horizontal drilling device in a perspective view;
FIG. 7 a an isolated representation of the rod assembly receiver of the horizontal drilling device in a first operating position in a perspective view;
FIG. 7 b an isolated representation of the rod assembly receiver of the horizontal drilling device in a first operating position in a sectional view;
FIG. 8 a an isolated representation of the rod assembly receiver of the horizontal drilling device in a second operating position in a perspective view;
FIG. 8 b an isolated representation of the rod assembly receiver of the horizontal drilling device in a second operating position in a sectional view;
FIG. 9 a an isolated representation of the catch ring of the rotational drive including a rod assembly section in a first operating position in an isometric view;
FIG. 9 b a front view of the catch ring and the rod assembly section shown in FIG. 9 a;
FIG. 10 a an isolated representation of the catch ring of the rotational drive including a rod assembly section in a second operating position in an isometric view;
FIG. 10 b a front view of the catch ring and the rod assembly section shown in FIG. 10 a ; and
FIG. 11 an isolated representation of the rod assembly receiver and the lower section of the rod assembly lift in an isometric view.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows in an isometric view a horizontal drilling device according to the invention 1 during the introduction of a pilot bore into the soil.
The horizontal drilling device includes a cylindrical housing 2 , which is partially closed via a cylindrical sheath 3 . Functionally, the horizontal drilling device 1 or respectively, the housing 2 of the horizontal drilling device 1 is divided into two sections, namely a lower section referred to as “pit section”, which is located within an excavation pit 4 which was excavated especially for receiving the horizontal drilling device 1 . In the pit section of the horizontal drilling device 1 the housing 2 is essentially completely closed by the sheath 3 . This prevents that soil which becomes dislodged from the walling of the excavation pit 4 falls into the hollow space which is formed in the housing 2 where further functional elements of the horizontal drilling device 1 and in particular a combined linear/rotational drive 5 are located. Soil which falls into the hollow space might otherwise contaminate these functional elements thereby impairing the function of the horizontal drilling device 1 .
In the upper section of the horizontal drilling device 1 according to the invention, also referred to as “surface section”, the housing 2 is partially configured open in order to provide access for operating personnel to a rod assembly lift 6 which extends as far as into this region.
The horizontal drilling device 1 is positioned “suspended” within the excavation pit i.e., the horizontal drilling device 1 is supported not on the floor of the excavation pit 4 , but rather via a support device with a total of three support legs 7 which are fastened in the region of the surface section of the horizontal drilling device 1 on longitudinal supports 8 of the housing 2 . Each of the support legs 7 can be fastened to a total of five different points on the respective longitudinal support 8 . This allows for a height adjustment of the horizontal drilling device 1 which is suspended in the excavation pit 4 . This height adjustment is important, for example for positioning the linear/rotational drive 5 which is located in the pit section, at the correct height for introducing the pilot bore into the soil. A fixing of the support legs 7 at the different points along the longitudinal supports 8 occurs via a respective transverse bolt 9 , which is inserted through a through-bore in a transverse support 10 of the respective support leg 7 and the respective longitudinal support 8 of the housing 2 , and is then fixed.
Each of the support legs 7 further has a spindle support which is connected to the transverse support 10 of the respective support leg 7 via a pivot joint. The spindle support includes a threaded rod 11 which has a support foot 12 on its foot end. A handle 13 is provided on the end of the threaded rod 11 which is opposite the support foot 12 via which handle 13 the threaded rod 11 can be rotated about its longitudinal axis, thereby achieving a longitudinal displacement relative to the spindle housing 14 which surrounds the threaded rod. The spindle supports serve for accurately orienting the horizontal drilling device 1 within the excavation pit 4 after a first height adjustment was already achieved by the fastening of the support legs 7 on the longitudinal supports 8 of the housing 2 .
It can be recognized in FIG. 1 that the excavation pit 4 —like the housing 2 of the horizontal drilling device 1 —has a (substantially) cylindrical shape whose inner diameter essentially corresponds to the outer diameter of the housing 2 of the horizontal drilling device 1 . The sheath 3 of the horizontal drilling device 1 in the region of the pit section rests thus more or less directly against the wall of the excavation pit 4 . The fact that the inner diameter of the excavation pit and the outer diameter of the housing largely correspond to one another not only allows limiting the size of the excavation pit to be excavated to a minimum but also to achieve a most even support of the horizontal drilling device on a largest possible surface within the excavation pit 4 . The circular cross section of the excavation pit 4 and the housing further render the support independent of the respective rotational orientation (about the longitudinal axis of the horizontal drilling device).
The excavation pit 4 was excavated by first introducing a ring-shaped groove having the required (outer) diameter into the surface sealing (asphalt cover) with a core drill (not shown), removing the thus exposed disc-shaped asphalt cover and subsequently sucking away the soil located underneath with a suction dredger (not shown). The suction dredger which was used for this purpose includes a suction nozzle which also has a circular cross section. The excavation pit 4 is excavated somewhat deeper than necessary to allow for height adjustment of the suspensory supported horizontal drilling device 1 inside the excavation pit 4 , without causing an unintended touch down of the lower end of the horizontal drilling device 1 onto the pit bottom.
After excavation of the excavation pit 4 , the horizontal drilling device 1 was lowered into the excavation pit 4 by means of a crane (not shown) until the support legs 7 which where previously fastened to the longitudinal supports 8 of the housing 2 come into contact with the ground surface. The horizontal drilling device 1 was then rotatively oriented by means of the crane within the excavation pit 4 by rotating the horizontal drilling device 1 about its longitudinal axis until the bore axis which is defined by the linear/rotational drive which is arranged inside the pit section of the horizontal drilling device 1 points into the desired starting direction for the pilot bore. A fine adjustment of the working height of the horizontal drilling device 1 , and to a limited degree also the tilt of the horizontal drilling device 1 relative to the vertical, was then achieved via the spindle supports.
Because the wall of the excavation pit 4 —in particular in the case when it was excavated by means of a suction dredger—commonly is not configured evenly cylindrical, the horizontal drilling device 1 according to the invention has overall four support elements 15 in the region of the pit section which are evenly distributed across the circumference. These support elements 15 include support plates 16 which in a retracted position each form a section of the cylindrical sheath 3 of the horizontal drilling device. The support plates 16 can each be extended outward in radial direction by means of a hydraulic cylinder 17 to generate a direct contact of the horizontal drilling device 1 with the wall of the excavation pit 4 to securely support the horizontal drilling device 1 inside the excavation pit 4 .
The individual components of these support elements 15 are well recognizable in FIG. 3 . Each of the support plates 16 is connected to a first end of an extension lever 19 via a first pivot joint 18 , with the extension lever 19 being in turn rotatingly supported on the housing 2 of the horizontal drilling device 1 by means of a second pivot joint 21 . A second end of the extension lever 19 is connected to the head of a piston rod 20 of the hydraulic cylinder 17 . An extension or retraction of the hydraulic cylinder 17 thus causes a partial rotation of the extension lever 19 about the pivot joint 21 , whereby the respective support plate 16 can be radially extended or retracted again. End stops 22 prevent that the support plate 16 enters the inner space defined by the sheath of the housing when retracting the hydraulic cylinder 17 .
FIG. 2 shows a representation of the entire horizontal drilling device 1 which corresponds to the representation of FIG. 1 in which, however, a part of the sheath 3 in the excavation pit is removed to show the functional elements arranged therein.
FIGS. 3 to 5 show different views of this section of the horizontal drilling device 1 in enlarged representations. It can be seen that the combined linear/rotational drive 5 at the lower end of the horizontal drilling device 1 is arranged within the housing 2 . The linear/rotary drive 5 serves for rotatingly advancing a drill rod assembly which is composed of individual rod assembly sections 23 , into the ground.
FIG. 6 shows a partial section through the linear/rotational drive 5 in a representation in which the linear/rotational drive 5 is isolated from the remaining elements of the horizontal drilling device 1 . The linear/rotational drive 5 is formed by two hydraulic cylinders 25 . The piston rods 26 of the two hydraulic cylinders 25 traverse the respective cylinder tube 27 completely and are connected with their two ends to the housing 2 of the horizontal drilling device 1 . The piston rods 26 each have a centrally arranged piston (not shown) which divides the ring space which is respectively formed between the cylinder tube 27 and the piston rod 26 , into two working chambers, which can each be supplied with hydraulic oil via a hydraulic line 66 . Depending on the pressure of the hydraulic oil which is supplied to the individual working chambers, a movement of the respective cylinder tube 27 on the piston rod 26 in one or the other direction is achieved. The movement of the two hydraulic cylinders 25 of the linear drive is synchronized.
A rotational drive is arranged between the two cylinder tubes 27 of the hydraulic cylinders 25 which form the linear dive, and fastened to the two cylinder tubes 27 . The rotational drive includes a motor 29 (in particular a hydraulic or electromotor) which is flange-mounted to a hollow gear 28 . A drive shaft 30 of the motor 29 is connected with a differential gear wheel 31 , which in turn meshes with a gear ring 32 which in turn is connected to a drive sleeve 34 via screw connections 33 . The drive sleeve 34 is rotatingly supported within a housing 36 of the hollow gear 28 via two rolling bearings 35 . A rotation of the drive shaft 30 of the motor 29 thus causes a rotation of the drive sleeve 34 about its longitudinal axis. This longitudinal axis corresponds essentially to the drill rod assembly 24 held therein and therefore also the drilling axis i.e., the starting direction of a pilot bore to be introduced or the longitudinal axis of a bore or an old pipe extending in the wall of the excavation pit 4 .
For transmitting the rotational movement of the drive shaft 34 and the longitudinal movement which is generated by the hydraulic cylinders 25 of the linear drive to the drill rod assembly 24 which is held in the drive sleeve 34 , a catch ring 37 is used which—in an operating position of the drill rod assembly 24 within the catch ring 37 —fixes the drill rod assembly 24 in a form fitting manner. The catch ring 37 is form fittingly supported within the drive sleeve 34 and can be easily exchanged in case of wear, by first removing a retaining ring 63 from a corresponding groove in the inside of the drive sleeve 34 and then pulling out a spacer ring 64 from the drive sleeve. The catch ring 37 can then be easily pulled out of the drive sleeve 34 .
FIGS. 9 a and 9 b as well as 10 a and 10 b each show two views of the two operating positions of the drill rod assembly 24 within the catch ring 37 which are relevant for the operation of the horizontal drilling device 1 . These two operating positions differ in a 90° relative rotation of the catch ring 37 about its longitudinal axis relative to the drill rod assembly 24 . In the operating position shown in FIGS. 9 a and 9 b the drill rod assembly 24 is locked in the catch ring. This locking is achieved by the particular sheath shape of the rod assembly sections 23 of the drill rod assembly 24 , and a shape of the central opening of the catch ring 37 which is adjusted thereto.
Each rod assembly section 23 of the drill rod assembly 24 has a cylindrical basic shape with a middle section 38 with a relatively small diameter and two end sections 39 a , 39 b , with a relatively large diameter. In each of the end sections 39 a , 39 b of a rod assembly section 23 two parallel flat portions 40 are provided, thereby resulting in a cross section with two parallel straight sides and two opposing arched-shaped sides. The catch ring 37 forms a through-opening which corresponds to this cross section so that it is possible to insert the rod assembly section 23 into the through opening of the catch ring 37 and to freely move it (in longitudinal direction) therein, when the catch ring 37 and the rod assembly sections 23 guided therein are arranged in the rotational orientation relative to one another shown in FIGS. 10 a and 10 b.
For locking the rod assembly section 23 in the catch ring 37 , the catch ring 37 is moved inside the through-opening until two arched-shaped locking grooves 41 which are formed in each of the end sections 39 a , 39 b of the rod assembly section 23 , are located within the catch ring 37 . These locking grooves enable a relative clockwise rotation of the catch ring 37 by 90° into the operating position shown in FIGS. 9 a and 9 b (locking position). A rotation by more than 90° is also prevented by the fact that the two locking grooves 41 which are arranged offset to one another by 180° about the longitudinal axis of the rod assembly section 23 , are only arch-shaped within an angular section of 90° and then extend straight. As a result of this, two cams 42 are formed whose distance is greater than the narrow width (corresponds to the two straight edges of the through-opening of the catch ring) of the through-opening for the catch ring 37 . These cams 42 abut on the edges of the catch ring 37 in the locking position shown in FIGS. 9 a and 9 b and thus prevent a further (clockwise) rotation.
In the locking position of the rod assembly section 23 in the catch ring 37 , longitudinal forces (in longitudinal direction of the rod assembly section axes) and a rotational torque (in FIGS. 9 a to 10 b clockwise) can be transferred to the entire drill rod assembly via the catch ring 37 .
The center section 38 of each rod assembly section 23 has a reduced outer diameter in order to achieve a smaller (defined) bending stiffness relative to the end sections 39 a , 39 b . This is intended to enable the use of a controllable slanted drill head. By redirecting the drill head 43 in the soil, a drilling course which is arched in sections is achieved. The drill rod assembly 24 has to adjust to this arched drilling course which leads to a corresponding bending stress. The center section 38 of each rod assembly section 23 which has a reduced diameter and is thus relatively bending soft compared to the end sections 39 a , 39 b , serves for maintaining the rod assembly section 23 overall bending soft, however, at the same time serves for configuring the end sections 39 a , 39 b stiff which, due to the threads are particularly at risk of breaking.
Due to the arrangement of the combined linear/rotational drive 5 at the lower end of the pit section of the horizontal drilling device 1 , and due to the smaller dimensions of the horizontal drilling device 1 (the housing 2 has a maximal diameter of about 60 cm) the individual rod assembly sections 23 cannot be manually fed to the linear/rotational drive 5 . Rather, an automated rod assembly feed is provided for this purpose which is formed by a rod assembly receiver 44 , which is arranged at the height of the linear/rotational drive 5 and the rod assembly lift 6 .
The rod assembly receiver 44 is shown in the overall representation of FIGS. 4 and 5 and by itself in the representations of FIGS. 7 a , 7 b , 8 a and 8 b . The central element of the rod assembly receiver 44 is a receiving mandrel 45 which is supported in a bridge 46 which is connected to the two cylinder tubes 47 of two further hydraulic cylinders 48 . The hydraulic cylinders 48 are also of the kind in which the piston rod 49 protrudes out of the cylinder tube 47 on both sides. The two free ends of the two piston rods 49 are connected to the housing 2 of the horizontal drilling device 1 so that by a corresponding impingement of the hydraulic cylinders 28 with hydraulic oil, the cylinder tubes 47 and thus the rod assembly receiver 44 can be displaced on the stationary piston rods 49 in horizontal direction.
The receiving mandrel 45 of the rod assembly receiver 44 is supported within the bridge 46 for pivoting about a horizontal axis, wherein a pivoting between the two end positions shown on one hand in FIGS. 7 a , 7 b and on the other hand 8 a , 8 b is possible. The pivoting is achieved via a further hydraulic cylinder 50 which is supplied with hydraulic oil via corresponding hydraulic connections 65 .
In the orientation shown in FIGS. 7 a , 7 b , the longitudinal axis of the receiving mandrel 45 and a rod assembly section 23 attached onto the receiving mandrel 45 is coaxial to the drive sleeve 34 of the rotational drive and thus points in the drilling direction of the horizontal drilling device 1 . In the vertical operating position shown in FIGS. 8 a , 8 b which is thus pivoted by 90° relative to the operating position according to FIGS. 7 a and 7 b , the receiving mandrel 45 and the rod assembly section 23 attached onto it are positioned within a guiding track 51 of the rod assembly lift 6 . In this operating position of the receiving mandrel 45 , a rod assembly section 23 can be attached onto the receiving mandrel 45 from the rod assembly lift 6 or removed from the latter.
Within the guiding track 51 of the rod assembly lift 6 , a receiving sled 52 which can receive a rod assembly section 23 , is movably guided, wherein the receiving sled 52 is fastened at a trumm of a drive belt 53 which extends outside of the guiding rail 51 and parallel to the latter. An upper driving roller of the driving belt 53 is connected to the motor (not shown) in order to drive the latter. A lower deflection roller 54 is supported on an axle 55 which is guided at both its ends on a threaded rod 56 . By rotating the threaded rods 56 , the vertical position of the lower deflection roller 54 can be changed so as to tension the driving belt 53 . By means of the driving belt 53 the receiving sled 52 can be moved up and down in the guiding track 51 . In this way a rod assembly section 23 which is inserted into a loading station 58 in the surface section of the horizontal drilling device 1 by operating personnel, can be transported to the rod assembly receiver 44 in the pit section—and vice versa.
FIG. 11 shows in an isolated representation of the rod assembly receiver 44 and the lower part of the rod assembly lift 6 including the receiving sled 52 in which a rod assembly section 23 is held. The receiving sled 52 forms a through-opening in which the rod assembly section 23 can be inserted from the side by the operating personnel in the region of the loading station 58 . In the receiving sled 52 the inserted rod assembly section is supported suspensory, i.e., two pairs of projections 59 each form a free space which is only slightly broader than the diameter of the center section 38 and narrower than the broader side of the end sections 39 a , 39 b of the rod assembly section 23 . One of the projection pairs engages into the locking grooves 41 of the front end section 39 a , while the second projection pair engages in the center section 38 of the rod assembly section 23 . Via the two projection pairs of the receiving sled 52 , the rod assembly section 23 fixed therein is form fittingly held (in vertical and lateral direction). Of course it is also possible to use only one projection pair or only one single projection to hold the rod assembly section 23 within the receiving sled 52 .
By lowering the receiving sled 52 within the guiding track 51 of the rod assembly lift 6 , the rod assembly section 23 which is held in the receiving sled 52 is attached onto the vertically oriented receiving mandrel 45 (compare FIG. 5 [receiving sled not shown] and 8 a , 8 b ) The receiving mandrel is then pivoted by 90° into the horizontal operating position shown in FIGS. 4 and 7 a , 7 b , whereby the rod assembly section 23 is pivoted in lateral direction out of the receiving sled 52 . The receiving sled 52 can then be moved to the loading station 58 again so that a further rod assembly section 23 can be inserted.
The horizontal drilling device 1 is configured for carrying out flush drillings i.e., a drilling fluid is supplied via the rod assembly 24 to the drill head 43 which is arranged on the front side of the rod assembly 24 , which drilling fluid exits through front side and lateral exit openings. To enable the supply of drilling fluid to the drill head 43 , the individual rod assembly sections 23 of the drill rod assembly 24 are configured continuously hollow. The drilling fluid is supplied to the drill rod assembly 24 via the receiving mandrel 45 which for this purpose is also configured continuously hollow. Only on the rear side end i.e., the end which protrudes out of the attached rod assembly section 23 , the receiving mandrel is closed by means of a screw cap 60 . The drilling fluid is supplied to the inner space which is formed by the hollow receiving mandrel 45 via a shaft which is also configured hollow and on which the receiving mandrel is rotatingly supported. Two sealing rings on the outside of the receiving mandrel 45 prevent a leaking of the drilling fluid through the gap between the receiving mandrel 45 and the rod assembly section 23 . This allows easily achieving a secure and constructively simple connection of the pivotal receiving mandrel 45 to the source of the drilling fluid. In contrast, a connection to the drilling fluid source while at the same time maintaining the pivotability of the receiving mandrel via flexible supply tubes requires more constructive effort, because the high pressure with which the drilling fluid is supplied to such a rod assembly 24 necessitates the use of extremely pressure resistant and with this poorly elastic supply tubes, which in turn would impede the pivoting movement of the receiving mandrel 45 , which would require a greater and higher powered hydraulic cylinder 50 for the pivoting.
For generating a pilot bore, the horizontal drilling device 1 is used as follows.
Before lowering of the horizontal drilling device 1 into the excavation pit 4 , the drill head 43 shown in FIG. 1 is inserted into the drive sleeve 34 of the rotational drive through a through-opening 61 for the drill rod assembly which through-opening 61 is formed in the housing 2 . This is necessary because the drill head has an integrated transmitter for localization by means of a so called walk-over-receiver and is therefore longer than the rod assembly sections 23 . The drill head has a (rear) end section 62 which corresponds to the end sections 39 a , 39 b of the rod assembly sections 23 with regard to the geometric shape: Two arch-shaped locking grooves are introduced into the end section 62 with a cylindrical basic shape which is provided with parallel flat portions on two opposing sides, into which grooves the catch ring 37 can be rotated by a 90° clockwise rotation, whereby the drill head 43 is locked in the rotational drive. The rotational drive is located in the rear most position in which the latter can be driven as far as possible away from the through-opening 61 by means of the linear drive.
The horizontal drilling device 1 is then lowered into the excavation pit 4 , oriented and supported, as already described.
By using the linear/rotational drive 5 the drill head is then drilled into the soil as far as possible. Due to the length of the drill head 43 the drilling occurs with two strokes of the linear drive; in the first stroke the catch ring 37 is located at the front end of the two parallel flat portions so that the pressure forces are transferred over the protrusion formed there, and the rotational torque is transferred via the parallel flat portions which serve as wrench flats. After the first stroke, the linear drive is retracted so that the catch ring 37 can engage in the locking grooves and lock the drill head 43 . After this, the linear drive is moved forward again, whereby the drill head 43 is completely drilled in. The rotational drive is then located in the front most position shown for example in FIGS. 4 and 5 . A locking fork (not shown) provided in the region of the through-opening is then lowered. The fork width of the locking fork corresponds to the distance of the two parallel flat portions of the drill head 43 and the distance of the two locking grooves. Previously, the drill head 43 was oriented by means of the rotational drive so that the two flat portions of the end section are oriented vertically so that the locking fork can travel over the end section (in a section before the locking grooves) of the drill head 43 , thereby temporarily preventing a rotation of the drill head 43 by means of a form fitting fixing.
During the advancement of the drill head 43 into the soil, a first rod assembly section 23 was already inserted into the receiving sled 52 by an operating person and by displacing the rod assembly lift 6 attached onto the receiving mandrel 45 . After pivoting of the receiving mandrel 45 and the rod assembly section attached thereto, by 90° into its horizontal orientation, the rod assembly section 23 is in a predominantly coaxial position relative to the already drilled drill head 43 . By displacing the two hydraulic cylinders 48 of the rod assembly receiver 44 , the front side of the threaded plug of the rod assembly section 23 can be driven to the rear side threaded socket of the drill head 43 . The catch ring 37 is then released from the locking grooves of the drill head 43 and the linear/rotational drive 5 retracted until it is located in a defined region of the front end section 39 a of the first rod assembly section 23 . By actuating the rotational drive, the first rod assembly section 23 is screwed together with the drill head 43 which is fixed in rotational direction by the locking fork, wherein the rotational torque is transferred via the parallel flat portions 40 . Due to the fact that the catch ring 37 is not yet locked in the locking groove 41 , the rod assembly section can move in axial direction relative to the catch ring 37 during screwing. This allows realizing the longitudinal movement of the rod assembly section 23 which is necessary for the screwing of the rod assembly section 23 without an elaborate length compensation which is realized by the linear drive.
The position of the rotational drive during the screwing is chosen so that the locking grooves 41 of the front end section 39 a are located within the catch ring 43 after the rod assembly section 23 is completely screwed together with the drill head 43 so that the catch ring 37 , after a rotation of 90°, can engage directly i.e., without necessitating a further displacement of the linear drive, in the locking grooves 41 to fix the rod assembly section 23 also in longitudinal direction. The drill rod string is then drilled until the rotational drive reaches its front end-position again.
After this, the rotational drive is unlocked by a 90° rotation (in the opposite direction) of the catch ring and retracted by means of the hydraulic cylinder 25 of the linear drive until the catch ring 37 can engage in the locking grooves 41 of the rear end section 39 b of the first rod assembly section 23 ; there, the catch ring 37 is locked again by a 90° rotation. Then, the drill rod string composed of the drill head 43 and the first rod assembly section 23 , is advanced into the soil by a further working stroke of the linear drive by using the linear/rotational drive.
As soon as the rotational drive has reached its front end position, the rod assembly receiver 44 is moved back into the rear position and the receiving mandrel 45 is pivoted into the vertical position where the latter can receive a second rod assembly section 23 which was already inserted into the receiving sled 52 by the operating personnel which receiving sled 52 was moved into the loading station 58 .
After finishing the working stroke of the linear drive, the locking grooves of the front end section 39 a of the first rod assembly section 23 are located below the locking fork which can then be lowered to fix the drill rod string, while the second rod assembly section 23 is screwed to the existing drill rod string. For this, the second rod assembly section 23 is moved to the rear end of the first rod assembly section 23 by means of the rod assembly receiver 44 . At the same time, the rotational drive is released from the first rod assembly section 23 and moved backwards until it can engage on the parallel flat portions 40 in the front end section 39 a of the second rod assembly section 23 . By using the linear/rotational drive 5 , the second rod assembly section 23 is then screwed to the first rod assembly section 23 , wherein after finishing the screwing, the catch ring 37 locks again in the locking grooves 41 of the front end section 39 a of the second rod assembly section and the drill rod string is drilled until reaching the front end position (of the linear drive) again. The linear/rotational drive 5 is then released from the second rod assembly section 23 by a 90° relative rotation of the catch ring 37 and moved backwards again to lock the second rod assembly section 23 in the rear end section 39 b and to advance the drill rod string into the soil again by a further working stroke.
In contrast to the drill head 43 , the locking fork engages in the locking grooves 41 of the rod assembly sections 23 to lock the latter not only rotatively but also against a movement in longitudinal direction. This allows preventing the drill rod string from unintentionally becoming displaced due to elastic re-deformation of the compressed soil and the drill rod assembly which has been compressed or stretched by the loads.
The attachment and drilling of further rod assembly sections 23 occurs in an identical manner.
After the pilot bore is complete, the drill head 43 can be replaced by a widening device (not shown) to widen the bore during retraction of the drill rod assembly. Optionally, a new pipe (not shown) or another supply line (not shown) can be attached to the widening head which is drawn into the bore simultaneous with the widening device.
When retracting the drill rod assembly 24 , the latter is shortened step by step by one rod assembly section 23 at a time. This occurs in the following manner.
The catch ring 37 of the rotational drive is locked in the locking grooves 41 of the rear end section 39 b of the last rod assembly section 23 . The rotational drive is moved backwards by displacing the hydraulic cylinders 25 of the linear drive. The locking fork is then lowered and fixes the second to last rod assembly section 23 by engaging of the locking fork in the rear end section 39 b of this rod assembly section 23 . The linear/rotational drive 5 is then released from the rod assembly section 23 by a 90° rotation of the catch ring and moved forward again until the catch ring 37 can engage in the locking grooves of the front end section 39 a of the last rod assembly section 23 . By a further working stroke of the linear drive the drill rod assembly 24 is pulled out of the soil as far as to enable the locking fork to lock the second to last rod assembly section 23 in the front end section 39 a . Then, the last rod assembly section 23 can be screwed off from the second to last rod assembly section 23 by a counter clockwise rotation of the drive sleeve 34 . Due to the particular shape of the rod assembly section in the region of the end sections, a rotational torque can be transferred for releasing the threaded connection without the catch ring 37 being fixed in the locking groove 41 also in longitudinal direction. This allows the catch ring 37 to slide over the rod assembly section according to the thread pitch, which allows avoiding a length compensation via the linear drive. Simultaneously, the rod assembly receiver 44 moves forward to receive the unscrewed last rod assembly section 23 . The rod assembly receiver 44 then moves to its rear most position again and the linear/rotational drive 5 moves simultaneously forward so that the latter can engage on the rear end section 39 b of the then last (before second to last) rod assembly section 23 . The screwed-off rod assembly section 23 is then completely moved out of the drive sleeve 34 and can be inserted into the receiving sled 52 of the rod assembly lift 6 by pivoting of the receiving mandrel 45 into the vertical position. The receiving sled 52 can then be moved upwards to the loading station 58 where the rod assembly section can be retrieved by an operating person.
In the same manner, all rod assembly sections are successively released from the horizontal drilling device.
The shown horizontal drilling device is appropriate for use in non-urban environments and in particular for the generation of house connections in the supply field (in particular gas, water, electricity, fiber glass, etc). Bores of at least 20 m in length can be introduced which are then used for drawing in pipes or cables with an outer diameter of up to 63 mm. | A method for producing a horizontally drilled bore hole in the ground includes the steps of producing a pit having a circular cross-section; lowering a horizontal drilling device into the pit, the horizontal drilling device having a circular cross-section in at least part of the section in which it is positioned once it is lowered into the pit; and producing a horizontally drilled bore hole using the horizontal drilling device. |
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RELATED APPLICATIONS
[0001] This application claims priority to provisional application Ser. No. 61/347,609 filed on May 24, 2011 and incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] a. Field of Invention:
[0003] This invention pertains to a roman shade having telescoping rods enveloping the control cords.
[0004] b. Description of the Prior Art
[0005] The current types of Roman shade operating systems have been the subject of a series of recalls in the recent past as the US government views the lift cords behind the Roman shade fabric as one of the top hidden dangers to small children. Specifically, a lift cord can be formed into a loop by a child pulling on the exposed cord and inserting his or her head through the loop, with the resulting pressure on the neck may lead to injury.
[0006] The current known systems in the market predominantly use lift cords attached to the bottom bar by clips or rings, with the possibility of additional clips or rings on stiffening battens sometimes used above the bottom bar. These lift cords are then attached to various pulling and/or locking mechanisms in or on a head rail. Certain known systems use a narrow flat lift tape or ribbon instead of a cord. In either case, the lift cord or tape is accessible to a person reaching behind the front of the shade. This ability to access the cord or tape allows a loop to be formed and exposes a child to potential choking hazards.
SUMMARY OF THE INVENTION
[0007] The proposed invention provides a roman shade having a sheed partitioned into a plurality of panels. Two or more cords
[0008] ???????????????inserts a cord inside of a relatively stiff telescoping tube or pipe, which permits the shade to be raised or lowered by use of a pulling mechanism but does not allow a loop to be formed, thereby eliminating or minimizing the risk of strangulation. Successively wider pieces of tube or pipe nest on top of each other to allow retraction and expansion. When the shade is at its most open position (at the top of the window), the tubes or pipes are almost completely nested, with a “stack height” of such tubes being determined by the longest of the tubes. When the pulling or operating mechanism lowers the cord, which is attached to the bottom bar of the shade, the pieces of tube or pipe surrounding the cord successively separate to allow expansion or extension of the tube or pipe along with the lengthening of the cord, without the cord ever being exposed. The outside tube must be fastened to the top of the shade or head rail, as this member must be fixed and relatively immovable for the system to function properly. The tube or pipe surrounding the cord is sufficiently stiff to prevent a loop from forming, although the tube or pipe may be able to flex.
[0009] The invention allows virtually all elements of existing operating systems to remain unchanged, a significant benefit to manufacturers of such shades who have substantial investments in such systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a rear perspective view of the telescoping Roman shade system according to the present invention, showing the shade in a fully lowered or closed position;
[0011] FIG. 2 is a side view of the shade of FIG. 1 ;
[0012] FIG. 3 is a view similar to that of FIG. 1 , showing the shade in an intermediate position mid-way between its fully lowered or closed position and its fully raised or open position;
[0013] FIG. 4 is a side view of the shade of FIG. 3 ;
[0014] FIG. 5 is a view similar to that of FIG. 1 , showing the shade in a fully raised or open position;
[0015] FIG. 6 is a side view of the shade of FIG. 5 ; and
[0016] FIGS. 7-9 are views showing additional aspects of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] A roman shade system constructed in accordance with this invention is shown in FIG. 1 and is generally designated 10 . The system includes a sheet 12 forming the shade. Sheet 12 is formed with a series of pleated sections or panels, with the number of shade sections depending on the height of the window or other area to be selectively covered and the width of each shade section. For illustrative purposes only, sheet 12 is shown to have eight shade sections, 12 a - 12 h.
[0018] Roman shade system 10 also includes a plurality telescoping tubes or pipes 14 , 16 and 18 . Two of such telescoping tubes or pipes 14 and 18 are located near the sides of Roman shade 10 . Telescoping tube or pipe 16 is located midway of the Roman shade and is generally equidistant from telescoping tubes or pipes 14 and 18 . A standard lift cord 17 is threaded in each of the tubes and has a bottom end that is connected to a bottom rail 19 .
[0019] The number of telescoping tubes or pipes depends on the number of lift cords 17 which, in turn, depends on the width of the Roman shade and the ability of the lift cords to raise or lower the Roman shade. For example for relatively narrow Roman shades, two lift cords may be sufficient to raise or lower the shade and two sets of telescoping tubes or pipes 14 and 18 are provided. Wider Roman shades may require four lift cords to sufficiently raise or lower the shade and four sets of telescoping tubes or pipes would be used.
[0020] Each telescoping tube or pipe has a plurality of tube or pipe elements. For example and as shown in FIG. 2 , telescoping tube or pipe 14 includes tube or pipe elements 14 a - 14 h . The width of each tube or pipe element decreases from top to bottom thus enabling tube or pipe element 14 b to fit within tube or pipe element 14 a , enabling tube or pipe element 14 c to fit within tube or pipe element 14 b , etc.
[0021] Preferably, the number of tube or pipe elements corresponds to the number of pleated sections of Roman shade 10 . For example in the illustrative embodiment shown in FIGS. 1-6 , Roman shade 10 has eight pleated sections, 12 a - 12 h , and likewise telescoping tube or pipe 14 has eight tube or pipe elements, 14 a - 14 h . Moreover, pleated section 12 a is connected to tube or pipe element 14 a , pleated section 12 b is connected to tube or pipe element 14 b , etc.
[0022] The topmost tube or pipe element 14 a is connected to the top of Roman shade 10 or to a head rail 20 .
[0023] FIG. 5 shows Roman shade 10 in its fully raised or most open position at the top of a window (not shown). In this position, telescoping pipe or tube 14 , telescoping pipe or tube 16 and telescoping pipe or tube 18 are in their respective completely nested positions. For example as shown in FIG. 6 , all of the tube or pipe elements 14 b - 14 h are nested within tube or pipe element 14 a.
[0024] As the Roman shade is lowered, for example, by use of a separate pulling or operating mechanism (not shown), the lift cords, which are connected to the bottom rail 19 , enter into the tube or pipe elements while the weight of the shade panels and rail cause these elements to successively separate one from the other. For example, FIG. 3 and FIG. 4 show Roman shade 10 in a mid-way position, e.g., in a position between the fully raised or open position at the top of a window and a fully lowered or closed position at the bottom of the window. In this mid-way position, tube or pipe elements 14 b - 14 d have telescoped out of tube or pipe element 14 a along with the length of the lift cord contained therein. For this purpose, the tube or pipe elements forming the telescoping tubes are loosely coupled to each other so that they slide easily with respect to each other as the shade is raised lowered.
[0025] FIG. 1 and FIG. 2 show Roman shade 10 in its fully lowered or closed position at the bottom of a window. In this position, all of tube or pipe elements 14 b - 14 h have telescoped out of tube or pipe element 14 a along with the length of the lift cord contained therein.
[0026] FIGS. 7-9 show additional details of the present invention including how tubes or pipes 14 , 16 and 18 are connected to Roman shade 10 and/or to head rail 20 .
[0027] More particularly, the outside topmost tube or pipe element 18 a is attached to head rail 20 by inserting the tube or pipe element into an aperture 22 a of a retainer 22 , which then is fastened to the bottom 20 a of head rail 20 . Retainer 22 may be fastened to head rail 20 in various ways. For example, retainer 22 may be fastened by sliding the retainer into an existing groove in head rail 20 . Alternatively, retainer 22 could be riveted or otherwise fastened to the bottom 20 a of head rail 20 .
[0028] Tube or pipe element 18 a may be slightly conical so as to seat within aperture 22 a without falling through retainer 22 . Tube or pipe element 18 a may be formed to have a flange 24 which assists in maintaining the tube or pipe element within retainer 22 . Alternatively, tube or pipe element 18 a may be generally cylindrical with top flange 24 seating the tube or pipe element within aperture 22 . Retainer piece 22 can be made out of any material, including plastic or metal.
[0029] It is desirable that the tube or pipe elements are not connected directly to the sheet 12 . Rather and as shown in FIGS. 7-9 , small loops or rings 26 , formed of plastic or cord or other suitable material, surround tube or pipe elements 14 b , 16 b and 18 b . Each loop or ring is attached to the fabric. For example, loops or rings 26 are tied to U-shaped elements 28 which extend from sheet 10 . In one embodiment, a plurality of transversal slats (not shown) separate the sheet into the individual panels 12 a - 12 h . The slats may be made of plastic, metal or other suitable material and are sewn or glued to the sheet. Alternatively, the sheet is made with transversal pockets holding the slats. The U-shaped elements 28 are then attached to the slats.
[0030] In order to facilitate the retraction of the tube or pipe elements as roman shade 10 is raised and to facilitate the extension of the tube or pipe elements as roman shade 10 is lowered, there should be some play between the loops or rings and the tube or pipe elements. For example, there should be some play between loops or rings 26 and the respective tube or pipe elements 14 b , 16 b and 18 b.
[0031] Tube or pipes 14 , 16 and 18 may be attached to the bottom rail 19 of roman shade 10 in various ways. For example, the lowermost tube or pipe elements 14 h , 16 h and 18 h could be attached to the bottom rail 19 by a small ring (like a fishing rod), may be sewn to a bottom bar of the roman shade 10 .
[0032] It will be appreciated that by locating the lift cords of a roman shade within the telescoping tubes or elements, the danger that a child will be injured by a loop formed in the lift cord is greatly, if not totally, eliminated.
[0033] The invention has applicability to most shade systems or blind systems having lift cords that might “loop” and is not limited to use with a roman shade. Moreover, numerous modifications may be made to the invention without departing from its scope as defined in the appended claims. For example, the telescoping tubes may be fixedly mounted to the bottom rail 19 and arranged so that the innermost tube elements rise slowly out of the remaining elements as the shade is lowered. Moreover, the tubes or pipes can have circular, oval, square, rectangular or other similar cross-section. | A window shade includes a sheet extending down from a head rail and is operated by a plurality of cords. Each cord extends from the head rail to the bottom of the shade. A plurality of tubes also extend from the head rail to the bottom of the shade and house one of the respective cords. The tubes are formed of a plurality of nested tube elements telescopically interengaged. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to subterranean fluid lines. More specifically, the invention relates sewage systems. More particularly still, the invention relates to improved methods and apparatus for isolating a section of a fluid line.
[0003] 2. Description of the Related Art
[0004] Pumping stations in sewage collection systems, also called lift stations, are normally designed to handle raw sewage that is fed from underground gravity pipelines (pipes that are laid at an angle so that a liquid can flow in one direction under gravity). Sewage is fed into and stored in an underground pit, commonly known as a wet well. The well is equipped with electrical instrumentation to detect the level of sewage present. When the sewage level rises to a predetermined point, a pump or pumps will be started to lift the sewage upward through a pressurized pipe system from where the sewage is discharged into a gravity manhole. From there, the cycle starts all over again until the sewage reaches its point of destination—usually a treatment plant. By this method, pumping stations are used to move waste to higher elevations.
[0005] Sewage pumping stations are typically designed so that one pump or one set of pumps will handle normal peak flow conditions. Redundancy is built into the system so that in the event any one pump is out of service, the remaining pump or pumps will handle the designed flow. There are a lot of electronic controllers designed specially for this application. The storage volume of the wet well between the ‘pump on’ and ‘pump off’ settings is designed to minimize pump starts and stops, but is not so long a retention time as to allow the sewage in the wet well to overflow. In the case of high sewage flows into the well (for example during peak flow periods and in system also handling rain water), additional pumps will be used. If this is insufficient, or in the case of failure of the pumping station, a backup in the sewer system can occur leading to a sanitary sewer overflow—the discharge of raw sewage into the environment.
[0006] Pump stations and/or sections of sewer lines are taken off-line for a variety of reasons including equipment failure and/or maintenance. Breakdown due to corrosion is typical. Sewage infrastructure corrosion occurs when sewage gas (H 2 S) is converted to sulfuric acid (H 2 SO 4 ) by the action of bacteria. Currently, the stations are taken off-line using methods that are time-consuming, difficult and dangerous. For example, in one method an inflatable pig-like device is inserted in the sewer via a manhole at some location upstream of the trouble zone. Thereafter, the pig is inflated in order to expand and block the flow of fluid. At the same time, the fluid is re-routed at a location downstream of the pig. Isolating a section of sewer in this manner is effective, but working downstream of an inflated pig is inherently dangerous in the event of deflation or rupture of the pig, which can result in a renewed flow of fluid in the direction of workers in the sewer who may not have an avenue for safe exit. In other instances, lift stations at water treatment facilitates fail and the resulting repairs on pumps is inefficient due to the presence of temporary pumps and flow lines in and around the facility.
[0007] What is needed is an efficient and safe way to isolate one section of a sewer from another section or from a lift or treatment facility.
SUMMARY OF THE INVENTION
[0008] The invention includes method and apparatus for isolating a section of fluid line. In one embodiment, a chamber is provided that extends into the ground and intersects a sewer pipe. Thereafter, the fluid in the sewer pipe is exposed to an interior of the chamber and a dam is placed in the chamber to isolate an upstream portion of the chamber from a downstream portion. As fluid collects in the upstream side of the camber, at least one pump is used to control the fluid level in the upstream portion by transferring the fluid from the chamber to a predetermined, remote location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0010] FIG. 1 is top view of a diversion chamber installed in the ground and intersecting a sewer pipe.
[0011] FIG. 2 is another top view of the diversion chamber showing a pump assembly at an upper edge of the chamber and a dam installed in the chamber.
[0012] FIG. 3 is a side view of the chamber, in section, showing the dam and its position relative to the sewer pipe.
DETAILED DESCRIPTION
[0013] In this specification, the term “sewage” or “sewer line” refers to any subterranean fluid path in a conductor regardless of the type of fluid. For instance, the principles of the invention are equally usable with waste sewage or storm sewage or both.
[0014] FIG. 1 is a top view of a diversion chamber 100 formed in the ground to access a sewer line 200 , which in the case of FIG. 1 is a tubular member. The chamber is a relatively large diameter (typically 20 feet) and is either constructed over an existing, large diameter sewer pipe (48 inches in diameter for example) or constructed at the time the sewer is originally installed. The chamber 100 is made of reinforced structural concrete usually by driving piles in the ground and then using the inwardly facing surface of each pile to form the wall 110 of the chamber. The interior walls are lined with a non-corrosive material 120 , like PVC, to prevent corrosion. The location of the chamber is typically adjacent to and just upstream of a pump station wet well or influent junction box that might need to be taken off-line at any time. The most likely candidate for a diversion chamber is a lift station at a sewage treatment facility where current methods of diversion cause the most disruption. In another instance, a chamber might be built upstream of a problem area of sewer pipe (due to breakage or collapse) or even to bypass a section of sewer while unrelated road or other infrastructure work takes place.
[0015] Sewer lines can be anywhere from 20 to 100 feet or more underground, and the chamber is designed and built whereby the floor 125 of the chamber is at a depth of the centerline of the sewer pipe 200 . In this manner, the top half of the sewer pipe can be removed and the bottom half left in place to operate as a trough for fluid. For example, if the chamber is retrofit to an existing sewer line, the depth of the line is determined and the chamber is excavated to a depth equal to the centerline of the sewer pipe. If the chamber is built at the time the sewer pipe is laid, its floor is similarly positioned relative to the pipe. The chamber is typically round and includes a precast, removable top slab (not shown) that can be covered with any material including pavement to conceal the existence of the chamber. Under normal conditions, the chamber is a static access point to the sewer and includes no permanent equipment like valves, gates or pumps. The purpose of the chamber 100 is to remain protected from long-term deterioration but be functional when needed.
[0016] FIG. 2 is another top view of the diversion chamber 100 showing a pump assembly 300 at an upper end of the chamber and a dam 400 installed in the chamber. In FIG. 2 , the chamber appears as it would just prior to a diversion operation. The pump assembly 300 includes a frame 310 designed to be a temporary and simple means of providing pumps 350 at the location of the chamber in the event a diversion is necessary. The frame 310 is supported by the walls 110 of the chamber and in turn supports the weight of the pumps 350 that are used to divert fluid from the chamber 100 to a remote location. In FIG. 2 , three pumps 350 are shown but any number can be used depending on requirements of a particular diversion job. The pumps 350 are lowered into the chamber 100 with a crane (not shown). Thereafter, they are suspended from the frame 310 by steel pipes (not shown) which provide a conduit for the fluid between the pump output and the top of the chamber. High-density PVC pipe (not shown) carries the diverted fluid to another location where it is re-introduced into the permanent sewer line, or in some cases, directly into a treatment plant. Pipe used to carry diverted fluid can be of most any construction and type so long as it is sized to handle the given volume of fluid. The pumps 350 are typically submersible pumps that are powered either by a generator or a nearby power source, and temporary controls, including fluid level sensors, are installed with the assembly 300 .
[0017] Also visible in FIG. 2 is dam 400 , like a coffer dam that serves as an enclosure within a water environment to allow water to be pumped out and replaced by air for the purpose of creating a dry environment. The dam is shown in other detail in FIG. 3 . The dam 400 includes vertical sections 401 , 402 that can be stacked to increase the overall height of the dam depending upon the level of fluid in the chamber 100 during a diversion. For example, if fluid is expected to rise to a level of 50 feet, five 10-foot sections 401 - 405 can be assembled and installed in the chamber to provide the adequate height. A tongue portion 425 formed at a lower end of the lowermost section 401 of the dam 400 is constructed and arranged to extend into and seal against a half-circle shape 205 of the sewer pipe 200 that remains after the top portion of the pipe is removed. The dam 400 is also designed to seal against the chamber wall 110 due to hydraulic pressure of fluid acting upon a convex side 430 of the dam. Corrosive resistant rubber seals (not shown) between the edges of the dam and the chamber wall ensure a watertight seal. Both the dam 400 with its multiple sections 401 , 402 and the pump assembly 300 are intended to be easily installed in the chamber 100 when they are needed and easily removed after a diversion job is complete. Typically, each will be stored in a location where they are rapidly deployable.
[0018] In the event a nearby, downstream lift station needs to be taken off-line for maintenance or in the event of a failure, the chamber 100 is exposed when the top is removed, making the chamber fully accessible from above. First, the pump assembly 300 and the dam 400 are deployed to the site. Thereafter, the pumps 350 are installed and the piping plumbed to the top of the chamber 100 and onwards to a downstream point where the fluid will be re-introduced into the sewer. The dam 400 is assembled using the required number of portions to ensure its height in relation to the fluid level expected in the chamber 100 during the diversion job. Prior to installing the dam, with the flow at some reduced level through the sewer line, the top half of the sewer pipe 200 is removed, leaving the trough-shaped lower portion 205 . At this point, the floor 125 of the chamber 100 might be poured and extend over the remaining edges of the pipe 200 as shown in FIG. 3 . The dam is then installed in the chamber, and all personnel are evacuated from the chamber. Thereafter, with fluid flow blocked in a downstream direction, the fluid level in the chamber 100 rises. At a predetermined level, one or more of the pumps 350 will begin operating to move the fluid through the diversion pipe. With the sewer section and/or station isolated, work can begin while the chamber and its equipment keep the fluid diverted. After the repairs or maintenance are complete, the dam 400 is removed along with the pump assembly 300 , and associated equipment and the top is retuned to the chamber. At any time thereafter, the chamber can be used to again isolate a section of sewer or a facility.
[0019] Using the apparatus and methods described, a pump station or section of sewer line can be completely bypassed and all parts of it accessible for repairs, maintenance or modifications. When bypassing is no longer needed, the dam will be removed, the pump station restarted and the bypass pumps removed. The dam and pump support frame can be returned to storage. The same dam and pump support frame can be used at other similar facilities. This same type of chamber can be constructed as part of a new pump station provide a way to effectively deal with emergencies in the future. The installation of the diversion chamber can be done relatively quickly and does not require a shored excavation or an extensive groundwater pumping system.
[0020] The invention has been described as utilizing a number of steps. While the steps have been described as occurring in a certain order it will be understood that such a particular order is not necessary. For instance, the order in which the pump(s) and dam are installed is flexible so long as an upstream side of the chamber is isolated from a downstream section prior to evacuation and transfer of fluid from the upstream side to a remote location.
[0021] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | A method and apparatus for isolating a section of sewer line. In one embodiment, a chamber is provided that extends into the ground and intersects a sewer pipe. Thereafter, the fluid in the sewer pipe is exposed to an interior of the chamber and a dam is placed in the chamber to isolate an upstream portion of the chamber from a downstream portion. As fluid collects in the upstream side of the chamber, at least one pump is used to control the fluid level in the upstream portion by transferring the fluid from the chamber to a predetermined, remote location. |
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FIELD OF THE INVENTION
The invention relates to a method for preparing memorial products, an apparatus for preparing memorial products, and a memorial product. In particular, the invention relates to a computer controlled method and apparatus for recessing memorial information into a metal surface to provide a memorial product.
BACKGROUND OF THE INVENTION
Memorial products are commonly prepared by a casting process. Typically, a pattern is formed which includes memorial information such as an epitaph and design. The epitaph and design are generally raised. That is, they extend away from the surface of the pattern. A considerable amount of labor is generally required to hand place the letters on the pattern for providing the epitaph information. In addition, designs often require the preparation of a separate pattern which involves cutting away portions of a material to provide the desired design features. The pattern is then used to create a mold. In general, a mixture of silica, sand, and resin is packed around the pattern. The mold is separated and the pattern is removed. Then molten metal, such as a bronze alloy, is poured into the mold to create a memorial product. The surface of the memorial product is then trimmed and polished to provide a desirable finish. The production of memorial products by casting is a fairly labor intensive and time consuming process.
SUMMARY OF THE INVENTION
A method implemented by a computer controlled routing machine for generating memorial products having recessed memorial information therein is provided by the present invention. The method includes steps of inputting data representing memorial information into a computer to provide inputted data, processing the inputted data to provide instructions for controlling a routing machine, and routing memorial information into a metal surface according to the instructions to provide a memorial product.
It should be appreciated that memorial information generally refers to epitaph information and designs. In general, an epitaph includes a brief statement commemorating or epitomizing a deceased person or something past, and usually includes dates. An epitaph can refer to a deceased person or a thing or event. In the case of a deceased person, the epitaph generally includes dates of birth and death, and often a brief statement about the deceased person or by the deceased person, handwritten personal information, poem, and/or signature. The epitaph may additionally include a hand or palm imprint or a foot imprint. Artistic designs are generally popular on memorial products. Exemplary types of designs commonly found on memorial products include angels, religious emblems, and floral borders.
The memorial information can be inputted into the computer using any commonly available type of inputting device. Exemplary inputting devices include scanners, keyboards, and mouse or menu driven software. Preferably, a signature or handwritten letter or poem can be inputted into the computer by scanning.
The metal surface is preferably part of a metal plate which can be fed to the routing machine. In the case of memorial products, bronze is a commonly used metal material. In general, bronze is a material which includes at least about 50% by weight copper. In the case of bronze for use as a memorial product, it is advantageous to provide the copper component in an amount of about 87% by weight or higher. It should be appreciated, however, that various types of materials can be processed by the invention. Bronze is preferable because of its longevity.
A computer controlled routing apparatus for generating memorial products having recessed memorial information therein is provided by the present invention. The apparatus includes a computer including a processor and data storage, a data input device, and a routing machine. The data input device is provided for inputting data representing memorial information into the computer. The processor is provided for processing inputted data, optionally in combination with data provided in the data storage, and providing instructions for controlling the routing machine. The routing machine is provided for receiving instructions from the computer and routing memorial information into a surface of a metal plate to provide a memorial product.
A method for preparing a memorial product is provided by the present invention. The method includes steps of providing a metal substrate, at least a portion of the substrate including a surface for receiving recessed memorial information, and recessing memorial information into the surface for receiving recessed memorial information to provide a metal substrate having recessed memorial information. Preferably, the memorial information includes lettering. The method can further include a step of attaching the metal substrate having recessed memorial information to a stone. Lettering is preferably routed to a depth of at least about {fraction (1/16)}inch to provide sufficient relief. In order to avoid providing too much relief, lettering is preferably recessed to a depth of no greater than about ⅛inch below the substrate surface.
A memorial product is provided according to the present invention. The memorial product includes a bronze plate having a surface including recessed lettering. The recessed lettering is provided at a depth of at least about {fraction (1/16)}inch below the surface of the bronze plate. Preferably, the lettering is provided at a depth which is not greater than about ⅛inch below the bronze plate surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a memorial product including recessed lettering a cast design according to the present invention; and
FIG. 2 is a memorial product including recessed lettering and recessed design according to the present invention;
FIG. 3 is a memorial product including recessed signature according to the present invention;
FIG. 4 is a schematic diagram showing the method for manufacturing a memorial product according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A memorial product is provided having memorial information therein. In the context of a memorial product, it should be understood that the phrase “memorial information” generally refers to epitaph information and designs. In general, an epitaph includes a brief statement commemorating or epitomizing a deceased person or something past, and usually includes names and dates. In the case of a deceased person, the epitaph generally includes dates of birth and death, and often a brief statement about the deceased person or by the deceased person, handwritten personal information, a poem, and/or a signature. In the case of infants or small children, the epitaph may include a hand or palm imprint or a foot imprint. Designs are often popular on memorials. The designs are generally artistic in nature. Popular design provided on memorials for deceased persons include angels, religious emblems, and floral borders.
According to the invention, at least a portion of the memorial information can be recessed into the surface of a metal substrate. Applicants have discovered that by recessing at least a portion of the memorial information into the surface of a metal substrate, it is possible to provide a relief of the memorial information while avoiding the time consuming and labor intensive technique steps provided by the prior casting techniques. Accordingly, a memorial product can be customized more quickly and at a lower cost by recessing memorial information compared with prior casting techniques.
Recessed memorial information includes relief information which is provided below the surface of the memorial product. In contrast to raised memorial information provided by conventional casting techniques, recessed memorial information can be provided by routing or engraving into the surface of the memorial product. In the case where the information includes lettering, the lettering is preferably provided at a depth of between about {fraction (1/16)}inch and about ⅛inch. It should be appreciated that the recessed memorial information is preferably provided at a depth which will provide the desired relief. To provide desired relief in bronze, it is generally desirable to recess to a depth of at least about {fraction (1/16)}.
Now referring to FIG. 1, a memorial product according to the invention is provided at reference numeral 10 . The memorial product 10 includes a metal plate 12 and memorial information 14 . As shown, the memorial product 10 is mounted to a stone base 16 , but can be mounted to the other type of desired surface including a wall. Alternatively, the memorial product 10 can be provided without a base and used as a marker. That is, the memorial product can be laid upon the ground or placed on a surface to act as a marker. When attached to a stone base 16 , it is preferable that the stone base is granite. Alternatively, the stone base 16 can be a marble or a synthetic stone product.
The metal plate 12 is preferably a metallic material having a surface 13 which can be machine recessed in order to provide the recessed memorial information 18 . Preferably, the metal plate 12 includes a bronze alloy. In general, a bronze alloy contains at least about 50% by weight copper. A preferred bronze alloy includes about 87% copper, about 5% tin, about 2% zinc, and about 1% lead. It should be appreciated, however, that the bronze alloy which can be used according to the invention is not limited to the preferred bronze alloy identified above.
The dimensions of the metal plate can certainly vary depending upon a application. In the case of a metal plate which is intended to be used as a memorial marker at a grave site, the metal plate preferably has a thickness of between about 0.5 inch and 2 inches. When used as a marker at a grave site, it is preferable that the metal plate has a length of between about 24 inches and 60 inches, and a width of between 14 inches and 30 inches.
The memorial information 14 can include any type of information commonly found on memorialization products. The recessed memorial information 18 in FIG. 1 is shown as “NAME” and is intended to include the name of the deceased person as well as any other desired type of epitaph information including the birth and death dates of a deceased, personal information or letters, handwritten information, signatures, poems, hand or palm imprints, and foot imprints. Raised memorial information 20 can include any type of epitaph or design information. Exemplary types of design information includes artistic work including, for example, angels, religious emblems, and floral designs. A border 21 is shown which is preferably a floral border.
By recessing at least a portion of the memorial information, it is possible to avoid the time and labor intensive steps required in prior art casting operations for that information while providing the memorial information in relief. In the case of memorial product 10 , the metal plate 12 can be provided as a cast metal plate including raised memorial information 20 and 21 . The memorial product 10 can then be customized for a particular person or thing by introducing the recessed memorial information 18 .
The recessed memorial information 18 is preferably provided by routing or inscribing into the surface 13 of the metal plate 12 . That is, the information is not provided in a raised fashion which is commonly the result of a casting process. Accordingly, the recessed memorial information 18 can be referred to as routed information.
Now referring to FIG. 2, a memorial product 30 is provided mounted on a stone base 31 . The memorial product 30 includes a metal plate 32 having a surface 33 including recessed memorial information 34 including epitaph information 36 and design information 38 . Additionally included is an optional recessed border design 39 . The metal plate 32 can be a cast plate or a rolled plate. The memorial product 30 is shown without any relief created by casting. Accordingly, the entire relief can be introduced into the surface 33 by routing or engraving.
Now referring to FIG. 3, a memorial product 40 is provided which includes memorial information 42 including a recessed signature 44 in the surface 46 of the metal plate 48 . The signature 44 can be provided as a copy of the signature of the deceased person. Design information 49 including a border 47 can be provided as either recessed information (by routing) or raised information (by casting).
Now referring to FIG. 4, a schematic diagram is provided showing a preferred method for manufacturing a memorial product. Information 50 can be inputted into a computer 52 by using a scanner 54 , a keyboard 56 , a mouse 58 or any combination of these or any other type of data input device. The inputted information is then processed by the processor in the computer 52 into a language 53 suitable for controlling the operation of a routing machine 60 . The processing of the information includes cleaning up certain lines and/or angles to provide a desired relief information 62 for recessing into the metal surface 64 . The routing machine 60 then recesses the relief information 62 into the metal surface 64 . Preferably, the metal surface 64 is part of a metal plate 66 which is preferably a bronze alloy.
The computer is preferably driven by a graphics software package. A preferred graphics software package which can be used is available as Scanveg software from Scanveg of Chicago, Illinois. A preferred routing machine which can be used according to the invention is available from Komo Machine, Inc. of Saulk Rapids, Minn. as the CNC Router. The router preferably has a variable speed spindle, movable set up, and lubricant free tool. When routing bronze, it is desirable to rout without the use of oils and/or water which cause staining or require additional processing for the removal thereof.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A method implemented by a computer controlled routing machine for generating memorial products having recessed memorial information therein is provided. The method includes inputting data representing memorial information into a computer to provide inputted data, processing the inputted data to provide instructions for controlling a routing machine, and routing memorial information into a metal surface according to the instructions to provide a memorial product. A computer controlled routing apparatus for generating memorial products having recessed memorial information therein is provided. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Divisional of U.S. patent application Ser. No. 10/962,909, filed Oct. 12, 2004 now U.S. Pat. 7,055,270, entitled CUTTING ELEMENT SUPPORTED ON A DRUM, and is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
FIELD OF THE INVENTION
The present invention relates to a mounting arrangement for mounting a cylindrical cutting element to a chain to provide support necessary for cutting difficult materials such as rock formations, and road surfaces.
BACKGROUND OF THE INVENTION
Cylindrical cutting elements are often mounted to a variety of driven elements to perform excavations of various difficult type of ground, including compacted sands, clay, gravel and rock. The driven elements include drums and chains. FIGS. 1-4 illustrate a prior art trencher 100 with a typical roller chain assembly 10 . FIG. 1 illustrates the trencher 100 with a boom 102 in a raised position, and a lowered position. In the lowered position, the boom 102 forces the roller chain assembly 10 into engagement with the ground. The chain is powered by a drive sprocket, not shown, such that end idler 104 will rotate clockwise, and the bottom strand of the roller chain assembly 10 will move from right to left. When in engagement with the ground the chain assembly 10 will excavate and transport cuttings to a discharge conveyor 106 , thus forming a trench as the trencher 100 moves from right to left. FIG. 2 illustrates a typical roller chain assembly 10 comprising attachment links 12 , side links 14 , and rollers 16 .The chain assembly 10 further comprises base plates 18 , conical cutters 20 , tool holders 22 and back bend bars 24 , as illustrated in FIGS. 3 and 4 . FIG. 3 illustrates a double chain assembly where the base plates are each attached to 2 chains. The conical cutters 20 are positioned on the base plates at an angle such that they contact the ground at the required orientation. The chain assembly 10 will move from left to right as illustrated in FIG. 4 , with the conical cutter 20 contacting the ground. This contact will generate an excavation force F 1 on the tip of the conical cutter 20 A. Conical cutter 20 A is mounted to baseplate 18 A which is mounted to attachment links 12 A. The force F 1 will generate a moment, substantially around axis 13 . The chain assembly 10 will flex until backbend bars 24 A contact side links 14 A. In this manner the back bend bars 24 stiffen the chain assembly 10 .
When utilized in extreme conditions this type of drive and mounting arrangement is has been found to be insufficient. There are times that the tool holders 22 are not sufficiently attached to the base plates and that the overall chain assembly includes sufficient flexibility to induce unwanted vibrations.
An improved mounting arrangement is needed for application of this type of excavation assmbly in extreme conditions.
BRIEF SUMMARY OF THE INVENTION
According to the present invention there is provided an improved mounting arrangement for a conical cutter to a chain assembly
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of a prior art trencher with a boom in 2 positions with a prior art chain assembly;
FIG. 2 is an isometric view of a prior art roller chain;
FIG. 3 is a top view of a prior art chain assembly;
FIG. 4 is a side view of a prior art chain assembly;
FIG. 5 is a top view of the chain assembly of the present invention;
FIG. 6 is a side view of the chain assembly of the present invention;
FIG. 7 is a side view of a boom assembly utilizing a chain assembly of the present invention;
FIG. 8 is a side plan view of a trencher including a chain boom and excavating drums; and
FIG. 9 is a side view of an excavating drum configured according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, like reference numerals designate identical or corresponding parts throughout the several views. The included drawings reflect the current preferred embodiment. There are many additional embodiments that may utilize the present invention. The drawings are not meant to include all such possible embodiments.
FIGS. 5 and 6 illustrate the tool holder 22 supported on a bottom plate 30 and a support gusset 32 . Support gusset 32 is attached on a first end to bottom plate 30 and on its opposite end to the tool holder 22 . Bottom plate 30 is secured to the base plate 34 A and also supported by contact with base plate 34 B, when in the configuration illustrated in FIG. 6 . In this manner the resulting chain assembly provides improved stiffness, and a more robust mounting arrangement for tool holder 22 . The bottom plate 30 and the support gusset 32 can be made in one piece or several pieces connected together. Even the tool holder 22 for holding tooth 20 can be make in one piece with the bottom plate 30 and the support gusset 32 if desired. The supporting gusset 32 extends from directly behind the cutter or tooth 20 , and it contacts the base plate 32 and not the chain link 14 when forces are applied to the tooth 20 while in operation of the chain trencher.
The resulting chain is illustrated in an assembly between a drive sprocket 110 and an end idler 112 in FIG. 7 . As the chain assembly travels around the drive sprocket 110 and end idler 112 the bottom plate 30 will separate from the trailing base plate such that the extra rigidity resulting from the contact between the bottom plate 30 and its trailing base plate 34 . Gusset 32 , however, provides additional support of the tool holder 22 such that, even in the position where the chain is travelling over the end idler 112 , the connection of the tool holder to the base plate 34 is enhanced.
Gusset 32 sweeps back in a configuration such that it is always positioned at an effective radius that is less than the effective radius swept out by the point of the conical cutter 20 .
FIG. 8 illustrates a trencher 200 with a boom assembly including a center excavating chain 202 and 2 excavating drums 204 as described in pending U.S. patent application Ser. No. 10/227,838 filed Aug. 27, 2002, filed by assignee entitled excavation apparatus, which application is incorporated herein by reference. The excavating chain 202 of trencher 200 is configured to include the gusset 32 and bottom plate 30 supporting tool holder 22 . The tool holders 22 that are attached to the excavating drums are similarly supported by gussets 34 , and bottom plate 36 as illustrated in FIG. 9 .
Obviously many modifications and variations of the present invention are possible in light of the above teachings, including variations in the shape of the knife mount pin and cooperating apertures in the knife adapter. It is known to use various configurations of these components, other than the herein specified cylindrical shapes. These would include conical sections, and could include pins with various cross-sections such as square or hexagonal. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
Claims 5 - 8 are duplicative of claims 1 - 4 except for the reference numerals. It is believed that leaving the reference numerals in claims 1 - 4 will help the Examiner examine these all of these claims. Accordingly, applicants will authorize cancellation of claims 1 - 4 after the first Office Action, as well as authorization to cancel this paragraph. | In a chain excavator including an excavation chain with links routed around a drive sprocket and an end idler with a base plate mounted to a link for supporting excavation implements, a stabilizing element extends rearwardly from directly behind the excavation implement in order to contact and be supported by its trailing base plate. |
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TECHNICAL FIELD OF THE INVENTION
The present invention generally relates to portable buildings and, more particularly, to a level transition device for portable buildings.
BACKGROUND OF THE INVENTION
Portable buildings, such as small garden sheds or yard barns, are popular means for providing an enclosed storage area or workspace near one's home. Typically, the portable building is either constructed on-site or constructed off-site and transported to the site where the building is to be used. In either case, the building is typically constructed so that it simply rests upon a relatively flat piece of ground, with no masonry foundation. Not only does this reduce cost, but it allows for easy movement of the building to another location in the future.
One drawback of the lack of a finished foundation is that the floor threshold at the entrance to the portable building is raised significantly above the level of the surrounding ground, typically about eight (8) inches. While this height differential is not significant for persons walking into and out of the portable building, it does represent a significant obstacle to rolling implements, such as lawn mowers, wheelbarrows and hand trucks.
There is therefore a need to a device that will allow for rolling implements to easily ingress and egress to and from a portable building. The present invention is directed toward meeting this need.
SUMMARY OF THE INVENTION
The present invention comprises various combinations of 2″×4″, 2″×6″, 2″×8″, 2″×10″ and 2″×12″ members stacked on top of one another with one longitudinal edge of each member co-aligned. In this configuration, the non-aligned longitudinal edges form shallow steps which act as a ramp, allowing wheeled implements to easily transition from ground level to the floor level of the portable building.
In one form of the invention a level transition device for a portable building is disclosed, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×6″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×10″ and cut to the predetermined length; a fourth board having cross-sectional dimensions of approximately 2″×12″ and cut to the predetermined length wherein the first, second, third and fourth boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, third and fourth boards; a second hole drilled through the first, second, third and fourth boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt whereby the first, second, third and fourth boards are held securely together.
In another form of the invention, a portable building is disclosed comprising an enclosure; an opening in the enclosure; a sill disposed in the opening; a level transition device coupled to the sill, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×6″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×10″ and cut to the predetermined length; a fourth board having cross-sectional dimensions of approximately 2″×12″ and cut to the predetermined length wherein the first, second, third and fourth boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, third and fourth boards; a second hole drilled through the first, second, third and fourth boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt whereby the first, second, third and fourth boards are held securely together.
In yet another form of the invention, a level transition device for a portable building is disclosed, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×8″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×12″ and cut to the predetermined length; wherein the first, second, and third boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, and third boards; a second hole drilled through the first, second, and third boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt; whereby the first, second, and third boards are held securely together.
In another form of the invention, a portable building is disclosed comprising an enclosure; an opening in the enclosure; a sill disposed in the opening; a level transition device coupled to the sill, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×8″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×12″ and cut to the predetermined length; wherein the first, second, and third boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, and third boards; a second hole drilled through the first, second, and third boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt; whereby the first, second, and third boards are held securely together.
In another form of the invention, a level transition device for a portable building, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×6″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×8″ and cut to the predetermined length; a fourth board having cross-sectional dimensions of approximately 2″×10″ and cut to the predetermined length; a fifth board having cross-section dimensions of approximately 2″×12″ and cut to the predetermined length; wherein the first, second, third, fourth and fifth boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, third, fourth and fifth boards; a second hole drilled through the first, second, third, fourth and fifth boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt; whereby the first, second, third, fourth, and fifth boards are held securely together.
In yet another form of the invention, a portable building is disclosed comprising an enclosure; an opening in the enclosure; a sill disposed in the opening; a level transition device coupled to the sill, the level transition device comprising a first board having cross-section dimensions of approximately 2″×4″ and cut to a predetermined length; a second board having cross-sectional dimensions of approximately 2″×6″ and cut to the predetermined length; a third board having cross-sectional dimensions of approximately 2″×8″ and cut to the predetermined length; a fourth board having cross-sectional dimensions of approximately 2″×10″ and cut to the predetermined length; a fifth board having cross-sectional dimensions of approximately 2″×12″ and cut to the predetermined length; wherein the first, second, third, fourth and fifth boards are stacked such that a longitudinal edge of each of said boards are substantially co-aligned; a first hole drilled through the first, second, third, fourth and fifth boards; a second hole drilled through the first, second, third, fourth and fifth boards; a first bolt disposed through the first hole; a first nut secured to the first bolt; a second bolt disposed through the second hole; and a second nut secured to the second bolt; whereby the first, second, third, fourth and fifth boards are held securely together.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a preferred embodiment level transition device of the present invention.
FIG. 2 is a perspective view of the preferred embodiment level transition device of FIG. 1, installed on a portable building.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, and alterations and modifications in the illustrated device, and further applications of the principles of the invention as illustrated therein are herein contemplated as would normally occur to one skilled in the art to which the invention relates.
With reference to FIG. 1, a preferred embodiment level transition device of the present invention is illustrated and indicated generally at 10 . The level transition device 10 is comprised of four lengths of board stock (preferably treated wood) cut to a length substantially equal to the width of the door opening of the portable building to which it will be attached (typically four (4) feet).
A first board 12 is preferably formed from 2″×12″ board stock. A board 14 rests upon board 12 and is preferably cut from 2″×10″ board stock. A board 16 rests upon the board 14 and is preferably cut from 2″×6″ board stock. Finally, a board 18 rests upon the board 16 and is preferably cut from 2″×4″ board stock. All of the boards 12 - 18 are preferably cut to the same width (substantially corresponding to the width of the door opening). It will be appreciated by those having ordinary skill in the art that the dimensions given above are approximate and refer to standard dimensional labels given to the board stock, even though the finished dimensions of the board stock are typically slightly less than the quoted dimensions.
As can be seen from reference to FIG. 2, stacking the boards 12 - 18 results in a series of small steps 20 , which will behave as a discontinuous ramp when a wheel having a diameter of approximately four inches or greater is rolled up or down the steps 20 . This is because the two-inch rise of each step within the steps 20 is not a significant rise when compared to the diameter of the wheel.
As can also be seen from FIG. 2, the boards 12 - 18 are aligned with one another along one longitudinal edge 22 thereof. A hole 24 is then drilled through all of the boards 12 - 18 and a carriage bolt 26 is passed therethrough and secured with a nut 28 . In a preferred embodiment, the hole 24 is countersunk on both ends such that the head of the carriage bolt 26 and the nut 28 lie substantially flush with the surface of the level transition device 10 . Carriage bolts 26 are preferably secured near either end of the level transition device 10 , and additional carriage bolts 26 may be placed intermediate thereto, depending upon the width of the level transition device 10 . In a preferred embodiment, the carriage bolts 26 and the nut 28 are galvanized.
With reference to FIG. 2, the level transition device 10 is illustrated when installed at the opening of a portable building. As can be seen, the level transition device 10 provides for a relatively smooth transition between a ground level 30 and the sill 32 of the door opening. In a preferred embodiment, the level transition device 10 is secured to the portable building doorsill 32 by means of a pair of lag bolts 34 which are extended through holes 36 drilled transversely through the board 18 . The lag bolts 34 may then be screwed into the door opening sill 32 in order to securely attach the level transition device 10 to the portable building. In a preferred embodiment, the lag bolts 34 are placed near opposite ends of the level transition device 10 and are preferably galvanized.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, the preferred embodiment disclosed herein may be modified to accommodate various height transitions. For example, an approximately six inch (6″) height transition may use 2″×4″, 2″×8″ and 2″×12″ pieces of stacked board stock. Similarly, a ten inch (10″) height transition may use 2″×4″, 2″×6″, 2″×8″, 2″×10″ and 2″×12″ pieces of stacked board stock. | The present invention comprises various combinations of 2″×4″, 2″×6″, 2″×8″, 2″×10″ and 2″×12″ members stacked on top of one another with one longitudinal edge of each member co-aligned. In this configuration, the non-aligned longitudinal edges form shallow steps which act as a ramp, allowing wheeled implements to easily transition form ground level to the floor level of the portable building. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of co-pending U.S. application Ser. No. 14/404,565, filed Nov. 28, 2014, the disclosure of which is incorporated herein by reference. This application claims priority benefits under 35 U.S.C. §1.119 to Korean Patent Applications No. 10-2012-0103136 filed Sep. 18, 2012 and No. 10-2012-0128126 filed Nov. 13, 2012.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is for various types of surface signs printed on the surface of the road for signage purpose, more specifically, the surface sign would be in a form that appears to be elevated vertically making it easy for the driver to recognize the sign which can enhance readability, and it draws the drivers gaze to the road helping the driver practice safer driving.
[0004] 2. Description of Related Art
[0005] There are many printed surface signs on the road today. Such surface signs make it possible for drivers to know the direction for key points of traffic, when to change lanes before turning either right or left, and various information regarding warnings. In such surface road signs which are generally text that have been simply stretched lengthwise, far off horizontal lines give the feeling of being wider than close up horizontal lines, and vertical lines and lane markers and are parallel to the road making it difficult for the driver to recognize, therefore it is near impossible to recognize these two types of vertical lines, therefore resulting in the disadvantage of reduced readability. Accordingly, in order for the driver to become familiar with reading surface signs, the signage has to be printed several times for the message to be repeated enough, and since there are many traffic conditions where the driver is not narrowly focusing straight ahead what results is various warnings are not being recognized by the driver. Accordingly, this causes the driver to inaccurately recognize the words, and it also confuses the driver into thinking that the words are moving which leads to the necessity for a surface sign that can naturally catch the attention of the driver.
PRIOR TECHNOLOGY REFERENCES
Patent References
[0006] (Patent Reference 1) Korea Public Patent No. 10-0763512 (Registration No.) 2007 Sep. 27
BRIEF SUMMARY OF THE INVENTION
Technical Problem Solving
[0007] Accordingly, the purpose of this invention is to provide surface signs with an optical illusion effect presenting signage in a way that appears to have been vertically elevated to the driver enhancing the readability of the text.
[0008] Also, from the standpoint of the driver it has the appearance of moving on the road drawing the gaze of the driver to the sign, and providing surface signs with an optical illusion effect that can call attention to the sign which can help safe driving as it causes the driver to pay attention to warnings better.
[0009] Since this invention is printed onto the road surface creating surface signs using words or shapes that provide information to a far off driver the above surface sign from the standard distance between the above driver and the above surface sign a standard distance between the above driver and the above surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver, which is the feature of this invention.
[0010] Also, this invention has the feature of the painted length of the above surface sign, ‘y,’ where y=((X−Y)/(A−b))b for ‘b’ the random length of the roadside established from the point the furthest down of the above surface sign that is reflected in the field of vision of the above driver.
[0011] Also, a third features of this invention is that when the distance between the above driver and the above surface sign is ‘X’ and the above painted scope of the surface sign is ‘S’, then the formed angle of the above surface sign θ, is θ=2 tan −1 ((S/2)/X).
Beneficial Effect
[0012] In case the driver is at a distance from the surface sign( 1 ) the surface sign( 1 ) will appear as if it is laying flat on the road, but the shorter the standard distance used in the surface sign( 1 ) in the diagram, the surface sign( 1 ) will gradually elevate, and when the driver is in position the surface sign( 1 ) will become visible to the driver as if it were in its vertical form on the surface of the road, therefore this invention boosts the effect of the readability of the text.
[0013] Also, this invention would have the effect of aiding in safer driving because from the standpoint of the driver if the surface sign( 1 ) is elevated it becomes something that appears to be moving while lying flat on the road which could draw the driver's attention of the because of the human tendency recognize moving objects quicker than stationary ones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic view showing the surface signs with an optical illusion effect according to the implementation example of this invention.
[0015] FIG. 2 is conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0016] FIG. 3 is a conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0017] FIG. 4 is a conceptual view showing the left side angle of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0018] FIG. 5 is a conceptual view showing the length ratio formula of the underside and topside of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0019] FIG. 6 is the floor plan of the print example of the length of the painted surface signs with an optical illusion effect according to the daily standard length.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Below described in detail are the surface signs with an optical illusion effect of this invention according to the attached figures.
[0021] FIG. 1 is a schematic view showing the surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 2 is conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 3 is a conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 4 is a conceptual view showing the left side angle of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 5 is a conceptual view showing the length ratio formula of the underside and topside of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, and FIG. 6 is the floor plan of the print example of the length of the painted surface signs with an optical illusion effect according to the daily standard length.
[0022] By printing copy or shapes on the road in school zones, children protection zones, and copy and information about major intersections, and various guidance copy and shapes, this invention's surface signs with an optical illusion effect gives 3-D shape to surface signs( 1 ) within the field of view of the driver who is behind the wheel of the car, calling attention to the hazards the driver may face and improving the readability of the copy.
[0023] In order to do this, this invention as described in diagrams 1 through 5 , has a surface sign( 1 ) from the standard distance between the driver and the surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver. In more detail, when the height of the field of vision for the driver has been established as Am, and the height of the surface sign( 1 ) that can be seen in 3-D has been established as Bm, the printed length of the surface sign( 1 ) according to the distance between the driver and the surface sign( 1 ) uses a rule that has similar figures as a triangle and follows the formula below. Here, the distance between the driver and the surface sign( 1 ) means the furthest away distance from the driver to the surface sign( 1 ), and the height of the surface sign( 1 ) means the total length of the surface sign( 1 ) reflected in the field of view of the driver from the point the furthest up to the point the furthest down.
[0000]
X
:
A
=
Y
:
B
AY
=
BX
Y
=
B
A
X
Mathematical
Formula
1
[0024] The height of the field of view of the driver of a passenger car was established as 1.3 m, and the height of the surface sign( 1 ) seen three dimensionally was described in the case of being established at a height of 39 cm, but these are matters that can be selected by the person from the scope that applies the above formula, therefore the height of the field of view of the driver and the height of the surface sign( 1 ) in this invention is not fixed at a numerical value.
[0025] If the printed length of the surface sign( 1 ) according to the length of the distance between the driver and the surface sign( 1 ) according to the mathematical formula is 30 m,
[0000]
Y
=
0.39
1.3
30
=
9
Mathematical
Formula
2
[0000] then it becomes 9 m. Using the same method the printed length of the surface sign( 1 ) for distances of 15 m, 20 m, and 25 m between the driver and the surface sign( 1 ) would be 4.5 m, 6 m, and 7.5 m, respectively.
[0026] Also, as described in FIG. 3 , even the length that is shown in the same interval in the field of view of the driver, the printed length of this become longer the further up you go, but the distance of the point of ‘y’ as expressed on the actual surface of the height of the random point of b as seen three dimensionally in surface sign( 1 ) follows the following formula. Here, the random point ‘b’ means the random vertical length that is established from the lowest point of the surface sign( 1 ).
[0000]
y
+
(
X
-
Y
)
:
A
=
y
:
b
Ay
=
by
+
(
X
-
Y
)
b
(
A
-
b
)
y
=
(
X
-
Y
)
b
y
=
X
-
Y
A
-
b
b
Mathematical
Formula
3
[0000] Meaning, in order to see the row of the uppermost part and the lowermost part, the lower part of the uppermost row will be shown at a point of 29 cm, and the upper part of the lowermost row will be shown at a point of 10 cm, therefore each would be indicated
[0000]
y
=
30
-
9
1.3
-
0.29
0.29
=
6.03
y
=
30
-
9
1.3
-
0.1
0.1
=
1.75
Mathematical
Formula
4
[0000] at points of 6.03 m and 1.75 m. Accordingly, the upper part of the lowermost row would be indicated at a point of 9 m, and the print length would be 2.97 m, and with the print length of the lowermost row as 1.75 m, it would result in a ratio of about 1.7 times. The means that the print distance of the surface sign( 1 ) should be printed even more elongated the further you go from lower to upper for it all to be seen as the same length in the driver's field of view.
[0027] Also, that which can be known from the length of ‘y’ for the point ‘b’ is that if one wants to view both the horizontal and vertical at lengths of 10 cm, then as the length of the vertical described in the actual surface is about 1.75 m from the lower part of the surface sign( 1 ), and about 2.97 m in the upper part then the roadside length is 17˜30 times the wayside length.
[0028] Also, in the above, the upper and lower lengths of the surface sign( 1 ) according to the field of view of the driver were mentioned, so the right and left side angle of the surface sign( 1 ) according to the driver's field of view will be described.
[0029] When the distance between the driver and the surface sign( 1 ) as seen in FIG. 4 is Xm, and the range of printing of the surface sign( 1 ) is established, then the right and left side angle ‘θ’ is expressed in the following formula.
[0000]
θ
=
2
tan
-
1
S
2
X
Mathematical
Formula
5
[0030] This means that if the distance between the surface sign( 1 ) is 30 m, and the range of printing is 3.5 m, then the right and left side angle of the surface sign( 1 )
[0000]
θ
=
2
tan
-
1
3.5
2
30
=
6.68
Mathematical
Formula
6
[0000] becomes 6.68 m. In the same way, the criteria for the distance of 15 m, 20 m, and 25 m, between the driver and the surface sign( 1 ) each have a right and left side angle of the surface sign( 1 ) of 13.31, 10 and 8.01. This way, when establishing the right and left side angle of the surface sign( 1 ) according to the distance between the driver and the surface sign( 1 ) m , the field of view of the driver from the relevant distance makes the edge of uppermost right and left side and the edge of the lowermost right and left side appears at the same location, therefore the letters do not appear to be uneven.
[0031] The right and left side angle of this surface sign( 1 ) are matters that can be determined based on the range selected by the person that were applied according to the standard distance between the surface sign( 1 ) and the driver, the range of printing of the surface sign( 1 ), therefore this is not fixed at a numerical value.
[0032] For example, the above was described for when printing a surface sign( 1 ) on a standard road that is 3.5 m wide, but when printing on a range where the lanes are 3.15 m wide, the criteria distance of 15 m, 20 m, 25 m and 30 m would be replaced with left and right side angles that are 12 degrees, 9 degree, 7.2 degrees and 6 degrees, respectively.
[0033] The left and right angles of the surface sign( 1 ) are applied to each letter when printing, but the random vertical line that connects from the uppermost point to the lowermost point, for example, in case of the vowel “I”, the angle forming the left side version and the right side version would be printed in different ways from each other. When the vowel “I” is formed as a whole from the upper part of the surface sign( 1 ) to the lower part, when considering the left side version of the vowel “I” is at a distance of 1 m from the square center of the surface sign( 1 ) and the right side version of the vowel “I” is at a distance of 1.1 m from the square center of the surface sign, then the line dividing the left side and right side versions of the vowel “I” and the angle that is formed is
[0000]
Left
=
tan
-
1
1
30
=
1.91
Righ
=
tan
-
1
1.1
30
=
2.1
Mathematical
Formula
7
[0000] resulting in an angle of 0.19 formed by the left and right side of the vowel “I” that has a width of 10 cm.
[0034] If you substitute this in mathematical formula 5,
[0000]
θ
=
2
tan
-
1
0.1
2
30
=
0.19
Mathematical
Formula
8
[0035] This means it follows the range formula of the surface sign( 1 ) according to the field of view of the driver.
[0036] Accordingly, with the adding of the angles to each other that are formed from the separate letters in a fan-shape the formation of the final left and right side angle the left and right side angle of the surface sign( 1 ) that follows the driver's field of view, then it means that the meaning of the left and right side angle of the surface sign( 1 ) as defined in the terms of this invention is the angle that is formed from among the printed left and right side peripheral sides.
[0037] However, as above, for the furthest length s2 m of the upper side from the driver by the closest length lower side from the driver of the random vertical line of the vowel “I” that goes from the uppermost point of the surface sign( 1 ) to the lowermost point, this can be deduced as follows using the similar figures as a triangle as described in FIG. 5 .
[0000]
X
:
s
2
=
X
-
Y
:
s
1
(
X
-
Y
)
s
2
=
Xs
1
s
2
=
X
X
-
Y
s
1
Mathematical
Formula
9
[0038] Here, as above the printed length of surface sign( 1 ) of standard distances of 15 m, 20 m, 25, and 39 m, respectively, for the driver's field of view height of 1.3 m were each calculated in lengths of 4.5 m, 6 m, 7.5 m, and 9 m, therefore this was plugged into ‘X’ and ‘Y’, and when considering the length of the side of vowel “I” by 10 cm, the length of vowel “I” s2 was 14.29 cm,
[0000]
s
2
=
15
15
-
4.5
0.1
=
0.14285
s
2
=
20
20
-
6
0.1
=
0.14285
s
2
=
25
25
-
7.5
0.1
=
0.14285
s
2
=
30
30
-
9
0.1
=
0.14285
Mathematical
Formula
10
[0000] the same in all cases. Likewise, in accordance with the implementation of this invention, the upper side length of the lower side letters or shapes that appear as equal in width, regardless of the distance between the driver and the surface sign( 1 ) 1.43 times would be deemed appropriate, and this would be because the gap between driver and the surface sign ( 1 ) would narrow and instead of the left and right side angle of the vowel “I” getting larger the printing length of the surface sign( 1 ) would be just as narrow.
[0039] But, even in cases such as this, within the range of application of the formula above the above numerical value can be selected by the person in charge of the application, and according to the field of view of the driver, in case the length of the surface sign( 1 ) is varied the length of the upper side can also be varied of course, therefore this invention is not limited to the numerical value.
[0040] Examples about the particulars of the composition that makes up this invention of surface signs with an optical illusion effect are described in FIG. 6 . In FIG. 6 it could be seen among the embodiments of the present invention, with the reduction of the surface sign( 1 ) that was printed on the actual road for the case of a distance of 20 m between surface sign( 1 ) and the driver, a greater width was formed for the roadside to the far side from the drive rather than to the close side of the driver, also each roadside was formed to reach the mutually acute angles, and also, the print length of the upper line was formed in a way that was longer than the lower line.
[0041] Yet, in cases of trucks and buses where the field of view is higher than that of a passenger car, just as can inferred in FIGS. 1 and 2 it still works but when the location of the driver is further from the surface sign( 1 ), and likewise drivers of trucks and buses will be able to view surface sign of the 3-D formation from an even further location.
[0042] For the invention of surface sign( 1 ) with an optical illusion effect that was described in case the location of the driver is further away from the surface sign( 1 ), the surface sign( 1 ) will appear as if it is lying flat on the road, the narrower the gap to the standard distance used in the diagram of surface sign( 1 ) the more the surface sign( 1 ) would elevate, and when the driver comes into position at a standard distance used in the diagram of surface sign( 1 ), the surface sign( 1 ) would appear to the driver as seeming to be elevated erect, therefore it would aid in safer driving because from the standpoint of the driver if the surface sign( 1 ) is elevated becoming something that looks like it is moving while lying flat on the road this could draw the attention of the because of the human characteristics that more quickly recognize moving objects rather than stationary ones.
EXPLANATION OF MARKS
[0000]
Surface sign: 1 | Disclosed is a surface sign that is seen by the driver as raised vertically improving the readability by the driver, and as for the surface signs with an optical illusion effect that can aid the driver in driving safely due to the tendency of being able to capture the gaze of the driver printing onto the road surface creating surface signs that provides information to a far off above driver using copy or shapes, from the standard distance between the above driver and the above surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver, and the surface of the road is painted in order for the two nearby roadsides to form a mutually acute angle. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a 371 National Phase of International Application No. PCT/ES2006/000173, filed Apr. 10, 2006, which claims priority under 35 U.S.C. § 119 to Spanish Application No. 200500834 filed Apr. 11, 2005, both of which are hereby incorporated by reference in their entireties.
DESCRIPTION
[0002] 1. Technical Field
[0003] The present invention is intended to disclose a panel having advantageous characteristics for the shuttering of walls and pillars.
[0004] 2. Background
[0005] As is known, in building construction there is a need to shutter the elements of concrete of the structure, in particular walls and pillars. At present, different types of shuttering panels are available for determining the volume which the wall will occupy once the reinforcements are placed in position and the concrete has been poured, and also there are panels available for the construction of pillars in which it is necessary to solve the mounting of the different panels forming an enclosure closed by the lateral faces which the structure of the pillar has, that is, customarily a straight prismatic, very elongated structure.
SUMMARY
[0006] The aim of the present invention is to disclose panels which can simultaneously be used for the shuttering of walls and of pillars.
[0007] Another aim of the present invention is the production of the panels for shuttering walls and pillars simply of bent-over metal sheet and reinforcing cross members, avoiding the structures customarily used of the tubular type forming a frame and, separately, the plate which forms the shuttering face.
[0008] Another aim of the present invention is to disclose means for rapid and safe coupling of the panels for walls by their lateral edges.
[0009] Another aim of the present invention is to disclose means for coupling the panels perpendicularly to one another adjustably so as to obtain the shuttering of a pillar of variable dimensions.
[0010] The aims of the present invention are achieved through the constitution of the shuttering panel by means of a sheet metal element bent over at the edges, forming respective L-shaped profile sections, in order to define the lateral edges of the shuttering panel, and receiving, on the inside, crossbeams and cross-members also in the form of profile sections, for example U-shaped profiles, for reinforcing the panel and for receiving the members for interconnecting the panels laterally for the shuttering of walls or perpendicularly for the shuttering of pillars.
[0011] The connecting members for connecting the panels to one another are constituted by threaded rods with the head in the shape of an arrow tip, which are preferably associated with two sides of the panel, making it possible to join the panels to other adjacent ones when the arrow-shaped head penetrates into an opening of complementary shape of the panel mounted opposite, permitting its rotation in order to prevent it from coming out. The fixing of each of the retaining members is effected simply by means of an easy to manipulate wing nut which is screwed along the member and which is applied by tightening on an added-on bridge which is in turn fixed to the lateral edges of the panel.
[0012] The aforesaid members for joining to the adjacent panels, constituted by the joining rod with arrow-shaped head and the fixing wing nut, and also the clamping bridge, have dimensions such that they come within the width which corresponds to the lateral edges of the panel, so that they do not protrude transversely to the panel, in order to permit easy stacking and transport.
[0013] For the coupling of the panels by their lateral edges for the shuttering of walls, provision is made for all the lateral edges of the panel to be equipped with a plurality of openings of a shape complementary to the fixing members already explained, that is, of a shape complementary to that of the arrow tip or the like of the ends of the threaded rods in order to permit the coupling of panels one beside the other at the desired height positions.
[0014] The clamping members for clamping the panels by their lateral edges for the shuttering of walls are preferably arranged on two perpendicular sides of the panel, and provision will be made for offset mounting on panels with respect to others, in order, when joining panels by the faces equipped with fixing members, to prevent interference between the fixing members of one panel and those of the adjacent panel.
[0015] In order to allow the panels to be mounted perpendicularly for the shuttering of walls, provision is made for the arrangement on the inner face of the panel, that is, opposed to the shuttering face, of specific profiles equipped with a row of openings for coupling of the arrow-shaped heads or the like of the clamping members of another panel, which in this way will make it possible to fix one panel to another perpendicularly to each other in order to define the prismatic space of a column.
[0016] For greater understanding thereof, drawings corresponding to an exemplary embodiment of the present invention are appended by way of non-limiting example.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0017] FIGS. 1 , 2 and 3 show views of a panel in which can be seen two of its lateral edges and a view in elevation from the rear face of the panel.
[0018] FIG. 4 shows a view with two panels coupled by their minor sides.
[0019] FIG. 5 is a view similar to FIG. 4 , showing two panels coupled by their longer sides.
[0020] FIGS. 6 and 7 respectively show a view in elevation and partial section and a plan view of the panels of the invention arranged for the shuttering of a pillar.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] As can be observed in the drawings, the panel for shuttering walls and pillars which is the subject of the present invention comprises a sheet metal element which forms the shuttering face of the actual shuttering panel 1 of rectangular shape with four sides 2 , 3 , 4 and 5 , the structure of which preferably corresponds to an L-shaped profile section as can be observed in FIG. 6 , showing the sides 6 and 7 which, by bending over the sheet metal, constitutes the sides of the panel, which replace the customary tubular members.
[0022] The panel is reinforced by means of a variable number of crossbeams 8 , 8 ′, and also cross-members such as those indicated by the numbers 9 and 10 .
[0023] All the sides 2 , 3 , 4 and 5 of the panel are equipped with a plurality of alignments of apertures such as those indicated by the numbers 11 , 11 ′, 11 ″ in FIG. 1 , and 12 , 12 ′, 12 ″ in FIG. 3 . This allows the panels to be coupled by their lateral edges for the shuttering of walls, as can be observed in FIGS. 4 and 5 , with FIG. 4 showing two panels 13 and 14 joined by their minor sides 15 and 16 , and FIG. 5 showing two panels 17 and 18 joined by two of their major sides 19 and 20 .
[0024] The joining of two panels by their sides is preferably effected by the arrangement of coupling members on the inner part of two perpendicular sides of the panels, as is shown in FIG. 2 , which shows two fixing members respectively on the sides 2 and 3 and which have been designated by the numbers 21 and 21 ′, and 22 and 22 ′. Said fixing devices are formed by a threaded rod 23 , FIG. 2 , ending in a head 24 , the transverse shape of which is complementary to the shape of the openings 11 , 11 ′, 11 ″ and 12 , 12 ′, 12 ″ of the lateral edges, all of which are the same. The rod 23 is mounted on a support bridge 25 which is in turn fixed to the lateral edge of the panel and receives on the outside a strong, easily manipulated nut 26 for tightening the fixing device, the functioning of which is obvious, since it functions simply by introduction of the arrow tip or the like 24 into the corresponding opening of the facing panel, being retained inside it after rotation, for example through 90°, of the rod, so that the arrow-shaped head 24 will be arranged transversely to the corresponding opening, after which tightening will be effected by means of the nut 26 .
[0025] As will be understood, the specific shape of the head of the fixing device may vary within wide limits, provided that it fulfils the condition that its shape is complementary to that of the opening in the lateral of the panel on which it is to be fixed and that its fixing takes place after a rotation which prevents it from coming out. Thus, for example, any type of hook could be used, provided that it complies with the characteristics mentioned of transverse shape of the tip complementary to the shape of the corresponding opening and with the ability to be retained after an angular rotation to prevent it from coming out.
[0026] A description will now be given of the means used on the panel of the present invention to allow it to be mounted for the shuttering of pillars, as shown in FIGS. 6 and 7 . FIG. 7 shows four panels coupled perpendicularly to one another, indicated by the numbers 27 , 28 , 29 and 30 , which form a central space 31 which corresponds to the cross-section desired for the pillar. In order to permit the coupling of said panels, they have on the inside profiles, for example 32 and 33 , parallel to the shuttering face and equipped with respective alignments of openings for coupling fixing members of the same shape as those shown in FIGS. 1 and 3 . In this way, the members for fixing the lateral edges of one panel, for example the panel 30 in FIGS. 6 and 7 , and which have been designated by the numbers 34 and 35 , may be introduced into the desired openings of the transverse profiles of the panel arranged perpendicularly, in the case shown, the panel 29 , fixing being effected in the same manner as for the lateral extension of the panels for the shuttering of walls.
[0027] For the coupling of two panels parallel to each other, for the shuttering of walls on two faces, the panels have through-holes for introducing the corresponding tie-rods, which have been indicated by the numbers 36 , 37 , 38 and 39 in FIG. 2 .
[0028] As will be understood, the production of the shuttering panels of the present invention makes possible the rational and economic manufacture of same and also significant ease of storage and transport of the panels without interference between members, and also great ease of adaptation both for the shuttering of walls and for the shuttering of pillars of different dimensions.
[0029] Although the invention has been shown and explained with reference to a preferred example, it will be understood that it is not limited to what has been previously described and shown in the drawings, since any expert in the field, on seeing what is disclosed in the present invention, may introduce numerous variants which will be included within the scope of the present invention provided that they correspond to the definition of the invention according to the attached claims. | A panel consisting of a single covering member constituting the formwork surface and having folded edges forming the panel sides. The panel is lined with transverse and longitudinal reinforcing members and has coupling means provided on some of the side edges and on the inside thereof for joining together the sides of two adjacent panels in the case of wall formwork, or for joining one panel perpendicularly to another panel to define the cross-section of a column by perpendicularly coupling together four panels. |
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FIELD OF THE INVENTION
[0001] The invention relates to an expander for radially expanding a tubular element by axial movement of the expander through the tubular element, and to a method of radially expanding a tubular element.
BACKGROUND TO THE INVENTION
[0002] Radial expansion of tubular elements has been applied, for example, in wellbores whereby a tubular casing is lowered into the wellbore in unexpanded state through one or more previously installed casings. After the casing is set at the required depth, an expander is moved through the casing to radially expand the casing to an inner diameter which is about equal to the inner diameter of the previously installed casing. In this manner it is achieved that the inner diameters of subsequent casings are about equal as opposed to conventional casing schemes which have stepwise decreasing casing diameters in downward direction. For example, WO-A-93/25800 teaches expansion of a casing in a wellbore by a solid expansion mandrel, the mandrel being pulled through the tubular or hydraulically pushed through the casing.
[0003] Expansion of tubulars is discussed in, for example, U.S. Pat. No. 6,557,640, and published U.S. patent application Ser. No. 10/382,325, the disclosures of which are incorporated herein by reference.
[0004] Expandable expansion cones are suggested, for example, in U.S. Pat. No. 6,460,615 the disclosure of which is incorporated herein by reference. Expansion of a cone within a casing requires that the casing be expanded as the expansion cone is expanded. This requires considerably more force than the force needed to pull a mandrel through the casing once the cone has been expanded. Further, if the lower casing is to overlap the previously installed casing and the inside diameter of the final casing is to remain constant through the overlap section, then the overlap section of the upper casing needs to be expanded by more than the remainder of the casing. Some provision for this greater expansion also needs to be provided.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present invention, a duplex expansion apparatus for expanding a wellbore tubular to two different diameters from an initial diameter, the duplex expansion apparatus comprising: a first diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the internal diameter; a second diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the diameter of the first diameter expansion cone in the expanded state; and an assembly mandrel that is capable of transferring both the first diameter expansion cone and the second diameter expansion cone into their expanded states.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a partial cross sectional view of a lower end of an expandable casing and cement shoe.
[0007] FIGS. 2A and 2B are partial cross sectional views of an expandable casing and an unexpanded duplex expansion cone within the expandable casing.
[0008] FIG. 3 is a partial cross sectional view of an expandable casing and a sealing assembly within the expandable casing.
[0009] FIG. 4 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly.
[0010] FIGS. 5A and 5B are partial cross sectional views of an expandable casing and an unexpanded duplex expansion cone within the expandable casing.
[0011] FIGS. 6A and 6B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone which has been prepared for expansion within the expandable casing.
[0012] FIG. 7 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly set in a position for downward expansion by the duplex cone.
[0013] FIGS. 8A and 8B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone within the expandable casing, after the duplex cone has been hydraulically forced to the cement shoe of the expandable casing.
[0014] FIGS. 9A and 9B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone within the expandable casing, after the duplex cone has been prepared for upward expansion of the remainder of the expandable casing.
[0015] FIG. 10 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly set in a position for upward expansion by the duplex cone.
[0016] FIG. 11 is an isometric view of an upward expansion cone.
[0017] FIG. 12 is an isometric view of a downward expansion cone.
[0018] FIG. 13 is an isometric view of a mandrel for expanding a duplex cone.
[0019] FIG. 14 is an isometric view of an upper seal bushing.
[0020] FIG. 15 is an isometric view of a retrieving tool within which an upper seal bushing may be retrieved.
DETAILED DESCRIPTION
[0021] In this specification, a tubular to be expanded is referred to as a casing, but it is to be understood that the term casing is meant to include any tubular to be expanded. A open hole liner or other wellbore tubular may be expanded by the methods and apparatuses described and claimed herein. The expansion apparatus of the present invention is referred to as a duplex expansion apparatus or mandrel because the apparatus can be used for expansion of a larger bell at the bottom of a casing, plus the remainder of the casing to a somewhat smaller diameter. The difference between the inside diameter of the bell compared to the remainder of the casing can be between about 0.2 and about 1.5 inches, or it could be about 0.5 inches. The difference in diameter can be about twice the expanded thickness of a casing to be expanded in the next lower section of the wellbore. The duplex expansion apparatus could be arranged to first expand the upper portion of the casing, and then converted to a larger diameter mandrel and used to expand the bell. Alternatively, and as shown in the apparatus discussed below, the apparatus could be configured to expand the bell first, and then contracted to a smaller diameter mandrel, but still a larger diameter than the unexpanded casing, and then used to expand the rest of the casing.
[0022] Referring now to FIG. 1 , a lower end of an expandable casing 101 with a cement shoe 102 is shown. A threaded joint 103 is provided to connect an aluminium cement shoe with the expandable casing 101 . The joint is a pin-down joint to permit downward expansion without the threads spreading due to the expansion of the upper section before the lower section. The entire shoe is aluminium or another millable or drillable material so that it can be readily removed for drilling of a subsequent open hole interval. The subsequent open hole interval may then be cased or left uncased. The cement shoe includes a bottom which preferably has teeth 104 to enhance opening of a hole if it has partially closed in the time interval between drilling and insertion of the expandable casing and secure the casing against rotation. Ports 105 are provided to ensure that cement can exit the cement shoe to an annulus between the casing 101 and formation 106 through which the wellbore 107 is drilled. The cement shoe includes a check valve 108 to keep cement from backing up into the casing once the cement has been placed in the wellbore by pumping through the casing. In this embodiment, the check valve includes a spring 109 that urges a valve seat 110 upward to close against a fixed valve seat 111 . Millable check valves and complete millable cement shoes are commercially available from many sources.
[0023] The cement shoe of the embodiment shown includes a sliding valve 112 for sealing the cement shoe for upward expansion of the expandable casing. The sliding valve 112 is shown in an open position in FIG. 1 . The sliding valve is held in an open position by a snap ring 113 . The sliding valve has a top 114 sealed to a cylindrical section 115 . The bottom of the sliding valve preferably has engaging teeth 116 for engaging with seat teeth 117 for holding the sliding valve in a fixed position when the valve is transferred to a closed position. In the open position slots 118 allow fluids to bypass the sliding valve for circulation through the casing and into the wellbore. Seals 119 are shown for providing a good seal against the cylindrical section of the sliding valve after the sliding valve has been transferred to a closed position.
[0024] The bottom of the casing is shown in FIG. 1 in a configuration in which it is inserted into the wellbore. Cement is circulated through the casing into the wellbore in this configuration.
[0025] Referring now to FIGS. 2A and 2B , a duplex expansion mandrel is shown within an expandable casing in a configuration in which the duplex mandrel is inserted into a wellbore within a formation, 106 . This apparatus, including the expandable casing, may be inserted into the wellbore through a casing in an upper section of the wellbore, the casing having been previously expanded by an expansion apparatus of the same design as the apparatus being inserted. Thus the final cased wellbore could have the same diameter from top to bottom, or through a plurality of different cased intervals.
[0026] The expandable casing preferably has a preexpanded section 201 within which the duplex cone is placed. The preexpanded section has been expanded by about, for example a half-inch diameter increase. This relatively short section of preexpanded casing is still of a smaller outside diameter than the inside diameter of the expanded casing, by for example 0.1 to 1.2 inches to permit insertion through a previously expanded casing. It is not desirable to have an extended length of preexpanded casing because a small clearance between the external surface of the preexpanded casing and the internal surface of an expanded casing would make insertion of the casing through an expanded casing problematic. But a short section of a relatively small clearance does not create significant problems when inserted through a previously expanded casing. The casing can be placed into the wellbore suspended from a collapsed upper expansion cone 204 . The collapsed upper expansion cone 204 has an outer diameter larger than the inside diameter of the unexpanded casing above the preexpanded section 201 .
[0027] A threaded joint 202 is preferably provided in the preexpanded section and this joint is preferably the only joint in the bell section of the expanded casing. This threaded joint allows the casing to be joined around the duplex expansion cone. Alternatively, additional joints in the bell section of the expanded casing could also optionally be preexpanded. Having joints in the bell section of the expanded casing being preexpanded reduces the expansion force required for expansion of the joints to the larger diameter. Because more force is required to expand joints, and more force is required to expand casing to a larger diameter, preexpansion of joints in the bell section is desirable because it would otherwise require additional expansion force compared to the remainder of the casing.
[0028] The duplex cone includes a lower cone 203 , an upper cone 204 , and expansion die 205 , all assembled on an assembly mandrel 214 . The assembly mandrel pulls and pushes the two cones over the die to expand the duplex cone.
[0029] In the configuration shown in FIGS. 2A and 2B , fluids may pass through the center of the unexpanded duplex cone assembly. A flow tube 206 hold flapper valves 207 open within a flapper valve assembly 208 . The flapper valve assembly also provides a seal for lower cone ports 209 in this initial configuration of the duplex cone assembly.
[0030] Wipers 210 are shown attached to the lower cone assembly for keeping the casing clean prior to expansion by the duplex cone.
[0031] The lower cone is held by the assembly mandrel in an initial position by first dogs 211 . Second dogs 212 will later hold the cone in a second position with respect to the assembly mandrel. A spacer 213 is shown between the expansion die and the upper cone 204 . Seal assemblies 215 are attached to the upper cone to aid in upward expansion. The pulling assembly and the upper cone are in fixed relationship to each other, and in a movable relationship to the assembly mandrel. The pulling assembly may have a plurality of pulling chambers 218 , two are shown, containing a lower piston 219 and an upper piston 222 . The pulling chambers 218 are in fluid communication with a flow path 220 through the assembly mandrel 214 through high pressure ports 221 . The lower pistons movement with respect to the assembly mandrel 214 is shown to be limited by retainer tie 223 . Movement of the upper piston 222 with respect to the assembly mandrel 214 is shown to be limited by the shoulder of pin box 224 .
[0032] Vent ports 217 maintain fluid communication between low pressure sides of the pulling chambers 218 and an annulus around the pulling assembly and the expandable casing 101 . Thus when there is a pressure differential between the flow path 220 and the annulus around the pulling assembly 216 , this pressure will be translated into force pulling the bottom expansion cone and pushing the upper expansion cone over the expansion die to form an expanded duplex cone. The assembly mandrel is movable with respect to the pulling assembly, and the pulling assembly is shown in a fixed relationship to a drill string 225 . As the term is used in this description, the drill string is generally a typical string of pipes used for circulation of drilling muds while transmitting rotating forces to a drill bit, but in the practice of the present invention, additional features may be included in segments of the drill string, and segments could be utilized that differ from the segments typically used while drilling the wellbore. The flow path from the drill string through the assembly mandrel is passed through a flow path seal 226 which maintains a sealed and sliding relationship between the pulling assembly and the assembly mandrel. Seals such as o-rings 227 could be provided to improve the sealing relationship. To enable assembly, the pulling assembly could be constructed of a middle section, 228 , a lower head, 229 , and an upper head 230 , with the three sections connected by two threaded connections, both of the threaded connections preferably in lower pressure segments of the pulling chambers.
[0033] In the configuration shown in FIGS. 2A and 2B , is the configuration in which the expandable cone is lowered into the wellbore, preferably through previously expanded casing. In this configuration there is no significant pressure differential between the flow path 220 and the annulus between the pulling assembly and the expandable casing 101 . The number of pulling chambers and pistons may be chosen to have ample force to expand the duplex cone even while expanding the casing around the duplex cone.
[0034] Referring now to FIG. 3 , a sealing assembly section is shown. The sealing section is in the drill string above the pulling assembly 216 , and within the expandable casing 101 . The sealing section includes seals 301 for maintaining force for downward expansion by the duplex cone. The seals may be, for example, Giberson cup packers available from Halliburton, of Ducan Okla. Two of the seals are shown but either one or a plurality may be provided as needed for effective sealing during the downward expansion.
[0035] Referring now to FIG. 4 , an upper end 401 of an expandable casing 101 is shown. The upper end of the expandable casing is fitted with bushing 402 for sealing for downward expansion. The bushing is removable and therefore preferably placed at the top of the expandable casing so that it will not have to slide out a great length of the expandable casing upon removal of the bushing. The bushing is preferably equipped with inside seals 403 and casing seals 404 . FIG. 4 shows a configuration in which the casing is inserted into the wellbore, with communication between the annulus between the drill string 225 and the expandable casing 101 and the wellbore above the expandable casing 101 . The bushing is notched (not shown) in the bottom so that a corresponding fin 405 in the first drill string box can catch the bushing, and remove it by twisting it out of the upper casing. Two opposing fins are shown in FIG. 4 . Removal of the bushing allows for clearance for joint tools and the duplex expansion assembly above the expansion cone. The purpose of the bushing is to provide a seal for downward expansion. The seal is provide between the inside surface of the bushing and the outside surface of a slidable section of drill string 406 . While the expandable casing and duplex cone assembly is suspended from the drill string, the weight of the casing and duplex cone assembly rests on slidable section shoulder 407 , and rotational forces can be transferred through splined section 408 . Flowpath seal 409 is provided so that leakage from the drill string flow path and the wellbore outside of the drill string is prevented.
[0036] Referring now to FIGS. 5A and 5B , with previously mentioned elements numbered as in previous figures, the duplex cone is shown in an unexpanded position configured to be expanded upon pressurization of the flowpath within the assembly mandrel. This configuration is accomplished by inserting dart 501 , which is stopped in flow tube 206 . Although a dart is shown to be of an elongated shape, a ball or another shape could be utilized. The flow tube could be held in the initial position by a shear pin or a snap ring 231 that yields upon downward force being applied to the flow tube. The dart 501 includes a seal section 502 that seals inside of the flow tube, and the flapper valve 207 seals against the flapper valve seat 503 above the flow tube. After the flow tube 206 moves to the lower position, flapper valves 207 close. An advantage of the embodiment shown is that the flapper valve, including the seats for the valve, are protected by the flow tube from circulating fluids and cements prior to insertion of the dart 501 . Thus, they are clean and more likely to seal. The flapper valves 207 are therefore primary seals, but seals between the flapper assembly and the flow tube, and the flow tube and the dart provide secondary seals for sealing the inside of the flow path to permit expansion of the duplex cone.
[0037] Referring now to FIGS. 6A and 6B , the duplex cone within an expandable casing is shown with the duplex cone forced into an expanded position. This expanded position is achieved by over pressuring the fluids in the drill string with respect to the fluids outside of the drill string and forcing the pistons 219 and 222 into upper positions within the pulling chambers 218 .
[0038] Referring now to FIG. 7 , the top end of the expandable casing is shown configured for downward expansion of the casing. After expansion of the duplex cone, the cone is supported by the casing at the point it is expanded, and the casing can be set on the bottom of the wellbore. The drill string can therefore be lowered to engage the slidable section of the drill string 406 into the bushing 402 . This is the position shown in FIG. 7 . The slidable section shoulder 407 , when separated from the flow path seal 409 , has ports for communication of fluid from within the drill string to the annulus around the drill string. The seal at the top of the expandable casing permits pressurization of the volume between the drill string with the expandable casing. Seals 301 , shown in FIG. 3 hold the pressure between drill string 225 and the expandable casing 101 at the lower end. Downward pressure for downward expansion is thereby applied across the whole internal cross section area of the unexpanded expandable casing, due to pressure differential across flapper valve and drill string in addition to pressure differential across seals 301 . This downward pressure forces the duplex cone to the position shown in FIGS. 8A and 8B .
[0039] Referring now to FIGS. 8A and 8B , the nose of the lower cone 108 has forced the sliding valve 112 into a closed position, providing a positive seal at the bottom of the expandable casing. Seals such as o-rings 119 help maintain a positive seal. Snap ring 113 , shown in FIG. 1 , is sheared by the force of the downward movement of the duplex cone assembly thereby allowing the sliding valve to move downward. Dimensions of the nose of the lower cone and the cement shoe are selected so that in the resting position at the bottom of the well, the lower expansion cone has expanded the expandable casing 101 to the bottom of the expandable casing through threaded joint 103 so that only millable or drillable material remains below the expanded portion of the casing.
[0040] Referring to FIGS. 9A and 9B , the duplex cone configured for upward expansion is shown. To configure the duplex cone for upward expansion, the lower cone 203 is slid down the expansion die 205 so that it outer diameter is equal to or less than the outer diameter of the upper cone when the upper cone is engaged with the expansion die. The lower cone 203 was therefore able to expand the lower portion of the expandable casing to a diameter that is, for example, about a half of an inch greater than the diameter to which the rest of the expandable casing will be expanded. This forms a bell at the bottom of the casing into which a next lower casing section may be expanded after the next lower segment of the well is drilled.
[0041] The embodiment shown provides for movement of the lower cone to an unexpanded position by movement of the flapper valve assembly to a second position. The diameter of the duplex expansion apparatus is thereby changed from a larger diameter to a slightly lesser diameter to provide for expansion of the remainder of the casing to a less expanded state than the bell portion of the casing. Movement of the lower cone is provided by over pressuring the fluids within the flow path to a selected pressure greater than that used for the downward expansion. This pressure is selected to be high enough to shear a shear pin or snap ring holding the flapper valve assembly in the earlier position. For example, if the downward expansion is performed at a pressure of 5000 psia, an over pressure to 5500 psia may be selected to move the flapper valve assembly to the final position. The movement of the flapper valve assembly does two things. First, it uncovers lower cone ports 209 , allowing fluid communication between the inside of the drill string and the volume inside the expandable casing and outside of the duplex cone assembly. The second thing movement of the flapper assembly does is to remove inward support for the first dogs 211 . The first dogs are supported on fingers extending from a cylinder section of the assembly mandrel. The fingers are flexible enough to bend inward when the support of the flapper assembly is removed. The inward movement of the first dogs can be improved by providing that the surfaces between the dogs and the lower cone rest are at a slight angle from normal to the centreline of the duplex cone apparatus. Further, the fluid pressure within the flow path will exert a force on the lower cone tending to urge the lower cone away from the assembly mandrel. When the first dogs are disengaged, the second dogs 212 will catch support surfaces 901 to permit recovery from the wellbore of the lower cone with the rest of the duplex cone assembly.
[0042] Referring now to FIG. 10 , the top end of the expandable casing is shown configured for upward expansion of the expandable casing 101 . For upward expansion of the expandable casing, the slidable section 406 is pulled back upward to engage the slidable section shoulder 407 with the flow path seal 409 . Thus the drill string and the flow path are connected and isolated from the wellbore outside of the drill string above the upward expansion sealing assemblies 215 . As the drill string is raised along with upward movement of the duplex expansion cone, the first tool joint to contact the bushing 402 will remove the bushing so it will not block removal of the remainder of the duplex cone apparatus. The first tool joint may include a fin, or a plurality of fins 405 (two opposing fins shown) which will catch on slots in bushing 402 to allow engagement with the bushing, and rotation of the bushing to a position from which it may be removed from the top of the expandable casing.
[0043] Referring now to FIG. 11 , the upper expansion cone 204 is shown. The expandable cone section is divided into a plurality of deformable segments 1101 extending from base 1102 . The base has a smaller diameter than the initial inside diameter of the casing. Each of the deformable segments includes a deformable portion 1103 and an expansion surface 1104 which contacts the casing during an expansion process. In the embodiment shown, the segments are angular to the centreline of the cone over the expansion surface 1105 . The expansion surface is the surface that contacts the inner surface of the expandable casing during expansion. In the deformable portions of the deformable segments, the segments may be aligned with the centreline of the expandable mandrel. With the expansion surfaces aligned at an angle to the centreline of the expandable mandrel, the resulting expanded casing is expanded to a round shape. If the segments were aligned with the centerline of the cone, pipe expanded by the cone would have small ridges like rifling on the inside of the expanded pipe. This would be caused by gaps that would be formed when the deformable segments are deformed to the expanded diameter of the expandable mandrel. When the gaps resulting from the expansion of the cone over the expansion die are at an angle relative to the centerline of the apparatus (for example, between five and fifteen degrees from parallel to the centerline of the apparatus) the cone will expand the casing more evenly than it would with deformable segments. This more even expansion, or expansion to a more perfect circular cross section, is desirable. The deformable segments are, for example, deformed when the cone is pressed over the expansion die, so that the cone will partially retake its original form when force holding the cone onto the die is removed, or at least be readily bent back to the smaller diameter with a small amount of pressure so that the lower cone may be passed through the upper portion of the expanded casing which has not been expanded to as large of an internal diameter as the expanded lower cone and other forces applied.
[0044] Referring now to FIG. 12 , the lower expansion cone 203 is shown. The lower expansion cone is similar to the upper expansion cone in operation. Lower cone segments 1201 extend from lower cone base 1202 to form segments that can expand outward when the lower cone is forced over an expansion die. Each of the deformable segments includes a deformable portion 1203 and an expansion surface 1204 which contacts the casing during an expansion process. Lower cone ports 209 provide communication for fluids from within the flow path to outside of the duplex cone for upward expansion.
[0045] Referring now to FIG. 13 , the assembly mandrel is shown. First dogs 211 and second dogs 212 are shown with the first dogs on fingers 1301 . Depression 1302 for holding retainer tie 219 , and vent ports 217 are shown for the piston section of the mandrel. Spacer 213 , separating the expansion die from the upper cone is shown. Retainer tie 223 may be attached to the assembly mandrel, or may be fabricated as a part of the assembly mandrel.
[0046] Referring now to FIG. 14 , the upper end of the expandable casing 101 is shown with a j-hook notch 1401 for securing the bushing. FIG. 15 shows the bushing 402 with a load pin 1501 suitable for engagement into the j-hook notch of FIG. 14 . Casing seals 403 provide for sealing between the bushing 402 and the expandable casing 101 .
[0047] Referring now to FIG. 15 , bushing 402 is shown with key slot 1502 providing for engagement with a fin 405 attached to the first tool joint below the bushing. The fin 405 will catch in the key slot 1502 , and continued rotation of the drill string will move the load pin 1501 to the vertical section of the j-hook notch in the expandable casing 101 . Continued upward force may lift the bushing from the upper end of the expandable casing. Load pin 1501 may be held in the horizontal portion of the j-hook notch 1401 by action of a shear pin. The shear pin may be failed by torque applied through the fin 405 . | A duplex expansion apparatus for expanding a wellbore tubular to two different diameters from an initial diameter is provided. The duplex expansion apparatus includes: a first diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the internal diameter; a second diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the diameter of the first diameter expansion cone in the expanded state; and an assembly mandrel that is capable of transferring both the first diameter expansion cone and the second diameter expansion cone into their expanded states. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/756,154, filed on May 31, 2007, now U.S. Pat. No. 7,946,942. The entire disclosure of the above application is incorporated herein by reference.
FIELD
The present disclosure relates to pivot assemblies, and more specifically to power actuated pivot assemblies.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Plow systems are commonly used for all-terrain vehicles (ATVs). Current plow systems can require the driver to get off of the vehicle to adjust the pivot angle of the plow blade. A variety of other maintenance equipment used in combination with tractors and/or ATVs, such as lawn cutting and sweeper assemblies, can require a user to manually adjust a rotary orientation of the maintenance equipment.
SUMMARY
Accordingly, a pivot assembly may include first and second subassemblies. The first subassembly may be adapted to be coupled to a frame member and rotationally fixed relative thereto. The first subassembly may include a latch mechanism displaceable between locked and unlocked positions. The second subassembly may be adapted to be coupled to the frame member and may be rotatable relative thereto. The second subassembly may include a power pivot assembly and a cam member. The power pivot assembly may be drivingly engaged with the cam member and operable to rotate the cam member in a first rotational direction to a first position where the cam member urges the latch mechanism into the unlocked position.
An alternate pivot assembly may include a rotating member, a latch mechanism, and a power pivot assembly. The rotating member may be adapted to be rotatably coupled to a frame member. The latch mechanism may be adapted to be coupled to the frame member and may be displaceable between first and second positions. The latch mechanism may be engaged with the rotating member when in the first position to prevent relative rotation between the rotating member and the frame member. The latch mechanism may be disengaged from the rotating member when in the second position to allow relative rotation between the rotating member and the frame member. The power pivot assembly may include a drive assembly drivingly coupled to the rotating member and operable to displace the latch mechanism between the first and second positions.
The power pivot assembly may include a motor, a planetary gear assembly, and a housing having a splined inner surface. The motor may be drivingly coupled to the planetary gear assembly and the planetary gear assembly may be engaged with the splined inner surface. The planetary gear assembly is operable to displace the latch mechanism to the second position and to rotate the rotating member relative to the frame member.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a perspective view of a plow mount assembly according to the present disclosure;
FIG. 2 is a fragmentary perspective exploded view of the plow mount assembly of FIG. 1 ;
FIG. 3 is a perspective exploded view of a portion of the plow mount assembly of FIG. 1 ;
FIG. 4 is a perspective exploded view of a power pivot assembly of the plow mount assembly of FIG. 1 ;
FIG. 5 is a bottom plan view of a portion of the plow mount assembly of FIG. 1 in a first position;
FIG. 6 is a bottom plan view of a portion of the plow mount assembly of FIG. 1 in a second position; and
FIG. 7 is a side view of the plow mount assembly.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
With reference to FIG. 1 , a plow mount assembly 10 may include a frame assembly 12 , a base swivel 14 , and a power pivot assembly 16 . Frame assembly 12 may include a series of tubular frame members 18 , 20 , a vehicle mounting bracket 22 , and a base plate 24 . Vehicle mounting bracket 22 may provide for mounting of frame assembly 12 to a vehicle and base plate 24 may support base swivel 14 and power pivot assembly 16 thereon, as discussed below. With additional reference to FIGS. 2 and 3 , plow mount assembly 10 may further include first, second and third bearing plates 26 , 28 , 30 , a coupling plate 31 , first and second stop members 32 , 34 , first and second support members 36 , 38 , first and second pivot arms 40 , 42 forming a latch mechanism, a lock plate assembly 44 , a drive plate 46 and a cam member 48 .
As best shown in FIG. 3 , base swivel 14 may include a plate member 49 having arms 50 , 52 extending upwardly from opposite sides thereof. Plate member 49 may include a central aperture 54 and a series of slots 56 extending therethrough. Aperture 54 may be generally circular and may have a diameter similar to an outer diameter of first bearing plate 26 . Base swivel 14 may be disposed adjacent to the upper surface of base plate 24 , having first bearing plate 26 disposed within aperture 54 , such that base swivel 14 is rotatable relative to base plate 24 about first bearing plate 26 . Coupling plate 31 may be disposed between base swivel 14 and drive plate 46 .
Drive plate 46 may be disposed adjacent to an upper surface of base swivel 14 and may include a plate member 58 having arms 60 , 62 extending upwardly from opposite sides thereof and a flange portion 64 extending from a side between arms 60 , 62 . Arms 60 , 62 may generally oppose inner surfaces of arms 50 , 52 of plate member 49 . Plate member 58 may include a central aperture 66 extending therethrough and a series of slots 68 extending through flange portion 64 and generally aligned with slots 56 in plate member 49 . Aperture 66 may be generally circular and may have a diameter similar to an outer diameter of second bearing plate 28 . Second bearing plate 28 may be disposed within aperture 66 , such that drive plate 46 is rotatable thereabout.
With additional reference to FIGS. 2 and 5 , lock plate assembly 44 may be disposed adjacent to an upper surface of drive plate 46 and may include first and second plates 70 , 72 fixed to one another. First plate 70 may include first and second arcuate-shaped apertures 74 , 76 generally opposite one another, a central aperture 78 , and a series of slots 80 extending therethrough and aligned with slots 68 in drive plate 46 . Second plate 72 may include a generally circular central opening 82 having first and second sets of teeth 84 , 86 generally opposite one another formed on an inner circumference thereof adjacent first and second arcuate portions 88 , 90 . Second plate 72 may further include a series of slots 92 extending therethrough and aligned with slots 80 in first plate 70 .
First and second stop members 32 , 34 , first and second support members 36 , 38 , first and second pivot arms 40 , 42 , and cam member 48 may be disposed within lock plate assembly 44 . More specifically, stop members 32 , 34 may have generally arcuate bodies and may be disposed adjacent to arcuate portions 88 , 90 of second plate 72 . Outer circumferential surfaces of stop members 32 , 34 may form bearing and guide surfaces for rotation of lock plate assembly 44 thereabout, as discussed below. First and second support members 36 , 38 may have generally arcuate bodies and may be disposed within first and second arcuate-shaped apertures 74 , 76 of first plate 70 . Outer and inner circumferential surfaces of support members 36 , 38 may form bearing and guide surfaces for rotation of lock plate assembly 44 thereabout, as discussed below. First and second pivot arms 40 , 42 may be disposed within second plate 72 adjacent to first and second sets of teeth 84 , 86 , best shown in FIG. 5 .
First and second pivot arms 40 , 42 may be generally similar to one another, therefore, only first pivot arm 40 will be discussed in detail with the understanding that the description applies equally to second pivot arm 42 . First pivot arm 40 may include an aperture 93 having a pin 94 extending therethrough and through an aperture 95 in first support member 36 , rotatably coupling first pivot arm 40 thereto. First pivot arm 40 may further include first and second end portions 96 , 98 . First end portion 96 may include a recess 100 therein and second end portion 98 may include teeth 102 for engagement with teeth 84 in second plate 72 , as discussed below.
Cam member 48 may be disposed within a central portion of second plate 72 and may include a central portion 104 having first and second arms 106 , 108 extending radially outwardly therefrom. Central portion 104 may include an aperture 110 ( FIG. 2 ) generally aligned with aperture 78 in first plate 70 . Arms 106 , 108 may include arcuate radially outer surfaces for slidable engagement with arcuate inner surfaces of stop members 32 , 34 , as discussed below.
With additional reference to FIG. 2 , power pivot assembly 16 may be disposed adjacent to an upper surface of lock plate assembly 44 . As shown in FIG. 4 , power pivot assembly 16 may include a motor assembly 112 , a gear housing assembly 114 , and a gear assembly 116 . Motor assembly 112 may include a motor 118 and a drive gear 122 . Drive gear 122 may be in a driven engagement with motor 118 . Gear housing assembly 114 may include an end plate 124 and a gear housing 126 . End plate 124 may be fixed to an upper portion of gear housing 126 and may have motor 118 fixed thereto. End plate 124 may include an aperture 127 allowing engagement between motor 118 and drive gear 122 . Gear housing 126 may include a generally cylindrical body having a splined inner surface 128 , which may operate as a ring gear, as discussed below.
Gear assembly 116 may include a series of compound planetary gears 130 , 131 , 133 , 135 rotatably coupled to respective cages 132 , 137 , 139 , 141 . Cages 132 , 137 , 139 , 141 each may include lower plates 134 , 143 , 145 , 147 having driven gears 136 , 149 , 151 , 153 coupled thereto for rotation therewith. Planetary gears 130 , 131 , 133 , 135 may be engaged with splined inner surface 128 of gear housing 126 , as discussed below. Driven gear 136 may extend axially beyond gear housing 126 and may be drivingly engaged with cam member 48 . More specifically, aperture 110 in cam member 48 may include a splined inner surface 138 engaged with driven gear 136 , causing rotation of cam member 48 with driven gear 136 , as discussed below.
Gear housing 126 ( FIG. 4 ) may include a series of apertures 111 aligned with a series of apertures 113 in first plate 70 ( FIG. 2 ). Pins 117 ( FIG. 2 ) may be located in apertures 111 and apertures 113 , fixing first plate 70 for rotation with gear housing assembly 114 , as discussed below. Third bearing plate 30 may include a central aperture 140 having gear housing 126 located therein. A circumferential surface 142 of aperture 140 may provide a bearing surface for gear housing 126 , as discussed below.
Third bearing plate 30 may include a series of apertures 144 disposed about a circumferential portion thereof and aligned with a series of apertures 146 , 148 in support members 36 , 38 , a first series of apertures 150 , 152 in stop members 32 , 34 , a first series of apertures 154 in second bearing plate 28 , a first series of apertures 157 in coupling plate 31 , a first series of apertures 155 in first bearing plate 26 , and a first series of apertures 156 in base plate 24 . A first series of fasteners 158 may pass through apertures 144 , 146 , 148 , 150 , 152 , 154 , 155 , 156 , 157 and may receive nuts 160 on ends thereof, fixing first, second and third bearing plates 26 , 28 , 30 , first and second stop members 32 , 34 , and first and second support members 36 , 38 to base plate 24 .
More specifically, first series of apertures 157 in coupling plate 31 may include a threading. First series of fasteners 158 may threadingly engage first series of apertures 157 . Power pivot assembly 16 , third bearing plate 30 , lock plate assembly 44 , first and second support members 36 , 38 , cam member 48 , first and second stop members 32 , 34 , stop first and second pivot arms 40 , 42 , second bearing plate 28 , drive plate 46 , and coupling plate 31 may be fixed to one another by the threaded engagement between first series of fasteners 158 and coupling plate 31 . Threaded ends of fasteners 158 may pass though apertures 155 in first bearing plate 26 and apertures 156 in base plate 24 . Fasteners 158 may then receive nuts 160 on ends thereof. Therefore, first, second and third bearing plates 26 , 28 , 30 , first and second stop members 32 , 34 , first and second support members 36 , 38 may form a first subassembly that is rotationally fixed relative to base plate 24 .
A second set of fasteners 162 may extend through a second series of apertures 163 in stop members 32 , 34 , a second series of apertures 165 in second bearing plate 28 , a second series of apertures 159 in coupling plate 31 , a second series of apertures 167 in first bearing plate 26 , and a second series of apertures 169 in base plate 24 . Second set of fasteners 162 may receive nuts 164 on ends thereof, further securing stop members 32 , 34 , second bearing plate 28 , and first bearing plate 26 to base plate 24 . Base swivel 14 , power pivot assembly 16 , lock plate assembly 44 , drive plate 46 , and cam member 48 may be rotatable relative to base plate 24 and may form a second subassembly that is rotatable relative to base plate 24 , as discussed below. Base swivel 14 , lock plate assembly 44 , and drive plate 46 may form a plow rotating member.
With reference to FIG. 5 , an initial orientation of lock plate assembly 44 is illustrated and generally corresponds to a straight orientation of base swivel 14 seen in FIG. 1 . In the initial orientation, cam member 48 is generally centered between stops 166 , 168 of stop members 32 , 34 and teeth 102 of pivot arms 40 , 42 are biased into engagement with teeth 84 in second plate 72 through biasing members 170 , 172 acting on pivot arms 40 , 42 . In this initial orientation, lock plate assembly 44 is generally rotatably fixed relative to base plate 24 since pivot arms 40 , 42 are coupled to support members 36 , 38 which are fixed to base plate 24 . However, lock plate assembly 44 may be rotated in either a clockwise or counterclockwise direction, as discussed below. For exemplary purposes, rotation of lock plate assembly 44 in the counterclockwise direction is discussed below.
Motor 118 may rotate drive gear 122 in a clockwise direction. When drive gear 122 is rotated in a clockwise direction, planetary gears 130 , 131 , 133 , 135 are rotated in a counterclockwise direction. Since lock plate assembly 44 is generally rotationally fixed by pivot arms 40 , 42 when in the initial orientation, planetary gears 130 , 131 , 133 , 135 may drive cages 132 , 137 , 139 , 141 , and therefore driven gears 136 , 149 , 151 , 153 and cam member 48 , in a clockwise direction. When driven in the clockwise direction, cam member 48 will eventually abut stops 166 , 168 on stop members 32 , 34 (seen in FIG. 6 ), preventing further rotation of cages 132 , 137 , 139 , 141 and cam member 48 relative to base plate 24 . When cam member 48 abuts stops 166 , 168 , arm 108 of cam member 48 may engage pivot arm 40 , biasing teeth 102 thereof out of engagement with teeth 84 of second plate 72 . Lock plate assembly 44 may then be rotated in a counterclockwise direction.
As drive gear 122 continues to rotate in a clockwise direction, planetary gears 130 , 131 , 133 , 135 continue to rotate in a counterclockwise direction. However, since cage 132 is fixed against rotation in the clockwise direction due to the engagement between cam member 48 and stop members 32 , 34 , gear housing 126 is rotated. More specifically, as planetary gears 130 , 131 , 133 , 135 rotate in the counterclockwise direction, the engagement between planetary gears 130 , 131 , 133 , 135 and splined inner surface 128 of gear housing 126 drives gear housing 126 in the counterclockwise direction. Since gear housing 126 is rotationally fixed to lock plate assembly 44 , rotation of gear housing 126 causes rotation of lock plate assembly 44 as well. Rotation of lock plate assembly 44 may be further translated to drive plate 46 through a series of pins 170 ( FIG. 2 ).
More specifically, slots 80 , 92 in first and second plates 70 , 72 may be aligned with slots 68 in drive plate 46 and slots 56 in base swivel 14 . Pins 170 may extend into slots 80 , 92 , 68 , 56 , fixing drive plate 46 and base swivel 14 for rotation with gear housing 126 . Pins 170 may be removed, allowing rotation of lock plate assembly 44 without any corresponding rotation of drive plate 46 or base swivel 14 .
Lock plate assembly 44 may be returned to the initial orientation corresponding to a generally straight orientation of base swivel 14 shown in FIG. 5 by rotating drive gear 122 in a counterclockwise direction. More specifically, since pivot arm 42 is engaged with teeth 82 in second plate 72 , lock plate assembly 44 is prevented from rotating in a clockwise direction. Therefore, when drive gear 122 is rotated in a counterclockwise direction while cam member 48 is engaged with stops 166 , 168 , cam member 48 is rotated in a counterclockwise direction. Once cam member 48 is generally centered between stops 166 , 168 lock plate assembly 44 is once again oriented in the initial position discussed above. While clockwise rotation of drive gear 122 has been discussed, it is understood that counterclockwise rotation of drive gear 122 will result in opposite clockwise rotation of base swivel 14 .
With reference to FIG. 7 , plow mount assembly 10 may be mounted to a vehicle, such as a utility vehicle 200 . Vehicle mounting bracket 22 of plow mount assembly 10 may be coupled to a frame 202 of vehicle 200 . More specifically, vehicle mounting bracket 22 may be laterally fixed relative to frame 202 and vertically pivotable for upward and downward displacement of plow mount assembly 10 . Base swivel 14 may have a plow blade 204 fixed thereto. Plow blade 204 may rotate with base swivel 14 during actuation of plow mount system 10 , as discussed above. Plow mount assembly 10 therefore provides powered rotation of plow blade 204 .
While shown and described as related to plow mount assembly 10 , it is understood that power pivot assembly 16 may be used in combination with a variety of other tools pivotally coupled to a mounting structure. For example, power pivot assembly 16 may be used in combination with maintenance equipment such as lawn cutting and sweeping assemblies. | A pivot assembly for a plow may include first and second subassemblies. The first subassembly may be adapted to be coupled to a frame member and rotationally fixed relative thereto. The first subassembly may include a latch mechanism displaceable between locked and unlocked positions. The second subassembly may be adapted to be coupled to the frame member and may be rotatable relative thereto. The second subassembly may include a power pivot assembly and a cam member. The power pivot assembly may be drivingly engaged with the cam member and operable to rotate the cam member in a first rotational direction to a first position where the cam member urges the latch mechanism into the unlocked position. |
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[0001] This application is a continuation-in-part of application, Ser. No. 60/217,220, filed Jul. 10, 2000, entitled PESTICIDE DISPENSING SYSTEM
FIELD OF THE INVENTION
[0002] This invention relates to a built-in pest control system wherein pesticides can be distributed and released into the walls of a building by means of a pre-built distribution system. More particularly, it relates to a system for distributing pesticide into building walls through a single port in the wall which is connected to a downstream manifold which directs the pesticides into various portions of the building through a plurality of lines.
BACKGROUND OF THE INVENTION
[0003] There are many methods known for controlling pests, such as bugs, insects and rodents, by distributing pesticide throughout a building. Liquid pesticide is commonly sprayed along most baseboards and other exposed areas of a house or office building, both on the inside and outside of the building. The depositing and spraying of liquid or solid pesticides has certain inherent dangers. Hazardous materials may inadvertently be contacted by infants or pets, or possibly contaminate food supplies. Thus, the application of pesticides in a building can create a health hazard. In addition, despite efforts to spray liquid or aerosol pesticide into cracks and crevices in building walls and baseboards, the pesticide does not access the area in which most bugs and insects live, i.e., in the interstices of the walls.
[0004] In an effort to direct pesticide into areas commonly occupied by pests, numerous systems have been developed in which a distribution system is installed through the studs, joists, rafters, and built-ins of building during the construction phase. Examples of such systems are shown in Ramsey, U.S. Pat. No. 3,676,949 and Lundwall, U.S. Pat. No. 4,028,841.
[0005] An improved system for distributing pesticides throughout the walls of a building is set forth in my previous U.S. Pat. Nos. 4,944,110 and 5,231,796, the disclosures of which are incorporated herein by reference. These patents disclose a system in which lengths of flexible tubing having a plurality of spaced, tiny discharge orifices are distributed throughout the walls of a building during construction. Individual lengths of tubing are extended throughout every interior and exterior wall. Perforations in the tubing have conical discharge orifices, enabling rapid expansion of the pesticide as it exits the tube. Each of the tubes have an open end which terminates at a location on the exterior of the building. Thus, when a service person desired to inject pesticide into the tube, each tube would be serviced individually. First, pesticide would be injected into the tube, and then the line would be flushed or purged with a follow-up injection of nitrogen. Service personnel would then go through each line sequentially, first injecting pesticide, and then purging with nitrogen.
[0006] The necessity for injecting pesticides, and subsequent purging with nitrogen, through a large number of individual lines can cause a number of unforeseen problems. Depending on the size of the building, it may be necessary to conduct the injection/purging operation on a dozen, or perhaps many more, lines. Service technicians may skip one of the lines, or inadvertently inject one of the lines more than once, resulting in distribution of an excessive amount of pesticide in a single area. Furthermore, the opportunities of spilling of pesticide in the treatment of a large number of individual lines is increased. In addition, when individual lines are serviced with portable equipment, it is common not to use any measuring equipment to determine how much pesticide has been injected into a single port. Frequently, service personnel will simply estimate the amount of pesticide injected into a port by the amount of time the pesticide line has been connected to the port after the valve has been turned on. However, since the lines inside the house may vary significantly in length (depending upon how far away the line must travel before it gets to its desired wall location), measurement may be quite inaccurate
[0007] In addition, in prior systems there was no way in which a service technician could determine whether or not the pesticide was actually reaching its intended destination within a building. If the interior lines had become crimped or plugged, there was no way for the technician to know that flow had become restricted.
[0008] In accordance with the present invention, sources of pesticide and compressed air or nitrogen are mounted on a vehicle. The vehicle may be a truck or a smaller cart which may be wheeled closer to the injection port in an exterior wall of the house. Separate lines for pesticide and compressed air extend from the sources to an injector gun. Valving associated with the injector gun permits selective injection of pesticide or purge gas. A flow meter and pressure gauge may be included on each line. If desired, a single line to the gun can be used, with pesticide and compressed air traversing the same line.
[0009] The injector gun mates with a single aperture in a manifold which is accessible from the exterior of the building. The manifold, which is located inside the exterior wall, has a plurality of nipples to which the flexible hoses which extend throughout the building are connected. To service the system, a technician attaches the gun to the manifold opening, and fills the manifold and lines with liquid pesticide while monitoring the pressure and flow meters. When the lines are filled to the desired degree, the valving is switched to permit purging of the lines with inert gas. The entire operation can be done without removing the injector gun from a single connection on the exterior of the house.
[0010] In a preferred embodiment, a computerized record of the servicing transactions is maintained on the vehicle. At the end of the service call, a computer will print out relevant information for the service call, such as the date and time of service, name of service technician, and quantity of pesticide distributed. The computer can also print out a billing for the service call which can be left at the building when the service has been completed.
[0011] In another embodiment of the invention, a coupling for lengths of distribution tubing is provided which creates an audible sound when a gas passes through the coupling. Preferably, the audible sound is that of a high-pitched whistle which is easily heard through a wall of the building. A technician can test the operability of the lines extending throughout the walls by attaching a source of compressed air to the single exterior port, and moving from room to room throughout the house to determine if the sound is heard in all of the rooms. If necessary, a listening device, such as a stethoscope, can be used to hear the noise emitted at the coupler.
BRIEF SUMMARY OF THE INVENTION
[0012] A system is provided for distributing pesticide into the interior walls of a building. An injection port is mounted in a wall of a building, preferably an exterior wall, where it can be accessed by service personnel. The system includes, in a preferred embodiment, a wheeled vehicle on which are mounted separately vessels containing pesticide and inert gas under pressure. Conduits connect the vessels to an injection gun, which has a valve permitting selective injection of pesticide or inert gas. A flow meter measures the amount of fluid passing through the injector gun. The flow meter is electrically connected to a data processor mounted on the vehicle. The data processor records, and a printer associated therewith prints out, information with respect to the amount of pesticide distributed into the wall.
[0013] Downstream of the injection port is a manifold to which a large number of flexible tubing members, having discharge openings spaced along the length of the tubing members, are attached. In a preferred embodiment, a device which emits an audible signal is attached at downstream portions of the tubing members to enable service personnel inside the building to confirm that fluid is indeed passing through each of the tubing members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention is best illustrated with respect to the drawings, in which:
[0015] [0015]FIG. 1 is a schematic block diagram of an embodiment of the invention;
[0016] [0016]FIG. 2 is a side view of a vehicle partially cut away to show a computer which will effect the monitoring and billing portion of the invention;
[0017] [0017]FIG. 3 is a perspective view of a service gun used in connection with the invention;
[0018] [0018]FIG. 4 is a plan view of a manifold used to distribute pesticide to various portions of the building;
[0019] [0019]FIG. 5 shows distribution of the pesticide from a manifold within the building; and
[0020] [0020]FIG. 6 shows a cutaway view of the wall port/manifold assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] In the preferred embodiment of the invention, pesticide is injected into a single port located in an exterior wall of the building. The port communicates with a manifold from which a plurality of flexible distribution tubings exit to various locations within the building. Because a substantial quantity of pesticide is injected into the entire system at the same time through the port, a single fluid injection device or gun is used for both the liquid pesticide and the purging air.
[0022] In another preferred embodiment of the invention, as shown schematically in FIG. 1 and in a drawing in FIG. 2, the sources of pesticide and inert gas, such as compressed air (or nitrogen), are mounted on a wheeled vehicle. This vehicle can be a truck, of the type shown in FIG. 2, or a smaller wheeled vehicle which can be pulled by hand to the building in the location of the injection port 9 .
[0023] Referring first to FIGS. 1 and 2, sources of pesticide 62 and compressed air 64 are mounted on truck 80 . The pesticide is maintained under pressure (which may be supplied by the compressed air), or is fed by means of a demand pump (not shown) through valve 5 , flow meter 56 and line 52 , which exits the truck. The source of compressed air 64 , which exits the truck through line 54 , is generally a tank of compressed air which may also be connected to a compressor to maintain the pressure at the desired level. Pressure in the tank is usually maintained at at least 200 psig.
[0024] The computer 82 is also located on the truck. The computer obtains information from flow meter 56 to record the quantity of pesticides actually provided to the building. At the end of the service call, the technician can print out from the computer stored information including the date, time of day of the service call, quantity of pesticide disbursed, and the name of the technician. If desirable, the technician can input any other information which he believes may be helpful to the company or the customer. Thereafter, a complete statement and billing 88 can be printed out by printer 86 , and left at the building for collection for later payment. By means of this system, billings can be delivered at an earlier date and with a higher probability of payment than previous systems.
[0025] Pressure gauges 57 , 59 are generally located in the vicinity of the gun so that the technician can confirm that adequate pressures of pesticide and purging gas are being delivered to the site. If the sources of pesticide and compressed air are on a hand cart, then the pressure gauges can be located on the cart. In the event that the pesticide and compressed air sources are located on a truck which may be parked a distance from the injection port 9 , the pressure gauges can be mounted immediately upstream of the injection gun. Flow meters such as the Green Garde® flow meter (which has a digital readout of flow rate and volume) can also be installed just upstream of the gun.
[0026] The service gun is best seen in FIG. 3. The gun 46 has a nozzle 50 having a threaded base 48 which is attached to the forward portion of the barrel 20 of the service gun. Any type of gun having the physical ability to distribute the pesticide and compressed air would be suitable for use in the invention. Example of a suitable service gun is the Green Garde® high pressure spray gun model JD 9 .
[0027] The service gun has two inlet ports 53 , 55 to which lines 52 and 54 are connected. The gun has a valve 61 (see FIG. 1) having a valve handle or control level 70 for switching the gun feed between pesticide and purge gas. As shown in FIG. 3, the valve lever 70 can move between the position shown in FIG. 3, to permit the passage of compressed air, to the position 76 shown in phantom, which would permit the flow of pesticide through the gun.
[0028] Actuation of the service gun is effected by squeezing the spring-loaded, pivotally-mounted trigger 72 to enable liquid or gas to flow through the gun.
[0029] Materials are injected into the outside of the building through the box fitting shown in FIG. 6. The fitting is mounted on the exterior of the building wall 10 . A service box 14 is mounted on exterior wall 10 by means of a mounting panel 11 , attached by screws (not shown). The service box has a hinged cover 16 , mounted on hinge pin 17 , enabling the lid to be lifted to expose the service port 9 .
[0030] A threaded nipple 15 is mounted in the service box and extends into the interior of the building walls. A grommet or O-ring 19 is mounted on the interior of the nipple to engage the nozzle 50 of the service gun. The grommet is preferably made from a somewhat flexible material, such as rubber or thermoplastic material, in order to provide a seal with the nozzle in order to prevent leakage.
[0031] The service assembly shown in FIGS. 4 and 6 are preferably mounted in the building at the time of original construction. Downstream of the nipple 15 , all of the remaining components are located between the exterior and interior walls of the building in the building framing. A 90° PVC coupler, or elbow, is threadedly mounted on nipple 15 . The other end of the nipple is connected to the threaded port 20 of distribution manifold 18 , best seen in FIG. 4. The manifold has a wrench-receiving ring 21 to enable easy connection of the manifold to the elbow. The manifold 18 is mounted vertically in the wall space, and comprises a body portion 24 having an internal cylindrical conduit and a closed end. A plurality of nipples 26 extend perpendicularly from the body of the manifold to direct fluid entering the manifold through flexible conduits or tubes attached to the nipples to various portions of the building. Laterally expanded ends 22 of the nipples frictionally engage the flexible tubing members.
[0032] An example of the tubing attachment is shown on FIG. 4 at manifold coupling nipple 26 A. The tubing 28 A slidably engages the end 22 A of nipple 26 A. The tubing end abuts a circular stop rib 25 A. Each nipple has stop ribs 25 located immediately downstream of the manifold body.
[0033] The flexible tubing lines, such as 28 A, attached to the nipple are non-perforated and contain the fluid until it reaches the portion of the building where distribution into the wall is desired. As shown in FIG. 4, the downstream 30 of the feed line is connected to a dispensing line 34 by means of a coupler 32 shown at the far end 30 of the feed line. In a preferred embodiment, the coupler is equipped with a whistle mechanism 40 , of conventional design, which emits a high-pitched, audible signal when compressed air passes through the coupler at high speed.
[0034] The coupler 40 connects the feed or connector line 28 A with a dispensing tube 34 . The upstream end 36 of tube 34 is inserted into the connector, and is either held by friction or an adhesive. The dispensing line 34 has a series of small openings or perforations 38 , spaced approximately every 12 inches, thus ensuring that each space between wall studs will have at least one perforation 38 in lines threaded through the studs as shown in FIG. 5. While perforation spacing can be altered to fit the design of any building, 12 inch spacings are generally acceptable. The end of each dispensing line 34 may be closed, or may have a whistle, shown in FIG. 4 in end plug 39 .
[0035] Upon completion of construction, all of the outlet tubes 22 of the manifold 18 are either connected to feed lines 28 A which extend into the building, or are capped off. The length of the feed lines will vary depending on the location of the building to which pesticide will be delivered. The feed line, which has no perforation, will carry the materials through portions of the building in which no spray of pesticide is desired from that particular line. When the feed line reaches the target zone, the dispensing line 34 is connected through a coupler and placed throughout the studs, as shown in FIG. 5, in the target zone. Thus, the feed lines 28 A and dispensing lines 34 will be of varying length dictated by the specific needs for each line.
[0036] The manifold 18 is generally made from molded plastic, and may be of any size necessary for a specific building. In addition, the number of outlet tubes to the manifold may vary, being at least two and up to thirty or more. Preferably, there are at least four, more preferably at least six or eight outlets. The manifold 18 shown in FIG. 4 has a ¾ inch body, with ¼ inch outlet tubes 22 , 22 A designed to accept ¼ inch tubing. While more than one manifold can be mounted in a building wall, the ratio of outlets to meet ports should remain as set forth herein.
[0037] The whistle couplers 40 are used to detect flow through the perforated tubing in each area of the building. After construction, when the walls enclose the tubing, there is no way for a technician to know if pesticide will reach all areas of the building where tubing has been placed. Whistles are placed in couplers and/or end caps of the distribution tubing, and make an audible sound when air is passed through the system. By attaching compressed air to the inlet port, the technician may go from room to room and listen, with the aid of a stethoscope, to ensure that pesticide will reach its desired destination. If a whistle is unable to be heard, then the line may be kinked or plugged, thus indicating that maintenance is necessary.
[0038] In use, the technician parks the truck 80 as close as possible to the portion of the building where the injection port 9 is located. If the injection materials are mounted on a wheeled cart, the technician brings the cart into the vicinity of the injection port 9 . The computer 82 on the truck 80 is activated, as is the air compressor and, if applicable, the demand pump for the pesticide. Next, the cover on the injection box is raised, exposing the injection port 9 .
[0039] The nozzle 50 of service gun 46 is then placed into the injection port 9 , until a seal is obtained between the nozzle 50 and the O-ring 19 in the injection port. If desired, at this point, the technician may wish to test the lines for integrity, blowing compressed air through the system and going room to room to listen to ensure that air is reaching the desired portions of the building.
[0040] Next, the valve handle 70 is set to a position to enable liquid pesticide to flow into the system, and the grip on the service gun is squeezed to allow liquid to pass into the system. When sufficient pesticide has been fed to the system to fill it entirely with liquid (which can be monitored by the pressure gauges 59 and associated flow meters), the valve handle 70 is then switched to the compressed air setting. When the trigger 72 is squeezed, compressed air blows the liquid out through the perforations, creating a mist in a manner similar to a high-pressure water misting system. Activation of the system is depicted in FIG. 5.
[0041] The schematic representation of a system according to the invention mounted in the wall of a building is shown in FIG. 5. A manifold 100 is shown mounted in the wall space between the vertical studs 102 and 104 . The manifold has ten connecting nipples 106 from which ten tubing lines extend. The top eight lines are non-perforated feeder lines 108 which extend into various parts of the building of which pesticide treatment is desired. The bottom two lines 110 , 112 extend in the close vicinity of the manifold, and are perforated to enable discharge of the pesticide when purge gas is attached to port 120 .
[0042] A schematic representation of a system according to the invention mounted in the wall of a building is shown in FIG. 5. A manifold 100 is shown mounted in the wall space between vertical studs 102 , 104 . The manifold has ten connecting nipples 106 from which ten tubing lines extend. The top eight lines are non-perforated feeder lines 108 which extend into various parts of the building for which pesticide treatment is desired. The bottom two lines 110 , 112 extend in the close vicinity of the manifold, and are perforated to enable discharge of the pesticide when purged gas is attached to port 120 . Pesticide exits the perforations in a cloud of mist shown for example at 130 . | A system is provided for distributing pesticide into the interior walls of a building includes an injection port in a wall of a building, connected to a manifold to which a large number of flexible tubing members, having discharge openings spaced along the length of the tubing members, are attached. The system may include a wheeled vehicle with separate vessels containing pesticide and inert gas under pressure connected to an injection gun. A flow meter is electrically connected to a data processor which records and prints information with respect to the amount of pesticide distributed into the wall.
In a preferred embodiment, a device which emits an audible signal is attached at downstream portions of the tubing members to enable service personnel inside the building to confirm that fluid is indeed passing through each of the tubing members. |
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This is a continuation of application Ser. No. 08/178,967 filed on Jan. 7, 1994, now abandoned which is a continuation of application Ser. No. 08/598,072 filed on Feb. 7, 1996, now abandoned.
BACKGROUND OF THE INVENTION
This Invention pertains to the field of soil irrigation and drainage field systems, piping, plumbing and components.
U.S. Pat. No. 2,653,449 to Stauch shows a soil irrigation system comprising a plurality of end to end connected pipes buried beneath the soil in varying depth terrain. Each of the pipes has an almost completely sealed surface, having an area of restricted permeability, to restrict water flow into the soil so as to insure uniform flow of water throughout the length of the pipe.
U.S. Pat. No. 4,950,103 to Justice discloses a corrugated drainage tube of a type suitable for making an irrigation field, the tube having annular peaks and valleys on the exterior wall and periodic holes in the wall of the tube for drainage.
U.S. Pat. No. 2,817,956 to Young discloses a soil moisture controlled irrigation system in which a drainage field is constructed of an array of end connected piping; periodically located along the piping are larger permeable tubes forming an open annular space for filling with water.
U.S. Pat. No. 3,936,380 to Boske discloses a drainage or irrigation pipe surrounded by a fibrous material to prevent clogging of the holes in the pipe.
U.S. Pat. No. 5,051,028 discloses a drainage unit formed by bagging a loose aggregate around the exterior of the drainage pipe as a replacement for burying aggregate in a trench and burying a pipe in the trench.
U.S. Pat. No. 4,904,112 to McDonald discloses an underground irrigation system in which two concentric tubes, an inner water pipe with periodically spaced drain holes, and an outer permeable pipe surrounding are installed in a field for drainage.
U.S. Pat. No. 3,220,194 to Lienard discloses a drainage system including a series of compartments each filled with an absorbent sponge-like material to control the flow of liquid into the field.
U.S. Pat. No. 3,946,762 to Green discloses an underground irrigation system comprising an end to end connected series of drainage pipes with periodically spaced apertures surrounded by a cloth material or fabric sheet to prevent incursion of soil and salts into the drainage pipe. Specific fabrics are disclosed as suitable for this purpose.
SUMMARY OF THE INVENTION
The Invention relates to the construction of draining piping for forming buried drainage fields.
Prior art drain pipe is either porous or open bottomed clay pipe or plastic pipe with repeated drain holes. Such pipe must be laid in a prepared drain field in which an open trench, which must be larger than the pipe, is backfilled with crushed stone and the pipe laid in the stone to form a drainage field. The principle problem to avoid is dirt entering and clogging the pipe drain holes, and equally, sludge clogging the drain holes because free drainage flow from the pipe is impeded.
The invention is a flexible plastic pipe having periodically spaced restricted flow orifices. Around each flow orifice is placed a larger diameter section of highly perforated or permeable drain pipe to form a drain cell; the cell is wrapped with a porous plastic cloth wrap (e.g. GeoTextile™--a known membrane cloth for preventing dirt migration).
This pipe can be directly buried in dirt filled trenches; no special drainage provisions, such as crushed stone are required. More importantly each cell individually fills with and drains waste water and sludge, The inventive pipe can be laid in uneven terrain, including areas win which the water table may rise above the level of some sections of pipe. Even if drainage is temporarily blocked from one cell, the pipe will properly drain through the other cells.
The drain field of the invention is described in terms of a disposal field for liquid effluent or treated waste water. It also can be used for small field irrigation.
Since plastic pipe, the usual material from which the invention is constructed, is undetectable, it may be desirable as an option to install a wire along the pipe, which can be detected by standard buried wire detection equipment.
It is an object of the invention to disclose a drainage pipe which is insensitive to the local slope and terrain of the ground within which it is buried.
It is a further object of the invention to disclose a drainage pipe which provides for uniform distribution of water in a drainage field without requiring terracing or extensive ground preparation to insure soil slope or permeability.
It is a further object of the invention to disclose a drainage pipe which is relatively insensitive to local soil saturation or depth, in maintaining a uniform distribution of water to the entire drainage field.
It is a further object of the invention to disclose a drainage pipe which maintains a uniform water distribution to a drainage field, and is relatively unaffected by varying soil conditions or terrain within the field.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a depiction of a buried drainage field.
FIG. 2 is a sectional view of a drainage cell of the invention.
DETAILED DESCRIPTION OF THE INVENTION
This Invention deals with irrigation or drain fields and the associated plumbing, piping and equipment necessary for irrigation, waste water disposal, or for drainage into a large ground area, of water or of liquid effluent from water treatment, plants or water treatment systems.
Referring to the general outline figure, FIG. 1, a typical irrigation or waste water disposal system (1) will consist of a treatment plant (10) which, through various biologically active processes, neutralizes and treats waste water, separating the waste water into a treated liquid effluent and a solid which will be received and held within the treatment plant for separate disposal. The treated effluent from the treatment plant normally is then drained off into a holding tank (12) and is pumped into a drain field (14). In the prior art a drain field generally consists of various forms of long drainage pipes (2), perforated or otherwise permeable to water, which are laid out underground over a large ground area so that the water will soak gradually into the ground (16) and be recycled into ground water. Similar systems are used for irrigation of crops.
Since water follows well-known hydrostatic principles, pooling in low spots, and since perforated drain pipes (2) only drain water when there is a differential hydrostatic pressure across the pipe, the outside soil must be drier than the pipe in order for water to percolate into the soil. It is normally necessary to prepare the drain field by tillage, trenching and the like, to establish a preferred slope for even flow of the water through each of the drain pipes, and, additionally, to ensure that the drain pipes are above the water table under all conditions, so that the drain pipes will evenly drain. Failure to do this results in a completely uneven distribution of water flow throughout the drain field and a much less effective disposal of water as large areas of the drain field may be rendered non-functional due to lack of flow of water or due to pooling of the water within lower sections of the field.
The Invention overcomes these problems by providing a unique form of pressure cell drain pipe (2) using repeatedly occurring pressure drainage cells (4) interconnected by drain pipe as more particularly shown in FIG. 2.
Within FIG. 2, we show a specific pressure cell (4) installed around the outer periphery of a length of flexible water pipe (6), typically one-half inch diameter or larger. This water pipe is interconnected in an array (14) and forms a distribution field for pumping water or a drainage effluent to each of the pressure cells (4). Along each length of water pipe (6) a plurality of series of pressure cells (4) is periodically installed at various spacings which depend upon the nature, porosity and dryness of the surrounding soil.
Each pressure cell (4) consists of a length of outer perforated drain pipe (8) circumferentially spaced around the water pipe (6) so as to form an open enclosed space (18) around a length of the flexible water pipe (6) which is free from dirt or soil. The perforated drain pipe (8) may be secured to the water pipe (6) by a filter wrap (20). The filter wrap (20) preferably is a fabric wrap, such as a geotextile which prevents soil particles and dirt from contacting or filling the perforations within the perforated drain pipe (8). Various fabric or woven plastic wraps are known to be suitable for such use.
The outer drain pipe (8) has sufficient perforations or is sufficiently permeable that it rapidly drains into dry soil (16). In the open interior annular space (18) defined by positioning the perforated drain pipe (8) around the flexible water pipe (6), a restricted water passage hole (24) connects for water flow from the water pipe into the annular space (18). This hole (24) is designed specifically so that the maximum flow rate of effluent water, under pressure in the water pipe (6), through the hole (24) and into the open annular space (18) is significantly less than the flow rate of water out of the drain pipe (8) into soil (16). Additionally, the flow rate through all individual hole (24) under the total range of pressures from highest possible to lowest general pressure of water in the water pipe (6) is significantly less than the unrestricted flow rate of water through the flexible water pipe (6).
As an example, in one particular embodiment of the Invention, using one-half inch flexible water pipe (6) interconnecting in a field (14) using cells (4) spaced at approximately two foot lengths along the water pipe (6), the cell (4) would be created in each case by a four inch diameter perforated drain pipe (8) forming the annular space (18) of one and three quarters inch radial cross section, each perforated drain pipe (8) being three feet long, and the drain hole (24) into the annular space (18) is a single three-sixteenths inch diameter drain hole (24).
As a result of the flow restriction imposed by drain hole (24) into the large open annular drain space (18) created in the pressure cell (4) which is free of soil but free to be filled with water. The resulting drain field (14) may be laid without regard to the relative height or depth of any particular pressure cell (4) and without regard to the presence or absence of the water table or saturated soil at lower elevations, which may fill one or more of the individual pressure cells with water. Thus, the drain field (14) may be laid over irregular terrain simply by trenching and burying the drain field (14) a shallow distance under the level of the ground. Typically, if the drainage field is made of a plurality of one-half inch diameter flexible water pipes (6), each water pipe (6) will be connected at a head end to a header line (26), which may be one and one-half inches in diameter. The header line (26) is connected to a supply line (18) from the holding tank (12) and pump for effluent or irrigation water source, and the far end of each one-half inch flexible water pipe (6) line is capped and closed. The fact that an individual pressure cell (4) may be higher or lower than the adjacent pressure cell (4) and that the entire drain line (2) may follow an undulating or irregular height does not cause puddling of the water, because the individual drain holes (24) into each pressure cell (4) are sufficiently smaller than the typical percolation rate from the cell (4) and are also sufficiently smaller in terms of the total flow rate of water through the water pipe (6) that there is no preferential puddling or pooling of water in an individual pressure cell (4) due to the height or depth of the pressure cell (4) with respect to the average height or depth of the rest of the drain field (14). As a result, each pressure cell (4) will receive a uniform supply of water, and each area of the drainage field (14) will, therefore, be uniformly wet.
It may be that during saturated soil conditions, one or more of the pressure cells (4) will actually fill with water. The result in this case will simply be that no water will flow through the pressure hole (24) from the water pipe (6) into that particular pressure cell (4). None the less, the back pressure on the hole (24) will have negligible effect on the overall behavior of the rest of the drain field (14) and all the individual pressure cells (4) not fully saturated with water will continue to flow at the design rate determined by the water pressure head within the flexible water pipe (6) and the diameter of the single feed hole (24) into each individual pressure cell (4).
As a result, a drain field (14) utilizing sequential series of pipes (6) and pressure cells (4) of the Invention may be laid without requiring extensive preparation, leveling or other extensive trenching operations to prepare trenches for even flow of water. Further, the drain field (14) may be laid without significant concern for the possibility of occasional flooding of low-lying areas or water saturation of low-lying areas in the drain field (14). It is, thus, possible to lay a drain field (14) directly in soil (16), without requiring gravel beds or other preparation; the drain field (14) can follow the natural slope of the terrain (16) without concern for the relative individual height or depth below water head of each individual pressure cell (4). Each drain cell (4) forms a large water absorbing volume, relatively speaking, with respect to the water flow rate of a single drain hole (24) from the water supply pipe (6) into the pressure cell (4). As a result, the back pressure, if any, on any particular drain cell (4) will not adversely effect the flow rate of water throughout the entire drain field (14), and each drain cell (4) is, therefore, decoupled essentially from the performance of the rest of the drain line (2). Individual cells (4), therefore, provide optimal drainage of water into the local soil (16) within which they are buried. They do not adversely effect or provide back pressure against the flow of water to other individual pressure cells (4) and, therefore, the drainage field (14) stabilizes at an optimum overall absorption of water into the ground (16), each individual pressure cell (4) providing optimum seepage of water into its local environment without adversely effecting the flow or capturing the flow of water from the remainder of the field (14).
It can, thus, be seen that, in addition to significantly reducing the cost of preparation of a drain field (14) for receiving the inventive array of pressure cells (4) connected by pipes (6), the Invention provides an additional advantage in that it provides a more uniform distribution of water throughout the drain field (14), minimizing puddling and saturation in local areas of the drain field (14) which may be lower or more absorptive than other areas. Further, a drain field (14) having varied soil types, having different percolation rates for water, will not result in saturation by water in the low percolation areas, nor will it divert water to the high percolation areas, but, rather, will ensure a uniform distribution of water throughout the field (14) independently of the soil percolation rates or absorptions in any localized area of the drain field (14).
A particular size has been shown as an example to guide the user, but it must be understood the Invention extends to all combinations of drain fields in which water supply pipes (6) have periodically positioned pressure cells, each pressure cell being connected to the water supply pipe by a restricted orifice (24) or opening which isolates water flow restrictions and flow properties of a particular pressure cell (4) from the overall flowrate of water in the drain pipes (6).
The Invention, therefore, extends to those broader equivalents inherent in the Claims. | A drain piping for forming buried drainage fields is formed from a flexible plastic pipe having periodically spaced restricted water flow orifices. Around the flexible pipe at each orifice is placed a larger diameter section of highly perforated drain pipe forming a drain cell; the cell is wrapped with a porous plastic cloth wrap (e.g. GeoTextile™--a known membrane cloth for preventing dirt migration). This pipe can be directly buried in dirt filled trenches; no special drainage provisions, such as crushed stone are required. Each cell individually fills with and drains waste water and sludge. The inventive pipe can be laid in uneven terrain, including areas win which the water table may rise above the level of some sections of pipe. Even if drainage is temporarily blocked form one cell, the pipe will properly drain through the other cells. |
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FIELD OF THE INVENTION
This invention relates generally to the field of in situ hydrocarbon extraction and more particularly to in situ extraction of hydrocarbons by means of a condensing solvent process which mobilizes the hydrocarbons for extraction by, for example, gravity drainage.
BACKGROUND OF THE INVENTION
Tar sands or oil sands such as are found in Canada, contain vast reserves of hydrocarbon resources of the type referred to as heavy oil or bitumen. Such heavy oil or bitumen is a hydrocarbon that has a high specific gravity and viscosity. These properties make it difficult to extract the hydrocarbon from the tightly packed sand formations in which it is found because unlike lighter oil deposits, heavy oil and bitumen do not readily flow at in situ conditions.
In prior Canadian Patent No. 2,299,790, a condensing solvent based in situ hydrocarbon recovery process is disclosed. This patent teaches, among other things, using a condensing solvent and controlling the in situ pressure to achieve a condensation temperature for the solvent within the formation which is suitable for reducing a viscosity of the in situ hydrocarbon by warming and solvent effects so that the hydrocarbon will flow under the influence of gravity. The result of this process is a volume in the formation which is stripped of the mobilized hydrocarbons, and which is called a gravity drainage chamber. As more solvent is circulated more hydrocarbon is removed resulting in a chamber which grows upwardly and outwardly from the injection well.
Canadian Patent No. 2,351,148 teaches, among other things, using a solvent which has been purified sufficiently to allow the solvent to achieve bubble point conditions at the extraction interface of the gravity drainage chamber whereby non-condensable gases naturally arising from the warming bitumen or hydrocarbon will be carried away with the draining liquids also in liquid form. In this way, a continuous extraction process is achieved at the extraction interface, because the potential impediment of an insulating layer of non-condensable gases existing between the incoming condensing solvent and the extraction interface is removed as part of the process.
The geological characteristics of the tar sands or oil sands can vary from deposit to deposit. While some deposits are relatively thick deposits in the order of 40 to 50 or more meters thick, many deposits are relatively thin being less than 20 meters thick and in many cases even 10 meters or less thick. In addition, the characteristics of the overburden can vary considerably. In some cases, the overburden is comprised of the cap rock which can act as a containment layer, but in other cases the overburden may be a sand layer or gravel or other porous material that provides poor confinement.
Where good confinement is available it is preferred to let the chamber grow to all the way to the overburden layer to extract all of the available hydrocarbon, but, leaving the overburden exposed to condensing solvent in the chamber is undesirable. More specifically, the overburden will continue to attract condensing solvent and the latent heat of condensation of such condensing solvent will be passed to the overburden but to no useful extraction effect. There is simply no hydrocarbon located in the overburden which can be warmed and removed. Therefore, any heat transfer to the overburden layer is wasted, thereby reducing the efficiency of the condensing solvent process.
In some cases, the overburden layer may not be a good confinement layer. In cases where the overburden layer is sand or other porous material it may also be saturated with water. In such a case, if the chamber growth extends vertically to the overburden layer the water will be provided with a pathway into the chamber which could result in the chamber being water flooded. Once the chamber is water flooded, further extraction from the chamber through a condensing solvent process is unlikely. Thus, when poor confinement exists it is preferred to stop vertical chamber growth at a point below the overburden layer to preserve a layer of hydrocarbon to that provides the necessary confinement.
SUMMARY OF THE INVENTION
What is desired is a method of controlling the location in the gravity drainage chamber where the solvent condensation occurs to control the flow of heat and chamber growth in a condensing solvent process to more efficiently extract in situ heavy oil and bitumen from an oil sand deposit under an overburden layer. In other words, it is desirable, in some circumstances, to preserve the integrity of a layer of bitumen saturated sand at the top of the reservoir in order to provide a confining barrier for the extraction chamber. In other circumstances it is desirable to control the location of condensation in the extraction chamber in order to maximise the thermal efficiency of the condensing solvent process.
According to the present invention the growth of the extraction chamber in situ can be controlled through the accumulation of non-condensable gases within the extraction chamber that act as a thermal barrier between the condensing solvent on a warm side of said layer, and the overburden or unextracted bitumen on a cold side of said layer. The vapour density of the non-condensable barrier gas, relative to the vapour density of the solvent vapour, at in situ or extraction conditions can be selected to optimize chamber growth and improve extraction effectiveness. By accumulating non-condensable gases having a vapour density which is less than the vapour density of the condensing solvent at extraction conditions, the barrier layer can be preferentially located or floated to a top or attic of a gravity drainage chamber. In this manner, vertical heat flow and vertical chamber growth can be restricted when desired, without stopping continued chamber growth in other directions, such as horizontally along a bitumen layer. By limiting vertical heat flow and vertical growth while encouraging horizontal growth, the horizontal wells may be spaced within the layer to optimise capital costs.
According to a preferred aspect of the current invention, a relatively pure solvent can be used to commence initial extraction of hydrocarbons in situ to form an extraction chamber. According to the invention of U.S. Pat. No. 2,351,148 the purer the solvent the more non-condensables can be removed from the extraction chamber. Most preferably, the removal of heat transfer poisoning non-condensable gases, which arise for example, from the mobilization and extraction of the reduced viscosity hydrocarbons will occur at a rate that prevents non-condensable gas from accumulating within the extraction chamber, thereby permitting continued chamber growth to occur.
According to the present invention, the vertical heat flow and vertical growth of the chamber can be measured over time and at a time at or before the vertical growth reaches the top of the bitumen layer, i.e., reaches to the overburden layer, the solvent purity can be temporarily varied to permit non-condensable barrier gas to accumulate in the chamber. The non-condensable barrier gas can arise either naturally from the bitumen which is being warmed and extracted, or, can be specifically added to the solvent to be carried to the extraction surface by the solvent within the chamber and may be one or more than one species of non-condensable gases.
Therefore, according to one aspect of the present invention there is provided a method of forming an in situ gravity drainage chamber while extracting hydrocarbons from a hydrocarbon bearing formation, the method comprising:
a. Injecting a condensing solvent which is sufficiently pure, having regard to the in situ conditions, to extract non-condensable gases from said chamber in liquid form; b. Monitoring a growth of said chamber in a vertical direction; and c. Establishing a non-condensable barrier gas layer at a top of said chamber to reduce the vertical heat flow and vertical growth rate of said chamber at or before said chamber reaches an overburden layer.
According to a further aspect of the invention there is provided a method of forming an in situ gravity drainage chamber in a hydrocarbon bearing formation comprising injecting a condensing solvent into said formation and varying a solvent purity over time to cause enough of a barrier gas to be introduced into said chamber to halt vertical growth of said chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to preferred embodiments of the present invention, by way of example only, and in which:
FIG. 1 shows a schematic of solvent purity of injected solvent over time according to one aspect of the present invention;
FIG. 2 shows an extraction chamber being extracted during an initial stage with substantially pure solvent according to the present invention;
FIG. 3 shows the chamber of FIG. 2 at a later stage of extraction where the vertical growth of the chamber has reached a desired upper limit and a barrier gas is being accumulated in the chamber at the extraction (condensation) interfaces;
FIG. 4 is a different cross section view of the chamber of FIG. 3
FIG. 5 is a subsequent cross-section view similar to FIG. 4 ; showing that after a period of time, the barrier gas floats up towards the top of the chamber and begins to accumulate there;
FIG. 6 is the chamber of FIGS. 3 and 4 after a further period of time under substantially pure condensing solvent injection showing the continued horizontal extraction or growth of the chamber but very limited vertical growth according to the present invention;
FIG. 7 shows a buoyancy curve of methane in propane at various pressures and saturation temperatures;
FIG. 8 shows a buoyancy curve of methane and hydrogen or a 1:1 ratio in propane at various pressures and saturation temperatures; and
FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of chamber pressure and local temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , a time line schematic is provided that generally illustrates the trends of purity of the injected condensing solvent over time according to a first aspect of the present invention. The horizontal or x-axis represents time, and the vertical or y-axis represents solvent purity. A horizontal denoted line 10 is also shown, which represents a desired purity of the solvent which is capable of extracting hydrocarbons and bitumen from the formation. This purity is referred to here in as extraction purity since at this purity hydrocarbon extraction occurs. Extraction purity means a solvent that is pure enough to continuously remove non-condensable gases from the chamber. The precise solvent purity required for extraction purity will vary from reservoir to reservoir depending upon in situ conditions such as pressure, temperature and amount of non-solvent gas naturally present and dissolved into the bitumen.
Also shown is an injected solvent purity line 12 , which represents the purity of the injected condensing solvent over time. For efficient non-condensable gas removal the extraction purity is able to achieve bubble point conditions for the condensing solvent at the extraction interface in the chamber. To achieve effective chamber growth rates, it is most desirable to remove any such expressed non-solvent gases, which are non-condensable at extraction conditions, from the chamber. At extraction purity for the solvent such other gases are able to dissolve into the solvent condensing onto the bitumen interface to permit these other gases to be carried away in a liquid form out of the chamber.
As fresh solvent is continually injected into the extraction chamber, it condenses onto and mobilizes the bitumen, scavenges other non-solvent gases present and results in a liquid mixture of solvent and hydrocarbons and other liquids draining down the chamber walls to collect in the bottom of the extraction chamber. From there the liquids are lifted or pumped to the surface for separation of solvent and hydrocarbons and then purification and preferably reuse of the solvent in the formation. Over time the extraction chamber will grow as more solvent is circulated and more hydrocarbon and bitumen is produced. Provided that the bubble point conditions are achieved at the interface, due to the solvent being at extraction purity, the chamber will grow outwardly both horizontally and vertically without undue accumulations of non-condensable gases occurring within the chamber. As the chamber grows, the vertical growth will eventually reach a point where it is at or near the overburden, or at a maximum desired vertical height.
According to the present invention, it is desirable to monitor the vertical growth of the chamber to be able to identify when the vertical growth is at or near the overburden layer or more specifically at an optimum height. This, according to the present invention, is the time to preferentially reduce and restrict further vertical growth. The preferred means used to measure vertical growth of the chamber of the present invention is discussed in more detail below.
FIG. 2 shows an injection well 20 with extraction purity condensing solvent being injected (arrows 22 ) during an initial time period 15 ( FIG. 1 ). The condensing solvent 22 exits the injection well 20 into an extraction chamber 24 where it is shown flowing by convection outwardly as arrows 23 . It condenses on the extraction interface and results in draining liquids 26 which drain down the sides of the chamber 24 under the influence of gravity. These liquids 26 enter the production well 28 , and are pumped to the surface by a pump 30 . The hydrocarbon bearing formation 32 includes an overburden layer 34 , a hydrocarbon pay zone 36 , and an underburden 38 . FIG. 2 depicts the chamber at a point in time towards the end of the time period 15 of FIG. 1 .
While FIG. 2 and the other figures depict horizontal well pairs it will be understood that the wells need not be truly horizontal and may be sloped or the like. Thus the term horizontal as used herein means somewhat or generally horizontal. Further other well configurations are contemplated by the present invention, such as a generally vertical single well arrangements or configurations of multiple generally horizontal wells.
As can now be understood, during this part of the process (time period 15 ) the solvent has extraction purity and gases other than the solvent gas, which are noncondensable at the condensing conditions for the solvent, are being removed from the chamber 24 at a rate which permits extraction to continue. In other words, these other gases are not allowed to accumulate in the chamber to any significant degree during this step in the process and thus are not present in FIG. 2 . Time period 15 ends when the extraction chamber has reached its desired maximum height.
Once the maximum chamber height is reached, the present invention provides that the solvent purity of the injected condensing solvent is changed. This is shown in FIG. 1 , at 14 . At this point, it is desirable to reduce the solvent purity and introduce more non-condensable barrier gas into the chamber, in other words the injection solvent purity is no longer at extraction purity. The change in injection solvent purity will have two in situ effects according to the present invention. The first effect is that more non-condensable barrier gas will be carried into the chamber by the solvent itself and then concentrated at the condensation surfaces as the solvent condenses. The second effect is that the condensed liquid solvent leaving the chamber is less able to extract the non-solvent gases arising naturally in the formation as liquids as the solvent is somewhat or fully saturated with barrier gases already. Depending upon how far below extraction purity the solvent is it can only scavenge barrier gases from the chamber at a reduced rate, if at all. As a result, non-solvent barrier gases now begin to accumulate within the chamber, at the condensation surfaces, over the time period 16 of FIG. 1 .
According to the present invention the preferred non-solvent barrier gas is a light gas having a vapour density which is most preferably significantly lower than the vapour density of the solvent at extraction or in situ conditions. The density difference should be sufficient, at the extraction chamber temperature and pressure to permit the barrier gas to accumulate at a preferred location in the chamber, such as at the roof of the chamber as described below.
FIG. 3 shows the in situ conditions in the extraction chamber corresponding to the end of the time period 16 on FIG. 1 . As shown in FIG. 3 , as the condensing solvent carries the non-condensable or barrier gas into the formation where it will be released at the extraction interface around the perimeter of the chamber when the solvent condenses. The barrier gas will, over time, build up as a relatively thick barrier layer 50 on all of the surfaces on which the condensing solvent is condensing.
FIG. 4 is a different cross-sectional view of FIG. 3 and like numbers are used for like elements. Again the barrier gas layer can be seen on all of the condensing surfaces. At a certain point enough noncondensable gas has been allowed to accumulate in the chamber to form the desired barrier layer.
Turning back to FIG. 1 , during the time period 16 , the purity of the condensing solvent has been decreased to introduce an appropriate amount of barrier gas into the extraction chamber. The appropriate amount will depend upon the size of the chamber and the rate of extraction and will vary from chamber to chamber. However, for the purposes of this specification, it will be understood that an appropriate amount means an amount that will permit the barrier gas to accumulate in the chamber and form a barrier layer.
FIG. 5 is later in time than FIGS. 3 and 4 and depicts a transition period represented by the time span 52 in FIG. 1 . The solvent purity of the injected solvent has been changed again and the solvent is now at extraction purity again. In FIG. 5 the accumulated non-solvent barrier gases are shown moving towards the top of the chamber since they are less dense than the condensing solvent vapour. Eventually the non-condensable gases will accumulate and be confined to a layer which is floating at the top of the chamber into a relatively thicker layer 60 .
FIG. 6 shows the effect of the continued steady state extraction, further along in time period 52 of FIG. 1 . As can be seen the barrier layer 60 is restricting further vertical growth and vertical heat loss, while the absence of a barrier layer on the vertical surfaces of the chamber is permitting further horizontal growth of the chamber at 62 .
It can now be appreciated that the present invention provides a solution to both undesirable effects of having a chamber grow uncontrolled into the overburden layer. Firstly, the non-condensable barrier gas layer will prevent heat loss through the top of the chamber. This will permit more heat to be contained within the chamber and directed usefully to heating the bitumen at the extraction interfaces for continued horizontal extraction. Secondly, the presence of the barrier gas or insulating layer will prevent the extraction interface from continuing to grow upwardly limiting vertical chamber growth. In this manner, the chamber can be prevented from being flooded, for example from an overlying water layer. At the same time, a continued extraction can occur in the horizontal directions by means of the solvent which is at extraction purity. According to an alternate embodiment of the present invention during the time period 16 (after point 14 ) the solvent injection could stop altogether, to be temporarily replaced with an injection of an amount, preferably a defined amount, of non-solvent barrier gas. Thus the schematic of FIG. 1 is also intended to comprehend that solvent injection may temporarily halt at point 14 in order to permit a volume of non-condensable gases to be injected over a short period of time. Injection of the non-condensable gases then ceases and thereafter continued solvent extraction through use of extraction purity solvent can recommence. Convection flow will carry the barrier gases outwardly and distribute the barrier gas around the perimeter of the chamber on the condensing surfaces.
Although many different gases are comprehended by the present invention as the barrier gas, when the solvent gas is propane, the preferred barrier gas is one or more of helium, hydrogen, methane or ethane. Methane is desirable because it is naturally occurring and typically in abundance at the extraction site and has a low vapour density relative to propane. It will therefore tend to rise to the top of the chamber and form a barrier layer. Helium and hydrogen are desirable in that each is also a light gas which can be easily obtained and introduced in the chamber as needed to provide buoyancy. Other barrier gases are also comprehended by the present invention provided they meet the vapour density criteria of being able to rise within and remain above the solvent gas. In this specification the term solvent gas is meant to comprehend many different solvents, such as propane, ethane, butane, and the like. The choice of the condensing solvent will depend upon the reservoir conditions. According to the present invention, the choice of barrier gas will be one that is less dense than the selected solvent gas at reservoir conditions.
FIG. 7 shows the vapour density of various concentrations of methane in propane at various temperatures. FIG. 8 shows the vapour density of various concentrations of methane/hydrogen at 1:1 ratio in propane over a range of temperatures FIG. 7 shows the density of pure propane vapour as a function of saturation temperature. FIG. 7 also has a series of curves showing the density of saturated propane vapour at fixed pressures, ranging from 0.75 MPaA to 2.5 MPaA. In these curves, at fixed pressures, the saturation conditions are achieved by dilution of the propane vapour with a non-condensable gas, methane.
FIG. 8 is similar to FIG. 7 , except than the non-condensable gas is a 50/50 mixture of methane and hydrogen instead of methane. The hydrogen vapour has a lower density that the methane so the 50/50 mix is more likely to rise than methane alone. Consequently the curves of FIG. 8 show lower density at a given temperature and pressure than the curves of FIG. 7 .
As can now be appreciated from FIGS. 7 and 8 the barrier gas which is at the same pressure as the chamber, but at a lower temperature due to the non-condensable gas, has a vapour density which is less than that of pure propane vapour at the same pressure. This is relevant because this density difference provides a buoyancy driving force tending to float the barrier gas upwards towards the top of the chamber. Furthermore, the higher the accumulation of non-condensable gas (i.e. the lower the saturation temperature) in the barrier gas, the greater the buoyancy driving force.
Another aspect of the present invention is the convection flow rate of solvent through the chamber. If the solvent flow rate is very slow, diffusion forces can cause the non-condensable barrier gases to diffuse throughout the chamber and away from the condensation or extraction surfaces. However, providing that there is a sufficient flow of fresh condensing solvent gas flowing towards the condensing surfaces the diffusion effects will be mitigated. Thus, an aspect of the present invention is to maintain a sufficient flow of injection solvent through the chamber towards the extraction surfaces to overcome any diffusion effects that might otherwise encourage the barrier gases to diffuse through the chamber, and thus limit their effectiveness as a barrier gas. The exact rate will vary depending upon the chamber characteristics, but a flow rate of solvent that is higher than the diffusion rate of the barrier gas is most preferred.
To facilitate the operation of the present invention, it is desirable to know where the extraction interface which defines the extraction chamber is located. The present invention comprehends monitoring the movement of the extraction interface over time to ensure that the vertical growth of the chamber can be controlled. Various means of monitoring the extraction rate and the chamber growth can be used however, a preferred method according to the present invention is to position an observation well or wells in the formation at a location which is at or near a middle of said chamber (i.e., where the peak of the chamber roof will be). An example of such an observation well is shown as 70 in FIG. 6 . The position of the observation well may be offset slightly from production and injection wells to reduce the risk of damage of one or the other during well drilling as shown in FIG. 6 or could be directly above, but not as deep as these wells. A logging tool 72 such as a reservoir saturation tool (RST) can be used to determine the nature of the material in the pores space (i.e., gas, water or hydrocarbon liquid). This tool can be used to periodically locate the roof of the vapour chamber. A temperature sensor 74 located within the observation well 70 can provide temperature measurements at specific locations or heights within the chamber.
FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of temperature for various chamber pressures. The data of FIG. 9 can be used to relate the reduced temperatures within the barrier gas to the local concentration of propane solvent in the vapour. In this way, a real time vertical temperature profile can be used to calculate non condensable gas concentrations within the barrier gas blanket to determine its thickness and composition. This information can be used to monitor the gas blanket and relate the characteristics of the gas blanket to the vertical growth rate of the gravity drainage chamber. While this is the preferred method, the invention is not limited thereto and other methods of monitoring the chamber growth are also comprehended.
Prior to the extraction process being started, the position of the overburden layer will be identified. Then, it is a matter of monitoring a rise in temperature up the vertical column of the observation well or wells to monitor chamber growth.
In situations where the overburden is not capable of acting to confine the chamber, it will be desirable to maintain a pressure within the chamber at or slightly above formation pressure. This is to prevent leakage of fluid from the overburden layer of water into the chamber.
This invention comprehends that multiple adjustments to the solvent purity, may be necessary from time to time, to manage the barrier gas layer thickness and prevent it from thinning too much as the chamber grows horizontally. The horizontal growth of the chamber and/or removal of the barrier gas from the chamber via dissolution in the draining liquids would tend to thin the gas layer. By further adjustments to the solvent purity, it is possible to maintain the barrier layer to continue to restrict the upwards growth rate of the chamber and also reduce heat losses to the overburden.
In some cases the barrier layer may tend to be persistent in the attic region of the vapour chamber. This is because solvent condensation in the cooler region of the gas blanket will produce gas saturated liquid solvent. As this liquid drains down towards the bottom of the chamber, it will encounter warmer temperatures and consequently the non-condensable gas will be preferentially stripped out of the liquid. This non-condensable gas will then be returned to the gas blanket by convection movement of the injected condensing solvent in the gas phase.
It will be understood that as the chamber grows in size the heat losses to the overburden will increase and this has the effect of increasing the solvent to oil ratio. If the ability to recover and recycle the solvent is restricted, say by processing plant capacity, then it may not be feasible to maintain the chamber pressure at the desired pressure. In this situation, the use of a barrier layer to reduce overburden heat loss and consequently reduce solvent demand is desirable to allow the chamber pressure to be maintained at the preferred value.
It will be appreciated by those skilled in the art that while reference has been made to a preferred embodiment of the present invention above, various modifications and alterations can be made without departing from the broad spirit of the appended claims. Some of these variations have been discussed above and others will be apparent to those skilled in the art. What is desired according to the present invention is the use of a condensing solvent process to form an in situ gravity drainage chamber, where the chamber has a source of condensing fluid injection, a production means to remove extracted hydrocarbons and a system to monitor chamber growth and a means to preferentially accumulate barrier gas with the chamber. The precise choice of solvent and barrier gas can vary, provided that the barrier gas layer can be established where desired. | A solvent based gravity drainage process whereby the vertical growth rate of the chamber is restricted by placing, monitoring and managing a buoyant gas blanket at the top of the vapor chamber. The process reduces the heat loss to the overburden as well as providing a means to preserve a barrier layer of bitumen saturated reservoir sand at the top of the pay zone in reservoirs where there is limited or no confining layer present. |
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BACKGROUND OF THE INVENTION
This invention relates generally to fixtures such as are used to suspend plant pots from a ceiling.
It is well known that a variety of plastic and macrame type plant pots can be suspended by way of a hook secured to the ceiling. This however makes watering and general maintenance difficult since the plant is often too high off the ground to be easily reached. A further drawback is that existing ceiling hooks do not permit easy rotation of the plant, a feature necessary for even distribution of sunlight and the general well-being of the plant.
Finally, as a plant grows and matures its appearance may be enhanced by suspending it closer to or further away from the ceiling and rotating it so that it can be viewed from its most appealing side.
SUMMARY OF THE INVENTION
Therefore it is the principal object of the present invention to provide a way to suspend a plant pot from a ceiling in such a manner that the pot may be easily pulled down to a convenient level for maintenance.
A further object is that the plant pot may be suspended at any of a number of different levels from the ceiling to enhance beauty and exploit the available sunlight to its fullest.
A final object is to permit easy rotation of the plant pot to further enhance beauty and exposure to sunlight.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings,
FIG. 1 is a front view of the present invention with a plant pot suspended close to the ceiling.
FIG. 2 is a front view of the present invention with the same plant pot suspended far from the ceiling.
FIG. 3 is a perspective view of the present invention.
FIG. 4 is an exploded side view showing all of the components of the present invention.
FIG. 5 is a front view of the assembly housing of the present invention.
FIG. 6 is a front view of the extension spool of the present invention.
FIG. 7 is a front view of the assembly housing seal of the present invention.
FIG. 8 is a sectional view taken generally along the line 8--8 of FIG. 5.
FIG. 9 is a rear view of the extension spool of the present invention.
FIG. 10 is an enlarged sectional view taken generally along the line 10--10 of the assembly housing in FIG. 4 with all of the components of the invention in place.
FIG. 11 is a side view of the extension spool with the extension line and extension line grip in place.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 through 3 I show a threaded securing shaft 20 inserted into a cross section of household ceiling 22 and held thereto by the standard leaf spring bracket 21. The assembly housing post 23 is pressed firmly against the cross section of household ceiling 22 when the extendible ceiling hook is screwed firmly in place. The assembly housing seal 24 is adhered to the assembly housing 30.
The extension line 25 is looped around the plant pot hook 27 and the extension line grip 26 is hooked onto the extension line 25 to form a secure loop on which the plant pot hook 27 rests. The plant 29 resides inside the plant pot 28.
When the plant pot 28 is raised slightly in the direction indicated by arrow 90 and then pulled rapidly downwards in the direction indicated by arrow 92 it can be made to rest in the position illustrated in FIG. 2 or any of several intermediate positions in between by a manner which will be explained below. Since the extension line 25 is made of a light gauge nylon or cord the plant pot 28 can be easily rotated to any desired angle.
Referring now to FIGS. 4 through 11 I show a hub 54 with left axle indentation 56 and notch 52 protruding from the assembly housing 30. The notch face 53 forms one side of the notch 52. The left guide 50 is a small indentation in the assembly housing 30.
The extension spool 43 consists of a reel 38 with thread hole 39 and axle shaft 35. The left wheel 34 has the left stop notch 61, the left smooth edge 60 and the left sharp edge 62 on its outer perimeter. The right wheel 36 has the right stop notch 74, the right smooth edge 76 and the right sharp edge 72 on its outer perimiter. The spring sleeve 32 with sleeve notch 63 is mounted coaxially to the left wheel 34. The friction hub 37 is mounted coaxially to the right wheel 36.
The extension line 25 is threaded through the thread hole 39, secured thereto by means of a knot and wrapped around the reel 38 in the manner illustrated in FIG. 11. The axle 40 is inserted into the axle shaft 35. The spring 31 is placed inside the spring sleeve 32 with the outer end 82 secured inside the sleeve notch 63. The inner end 86 is wrapped around the axle 40 as illustrated in FIG. 10. The stop rod 33 is then placed to rest between the left stop notch 61 and the right stop notch 74.
The extension line grip 26 is removed by untieing the knot 80 thus allowing the extension line 25 to be threaded through the line feed hole 70 in the assembly housing 30. Once threaded the extension line 25 is secured to the extension line grip 26 again by means of the knot 80 as illustrated in FIG. 10.
With the extension spool 43, extension line 25, spring 31, axle 40, extension line grip 26 and stop rod 33 thus assembled the entire combination is placed inside the assembly housing 30 so that the left side 45 of the axle 40 rests in the left axle indentation 56 and the inner end 86 of the spring 31 mates with the notch 52 as illustrated in FIG. 10. The left end 47 of the stop rod 33 rests loosely in the left guide 50 of the assembly housing 30.
The assembly housing seal 24 is then glued or press fit against the open side of the assembly housing 30 so that the right side 46 of the axle 40 rests inside the right axle indentation 44 and the right end 48 of the top rod 33 rests loosely inside the right guide 42. With the entire combination thus assembled I now refer to FIGS. 1 through 11 and in particular to FIG. 10 to explain fully the operation of the invention.
The spring 31 governs the rotation of the extension spool 43 upon the axle 40. The stop rod 33 rests loosely between the left guide 50 and the right guide 42 and upon the outer perimeters of the left wheel 34 and the right wheel 36.
FIG. 10 shows the stop rod 33 resting in the left stop notch 61 and the right stop notch 74. The weight of the plant pot 28 secured to the extension line 25 as in FIG. 2 exerts a force in the direction indicated by arrow 92 in FIG. 10. The stop rod 33 prevents the extension spool 43 from unwinding in the direction indicated by arrow 94 thus keeping the plant pot 28 at a fixed distance from the assembly housing 30. If the plant pot 28 is hand lifted in the direction of arrow 90 the spring 31 causes the extension spool 43 to rotate in the direction of arrow 96 thus allowing the stop rod 33 to be disengaged from the left stop notch 61 and the right stop notch 74 and placed upon the outer perimeters of the left wheel 34 and the right wheel 36.
A rapid pull of the extension line 25 in the direction of arrow 92 at this time will cause the stop rod 38 to ride the outer perimeters of the left wheel 34 and the right wheel 36 to the left smooth edge 60 and the right smooth edge 76. Due to the rapid motion of the extension spool 43 the stop rod 33 then moves over the left stop notch 61 and the right stop notch 74 to the left sharp edge 62 and the right sharp edge 72 at which time the stop rod 33 continues to ride the outer perimeters of the left wheel 34 and the right wheel 36 due to the continuing rapid rotation of the extension spool 43.
This happens for every rotation of the extension spool 43 in the direction of arrow 94 as long as said rotation is rapid. As soon as the pull in direction of arrow 92 is slowed down and the speed of rotation of the extension spool 43 in the direction of arrow 94 is consequently slowed down then the next encounter the stop rod 33 has with the left smooth edge 60 and the right smooth edge 76 will guide the stop rod 33 to rest again between the left stop notch 61 and the right stop notch 74 thus locking the extension line 25 and plant pot 28 at a new position from the assembly housing 30.
To return the plant pot 28 to the original position close to the assembly housing 30 the plant pot 28 is again hand lifted in the direction of arrow 90. This causes the spring 31 to rotate the extension spool 43 in the direction of arrow 96 thus reeling in the extension line 25. The extension line 25 is locked in position in the same manner as described above.
It can be seen that each rotation of the extension spool 43 offers a position at which the plant pot 28 can be locked. The total number of locking positions available is dependant on the length of the extension line 25, the number of turns on the spring 31 and the diameter of the reel 38. The assembly housing 30, extension spool 43 and assembly housing seal 24 can be of durable plastic or a metal alloy and the axle 40, stop rod 33, extension line grip 26 and threaded securing shaft 20 can be of steel, brass or other suitable strong metal. The extension line 25 can be of light gauge nylon, cord, catgut or other strong material.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made those skilled in the art without departing from the spirit of the invention. For example, more than one stop rod 33 may be provided to increase the total number of locking positions available.
I believe the nature of my invention, its purpose and its operation will now be clearly understood. | An extendible ceiling hook comprises an apparatus for suspending a hanging plant at various distances from a ceiling for the purposes of ease of maintenance, appearance and the general well being of the plant. An extension line, wound on an extension spool inside the extendible ceiling hook may be reeled in or out or made to rest at a desired distance from the ceiling by raising or lowering the suspended plant pot in a controlled fashion. The suspended plant can also be easily rotated to any desired angle to fully exploit any available sunlight and further enhance its appearance. |
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RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 11/364,112 which is a continuation-in-part of PCT application PCT/CA2005/000883 filed on Jun. 6, 2005 in which the United States was designated, claiming priority from U.S. Provisional Application 60/577,779 filed Jun. 7, 2004, each of which are incorporated herein by reference in their entirety and for all their teachings, disclosures and purposes.
FIELD OF THE INVENTION
[0002] This invention relates to a process for improved safety and productivity when undertaking oil recovery from an underground reservoir by the toe-to-heel in situ combustion process employing horizontal production wells, such as disclosed in U.S. Pat. Nos. 5,626,191 and 6,412,557. More particularly, it relates to an in situ combustion process in which a water, steam, and/or a non-oxidizing gas which in a preferred embodiment is carbon dioxide which acts as a gaseous solvent, is injected into the reservoir for improving recovery in an in situ combustion recovery process.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. Nos. 5,626,191 and 6,412,557, incorporated herein in their entirety, disclose in situ combustion processes for producing oil from an underground reservoir ( 100 ) utilizing an injection well ( 102 ) placed relatively high in an oil reservoir ( 100 ) and a production well ( 103 - 106 ) completed relatively low in the reservoir ( 100 ). The production well has a horizontal leg ( 107 ) oriented generally perpendicularly to a generally linear and laterally extending upright combustion front propagated from the injection well ( 102 ). The leg ( 107 ) is positioned in the path of the advancing combustion front. Air, or other oxidizing gas, such as oxygen-enriched air, is injected through wells 102 , which may be vertical wells, horizontal wells or combinations of such wells. The process of U.S. Pat. No. 5,626,191 is called “THAI™”, an acronym for “toe-to-heel air injection” and the process of U.S. Pat. No. 6,412,557 is called “Capri™”, the Trademarks being held by Archon Technologies Ltd., a subsidiary of Petrobank Energy and Resources Ltd., Calgary, Alberta, Canada.
[0004] High-Pressure-Air-Injection, HPAI, is an in situ combustion process that is applied in tight reservoirs containing light oil. In these reservoirs, a liquid such as water cannot be effectively injected because of low reservoir permeability. Air is injected in the upper reaches of the reservoir and oil drains into a horizontal well placed low in the reservoir. The process provides some heat by low-temperature oil oxidation and more importantly, it provides pressure-maintenance to enable high sustained oil rates. This process can be applied in any reservoir that contains oil that is mobile at reservoir conditions.
[0005] Of concern is the safety of the THAI™ and Capri™ processes with respect to oxygen entry into the horizontal well, which would cause oil burning in the well and extremely high temperatures that would destroy the well. Such oxygen breakthrough will not occur if the injection rates are kept low, however, high injection rates are very desirable in order to maintain high oil production rates and a high oxygen flux at the combustion front. A high oxygen flux is known to keep the combustion in the high-temperature oxidation (HTO) mode, achieving temperatures of greater than 350° C. and combusting the fuel substantially to carbon dioxide. At low oxygen flux, low-temperature oxidation (LTO) occurs and temperatures do not exceed ca. 350° C. In the LTO mode, oxygen becomes incorporated into the organic molecules, forming polar compounds that stabilize detrimental water-oil emulsions and accelerate corrosion because of the formation of carboxylic acids. In conclusion, the use of relatively low oxidant injection rates is not an acceptable method to prevent combustion in the horizontal wellbore.
[0006] What is needed is one or more methods to increase the oxidizing gas injection rate while preventing oxygen entry into the horizontal wellbore The present invention provides such methods.
SUMMARY OF THE INVENTION
[0007] The THAI™ and Capri™ processes depend upon two forces to move oil, water and combustion gases into the horizontal wellbore for conveyance to the surface. These are gravity drainage and pressure The liquids, mainly oil, drain into the wellbore under the force of gravity since the wellbore is placed in the lower region of the reservoir. Both the liquids and gases flow downward into the horizontal wellbore under the pressure gradient that is established between the reservoir and the wellbore.
[0008] During the reservoir pre-heating phase, or start-up procedure, steam is circulated in the horizontal well through a tube that extends to the toe of the well. The steam flows back to the surface through the annular space of the casing. This procedure is imperative in bitumen reservoirs because cold oil that may enter the well will be very viscous and will flow poorly, possible plugging the wellbore. Steam is also circulated through the injector well and is also injected into the reservoir in the region between the injector wells and the toe of the horizontal wells to warm the oil and increase its mobility prior to initiating injection of oxidizing gas into the reservoir.
[0009] The aforementioned patents show that with continuous oxidizing gas injection a quasi-vertical combustion front develops and moves laterally from the direction of the toe of the horizontal well towards the heel. Thus two regions of the reservoir are developed relative to the position of the combustion zone. Towards the direction of toe, lies the oil-depleted region that is filled substantially with oxidizing gas, and on the other side lies the region of the reservoir containing cold oil or bitumen. At higher oxidant injection rates, reservoir pressure increases and the fuel deposition rate can be exceeded, so that gas containing residual oxygen can be forced into the horizontal wellbore in the oil-depleted region.
[0010] The consequence of having oil and oxygen together in a wellbore is combustion and potentially an explosion with the attainment of high temperatures, perhaps in excess of 1000° C. This can cause irreparable damage to the wellbore, including the failure of the sand retention screens. The presence of oxygen and wellbore temperatures over 425° C. must be avoided for safe and continuous oil production operations.
[0011] Several methods of preventing oxygen entry into the producing wellbore are based on reducing the differential pressure between the reservoir and the horizontal wellbore. These are 1. to reduce the injection rate of the oxidizing gas in order to reduce the reservoir pressure, and 2. to reduce the fluid drawdown rate to increase wellbore pressure. Both of these methods result in the reduction of oil rates, which is economically detrimental. Conventional thinking would also state that injecting fluid directly into the wellbore would increase wellbore pressure but would be very detrimental to production rates.
[0012] Importantly, it has been discovered that in an in situ combustion process generally, if carbon dioxide is injected into the reservoir along with the oxidizing gas, the oil recovery rate is increased This is true whether the ISC process is of the traditional, THAI™, Capri™, HPAI or any other type.
[0013] Specifically, when the injected non-oxidizing gas which is injected with oxygen comprises only carbon dioxide in the absence of nitrogen, the improvement can be dramatic.
[0014] Thus in a preferred embodiment of the invention, the injected non-oxidizing gas is carbon dioxide.
[0015] Advantageously, in an in situ combustion recovery process, when O2 is injected alone, the recovered combustion gas, which substantially comprises CO2, can be compressed and mixed with the oxygen Any ratio of O2 to CO2 can be attained by adjusting the percentage of recycled produced CO2.
[0016] If the produced combustion gas contains impurities, these will not build-up if an appropriate slip stream of combustion gas is disposed.
[0017] Since the disposed gas will be typically about 95% CO2 it can be sold without purification for enhanced oil recovery by miscible flooding, or can be disposed into a deep aquifer.
[0018] It is not required that the CO2 be miscible (ie. soluble in all proportions) in the oil under reservoir conditions. Partial solubility is adequate.
[0019] While the mechanics of how adding a particular non-oxidizing gas such as CO2, as opposed to other non-oxidizing gases, further increases the mobility of hydrocarbons in a reservoir are not precisely understood, and without being in any way held to an explanation as to why such important increases in recoverability are obtained as a result of CO2 injection, it is suspected that CO2 acts as a solvent and decreases the oil viscosity ahead of the combustion zone, thereby enhancing the combustion process and thus further liquefying oil ahead of the combustion zone. The added dissolution of some CO2 in the combustion front also facilitates the transfer of heat from the combustion gas into the oil, which also reduces the oil viscosity, thus increasing recovery.
[0020] Thus in order to overcome the disadvantages of the prior art, and to improve the safety or productivity of hydrocarbon recovery from an underground reservoir, the present invention accordingly in a first broad embodiment comprises a process for extracting liquid hydrocarbons from an underground reservoir comprising the steps of:
(a) providing at least one injection well for injecting an oxidizing gas into the underground reservoir; (b) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, wherein the substantially horizontal leg extends toward the injection well, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg, wherein the toe portion is closer to the injection well than the heel portion; (c) injecting an oxidizing gas through the injection well to conduct in situ combustion, so that combustion gases are produced so as to cause the combustion gases to progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction from the toe portion to the heel portion of the horizontal leg, and fluids drain into the horizontal leg; (d) providing a tubing inside the production well for the purpose of injecting steam, water or non-oxidizing gas into said horizontal leg portion of said production well; (e) injecting a medium selected from the group of mediums comprising steam, water, or non-oxidizing gas, into said tubing so that said medium is conveyed proximate said toe portion of said horizontal leg portion via said tubing; and (f) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0027] In a further broad embodiment of the invention, the present invention comprises a process for extracting liquid hydrocarbons from an underground reservoir, comprising the steps of:
(a) providing at least one injection well for injecting an oxidizing gas into an upper part of an underground reservoir; (b) providing at least one injection well for injecting steam, a non-oxidizing gas, or water which is subsequently heated to steam, into a lower part of an underground reservoir; (c) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, wherein the substantially horizontal leg extends toward the injection well, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg, wherein the toe portion is closer to the injection well than the heel portion; (d) injecting an oxidizing gas through the injection well for in situ combustion, so that combustion gases are produced, wherein the combustion gases progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction from the toe portion to the heel portion of the horizontal leg, and fluids drain into the horizontal leg; (e) injecting a medium, wherein said medium is selected from the group of mediums comprising steam, water or a non-oxidizing gas, into said injection well; and (f) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0034] In a still further embodiment of the invention, the present comprises the combination of the above steps of injecting a medium to the formation via the injection well, and as well injecting a medium via tubing in the horizontal leg. Accordingly, in this further embodiment the present invention comprises a method for extracting liquid hydrocarbons from an underground reservoir, comprising the steps of:
a) providing at least one injection well for injecting an oxidizing gas into an upper part of an underground reservoir; b) providing at least one injection well for injecting steam, a non-oxidizing gas, or water which is subsequently heated to steam, into a lower part of an underground reservoir; c) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, wherein the substantially horizontal leg extends toward the injection well, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg, wherein the toe portion is closer to the injection well than the heel portion; d) providing a tubing inside the production well for the purpose of injecting steam, water or non-oxidizing gas into said horizontal leg portion of said production well; e) injecting an oxidizing gas through the injection well for in situ combustion, so that combustion gases are produced, wherein the combustion gases progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction from the toe portion to the heel portion of the horizontal leg, and fluids drain into the horizontal leg; f) injecting a medium, wherein said medium is selected from the group of mediums comprising steam, water or a non-oxidizing gas, into said injection well and into said tubing; and (g) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0042] If the medium is steam, it is injected into the reservoir/formation, via either or both the injection well or the production well via tubing therein, in this state, typically under a pressure of 7000 KpA.
[0043] Alternatively, where the injected medium is water, such method contemplates that the water become heated at the time of supply to the reservoir to become steam. The water, when it reaches the formation, via either or both the injection well and/or the tubing in the production well, may be heated to steam during such travel, or immediately upon its exiting of the injection well and/or tubing in the production well and its entry into the formation.
[0044] Lastly, in a further broad aspect of the present invention for use in an in-situ combustion hydrocarbon recovery process from subterranean deposits, the method of the present invention comprises the steps of:
[0000] (a) providing at least one injection well for injecting an oxidizing gas into an upper part of an underground reservoir;
(b) said at least one injection well further adapted for injecting carbon dioxide into a lower part of an underground reservoir;
(c) providing at least one production well;
(d) injecting an oxidizing gas through the injection well for in situ combustion, so that combustion gases are produced;
(e) injecting carbon dioxide alone or in combination with oxygen into said injection well; and
(f) recovering hydrocarbons from said production well.
[0045] In another variation of the above, the method of the present invention comprises a process for extracting liquid hydrocarbons from an underground reservoir, comprising the steps of:
[0000] (a) providing at least one oxidizing gas injection well for injecting an oxidizing gas into an upper part of an underground reservoir;
(b) providing at least one other injection well for injecting carbon dioxide into a lower part of an underground reservoir;
(c) providing at least one production well;
(d) injecting an oxidizing gas through the oxidizing injection well for in situ combustion, so that combustion gases are produced;
(e) injecting carbon dioxide alone or in combination with oxygen into said other injection well; and
(f) recovering hydrocarbons from said production well.
[0046] It is to be noted that, where CO2 is injected into the injection well, one or more additional non-oxidizing gasses could also be injected at the same time in combination with the CO2
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a schematic of the THAI™ in situ combustion process with labeling as follows:
[0048] Item A represents the top level of a heavy oil or bitumen reservoir, and B represents the bottom level of such reservoir/formation.
[0049] C represents a vertical well with D showing the general injection point of a oxidizing gas such as air.
[0050] E represents a general location for the injection of steam or a non-oxidizing gas into the reservoir. This is part of the present invention.
[0051] F represents a partially perforated horizontal well casing. Fluids enter the casing and are typically conveyed directly to the surface by natural gas lift through another tubing located at the heel of the horizontal well (not shown).
[0052] G represents a tubing placed inside the horizontal leg. The open end of the tubing may be located near the end of the casing, as represented, or elsewhere. The tubing can be ‘coiled tubing’ that may be easily relocated inside the casing. This is part of the present invention. The elements E and G are part of the present invention and steam or non-oxidizing gas may be injected at E and/or at G. E may be part of a separate well or may be part of the same well used to inject the oxidizing gas. These injection wells may be vertical, slanted or horizontal wells or otherwise and each may serve several horizontal wells. For example, using an array of parallel horizontal leg as described in U.S. Pat. Nos. 5,626,191 and 6,412,557, the steam, water or non-oxidizing gas may be injected at any position between the horizontal legs in the vicinity of the toe of the horizontal legs.
[0053] FIG. 2 is a schematic diagram of the Model reservoir. The schematic is not to scale. Only an ‘element of symmetry’ is shown. The full spacing between horizontal legs is 50 meters but only the half-reservoir needs to be defined in the STARS™ computer software. This saves computing time. The overall dimensions of the Element of Symmetry are:
[0054] length A-E is 250 m; width A-F is 25 m; height F-G is 20 m.
[0055] The positions of the wells are as follows:
[0056] Oxidizing gas injection well J is placed at B in the first grid block 50 meters (A-B) from a corner A. The toe of the horizontal well K is in the first grid block between A and F and is 15 m (B-C) offset along the reservoir length from the injector well J. The heel of the horizontal well K lies at D and is 50 m from the corner of the reservoir, E. The horizontal section of the horizontal well K is 135 m (C-D) in length and is placed 2.5 m above the base of the reservoir (A-E) in the third grid block.
[0057] The Injector well J is perforated in two (2) locations. The perforations at H are injection points for oxidizing gas, while the perforations at I are injection points for steam or non-oxidizing gas. The horizontal leg (C-D) is perforated 50% and contains tubing open near the toe (not shown, see FIG. 1 ).
[0058] FIG. 3 is a graph plotting oil production rate vs. CO2 rate in the produced gas, drawing on Example 7 discussed below.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0059] The operation of the THAI™ process has been described in U.S. Pat. Nos. 5,626,191 and 6,412,557 and will be briefly reviewed. The oxidizing gas, typically air, oxygen or oxygen-enriched air, is injected into the upper part of the reservoir. Coke that was previously laid down consumes the oxygen so that only oxygen-free gases contact the oil ahead of the coke zone. Combustion gas temperatures of typically 600° C. and as high as 1000° C. are achieved from the high-temperature oxidation of the coke fuel. In the Mobile Oil Zone (MOZ), these hot gases and steam heat the oil to over 400° C., partially cracking the oil, vaporizing some components and greatly reducing the oil viscosity. The heaviest components of the oil, such as asphaltenes, remain on the rock and will constitute the coke fuel later when the burning front arrives at that location. In the MOZ, gases and oil drain downward into the horizontal well, drawn by gravity and by the low-pressure sink of the well. The coke and MOZ zones move laterally from the direction from the toe towards the heel of the horizontal well. The section behind the combustion front is labeled the Burned Region. Ahead of the MOZ is cold oil.
[0060] With the advancement of the combustion front, the Burned Zone of the reservoir is depleted of liquids (oil and water) and is filled with oxidizing gas. The section of the horizontal well opposite this Burned Zone is in jeopardy of receiving oxygen which will combust the oil present inside the well and create extremely high wellbore temperatures that would damage the steel casing and especially the sand screens that are used to permit the entry of fluids but exclude sand. If the sand screens fail, unconsolidated reservoir sand will enter the wellbore and necessitate shutting in the well for cleaning-out and remediation with cement plugs. This operation is very difficult and dangerous since the wellbore can contain explosive levels of oil and oxygen.
[0061] In order to quantify the effect of fluid injection into the horizontal wellbore, a number of computer numerical simulations of the process were conducted. Steam was injected at a variety of rates into the horizontal well by two methods: 1. via tubing placed inside the horizontal well, and 2. via a separate well extending near the base of the reservoir in the vicinity of the toe of the horizontal well. Both of these methods reduced the prediliction of oxygen to enter the wellbore but gave surprising and counterintuitive benefits: the oil recovery factor increased and build-up of coke in the wellbore decreased. Consequently, higher oxidizing gas injection rates could be used while maintaining safe operation.
[0062] It was found that both methods of adding steam to the reservoir provided advantages regarding the safety of the THAI™ Process by reducing the tendency of oxygen to enter the horizontal wellbore. It also enabled higher oxidizing gas injection rates into the reservoir, and higher oil recovery.
[0063] Extensive computer simulation of the THAI™ Process was undertaken to evaluate the consequences of reducing the pressure in the horizontal wellbore by injecting steam or non-oxidizing gas. The software was the STARS™ In Situ Combustion Simulator provided by the Computer Modelling Group, Calgary, Alberta, Canada.
Table 4. List of Model Parameters.
Simulator: STARS™ 2003 13, Computer Modelling Group Limited
Model Dimensions:
[0064] Length 250 m, 100 grid blocks, eac
Width 25 m, 20 grid blocks
Height 20 m, 20 grid blocks
Grid Block dimensions: 2.5 m×2.5 m×1.0 m (LWH).
Horizontal Production Well:
[0065] A discrete well with a 135 m horizontal section extending from grid block 26, 1, 3 to 80, 1, 3 The toe is offset by 15 m from the vertical air injector.
Vertical Injection Well:
[0066] Oxidizing gas(air) injection points: 20, 1, 1:4 (upper 4-grid blocks)
Oxidizing gas Injection rates: 65,000 m3/d, 85,000 m3/d or 100,000 m31 d
Steam injection points: 20, 1, 19:20 (lower 2-grid blocks)
Rock/Fluid Parameters:
[0067] Components: water, bitumen, upgrade, methane, CO2, CO/N2, oxygen, coke
Heterogeneity: Homogeneous sand.
Permeability: 6.7 D (h), 3.4 D (v)
Porosity: 33%
[0068] Saturations: Bitumen 80%, water 20%, gas Mole fraction 0.114
Bitumen viscosity: 340,000 cP at 10° C.
Bitumen average molecular weight: 550 AMU
Upgrade viscosity: 664 cP at 10° C.
Upgrade average molecular weight: 330 AMU
Physical Conditions:
[0069] Reservoir temperature: 20° C.
Native reservoir pressure: 2600 kPa.
Bottomhole pressure: 4000 kPa.
Reactions:
1. 1.0 Bitumen---->0.42 Upgrade+1.3375 CH4+20 Coke
[0070] 2. 1.0 Bitumen+16O2A0.05---->12.5 water+5.0 CH4+9.5 CO2+0.5 CO/N2+15 Coke
3. 1.0 Coke+1.225O2---->0.5 water+0.95 CO2+0.05 CO/N2
EXAMPLES
Example 1
[0071] Table 1a shows the simulation results for an air injection rate of 65,000 m3/day (standard temperature and pressure) into a vertical injector (E in FIG. 1 ). The case of zero steam injected at the base of the reservoir at point I in well J is not part of the present invention. At 65,000 m3/day air rate, there is no oxygen entry into the horizontal wellbore even with no steam injection and the maximum wellbore temperature never exceeds the target of 425° C.
[0072] However, as may be seen from the data below, injection of low levels of steam at levels of 5 and 10 m3/day (water equivalent) at a point low in the reservoir (E in FIG. 1 ) provides substantial benefits in higher oil recovery factors, contrary to intuitive expectations. Where the injected medium is steam, the data below provides the volume of the water equivalent of such steam, as it is difficult to otherwise determine the volume of steam supplied as such depends on the pressure at the formation to which the steam is subjected to. Of course, when water is injected into the formation and subsequently becomes steam during its travel to the formation, the amount of steam generated is simply the water equivalent given below, which typically is in the order of about 1000× (depending on the pressure) of the volume of the water supplied.
[0000]
TABLE 1a
AIR RATE 65,000 m 3 /day-Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
410
90
0
35.1
28.3
5
407
79
0
38.0
29.0
10
380
76
0
43 1
29.8
*Not part of the present invention.
Example 2
[0073] Table 1b shows the results of injecting steam into the horizontal well via the internal tubing, G, in the vicinity of the toe while simultaneously injecting air at 65,000 m3/day (standard temperature and pressure) into the upper part of the reservoir. The maximum wellbore temperature is reduced in relative proportion to the amount of steam injected and the oil recovery factor is increased relative to the base case of zero steam. Additionally, the maximum volume percent of coke deposited in the wellbore decreases with increasing amounts of injected steam. This is beneficial since pressure drop in the wellbore will be lower and fluids will flow more easily for the same pressure drop in comparison to wells without steam injection at the toe of the horizontal well.
[0000]
TABLE 1b
AIR RATE 65,000 m 3 /day-Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m3/day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
410
90
0
35.1
28.6
5
366
80
0
43.4
30.0
10
360
45
0
43.4
29.8
*Not part of the present invention.
Example 3
[0074] In this example, the air injection rate was increased to 85,000 m3/day (standard temperature and pressure) and resulted in oxygen breakthrough as shown in Table 2a. An 8.8% oxygen concentration was indicated in the wellbore for the base case of zero steam injection. Maximum wellbore temperature reached 1074° C. and coke was deposited decreasing wellbore permeability by 97%. Operating with the simultaneous injection of 12 m3/day (water equivalent) of steam at the base of the reservoir via vertical injection well C (see FIG. 1 ) provided an excellent result of zero oxygen breakthrough, acceptable coke and good oil recovery
[0000]
TABLE 2a
AIR RATE 85,000 m 3 /day-Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m3/d
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
1074
97
8.8
5
518
80
0
12
414
43
0
36.1
33.4
*Not part of the present invention.
Example 4
[0075] Table 2b shows the combustion performance with 85,000 m3/day air (standard temperature and pressure) and simultaneous injection of steam into the wellbore via an internal tubing G (see FIG. 1 ). Again 10 m3/day (water equivalent) of steam was needed to prevent oxygen breakthrough and an acceptable maximum wellbore temperature.
[0000]
TABLE 2b
AIR RATE 85,000 m 3 /d. Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m3/d
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
1074
100
8.8
5
500
96
1.8
10
407
45
0
37.3
33.2
*Not part of the present invention.
Example 5
[0076] In order to further test the effects of high air injection rates, several runs were conducted with 100,000 m3/day air injection. Results in Table 3a indicate that with simultaneous steam injection at the base of the reservoir (ie at location B-E in vertical well C-ref. FIG. 1 ), 20 m3/day (water equivalent) of steam was required to stop oxygen breakthrough into the horizontal leg, in contrast to only 10 m3/day steam (water equivalent) at an air injection rate of 85,000 m3/day.
[0000]
TABLE 3a
AIR RATE 100,000 m 3 /day-Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m3/day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
1398
100
10.4
5
1151
100
7.2
10
1071
100
6.0
20
425
78
0
34.5
35.6
*Not part of the present invention.
Example 6
[0077] Table 3b shows the consequence of injecting steam into the well tubing G (ref. FIG. 1 ) while injecting 100,000 m3/day air into the reservoir. Identically with steam injection at the reservoir base, a steam rate of 20 m3/day (water equivalent) was required in order to prevent oxygen entry into the horizontal leg.
[0000]
TABLE 3b
AIR RATE 100,000 m 3 /d. Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m3/day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m3/day
*0
1398
100
10.4
5
997
100
6.0
10
745
100
3.8
20
425
38
0
33.9
35.6
*Not part of the present invention.
Example 7
[0078] Table 4 below shows comparisons between injecting oxygen and a combination of non-oxidizing gases, namely nitrogen and carbon dioxide, into a single vertical injection well in combination with a horizontal production well in the THAI™ process via which the oil is produced, as obtained by the STARS™ In Situ Combustion Simulator software provided by the Computer Modelling Group, Calgary, Alberta, Canada. The computer model used for this example was identical to that employed for the above six examples, with the exception that the modeled reservoir was 100 meters wide and 500 meters long. Steam was added at a rate of 10 m3/day via the tubing in the horizontal section of the production well for all runs,
[0000]
Total
Produced
Oil
Cumulative
Mol %
Mol %
Injection
Production Rate,
Gas
Rate
Oil
Test
Injection Rate, km 3 /day
Oxygen
CO2
Rate,
km3/day
Mol %
m3/day
Recovery
#
O2
CO2
N2
Injected
Injected
km 3 /day
CO2
N2
CO2
(1-year)
m3
1
17.85
0
67.15
21
0
85
13.1
67.2
16.3
41
9700
2
8.93
33.57
0
21
79
42.5
37.9
0.0
96.0
54
12780
3
25
0
0
100
0
25
21.3
0.0
96.0
47
10078
4
17.85
67.15
0
21
79
85
75.0
0.0
96.0
136
20000
5
42.5
0
0
100
0
42.5
38.1
0.0
96.0
57
12704
6
42.5
42.5
0
50
50
85
74.2
0.0
96.0
113
28104
7
8.93
42.5
33.57
11
50
85
47.2
33.6
57.4
70
12000
[0079] As may be seen from above Table 4 comparing Run 1 and Run 2, when the oxygen and inert gas are reduced by 50% as in Run2, the oil recovery is nevertheless the same as in Run 1, providing that the inert gas is CO2. This means that the gas compression costs are cut in half in Run 2, while oil is produced faster.
[0080] As may further be seen from above Table 4, Run #1 having 17.85 molar % of oxygen and 67.15% nitrogen injected into the injection well, estimated oil recovery rate was 41 m3/day. In comparison, using a similar 17.85 molar % oxygen injection with 67.15 molar % carbon dioxide as used in Run #4, a 3.3 times increase in oil production (136 m3/day) is estimated as being achieved.
[0081] As may be further seen from Table 4 above, when equal amounts of oxygen and CO2 are injected as in Run 6, still with a total injected volume of 85,000 m3/day, oil recovery was increased 2.7-fold.
[0082] Run 7 shows the benefit of adding CO2 to air as the injectant gas Compared with Run 1, oil recovery was increased 1.7-fold without increasing compression costs. The benefit of this option is that oxygen separation equipment is not needed.
[0083] Referring now to FIG. 3 , which is a graph showing a plot of oil production rate versus CO2 rate in the produced gas (drawing on Example 7 above), there is a strong correlation between these parameters for in situ combustion processes. CO2 production rate depends upon two CO2 sources: the injected CO2 and the CO2 produced in the reservoir from coke combustion, so there is a strong synergy between CO2 flooding and in situ combustion even in reservoirs with immobile oils, which is the present case.
SUMMARY
[0084] For a fixed amount of steam injection, the average daily oil recovery rate increased with air injection rate. This is not unexpected since the volume of the sweeping fluid is increased. However, it is surprising that the total oil recovered decreases as air rate is increased. This is during the life of the air injection period (time for the combustion front to reach the heel of the horizontal well). Moreover, with carbon dioxide injected in the vertical well, and/or in the horizontal production well, production rates improved production rates can be expected.
[0085] Although the disclosure described and illustrates preferred embodiments of the invention, it is to be understood that the invention is not limited to these particular embodiments. Many variations and modifications will now occur to those skilled in the art. For definition of the invention, reference is to be made to the appended claims. | A process for improved safety and productivity when undertaking oil recovery from an underground reservoir by the toe-to-heel in situ combustion process employing a horizontal production well. Water, steam, and/or a non-oxidizing gas, which in the preferred embodiment substantially comprises carbon dioxide which acts as a gaseous solvent, is injected into the reservoir for improving recovery in an in situ combustion recovery process, via either an injection well, a horizontal well, or both. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/145,155, filed Jan. 16, 2009, the disclosure of which application is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] Embodiments of the invention relate to methods of forming polycrystalline diamond cutting elements having at least a portion of a diamond table substantially free of catalytic material, and to cutting elements so formed.
BACKGROUND
[0003] Superabrasive cutting elements in the form of Polycrystalline Diamond Compact (PDC) structures have been commercially available for almost four decades, and PDC cutting elements having a polycrystalline diamond table formed on the end of a supporting substrate for a period in excess of twenty years. The latter type of PDC cutting elements commonly comprises a thin, substantially circular disc (although other configurations are available), commonly termed a “table,” including a layer of superabrasive material formed of diamond crystals mutually bonded under ultrahigh temperatures and pressures and defining a substantially planar front cutting face, a rear face and a peripheral or circumferential edge, at least a portion of which is employed as a cutting edge to cut the subterranean formation being drilled by a drill bit on which the PDC cutting element is mounted. PDC cutting elements are generally bonded over their rear face during formation of the superabrasive table to a backing layer or substrate formed of tungsten carbide, although self-supporting PDC cutting elements are also known, particularly those stable at higher temperatures, which are known as Thermally Stable Polycrystalline Diamond, or “TSPs.” Such cutting elements are widely used on rotary fixed cutter, or “drag,” bits, as well as on other bits and tools used to drill and ream subterranean formations, such other bits and tools including without limitation core bits, bi-center bits, eccentric bits, hybrid (e.g., rolling components in combination with fixed cutting elements), roller cone bits, reamer wings, expandable reamers, and casing milling tools. As used herein, the term “drill bit” encompasses all of the foregoing, and equivalent structures.
[0004] In the formation of either type of cutting element, a catalyst is usually employed to stimulate diamond-to-diamond bonding of the diamond crystals. Unfortunately, the presence of a catalyst in the diamond table may lead to thermal degradation commencing at about 400° C. due to differences in the coefficients of thermal expansion (CTEs) of the diamond and the catalyst, and commencing around 700-750° C. due to stimulation of back-graphitization of the diamond to carbon by the catalyst. Such temperatures may be reached by the cutting edge of a PDC cutting element during drilling of a formation, despite the use of drilling fluid as a cooling agent and despite relatively rapid heat transfer into the diamond table, the substrate and the body of the drill bit on which the cutting element is mounted.
[0005] It has been recognized in the art that removal of the catalyst used in the original synthesis manufacturing of the diamond table from the cutting surface of the diamond table, particularly at the cutting edge thereof and along the side of the diamond table proximate the cutting edge and extending toward the substrate, reduces the tendency of those portions of the diamond table to degrade due to thermal effects. Consequently, provided the depth of removal of the catalyst is sufficient, the life of the diamond table is extended. The recognition of the aforementioned thermal degradation effects and how and from what portion of the diamond table the catalyst may be beneficially removed is disclosed in, among many other documents, Japanese Patent JP59-219500, as well as in U.S. Pat. Nos. 4,224,380, 5,127,923, 6,544,308 and 6,601,662, U.S. Patent Publications Nos. 2006/0060390, 2006/0060391, 2006/0060392, 2006/0086540, 2008/0223623, 2009/0152018 and PCT International Publication Nos. WO 2004/106003, WO 2004/106004 and WO 2005/110648. The disclosure of each of the foregoing documents is hereby incorporated herein in its entirety by this reference.
BRIEF SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention relate to methods of forming polycrystalline diamond elements, such as cutting elements suitable for subterranean drilling, exhibiting enhanced thermal stability, and resulting cutting elements.
[0007] In one embodiment of the invention, a polycrystalline diamond compact comprising a diamond table is formed in a high pressure, high temperature process using a catalyst, and the catalyst is then substantially removed from the entirety of the diamond table. The diamond table is then attached to a supporting substrate in a subsequent high pressure, high temperature process using a binder material differing at least in part from a material of the catalyst. The subsequent high temperature, high pressure process may be conducted at a pressure comparable to that used to form the diamond table, or may conducted at a higher pressure or a lower pressure. Different temperatures may also be employed, respectively, to form the diamond table and during attachment of the diamond table to a supporting substrate.
[0008] In one specific embodiment, the binder material is permitted to penetrate substantially completely throughout the diamond table from an interface with the substrate to a cutting surface and side of the diamond table, and the binder material is selectively removed from a desired region or regions of the diamond table by a conventional technique.
[0009] Cutting elements formed and exhibiting structures according to embodiments of the methods of the present invention are also disclosed, and encompassed within the scope of the invention.
[0010] Drill bits employing cutting elements formed and exhibiting structures according to embodiments of the present invention are also disclosed and encompassed within the scope of the invention.
[0011] Other features and advantages of the present invention will become apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a flow chart of an embodiment of a method to form a polycrystalline diamond compact cutting element according to the present invention;
[0013] FIGS. 2A-2D depict the formation of a polycrystalline diamond compact cutting element according to the embodiment of FIG. 1
[0014] FIG. 3 depicts one example of a rotary drag bit having cutting elements according to an embodiment of the present invention mounted thereto.
DETAILED DESCRIPTION
[0015] Process flow of an embodiment of a method of the present invention is illustrated in FIG. 1 , and the associated structures formed during the process are illustrated in FIGS. 2A-2D . Referring to the foregoing drawing figures, in act 100 , a polycrystalline diamond compact 200 ( FIG. 2A ) in the form of diamond table 202 is formed from a mass of diamond particles (e.g., grit) in the presence of a catalyst 204 in a high pressure, high temperature process. As used herein, the terms diamond “particles” or diamond “grit” each include not only individual particles of diamond, but aggregates of individual diamond particles having diamond-to-diamond bonds therebetween. The diamond table 202 may be formed on a supporting substrate 206 (as shown) of cemented tungsten carbide or other suitable material as known in the art in a conventional process of the type described, by way of non-limiting example, in U.S. Pat. No. 3,745,623 or may be formed as a freestanding polycrystalline diamond compact (e.g., without supporting substrate) in a similar conventional process as described, by way of non-limiting example, in U.S. Pat. No. 5,127,923. The diamond grit may comprise natural diamond, synthetic diamond, or a mixture, and may comprise diamond grit of different sizes, or diamond grit in layers or other specific regions of different grain sizes or different average grain sizes, and the diamond table or one or more regions thereof may comprise a gradient of different grain sizes. The catalyst may be supplied in a supporting substrate 206 , if employed, or may be admixed with the diamond grit. The supporting substrate 206 , which is to be removed as described below, may be thin, on the order of a few millimeters, to permit simultaneous fabrication of relatively more diamond tables 202 in a given diamond press cell volume. In act 102 , the supporting substrate 206 (if present) is removed from diamond table 202 by leaching the material of the supporting substrate 206 from the diamond table 202 while simultaneously substantially removing the catalyst 204 from the diamond table 202 . Specifically, as known in the art and described more fully in the aforementioned U.S. Pat. No. 5,127,923 and in U.S. Pat. No. 4,224,380, aqua regia (a mixture of concentrated nitric acid (HNO 3 ) and concentrated hydrochloric acid (HCl)) may be used to dissolve at least a portion of the supporting substrate (if present), to substantially remove the catalyst 204 from interstitial voids between the diamond crystals of the diamond table and from the crystal surfaces, and to dissolve catalytic binder material at an interface between the substrate 206 and the diamond table 202 resulting in separation therebetween. It is also known to use boiling hydrochloric acid (HCl) and boiling hydrofluoric acid (HF), as well as mixtures of HF and HNO 3 in various ratios. Other techniques for catalyst removal are also known in the art.
[0016] In additional embodiments, the substrate 206 may be removed from the diamond table 202 prior to removing catalyst 204 from interstitial voids between the diamond crystals of the diamond table 202 , or the substrate 206 may be removed from the diamond table 202 after removing catalyst 204 from interstitial voids between the diamond crystals of the diamond table 202 . Furthermore, methods other than acid leaching may be used to remove the substrate 206 from the diamond table 204 . Such methods may include, for example, one or more of grinding, cutting, and laser ablation.
[0017] The resulting structure ( FIG. 2B ) is diamond table 202 ′ with substantially no catalyst 204 present. As used herein, a diamond table or polycrystalline diamond compact having “substantially no catalyst” therein, or being “substantially free of catalyst” does not require complete removal of catalyst, as there may be some residual catalyst on the surfaces of diamond grit particles, as well as in some substantially closed voids between particles wherein the leaching agent has not penetrated fully. In act 104 , another supporting substrate 208 is placed adjacent diamond table 202 ′ and secured thereto in another conventional high temperature, high pressure process in the presence of a binder material differing at least in part from a material of the catalyst 204 . Supporting substrate 208 may comprise a cemented tungsten carbide or other suitable material as known to those of ordinary skill in the art. As depicted in FIG. 2C , binder material 210 may be present at the commencement of act 104 in (for example) powder form or in the form of a thin disc 210 a in a layer disposed between diamond table 202 ′ and supporting substrate 208 , as an integral portion 210 b of the material of supporting substrate 208 , or both. At the conclusion of act 104 , polycrystalline diamond compact 200 ′ having diamond table 202 ″ including binder material 210 therein results due to migration of the binder material 210 from the source or sources thereof into interstitial voids between the diamond crystals in the polycrystalline diamond compact 200 ′ that were vacated upon removal of the catalyst 204 therefrom in act 102 .
[0018] As noted above, the another conventional high temperature, high pressure process conducted in the presence of a binder material 210 may be at a temperature and pressure comparable to that used to form the diamond table 202 or may be at a lower pressure and temperature. For example, the diamond table 202 may be formed at a pressure of at least about 5 GPa and a temperature of about 1500° C., while the another high temperature, high pressure process may be conducted at a substantially different, higher pressure, such as in the range of about 6 to about 7 GPa, or even as much as about 8 GPa or more, and at a temperature in the range of about 1650° C. to about 2200° C. Conversely, the pressure used to form the diamond table may be in the range of about 6 to about 7 GPa, or even about 8 GPa or more, and the temperature may be in the range of about 1650° C. to about 2200° C., and the another high temperature, high pressure process conducted in the presence of a binder material may be conducted at a substantially different, lower pressure, for example at least about 5 GPa, and at a temperature of about 1500° C. to stay within the diamond stable region and prevent back-graphitization of the diamond table 202 ′ during act 104 . Such back-graphitization tendencies of the diamond table 202 ′ may be of particular concern in light of catalytic properties of the binder employed. In each of the foregoing examples, only pressure may be varied while temperatures employed to respectively form diamond table 202 and attach diamond table 202 ′ to supporting substrate 208 may be substantially the same. Conversely, temperatures may also be varied in the two respective acts 100 and 104 . Furthermore, the times at temperature and pressure for each of the processes may vary in a range extending from about twenty seconds to about twenty minutes or more.
[0019] In the first example set forth in the above paragraph, the diamond table 202 may be formed at a relatively lower temperature and pressure to produce a diamond-to-diamond bonded structure of lesser density and greater porosity to facilitate removal of catalyst 204 using an acid leaching or other conventional, invasive process. Subsequently, attachment of diamond table 202 ′ to supporting substrate 208 may be conducted at a significantly higher (e.g., by about an additional ten percent or more) pressure and temperature to enhance the density and strength of the resulting diamond table 202 ″. In the second example set forth in the above paragraph, the relatively higher pressure and temperature used to form diamond table 202 will provide a diamond structure of high density and strength, while the relatively lower pressure and temperature used to attach diamond table 202 ′ to supporting substrate 208 will not compromise the density and strength of the resulting diamond table 202 ″ while reducing cycle time for addition of binder material 210 and attachment of substrate 208 .
[0020] In a further act 106 , a region or regions 212 a , 212 b of the diamond table 202 ″ (being, respectively and by way of non-limiting example, a region adjacent a cutting face and a region adjacent a side surface 214 of diamond table 202 ″) have the binder material 210 substantially and selectively removed therefrom while precluding contact with the supporting substrate 208 and, by way of non-limiting example, a portion of the side surface 214 of diamond table 202 ″ with a leaching agent. Of course, the binder material may be removed from diamond table 202 ″ to any substantial extent, or depth, desired. Suitable depths may range from, by way of non-limiting example, about 0.04 mm to about 0.5 mm. Any of the abovementioned leaching agents may be employed, and one particularly suitable leaching agent is hydrochloric acid (HCl) at a temperature of above 110° C. for a period of about 3 to about 60 hours, depending upon the depth of desired removal of the binder material 210 from a surface of diamond table 202 ″ exposed to the leaching agent, as depicted in FIG. 2D . Contact with the leaching agent may be precluded, as known in the art, by encasing substrate 208 and a portion of the diamond table 202 ″ in a plastic resin, by coating substrate 208 and a portion of the diamond table 202 ″ with a masking material, or by the use of an “O” ring seal resistant to the leaching agent, compressed against the side surface 214 of diamond table 202 ″ using a plastic fixture. The resulting polycrystalline diamond compact 200 ″ offers enhanced thermal stability and consequently improved wear resistance, during use due to the removal of binder material 210 from at least the region or regions 212 a , 212 b of diamond table 202 ″. The presence of binder material in another region or regions of the diamond table 202 ″ may enhance durability and impact strength thereof. The inventor herein has noted, surprisingly and contrary to conventional thought in the industry, that the strength of the resulting diamond table having a binder introduced therein after the initial removal of catalyst therefrom, is substantially the same as that of a diamond table having catalyst therein used to form the diamond table, for diamond tables of equal diamond density.
[0021] By way of non-limiting example, materials suitable for use as catalysts and binder materials in implementation of embodiments of the invention include Group VIII elements and alloys thereof, such as Co, Ni, Fe and alloys thereof. Thus, in one implementation, Co may be used as a catalyst in formation of a polycrystalline diamond compact which is then leached of the catalyst and the supporting substrate removed. Ni may then be used as a binder material to attach the resulting leached diamond table to another supporting substrate. In another implementation, a Fe alloy is used as a catalyst in formation of a polycrystalline diamond compact, which is then leached of the catalyst and the supporting substrate removed. Co may then be used as a binder material to attach the resulting leached diamond table to another supporting substrate. In another implementation, Co may be used as a catalyst in formation of a polycrystalline diamond compact, which is then leached of the catalyst and the supporting substrate removed. A Co/Ni alloy may then be used as a binder material to attach the resulting leached diamond table to another supporting substrate. In a variation of the foregoing implementation, Co may be used as a catalyst in formation of a polycrystalline diamond compact, which is then leached of the catalyst and the supporting substrate removed. An Fe/Ni alloy may then be used as a binder material to attach the resulting leached diamond table to another supporting substrate. As noted above, the binder material may be incorporated into a cemented tungsten carbide or other suitable substrate, may be applied to an interface between the leached diamond table and the another supporting substrate, or both. In a further variation, binder material 210 may be placed adjacent a surface or surfaces (for example, a surface of diamond table 202 ′ opposite substrate 210 ) to facilitate introduction of binder material 210 into diamond table 202 ′ in act 104 .
[0022] Referring to FIG. 3 of the drawings, drill bit 10 in the form of a rotary drag bit is shown. The drill bit 10 includes bit body 11 . The bit 10 includes conventional male threads 12 on a shank thereof configured to API standards and adapted for connection to a component of a drill string, not shown. The face 14 of the bit body 11 has mounted thereon a plurality of cutting elements 16 , at least some of which exhibit structure according to an embodiment of a cutting element of the present invention, each cutting element 16 comprising polycrystalline diamond compact (PDC) table 18 formed on a supporting carbide substrate. The cutting elements 16 are positioned to cut a subterranean formation being drilled while the drill bit 10 is rotated under weight on bit (WOB) in a bore hole about centerline 20 . The bit body 11 may include gage trimmers 23 , at least some of which may exhibit structure according to an embodiment of a cutting element of the present invention, each gage trimmer 23 including one of the aforementioned PDC tables 18 , such tables 18 being configured with an edge (not shown) to trim and hold the gage diameter of the bore hole, and pads 22 on the gage which contact the walls of the bore hole and stabilize the bit in the hole. As used herein, the term “drill bit” includes and encompasses drag bits, roller cone bits, hybrid bits, reamers, mills and other subterranean tools for drilling and enlarging well bores.
[0023] During drilling, drilling fluid is discharged through nozzle assemblies 30 located in nozzle ports 28 in fluid communication with the face 14 of bit body 11 for cooling the PDC tables 18 of cutting elements 16 and removing formation cuttings from the face 14 of drill bit 10 into passages 15 and junk slots 17 . The apertures 24 of nozzle assemblies 30 may be sized for different fluid flow rates depending upon the desired flushing required at each group of cutting elements 16 to which a particular nozzle assembly 30 directs drilling fluid.
[0024] Although the foregoing description contains many specifics and examples, these are not limiting the scope of the present invention, but merely as providing illustrations of some embodiments. Similarly, other embodiments of the invention may be devised which do not depart from the scope of the present invention. The scope of this invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions and modifications to the invention as disclosed herein and which fall within the meaning of the claims are embraced within their scope. | A polycrystalline diamond compact comprising a diamond table is formed in a high pressure, high temperature process using a catalyst, the catalyst being substantially removed from the entirety of the diamond table, and the diamond table attached to a supporting substrate in a subsequent high pressure, high temperature process using a binder material differing at least in part from a material of the catalyst. The binder material is permitted to penetrate substantially completely throughout the diamond table from an interface with the substrate to and including a cutting surface, and the binder material is selectively removed from a region or regions of the diamond table by a conventional technique (e.g., acid leaching). Cutting elements so formed and drill bits equipped with such cutting elements are also disclosed. |
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RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/704,625, filed Aug. 2, 2005, the entire teachings of which are incorporated herein by reference.
BACKGROUND
Lime plasters have a history that spans thousands of years. Historically, lime was used to plaster floors at least as early as 9.000 B.C. Lime plaster was used in Imperial Rome, 13 th -century England, 11 th -century Mayan cities, Japan, Germany, India, Southeast Asia, Central America and Colonial America.
Ancient lime plasters, renders, stuccos, and washes formed of lime have lasted to this day through history giving building lime an exceptional track record. Lime lasts a long period of time, making it an excellent medium for long term repairs and maintenance.
SUMMARY
Described herein are improved compositions for the long term restoration and repair of lime plasters, as well as for other structures and materials, such as ceramics, wood, and stone. Also disclosed are methods for using those compositions in assembly and new construction, as these methods are not limited to restoration and repair procedures. Two surfaces are bonded using a two-step procedure, wherein a conditioner composition is applied and then an adhesive composition is applied to the surface. An advantage of embodiments of these compositions is that they are less toxic and more environmentally safe compared to other construction adhesives.
For example, a method for adhering a plaster composition to a structure, e.g., a support structure such as a wooden lath or masonry (such as brick, terra cotta blocks, cement blocks or stone), is carried out by administering, e.g., by applying, injecting, spraying, painting, a conditioner composition into a gap between the plaster and the support structure, the conditioner composition comprising a polymer having the Chemical Abstracts registry number (CAS No.) 222414-16-6 (such as the commercially available RHOPLEX 1834 acrylic emulsion, which includes 47±0.05% solids, and has a pH of 9.3-10.2, a density of about 8.8 lbs/gal at 25° C. and a glass-transition temperature of 13° C. from Rohm & Haas of Philadelphia, Pa., USA), or similar acrylic emulsion, and administering, e.g., by applying, injecting, spraying, painting, an adhesive composition into the gap, the adhesive composition comprising RHOPLEX 1834, or similar acrylic emulsion among other modifiers.
In some embodiments, the method further comprises creating ports (i.e., bores) in the plaster through which the conditioner composition and the adhesive composition are injected. The plaster is brought toward the support structure (before or after injection of the adhesive composition) such that the adhesive composition can penetrate both into the plaster and into the support structure; and the position of the plaster relative to the support structure is maintained by a fastener, e.g., a screw, passed through the plaster and into the support structure.
The composition of the conditioner includes a polymer-containing emulsion such as RHOPLEX 1834, or similar acrylic emulsion. In various embodiments, the conditioner also includes water and/or isopropanol. For example, the conditioner composition includes: approximately 45 volume-percent RHOPLEX 1834, or similar acrylic emulsion; approximately 45 volume-% water; and, approximately 10 volume-% isopropanol. The adhesive composition optionally includes a polymer having the Chemical Abstracts registry number (CAS No.) 253351-13-2 (such as the commercially available RHOPLEX 1950 acrylic emulsion, which is about 63% solids, has a pH of about 5.0, a viscosity of about 150 cps at 25° C., a density of about 8.7 lb/gal at 25° C., and a glass-transition temperature of about −50° C., and which is also from Rohm & Haas of Philadelphia, Pa., USA), or similar acrylic emulsion. For example, the adhesive composition for use with plaster, metal and glass includes an adhesive foundation containing: approximately 60 volume-percent RHOPLEX 1834, or similar acrylic emulsion; and, approximately 40 volume-percent RHOPLEX 1950, or similar acrylic emulsion.
In another embodiment, a more-rigid adhesive for use in bonding ceramic tile includes RHOPLEX 1834, or similar acrylic emulsion, and RHOPLEX 1950, or similar acrylic emulsion, at a ratio of approximately 2 parts RHOPLEX 1834, or similar acrylic emulsion, and 1 part RHOPLEX 1950, or similar acrylic emulsion; this more-rigid formulation (2:1) is suitable in this context because ceramic tile applied to cement board has very little flexibility. The ratio can be increased to 90-100 volume-percent RHOPLEX 1834, or similar acrylic emulsion; and, 10-0 volume-percent RHOPLEX 1950, or similar acrylic emulsion, to make it less flexible if the situation calls for it. In yet another embodiment, the ratio of RHOPLEX 1834, or similar acrylic emulsion, and RHOPLEX 1950, or similar acrylic emulsion, is approximately 2:3. In a highly flexible embodiment that can be used, e.g., to bond wood structures, the ratio of RHOPLEX 1834, or similar acrylic emulsion to RHOPLEX 1950, or similar acrylic emulsion, is approximately 1:2; the bonding of wood to wood requires this increased flexibility to accommodate the natural flexibility and movement of wood.
The method includes a step of adding a thickener composition to the adhesive foundation to form the adhesive composition, the adhesive composition having a viscosity that is higher than that of the adhesive foundation. For example, the thickener composition and the adhesive foundation are mixed at concentrations in the following ranges: approximately 80 to 85 volume-% base adhesive composition; and, approximately 15 to 20 volume-% thickener composition. The thickener serves an important function in this adhesive system. On its own, the thickener is a high-viscosity material (i.e., a thick gel). Added to the mixture of acrylic emulsions, the thickener allows the mixed adhesive to function with two different viscosities. When at rest (subjected to low shear rates), the adhesive has high viscosity similar to that of shaving cream. When injected under pressure (high shear rates), the adhesive will flow easily, demonstrating low viscosity. This property (referred to as thixotropy) is of great advantage in vertical applications.
In a method of adhering a plaster or other substrate to a support structure, a conditioner is injected and allowed to set for 2, 5, 10, 15, 20, 30 minutes depending upon conditions (e.g., as temperature drops or as humidity rises, the conditioner can be allowed to set for a longer period of time); and then no later than ½ hour after the injection of the conditioner, the adhesive is applied. In one embodiment, the adhesive composition is delivered to the surfaces 10 minutes after the delivery of the conditioner composition. These techniques likewise apply to many other adhesive applications, including but not limited to new assemblies, new and existing construction, restoration, and repair.
Also disclosed is an adhesive foundation. For example, the adhesive foundation in this embodiment includes approximately 60 volume-% RHOPLEX 1834, or similar acrylic emulsion; and, approximately 40 volume-% RHOPLEX 1950, or similar acrylic emulsion. In another example, the adhesive composition contains: an adhesive foundation including approximately 60 volume-% RHOPLEX 1834, or similar acrylic emulsion and approximately 40 volume-% RHOPLEX 1950 or similar acrylic emulsion; and a thickener composition including approximately 16.8 volume-% of a polymer having the Chemical Abstracts registry number (CAS No.) 37325-11-4 (such as that known as ACRYSOL ASE-60 thickener, which includes 28% solids, and has a pH of 3.5, a specific gravity of 1.054 at 25° C., a viscosity of 10 mPa·s, and a glass-transition temperature of 13° C. from Rohm & Haas of Philadelphia, Pa., USA), or similar acrylic emulsion; and, approximately 81.9 volume-% water; and a weak or strong base in sufficient quantities to ensure the transformation of the ASE-60, or similar acrylic emulsion/water mixture into the “thickener gel.” In particular embodiments, the base can be ammonium hydroxide, potassium hydroxide, or morpholine (C 4 H 9 NO, CAS No. 110-91-8) at approximately 1 volume-% or less in the adhesive. In the formulation described above, the adhesive composition includes: approximately 80 to 85 volume-% adhesive foundation; and, approximately 15 to 20 volume-% thickener composition.
A kit for adhesive use contains the following items and/or compositions:
a) a first container containing a conditioner composition, the conditioner composition including:
i) approximately 45 volume-% RHOPLEX 1834, or similar, acrylic emulsion; ii) approximately 45 volume-% water; and iii) approximately 10 volume-% isopropanol.
b) the second container containing an adhesive composition, the adhesive composition including:
i) an adhesive foundation including:
a) approximately 60 volume-% RHOPLEX 1834, or similar, acrylic emulsion; and b) approximately 40 volume-% RHOPLEX 1950, or similar, acrylic emulsion; and
ii) a thickener composition including:
a) approximately 16.8 volume-% ACRYSOL ASE-60, or similar acrylic emulsion, thickener; and b) approximately 81.9 volume-% water; and c) a weak or strong base in sufficient quantities to ensure the transformation of the ASE-60, or similar acrylic emulsion/water mixture, into the “thickener gel” added to the adhesive foundation at a volume of approximately 15%-20% of the adhesive foundation.
A variety of advantages can be obtained via use of the compositions and methods described herein. The adhesive composition after setting is water resistant and provides a deep, strong bond between surfaces, even when used to bond dirty, gritty and/or friable surfaces, i.e., under conditions where many other types of adhesives are ineffective. The set adhesive composition remains flexible under cold conditions and maintains its structure and adhesion of the surfaces on a near-permanent basis in warm conditions. The use of the conditioner (primer) enhances the ability of the adhesive to bond in unfavorable circumstances, such as uneven or dirty surfaces, described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the stabilization of historic plaster.
FIG. 2 shows a masonry bit for drilling into the plaster.
FIG. 3 shows a dispersal device for delivering the conditioner composition.
FIG. 4 shows a screw and a washer used to bring the plaster into contact with the lath.
FIG. 5 shows the drilling of injection ports through the plaster.
FIG. 6 shows the delivery of conditioner composition through the ports.
FIG. 7 shows the injection of adhesive composition into the ports.
FIG. 8 shows the temporary clamping of the plaster into soft contact with the laths.
FIG. 9 shows the cleaning of exposed surfaces after the adhesion.
FIG. 10 shows the infrared spectrum for RHOPLEX 1834.
FIG. 11 shows the infrared spectrum for RHOPLEX 1950.
FIG. 12 shows the infrared spectrum for ACRYSOL ASE-60.
FIG. 13 shows the overlay of infrared spectra for RHOPLEX 1834, RHOPLEX 1950, and ACRYSOL ASE-60.
DETAILED DESCRIPTION
Specifically described in the foregoing text are methods for repairing, restoring, and preserving the integrity of historical and ornamental plasters, such as lime plasters, gypsum plaster, and Portland cement plaster, as well as additional structures and materials. These methods can likewise be used for new assembly, wherein original structures are constructed from newly manufactured materials. Additional materials that can be bonded via these methods include ceramic tile, vinyl tile, linoleum tile, wood, stone, leather, paper, metal, glass, terra cotta, brick, natural or synthetic fibers, fabric, foam, (such as foam made of polyurethane, polystyrene, or similar material), etc., and for other general repair or new assembly. The following description is particularly focused on the example of repairing lime plasters, though the same techniques are to be used with the repair and assembly of other materials.
Lime plasters have properties that make them excellent candidates for repair. Because lime crystallizes over an extended time frame, lime plasters are considered young at 100 years, and plaster may have had many decades to cure before repair is carried out. Additionally, lime plaster is flexible (relative to gypsum plaster or Portland cement plaster) and resistant to water damage. On exteriors, the outer-most layer is considered a sacrificial layer and is maintained with regular lime washes or treatment with limewater. With maintenance, historic plaster can last forever.
In either an interior or exterior repair context, an important factor is the compatibility of materials and building systems. This compatibility between the original material and the repair material is particularly important in an extreme environment. When the interior of the building has a wide range of environmental changes, e.g., humidity or temperature fluctuations, the compatibility issue becomes critical.
When in-kind replacements are the appropriate method of plaster repair, the repair material should have the same hardness, or be softer than the historic fabric, so that any loss of material comes from the repair and not from the original fabric.
Limestone is burned in a kiln to form quicklime (CaO) and then hydrated to form lime putty (building lime) [Ca(OH) 2 ]. The building lime is then allowed to cure by exposure to CO 2 (e.g., atmospheric) to form calcium carbonate (CaCO 3 ). Building limes are used to fabricate lime plasters, mortars, and washes.
The conservation of historic plasters is accomplished through the application of consolidates to friable areas and/or adhesive reattachment by injecting the conditioner and adhesive compositions between the plaster and its lath.
This lime plaster restoration procedure is determined, e.g., by the amount of separation of plaster from laths in the interior or exterior of a dwelling or other structure. If the plaster forms the ceiling of a room, and if the plaster separates from laths over time, then the plaster is likely to crack and sag, thereby causing the ceiling to droop downward. This phenomenon can occur with wall surfaces as well.
The stabilization of historic plaster 12 , as shown in FIG. 1 , includes the following four stages: (1) drilling injection ports 14 through the plaster 12 or through the wood laths 16 and inspecting the gap between the plaster 12 and the laths 16 ; (2) injecting a conditioner composition from a sprayer 24 (as shown in FIG. 6 ) into the gap 20 between the plaster 12 and the laths 16 , priming both surfaces; (3) injecting an adhesive composition 18 into the gap 20 ; and, (4) bringing the plaster 12 back toward the laths 16 , e.g., by clamping the plaster 12 to the laths 16 (using the screws 32 and washers 34 of FIG. 4 ) and tightening to insure “soft” contact between the adhesive composition 18 , the plaster 12 , and the lath 16 . In one embodiment, the steps are performed in the order listed above; alternatively, plaster 12 can be clamped before the injection of the conditioner composition and before the adhesive composition is applied into the gap 20 .
In stage (1), identified above (and illustrated in FIG. 5 ), injection ports (holes) 14 are drilled through the plaster 12 with a 3/16-inch masonry bit 22 (illustrated in FIGS. 2 and 5 ); the ports 14 can have, e.g., a diameter of 3/16 inches (4.8 mm). A measuring device or other object (e.g., an awl, or a screwdriver) can then be inserted through a port 14 , and one can measure the distance it travels before striking the lath and thereby gauge the size of the gap between the plaster and the lath. When selecting drilling sites for a vertical wall crack or a ceiling crack, one can commence by drilling 1.5 to 2 inches (approximately 3.8 to approximately 5.1 cm) away from the crack, every other lath or spaced approximately 2.75 to 3 inches (approximately 7.0 to approximately 7.6 cm) apart vertically (or laterally on a ceiling) along the entire length of the crack 23 . More or fewer injection sites can be used, depending on the severity of displacement. At greater distances of displacement between the two surfaces, a greater number of injection ports are used; i.e., the degree of displacement is directly correlated with the number of injection ports.
In stage (2), shown in FIG. 6 , a conditioner composition 26 is delivered, e.g., by injection, through the ports using a dispersal device 24 , e.g., a high-quality garden sprayer, to consolidate the fine dust and dirt found on the surfaces to be adhered. The conditioner composition 26 comprises the following ingredients:
(a) approximately 45 volume-% RHOPLEX 1834, or similar acrylic emulsion; and (b) approximately 45 volume-% water; and (c) approximately 10 volume-% isopropanol (99%).
“Similar” acrylic emulsions for use in the conditioner (and adhesive) composition will promote conditioning (and adhesive) properties similar to (or substantially the same as) those promoted by the RHOPLEX 1834 acrylic emulsion. Compositions that are substantially the same can also share the same chemical constituents as RHOPLEX 1834 acrylic emulsion, have the same polymer type, include approximately the same solids content, have approximately the same viscosity, and/or have approximately the same glass transition temperature. On the other hand, one example of a difference in a polymer that is nevertheless “substantially the same” can be, e.g., in polymer chain length. For example, the acrylic emulsion can be various copolymers formed from a mixture of monomers comprising at least two monomers selected from (C 1 to C 8 ) alkyl (meth)acrylates, (meth)acrylic acid, and styrene, as described in U.S. Pat. No. 6,423,805, which is incorporated herein by reference in its entirety. References herein to other emulsions and polymers that are “substantially the same as” recited commercial products and polymers having particular CAS numbers likewise share common properties, such as those noted above (including +/− 20% variance of the physical properties, such as adhesive strength, of the referenced compositions, such as RHOPLEX 1834 or 1950 acrylic emulsions).
The conditioner composition 26 prepares the surfaces of the plaster 12 and the laths 16 (e.g., by consolidating dirt and grit and by reducing friability of the matrices at the surfaces) to allow the adhesive composition (in stage 3) to better grip both surfaces and to draw acrylic chains into the matrices of the plaster and lath surfaces, thereby promoting a deep bond.
In stage (3), illustrated in FIG. 7 , an adhesive composition 18 , which includes an adhesive foundation thickened with a thickener composition, is injected into the ports 14 ten minutes after the injection of the conditioner composition in stage (2). An embodiment of the adhesive foundation comprises the following ingredients:
(a) approximately 60 volume-% RHOPLEX 1834 or similar acrylic emulsion; and (b) approximately 40 volume-% RHOPLEX 1950 or similar acrylic emulsion.
In the adhesive composition, the RHOPLEX 1834, or similar, acrylic emulsion is comparatively more rigid than the RHOPLEX 1950, or similar, acrylic emulsion. Accordingly, increasing concentrations of the less-rigid RHOPLEX 1950, or similar, emulsion increases the flexibility of the adhesive composition, thereby improving the flexible bonding capability of the adhesive composition. The adhesive composition initially is milky white, though it dries to a translucent, e.g., “water white” appearance. RHOPLEX 1950 emulsion (binder) is described in U.S. Pat. No. 6,613,832, which is incorporated herein by reference in its entirety.
Before use, the adhesive foundation is mixed with a thickener composition at an approximate ratio, e.g., of 80 to 85% adhesive foundation to 15 to 20 volume-% thickener composition. An embodiment of the thickener composition comprises the following ingredients:
(a) approximately 16.8 volume-% ACRYSOL ASE-60, or similar acrylic emulsion, thickener (an acid-containing acrylic emulsion copolymer); (b) approximately 81.9 volume-% water; and (c) a weak or strong base in sufficient quantities to ensure the transformation of the ASE-60, or similar acrylic emulsion/water mixture into the “thickener gel.”
The ACRYSOL ASE-60, or similar acrylic emulsion, thickener is alkali-activated so when the base is added, the thickener composition takes the form of a gel that can serve as a thickener when combined with the adhesive foundation.
After the adhesive foundation and the thickener are mixed to form the adhesive composition 18 to the approximate viscosity of shaving cream, the adhesive composition 18 can be injected through the ports 14 in the plaster 12 using a caulk gun 30 or other delivery device, employing approximately one handle squeeze of the gun 30 per port 14 (or approximately 0.5 ounce adhesive per injection site). The adhesive composition 18 flows from the caulk gun 30 under pressure into the gap 20 between the plaster 12 and the lath 16 and then stays in place. Both the conditioner composition and adhesive composition penetrate up to 1, 2, 5, 10, 20 or 50 mm into the surfaces to be bonded. The conditioner composition can be applied at a pressure, e.g., of 10, 25, or 50 pounds per square inch, while the adhesive composition can be applied at a pressure, e.g., of 25, 50 or 100 pounds per square inch.
Use of the conditioner composition and use of the water-borne acrylics in the adhesive composition allow for the formation of a soft bond shoulder (i.e., without a sharply defined border for acrylic penetration into the surfaces). For comparison, when traditional epoxies are used as consolidants, the epoxies cure in a manner that allows them to soak into the porous surfaces developing a “hard” or well-defined shoulder. This shoulder often becomes an area of future failure. In contrast, water borne acrylics, such as those described herein, cure (coalesce) via water evaporation leaving a less-defined, flexible edge, which is less prone to being a source of future fracture. Other chemistries, such as epoxies compounded to be soft, urethanes, and silicones, yield excellent results as well. Acrylics are our method of choice; the acrylics are pulled along, penetrating deeper into the plaster and wood/masonry lath matrices, with the water. Because the speeds of penetration and evaporation are slow, a diffuse border is formed between the areas of no acrylic and the areas completely filled with acrylic (i.e., there is a gradual change in acrylic concentration as one enters deeper into the structures to be bonded). Unlike “film” adhesives, the acrylic conditioner/adhesive compositions described herein penetrates to a substantial depth into the plaster and wood/masonry lath matrices (e.g., up to 1/16 inch, ⅛ inch or even ¼ inch), depending on the porosity of the matrices and on the amount of material applied.
The porosity of the materials being “glued together” has a direct effect on the degree to which the conditioner and adhesive penetrates the two surfaces. This adhesive coalesces by releasing water into the porous structure of the material and thereby evaporates. The greater the three-dimensional texture and porosity of a material, the greater the surface area for adhesion, and the more pores the adhesive can penetrate. Wood, pottery, and ceramic tiles are excellent examples of porous surfaces where the adhesive is able to form a deep, penetrating purchase. In particular embodiments, at least one of the materials to be bonded is porous. For example, as smooth as glass tiles are, they can be bonded to a porous material.
In stage (4), shown in FIG. 8 , the plaster 12 is temporarily clamped into soft contact with the laths via screws inserted through 2 -inch plastic washers 34 and then through the ports 14 in the plaster 12 and then to the laths, into which they are screwed, e.g., with a hand or power screwdriver 36 . The screws 32 are tightened until the plaster is drawn to a distance from the laths within the tolerance of the thickened acrylic-emulsion adhesive composition 18 (as much as 3/16 inch, preferably 1/32 to 1/16 inch) to adhere to and penetrate into both surfaces. As previously noted, stage (4) can be performed either before or after injection of the conditioner composition and injection of the adhesive composition into the gap between the plaster and the laths.
Finally, exposed surfaces can be cleaned with warm water and a soft sponge, 38 (as shown in FIG. 9 ). The adhesive is allowed to cure for a minimum of 24 hours. The washers or braces are then removed. Dried adhesive can be removed with a putty knife or metal window scraper. Drill holes and cracks can be filled with a material, such as plaster or joint compound.
The repair adhesive for plaster must be able to bond in difficult circumstances because the conditions encountered in re-establishing the bond between historic plaster and lath are adverse. These properties make the adhesive well suited for any type of adhesive task. In easy-to-bond circumstances it will function particularly well and outperform others. Whether easy or difficult conditions exist for bonding, the adhesive composition bonds by penetrating the matrices and consolidating the surfaces, thus allowing the adhesive to achieve complete attachment.
In addition to the use of these compositions and methods for adhering plaster to wood lath, brick or terra cotta block the compositions and methods can similarly be used to repair like materials, as well as to adhere different materials to each other (both structural and non-structural), such as plaster to plaster, wood to wood, glass to glass, metal to metal, plaster to wood, synthetic tile to plywood, ceramic tile to drywall, glass tile to cement board, metal to plaster, and wood to metal, foam to foam, foam to wood, foam to metal, foam to glass, fabric to fabric, fabric to most any other porous material, as well as many other unlike material uses.
In another application, where the adhesive is used to bond ceramic tile to a substrate, such as cement, the surfaces of the tile and substrate to be bonded are first cleaned. The conditioner composition is then applied (e.g., sprayed) onto both surfaces. After a ten-minute set time, (whereby the conditioner penetrates or soaks into the substrate), an even layer of the adhesive composition is spread using a ⅛-inch notched spreader on one surface. The tile is then set in place on the substrate and secured in place. The exposed surface of the tile and the surrounding area can then be cleaned with warm water and a soft sponge. The adhesive is then allowed to cure for at least 24 hours. If the tile is installed on a floor, a 72-hour cure should be provided to afford full strength of the bond. Because the adhesive is water-based, a longer setting period may be needed for particularly large or less porous tiles. After the adhesive has set, grout can be filled around the edges of the tile, as desired.
In another embodiment, where a wood bond is repaired, the surfaces to be bonded are again cleaned first. The conditioner is sprayed or brushed onto both surfaces. After a ten-minute set time, a thin layer (e.g., approximately 1/16-inch thick) of adhesive is applied to one surface. The two surfaces are then clamped or braced into soft contact (e.g., with mechanical fasteners or adjustable straps). The exposed surfaces can then be cleaned with warm water and a soft sponge, and the bond is allowed to cure for 24 hours.
In describing embodiments of the invention, specific terminology is used for the sake of clarity. For purposes of description, each specific term is intended to at least include all technical and functional equivalents that operate in a similar manner to accomplish a similar purpose. Additionally, in some instances where a particular embodiment of the invention includes a plurality of system elements or method steps, those elements or steps may be replaced with a single element or step; likewise, a single element or step may be replaced with a plurality of elements or steps that serve the same purpose. Moreover, while this invention has been shown and described with references to particular embodiments thereof, those skilled in the art will understand that various other changes in form and details may be made therein without departing from the scope of the invention. | Improved compositions for the restoration, repair and assembly of materials include (a) a conditioner composition including a polymer that matches or is substantially the same as that to which Chemical Abstracts registry number (CAS No.) 222414-16-6 is assigned (commercially available as RHOPLEX 1834 acrylic emulsion) and (b) an adhesive composition that also includes a polymer that matches or is substantially the same as that to which CAS No. 222414-16-6 is assigned. Adhesive composition can also include a polymer that matches or is substantially the same as that to which CAS No. 253351-13-2 (commercially available as RHOPLEX 1950 acrylic emulsion) is assigned. First, the conditioner composition is injected into a gap between the two structures to be adhered. Next, the adhesive composition is injected into the gap. In one embodiment, the compositions are used to restore and repair historic plaster ceilings and walls. |
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BACKGROUND OF THE INVENTION
In U.S. Pat. No. 4,286,613 granted on Sep. 1, 1981 to Marvin Lacoste, mention is made of allowing taps or faucets to drip thus preventing plumbing from freezing by allowing slow flow of water therethrough. If such taps are not opened in time or enough, damage to the water system, particularly through burst pipes, occurs. As a result of such ineffective efforts, a variety of automatic opening devices exist in the prior art.
One group of automatic opening devices effect automatic drip or slow water flow in associated water systems, such as U.S. Pat. No. 4,066,090 to Nakajima et al. and U.S. Pat. No. 3,369,556 issued to Allderdice on Feb. 20, 1968.
Other automatic opening devices automatically drain all water from the plumbing of associated water systems, such as U.S. Pat. No. 3,320,965 to Morgan, U.S. Pat. No. 1,820,473 to Milone and U.S. Pat. No. 1,558,276 to Peterson.
In many such water system freeze protecting devices, bellows are utilized, and, depending upon the specific type of device or its geographic location, the bellows might be filled with water which will freeze to ice or might be filled with a fluid, such as Freon or a Freon-gas mixture which contracts as the temperature drops and expands as the temperature rises. In either case, the bellows is associated with a valve for draining the particular water system. Unfortunately, each year though the cold months numerous water pipes freeze, burst, and thereby cause considerable damage, particularly in single family homes and residences. As an example of such damage, in 1996 nearly 20,000 State Farm policy holders in the United States and Canada suffered water damage to their homes (or apartments) because water pipes froze and burst. State Farm paid almost $57,000,000.00 to cover such frozen pipe damage losses, an average of approximately $2,871.00 per claim.
Many people follow conventional tips/wisdom for preventing frozen pipes, and thus do not think frozen pipes can happen to them. Typically, a homeowner will disconnect all garden hoses and other outside hose connections; insulate all exposed pipes and crawl spaces and attics since they are susceptible to freezing, set thermostats no lower than 55° F. (12° C.) even when the home is not occupied during the winter; let water drip (particularly overnight on extremely cold nights from both hot and cold faucets located along outside walls); and open cabinet doors so heat from a room can get to non-insulated pipes under sinks or the like. Unfortunately, a sudden cold snap combined with heavy wet snows and/or freezing rain can result in downed power lines which cut off power closing down household heating systems, including the thermostats thereof, for hours or days with the result that freezing occurs in the water systems irrespective of following prudent freeze prevention measures.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a novel automatic valve system which is connected to the main water supply line at its point of introduction into a house, an apartment or the like. The valve mechanism includes a housing having a water inlet connected to the water supply from the street, a water outlet and a main valve which is preferably locked in a first position at which a diametric port maintains the water inlet and the water outlet in fluid communication with each other. In this position water is delivered from the water outlet to sinks, toilets, water heaters, etc. A shaft connected to the main valve is normally spring-biased in a direction which would move the main valve to a second position closing off water flow between the water inlet and the water outlet. However, the main valve shaft is immobilized with the valve in the first position by a temperature sensing mechanism which includes a bellows containing Freon or similar gas or fluid which contracts as the temperature drops. The bellows carries a locking pin which seats in a notch of the main valve shaft and, thus, is retracted therefrom as the Freon in the bellows contracts under temperatures at or below freezing. Upon the retraction of the locking pin, the biasing spring urges the main valve to a closed position cutting off fluid flow between the water inlet and the water outlet.
Contemporaneous with the closing of water flow through the main valve, another portion of the main valve places the water outlet in fluid communication with a drain opening or drain port which is connected by a tube or conduit to a floor drain, for example. Since all plumbing in the house is connected to the main water outlet of the automatic valve mechanism, water from all of the internal plumbing drains in a reverse direction into the water outlet through a drain by-pass port of the valve and a drain outlet of the valve housing into the drain pipe and subsequently discharges into the floor drain. Accordingly, should temperature in the house drop to or substantially below freezing, all of the water in the house plumbing is drained and no damage can occur therein. Furthermore, the water inlet and the main water supply are preferably heavy insulated and rupture or pipe bursting in this area is virtually impossible. However, should even this occur, the automatic valve mechanism is located immediately in the area into which the main water supply from the street enters the home, and this is usually a basement or a crawl space or the like. Therefore, should the water inlet side burst, any water from the street would not effect the living quarters of the house but would instead drain into a crawl space or a basement, and more likely than not the latter includes a floor drain which is normally code-required. Thus, the automatic valve mechanism assures that the main water supply is not only terminated under substantially freezing water conditions, but the house plumbing is also completely drained of water thereby preventing plumbing/pipe/appliance damage.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded fragmentary perspective view, and illustrates a main water supply line entering a basement and connected thereto is an automatic valve mechanism of the present invention for precluding pipes from bursting at substantially freezing ambient temperature or below.
FIG. 2 is a perspective view of the automatic water drain mechanism, and illustrates an axially aligned water inlet and a water outlet, a drain associated with the water outlet, and openings for permitting ambient air to enter the housing.
FIG. 3 is a fragmentary top plan view of the automatic water drain mechanism of FIG. 2, and illustrates a temperature sensing mechanism connected by a conduit to a bellows housing Freon and a biasing spring normally biasing a valve rod or shaft to the left.
FIG. 4 is a side elevational view of the automatic water drain mechanism of FIG. 2 with parts broken away for clarity, and illustrates a detent or pin engaging a notch of the valve rod to prevent movement of the latter to the left, and a manually operable pin for overriding the biasing spring.
FIG. 5 is a fragmentary side elevational view of the automatic water drain mechanism, and illustrates a valve housing in cross section and a valve thereof in a first position in which water flows from the water inlet through a diametric port in the valve and out the water outlet.
FIG. 6 is a fragmentary side elevational view with parts also shown in cross-section similar to FIG. 5, and illustrates the valve in a second position closing off water flow between the water inlet and the water outlet and placing a drain opening and drain port in fluid communication with the water outlet to drain water from house pipes/plumbing/appliances into a drain line or dump line and an associated floor drain.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel automatic water cut-off and drain mechanism operative at low/freezing ambient temperatures to cut-off water flow and drain a water system is generally designated by the reference numeral 10 (FIG. 1 ).
The automatic drain mechanism 10 is best illustrated in FIG. 1 in association with a typical installation as might be found in a basement B of a residence, such as a single dwelling house, an apartment, a condominium or the like. The basement B includes a conventional wall W which might be constructed from concrete, cinder block, or a combination thereof, and a floor F, usually constructed from concrete, having a conventional floor drain D. Located in the basement B might be, for example, a conventional hot water heater H, a relatively deep wash sink S, and perhaps a clothes washer (not shown). The hot water heater H, the sink S, the clothes washer (not shown), a pedestal sink P located on the floor above the basement B and other associated water-usage appliances, such as kitchen and bathroom sinks, toilets, etc. are all interconnected by a conventional plumbing/watering system PS defined by numerous individual metal (copper) or plastic pipes or conduits C running throughout a conventional residence, including in or along walls, floors and ceilings thereof. Obviously, if any one or more of such pipes C of the plumbing system PS freezes and/or bursts under temperatures substantially at or below 32° F. (0° C.), extensive water damage more often than not would be expected.
The water for the plumbing system PS normally enters a residence somewhere in its basement or a crawl space associated therewith by means of a main water supply pipe or line M from a conventional street supply or a well. The main water supply line M is shown entering the basement B through the floor F, but it can as well enter through the wall W, normally sufficiently below the frost line to prevent freezing. Though not shown, the portion of the main water supply pipe M projecting into the basement B is heavily insulated after the installation of the automatic drain mechanism 10 to preclude water therein from freezing, as is essentially the entirely of the exterior of the automatic valve mechanism 10 , except for an apertured end thereof, as will be described more fully hereinafter.
A main gate valve G is located in a main line ML which provides water service to the entire plumbing system PS in a conventional manner. The main gate valve G is shown in its “ON” position, and when a handle (unnumbered) thereof is rotated, the main gate valve can be completely closed to prevent water from flowing into the plumbing system PS via the main line ML.
The automatic drain mechanism 10 includes a two-piece exterior housing defined by a first exterior housing body 11 and a second exterior housing body 21 .
The first exterior housing body 11 includes a rear wall 12 of a generally rectangular configuration, opposite end walls 13 , 14 , the latter of which is provided with a plurality of circular openings or apertures 15 , a partition wall 16 , an upper wall 17 having adjacent circular openings 18 , 19 , and a lower wall 20 .
The second housing wall 21 includes a relatively long rectangular front wall 22 , a top wall 23 having a generally U-shaped cut-out or slot 24 (FIG. 2) formed therein, a bottom wall (unnumbered) and opposite pairs of end flanges 25 , 26 which slidably mate with the opposite end walls 13 , 14 of the first exterior housing body 11 . In this manner the exterior housing bodies 11 , 21 define a relatively closed chamber which is, however, exposed to ambient temperature within the basement B through the plurality of holes or openings 15 in the end wall 14 .
The automatic drain mechanism 10 further includes a valve housing 30 defined by a main substantially cylindrical valve housing body 31 defining a substantially cylindrical internal surface 32 closed at axially opposite ends by conventional threaded cylindrical and conical end caps 33 , 34 , respectively. A water inlet port 35 carries a nut 36 and is in axial aligned relationship to a water outlet port 37 carrying a conventional threaded nut 38 . The nuts 36 , 38 unite the valve housing 30 to the respective main water supply line M and to the main line ML in the manner clearly illustrated in FIG. 1 of the drawings.
A drainage port or drainage outlet 40 opens through the cylindrical surface 32 and exits through the opening 18 in the upper wall 17 of the housing 11 , and is preferably placed in liquid communication with the drain D (FIG. 1) by a clear flexible polyethylene pipe 45 .
A generally cylindrical valve or valve body 50 is axially slidable along the cylindrical surface 32 between a first position shown in FIG. 5 and a second position shown in FIG. 6 . The valve 50 includes axially opposite ends 51 , 52 , the latter of which includes a threaded bore 53 into which is threaded a valve stem, shaft or rod 54 which is preferably of a rectangular transverse cross-section corresponding to a like rectangular opening 55 formed in a nut 56 which houses a washer 57 and is threaded to the conical end cap 34 . Due to the polygonal transverse cross-section of the rod 54 and the opening 55 , the rod 54 cannot rotate nor can the valve 50 carried thereby.
A diametrical port 60 is formed through the left end of the valve 50 , as viewed in FIGS. 5 and 6, and when in the position shown in FIG. 5, water flowing into the water inlet 35 passes through the diametric port 60 and flows into and through the water outlet 37 , as is indicated by the unnumbered headed arrow associated therewith. O-ring seals 61 , 62 seal against the cylindrical surface 32 of the cylindrical valve housing body 31 and prevent water leakage in the position illustrated in FIG. 5 of the drawings.
The right-hand side of the valve 50 , again as viewed in FIGS. 5 and 6, includes an axial passage or port 70 defined in part by a curved wall 71 which extends substantially between O-ring seals 72 and 73 . Another seal 74 is carried by the cylindrical surface of the valve 50 diametrically opposite from the channel 70 and between the seals 72 , 73 . When the valve 50 moves to the second position thereof shown in FIG. 6 under the influence of near freezing, freezing or lower than freezing temperatures in a manner to be described more fully hereinafter, the valve 50 is so positioned as to cut-off water flow between the inlet 35 and the outlet 37 (FIG. 6 ), noting that the seal 74 creates a seal with the opposing surface (unnumbered) of the port 35 , and in conjunction with the seals 72 , 73 assure that water from the plumbing system PS flowing under the influence of gravity flows downward into the water outlet 37 (FIG. 6 ), through the channel or port means 70 and into the drain port 40 exiting therefrom into the drain line 45 (FIG. 1) and eventually dumping into the floor drain D to completely drain the plumbing system PS.
Means 80 (FIGS. 5 and 6) in the form of a spring surrounding the shaft 54 seats against the partition wall 16 and against a pin or washer 81 fixed to the shaft 54 .
As is best illustrated in FIG. 5 of the drawings, two different means 85 , 90 are provided for selectively preventing automatically operative biasing means 80 from shifting the shaft 54 to the left, the first means 85 being a manual override of the automatic second means 90 which is operative under substantially freezing ambient outdoor temperatures to bias the valve 50 to the “dump” or “drain” position of FIG. 6 .
The manual override means 85 includes a lever 86 pivoted at 87 to the partition wall 16 and having an end (unnumbered) received in a notch 88 (FIG. 5) of the shaft 54 which carries an O-ring handle 89 . When the lever or detent 86 is seated in the notch 88 , the valve 50 occupies the first position thereof shown in FIG. 5 with the port 60 in diametric alignment with the inlet 35 and the outlet 37 . In this operative position of the manual override 88 , the automatic biasing means 80 is inoperative for its intended purpose irrespective of the position of a pin or detent 91 of the automatic second means 90 , as will be readily apparent immediately hereinafter.
The automatic second means 90 prevents the spring 80 from biasing the valve 50 from the position shown in FIG. 5 to the position shown in FIG. 6 when ambient temperatures are above freezing (32° F./0° C.), and also permits the spring 80 to bias the valve 50 to the position shown in FIG. 6 when ambient temperatures are at substantially freezing (32° F./0° C.). The means 90 includes a housing 92 suitable fixed in the position shown in FIGS. 5 and 6 to the interior of the first housing body 11 with an integral guide sleeve 93 thereof slidably receiving the pin or detent 91 in alignment with a notch 95 of the valve rod 54 . The detent 91 is carried by a hollow spring bellows 96 which is constructed to inherently return from its expanded position (FIG. 5) to its retracted position (FIG. 6) under the inherent spring-biased nature of the bellows itself. However, the bellows 96 is part of a closed fluid system which includes a pipe 97 and a conventional sensing bulb 98 located immediately adjacent the openings 15 of the end wall 14 (FIG. 2 ). The sensing bulb 98 , the pipe 97 and the bellows 96 contain Freon or a similar fluid or gas which is charged into the bellows 96 at temperatures well above 32° F. Freon or a Freon gas mixture will contract as temperature drops and, of course, expands as temperature rise. Thus, the closed-circuit system is pressurized sufficiently such that as temperature approaches 32° F., the Freon will contract, the bellows will similarly contract from the fully expanded position shown in FIG. 5, and at 31.5° F. the bellows will have sufficiently retracted to fully withdraw the detent 91 from the slot 95 resulting in the spring 80 biasing the rod 54 to the left from the first position shown in FIG. 5 to the second position shown in FIG. 6 . In the latter position, water in the plumbing system PS drains by gravity into the main house line ML, into the water outlet 37 , through the channel or passage 70 and eventually through the drain opening 40 and the drain pipe 45 into the floor drain D. Water from the main water supply pipe M is precluded from entering the valve body 31 because of the position of the valve 50 shown in FIG. 6 including the position of the seal 74 preventing water flow past the valve 50 . Thus, in the position shown in FIG. 6, the plumbing system is drained, and water from the main water supply line M cannot flow beyond the valve 50 . Furthermore, the high insulation earlier herein noted surrounding the pipes M and 35 and the automatic drain mechanism 10 (not shown in FIG. 1 ), except for the openings 15 , preclude freezing of the water therein. Thus, drainage of the plumbing system PS is assured and correspondingly water damage to the residence is precluded.
After the valve 50 has been shifted to the second position thereof (FIG. 6 ), should temperatures rise, the detent 91 will again move upwardly toward and against the rod 54 but will be ineffective for any purpose whatever. However, in order to re-establish water flow, the homeowner need but grasp the O-ring handle 89 , pull the rod 54 to the right, and the detent 91 will again engage in the slot 95 which once again “arms” the automatic valve mechanism 10 for subsequent operation.
The manual override 85 maybe maintained in its operative position (FIG. 5) during summer months to make certain that under any malfunction of the means 90 , the valve 50 will not move to the second/closed position of FIG. 6 . Since there is no particular concern of freezing during summer months, using the manual override 85 assures water flow in the event, for example, the bellows 96 might leak resulting in reduced pressure and the withdrawal of the detent 91 from the slot 95 . Thus, the automatic valve mechanism assures that the plumbing system PS is drained and also prevents water flow from the supply via the main water supply pipe M.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined the appended claims. | An automatic mechanism is provided for cutting-off water flow to a plumbing system of a house, an apartment, a business or the like, while at the same time draining water/plumbing systems when subjected to low/freezing ambient temperatures. The mechanism includes a valve body housing a reciprocal valve which is operative to place an inlet and an outlet in fluid communication while cutting off a drain port, and in a second position the inlet is closed and the outlet and the drain port are placed in fluid communication to drain the water system when the valve is shifted automatically under the influence of biasing means in reaction to low temperature sensing. |
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[0001] This application is a continuation of, and claims the benefit of, pending U.S. patent application Ser. No. 09/821,299 filed on Mar. 29, 2001, which is a continuation-in-part of pending U.S. patent application Ser. No. 09/654,024 filed on Sep. 1, 2000, and which is a continuation of U.S. Pat. No. 6,170,220, filed Jan. 16, 1998, and issued Jan. 9, 2001, all of which are incorporated herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention encompasses a building component used to make concrete structures.
[0004] 2. Background Art
[0005] Concrete walls in building construction are most often produced by first setting up two parallel form walls and pouring concrete into the space between the forms. After the concrete hardens, the builder then removes the forms, leaving the cured concrete wall.
[0006] This prior art technique has drawbacks. Formation of the concrete walls is inefficient because of the time required to erect the forms, wait until the concrete cures, and take down the forms. This prior art technique, therefore, is an expensive, labor-intensive process.
[0007] Accordingly, techniques have developed for forming modular concrete walls that use a foam insulating material. The modular form walls are set up parallel to each other and connecting components hold the two form walls in place relative to each other while concrete is poured therebetween. The form walls, however, remain in place after the concrete cures. That is, the form walls, which are constructed of foam insulating material, are a permanent part of the building after the concrete cures. The concrete walls made using this technique can be stacked on top of each other many stories high to form all of a building's walls. In addition to the efficiency gained by retaining the form walls as part of the permanent structure, the materials of the form walls often provide adequate insulation for the building.
[0008] One embodiment of form walls is disclosed in U.S. Pat. No. 5,390,459, which issued to Mensen on Feb. 21, 1995, and which is incorporated herein by reference. This patent discloses “bridging members” that comprise end plates connected by a plurality of web members. The bridging members also use reinforcing ribs, reinforcing webs, reinforcing members extending from the upper edge of the web member to the top side of the end plates, and reinforcing members extending from the lower edge of the web member to the bottom side of the end plates. As one skilled in the art will appreciate, this support system is expensive to construct, which increases the cost of the formed wall. Also, these walls cannot feasibly be used to make floors or roof panels.
SUMMARY OF THE INVENTION
[0009] The present invention provides an insulated concrete form comprising at least one longitudinally-extending side panel and at least one web member partially disposed within the side panel. The web member extends from adjacent the external surface of the side panel through and out of the interior surface of the side panel. Three embodiments of the present invention that may be used to construct a concrete form are described herein. The first embodiment uses opposed side panels that form a cavity therebetween into which concrete is poured and substantially cured. The second embodiment uses a single side panel as a form, onto which concrete is either poured or below which concrete is poured and the form inserted into. Once the concrete cures and bonds to the side panel in the second embodiment, it is used as a tilt-up wall, floor, or roof panel. The third embodiment operates similar to the first embodiment but, instead of having two opposed side panels to form the cavity, the present invention uses one side panel and an opposed sheet or other form on the opposed side to form the cavity. After the concrete substantially cures in the third embodiment, the sheet can be removed and reused again or, alternatively, remain as part of the formed structure. If the sheet is removed, the resulting structure is similar to a tilt-up wall formed using the second embodiment of the present invention.
[0010] In the first embodiment, the web member is preferably partially disposed in the side panel so that a portion of the web member projects beyond the interior surface of the side panel and faces but does not touch an opposing side panel. The first embodiment also uses a connector that attaches to the two web members in opposing side panels, thereby bridging the gap between the two side panels to position the side panels relative to each other. The connectors preferably have apertures to hold horizontally disposed re-bar. The connectors also have different lengths, creating cavities of different widths for forming concrete walls having different thicknesses. The connectors are interchangeable so that the desired width of the wall can be set at the construction site.
[0011] For the second embodiment, a portion of the web member preferably projects beyond the interior surface of the side panel. In one design, the side panel is first horizontally disposed so that the interior surface and portion of the web member extending therethrough are positioned upwardly. Forms are placed around the periphery of the side panel and concrete is then poured onto the interior surface. In a second design, the concrete is poured into a volume defined by perimeter forms and then the side panel is placed upon the fluid concrete so that at least a portion of the web member in the side panel is disposed in the concrete. Alternatively, a third design is formed as a hybrid of the first and second designs, namely, one side panel is horizontally disposed, concrete is poured onto the interior surface and contained by forms, and then another panel is place upon the poured concrete so that side panels are on both sides of the concrete. For all three designs, once the concrete substantially cures and bonds with the interior surface of the side panel and the portion of the web member extending therethrough, the side panels and connected concrete slab can be used as a tilt-up wall, flooring member, or roof panel.
[0012] The third embodiment of the present invention encompasses a process generally similar to the first embodiment, except that a sheet of plywood or the like is used instead of a second side panel. The sheet can either be removed after the concrete cures and used again or remain part of the formed structure.
[0013] The present invention further comprises components to improve the walls formed using side panels and to simplify the construction process.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of a first embodiment of the present invention.
[0015] [0015]FIG. 2 is a perspective side view of a FIG. 1 taken along line 2 - 2 .
[0016] [0016]FIG. 2A is an alternative view of FIG. 2 showing concrete disposed between the two opposed side panels. FIG. 2A also shows the tilt-up wall formed with side panels on the two opposed sides of the concrete that has been erected.
[0017] [0017]FIG. 3 is a perspective view of one side panel shown in FIG. 1, in which three web members show four attachment points extending through the interior surface of the side panel. Two of the web members show two connectors attached to attachment points and one web member shows two connectors and a stand-alone web member attached to those two connectors.
[0018] [0018]FIG. 4 is a perspective view of the connector shown in FIG. 3.
[0019] [0019]FIG. 4A is a perspective view of an alternative of the connector shown in FIG. 4.
[0020] [0020]FIG. 5 is a perspective view of one design of the side panel of the present invention, in which a portion of the side panel is cut away to show the body portion of the web member partially disposed and integrally formed therein.
[0021] [0021]FIG. 6 is an exploded perspective view of an alternative design of the web member shown in FIGS. 3 and 5 and having five attachment points instead of four. FIG. 6 also shows an anchor and an extender used in conjunction with the different embodiments of the present invention.
[0022] [0022]FIG. 7 is a perspective view of a second embodiment of the present invention showing generally the concrete formed below the side panel.
[0023] [0023]FIG. 8 is another perspective view of the second embodiment of the present invention showing generally the concrete formed above the side panel.
[0024] [0024]FIG. 9 is a perspective view of a third embodiment of the present invention showing a cavity defined by a side panel and a sheet.
[0025] [0025]FIG. 9A is an alternative view of FIG. 9 showing concrete disposed between the side panel and the sheet.
[0026] [0026]FIG. 10 is a perspective view of a stand-alone web member and a connector, both of which include a spacer.
[0027] [0027]FIG. 11 is a perspective view of an upstanding concrete structure formed by two of the second embodiments or the third embodiment of the present invention, which are shown in FIGS. 7, 8, 9 , and 9 A.
[0028] [0028]FIG. 12 is a cross-sectional side view showing two opposed side panels and the web members partially disposed therein, in which the side panels are interconnected in various combinations by flexible linking members joining extenders or slots formed into the web members.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, “a,” “an,” and “the” can mean one or more, depending upon the context in which it is used. The preferred embodiment is now described with reference to the figures, in which like numbers indicate like parts throughout the figures.
[0030] As shown in FIGS. 1 - 12 , the present invention comprises a concrete form system 10 used for constructing buildings. A first embodiment of the present invention, shown best in FIGS. 1 - 2 A, comprises at least two opposed longitudinally-extending side panels 20 , at least one web member 40 partially disposed within each of the side panels 20 , and a connector 50 disposed between the side panels 20 for connecting the web members 40 to each other. As shown in FIG. 2A, concrete C is poured between the side panels 20 so that it bonds with the side panels 20 and the web members 40 . Two designs of a second embodiment of the present invention, which is discussed in more detail below and shown in FIGS. 7 and 8, involves using a single side panel 20 that bonds with the concrete C, instead of using opposed side panels 20 on both sides of the concrete C. The second embodiment also includes a design in which the wall has side panels 20 on both sides of the concrete to appear as the wall in FIG. 2A, but is formed differently from the first embodiment. A third embodiment of the present invention is shown in FIGS. 9 and 9A and is similar to the first embodiment, but uses one side panel 20 and a sheet 80 instead of two opposed side panels 20 .
[0031] Each side panel 20 has a top end 24 , a bottom end 26 , a first end 28 , a second end 30 , an exterior surface 32 , and an interior surface 34 . The presently preferred side panel 20 has a thickness (separation between the interior surface 34 and exterior surface 32 ) of approximately two and a half (2½) inches, a height (separation between the bottom end 26 and the top end 24 ) of sixteen (16) inches, and a length (separation between the first end 28 and second end 30 ) of forty-eight (48) inches. The dimensions may be altered, if desired, for different building projects, such as increasing the thickness of the side panel 20 for more insulation. Half sections of the side panels 20 can be used for footings.
[0032] Referring now to FIGS. 1 and 2 showing the first embodiment of the present invention, the interior surface 34 of one side panel 20 faces the interior surface 34 of another side panel 20 and the opposed interior surfaces 34 are laterally spaced apart from each other a desired separation distance so that a cavity 38 is formed therebetween. Concrete—in its fluid state—is poured into the cavity 38 and allowed to substantially cure (i.e., harden) therein to form the wall 10 , as shown in FIG. 2A. Preferably, for the first embodiment, the opposed interior surfaces 34 are parallel to each other. The volume of concrete received within the cavity 38 is defined by the separation distance between the interior surfaces 34 , the height of the side panels 20 , and the length of the side panels 20 .
[0033] The side panels 20 are preferably constructed of polystyrene, specifically expanded polystyrene (“EPS”), which provides thermal insulation and sufficient strength to hold the poured concrete C until it substantially cures. The formed concrete wall 10 using polystyrene with the poured concrete C has a high insulating value so that no additional insulation is usually required. In addition, the formed walls have a high impedance to sound transmission.
[0034] As best shown in FIGS. 3 and 5, the interior surface 34 preferably includes a series of indentations 36 therein that increase the surface area between the side panels 20 and concrete C to enhance the bond therebetween. To improve further the bond between the side panels 20 and the concrete C poured in the cavity 38 , a portion of each of the web members 40 formed in or passing through the side panels 20 extends through the interior surface 34 of the side panels 20 into the cavity 38 . A portion of each web member 40 is preferably integrally formed within one side panel 20 and is also cured within the concrete C so that the web member 40 strengthens the connection between the side panel 20 and the concrete C. That is, since the web member 40 is preferably an integral part of the side panel 20 , it bonds the side panel 20 to the concrete C once the concrete is poured and substantially cures within the cavity 38 . However, other designs are contemplated, such as designs in which the web member is not integrally formed into the side panel and, for example, the web member is slid into slots precut into the side panel at the construction site.
[0035] As shown in FIGS. 1 - 3 and 5 , each side panel 20 has at least one web member 40 formed into it. Preferably, the each web member 40 formed within one side panel 20 is separated a predetermined longitudinal distance from other web members 40 , which is typically eight (8) inches. Based on the preferred length of the side panel 20 of forty-eight (48) inches, six web members 40 are formed within each side panel 20 , as shown in FIGS. 3 and 5.
[0036] Portions of each web member 40 that extend through the interior surface 34 of the side panel 20 forms one or more attachment points 44 . The attachment points 44 are disposed within the cavity 38 and are preferably spaced apart from the interior surface 34 of the side panels 20 in the first embodiment. However, as one skilled in the art will appreciate, the attachment points 44 may take any of a number of alternate designs formed by or independently of the web members 40 , including as examples: slots, channels, grooves, projections or recesses formed in the side panels; hooks or eyelets projecting from or formed into the side panels; twist, compression or snap couplings; or other coupling means for engaging cooperating ends of the connectors.
[0037] Preferably, as addressed in more detail below and as shown best in FIGS. 3, 5, and 6 , each attachment point 44 is substantially rectangular and flat in plan view to be complementarily and slidably received within one respective end 52 of the connector 50 . Thus, in the first embodiment, the connectors 50 shown in FIGS. 4 and 4A engage two attachment points 44 on opposed web members 40 , which position the interior surfaces 34 of the side panels 20 at a desired separation distance and support the side panels 20 when the fluid concrete is poured into the cavity 38 . In the preferred embodiment, the connector 50 makes a two-point connection with opposed web members 40 because each connector has two ends 52 that each couple to one attachment point 44 , although it is contemplated making a four-point connection (i.e., each connector 50 engages four attachment points 44 instead of two as illustrated in the figures).
[0038] Referring now to FIGS. 3, 6, and 10 , each web member 40 also preferably has an end plate 42 that is disposed adjacent the exterior surface 32 of the side panel 20 in the preferred embodiment. The end plates 42 are preferably substantially rectangular in plan view. Except when used as a stand-alone web member 40 ′ for the third embodiment as discussed below, each end plate 42 of the web members 40 is preferably completely disposed within a portion of one respective side panel 20 , as shown best in FIGS. 2 and 5. That is, the end plates 42 are located slightly below the exterior surface 32 of, or recessed within, the side panel 20 , preferably at a distance of one-quarter (¼) of an inch from the exterior surface 32 . This position allows for easily smoothing the surface of the side panels 20 without cutting the end plate 42 should the concrete, when poured, create a slight bulge in the exterior surface 32 of the side panels 20 . However, when embedded within the side panel 20 , it is desired that some visual indicia be included on the external surface 32 to enable the construction worker to locate quickly and accurately the end plate 42 . Alternatively, the end plates 42 can abut the exterior surface 32 of panels 20 so that a portion of the end plate 42 is exposed over the exterior surface 32 . It is also preferred in the first and third embodiments that each end plate 42 is oriented substantially upright and disposed substantially parallel to the exterior surface 32 of the side panel 20 when forming a concrete form 10 .
[0039] Similar to the end plate 42 , the attachment points 44 are also preferably oriented substantially upright in the first and third embodiments so that one attachment point 44 is disposed above another attachment point 44 . As best shown in FIGS. 2, 3, and 9 , in one design each of the web members 40 has four spaced-apart attachment points 44 , in which the attachment points 44 for each web member 40 are vertically disposed within the cavity 38 in a substantially linear relationship. The attachment points 44 are placed in two groups-a top group of two attachment points 44 and a bottom group of two attachment points 44 . Adjacent attachment points 44 in the two groups are spaced apart a first distance from each other, preferably approximately two and an eighth (2⅛) inches apart between center points. In addition, the closest attachment points 44 of the two groups, i.e., the lowermost attachment point 44 of the top group and the uppermost attachment point 44 of the bottom group, are spaced apart a second distance from each other. The second distance, which is approximately six (6) inches in the preferred embodiment for a twelve (12) inch connector, is more than double and almost triple the first distance.
[0040] In an alternative design, the web member 40 includes five attachment points 44 , which is illustrated best in FIG. 6. This design also has the two groups of two attachment points 44 as discussed above, but also includes a fifth attachment point 44 at approximately the center of the two groups. This design having five attachment points 44 is presently preferred over the web member 40 having four attachment points because it provides even greater flexibility for the architect and/or construction worker. As one skilled in the art will appreciate, the number of attachment points 44 used for each web member 40 can be further varied in number and spacing based on relevant factors such as the dimensions of the side panels 20 and the wall strength or reinforcement desired.
[0041] The designs of the multiple attachment points 44 of the present invention is an improvement over prior art systems, which lack multiple mounting points for attaching an interconnecting device. The side panels 20 and web members 40 in the present invention can be cut horizontally over a wide range of heights to satisfy architectural requirements, such as leaving an area for windows, forming odd wall heights, and the like, yet still have at least two or three attachment points 44 to maintain structural integrity of the wall. Prior art systems, in contrast, lose structural integrity if cut horizontally, thus requiring extensive bracing to resist collapsing when concrete is poured into the cavity between the panels. One skilled in the art, however, will appreciate that the web member of the present invention is not limited to these exemplary designs and can include other shapes in which a portion is disposed adjacent both the interior and exterior surfaces in which the web member is disposed.
[0042] Referring again to FIGS. 1 and 2 showing the first embodiment of the present invention, the attachment points 44 of the web members 40 extend into the cavity 38 and the attachment points 44 of each web member 40 formed within one side panel 20 are spaced apart from the attachment points 44 of the web members 40 formed within the opposed side panel 20 . Thus, the web members 40 preferably do not directly contact each other; instead, each attachment point 44 independently engages the connector 50 that interconnects the web members 40 and, accordingly, the side panels 20 .
[0043] Referring now to FIGS. 4 and 4A, the illustrated connectors 50 have opposed ends 52 and a length extending therebetween. The ends 52 of the connectors 50 are each of a shape to engage one attachment point 44 of two respective web members 40 within opposed panels. As mentioned above and as best shown in FIGS. 5, 6, and 12 , the attachment points 44 are preferably substantially rectangular and flat and a stem 48 extends the attachment point 44 through the side panel 20 from the remaining portions of the web member 40 . As such, the stem 48 and the attachment point 44 are “T” shaped in cross-sectional view, in which the attachment point forms the top of the “T.” In conjunction, as best shown in FIGS. 4 and 4A, each end 52 of the connector 50 has a track 54 into which the preferably rectangular attachment point 44 is complementarily and slidably received. The connector 50 , accordingly, is movable between a separated position and an attached position. In the separated position (as illustrated, for example, in FIGS. 4 and 4A), the end 52 of the connector 50 is spaced apart from the respective attachment point 44 to which it will be connected. In the attached position, the end 52 of the connector 50 is engaged to the attachment point 44 , which is shown, for example, in FIGS. 2 and 3.
[0044] In the preferred embodiment, the ends 52 of the connector 50 are detachably locked to the respective attachment points 44 when in the attached position. By being detachably locked, it will be appreciated that, while only contacting the connector 50 , an applying force needed to remove the connector 50 from the attachment point 44 is greater than a force needed to attach that connector to that attachment point 44 . Stated differently, an applying force needed to move the connector 50 from the separated to the attached position is less than a removing force needed to move the connector 50 from the attached to the separated position. The differences in the applying and removing forces may be slight or significant and still be within the scope of the present invention.
[0045] The present invention thus comprises a means for detachably locking the end 52 of the connector 50 into the attached position. The preferred embodiment of the locking means is illustrated in FIGS. 4A and 6. Referring first to FIG. 6, latching members 46 are disposed either above and below the attachment points 44 , although it is acceptable if only one latching member 46 is disposed either above or below the attachment point 44 . The latching members 46 are preferably integrally formed as part of the web member 40 , but can alternatively either be affixed to the web member 40 after it is formed or be connected to the side panel 20 . As shown in FIG. 6, the tip 47 of the latching member 46 is spaced apart from the attachment point 44 and, preferably, flexibly movable but predisposed or biased to be in an extended position, again as shown in FIG. 6. Since it is preferred that the tip 47 of the latching member 46 be flexible, the latching member 46 may be formed as a relatively thin component, which should not prevent the latching member 46 from performing its intended function.
[0046] In conjunction, referring again to FIG. 4A, the connector 50 has a detent 58 disposed above its track 54 . Specifically, the illustrated detent 58 is an indentation formed at the center of the closed end of the track 54 (which is shown as the top end in FIG. 4A). It is further preferred that the detent 58 include a raised back 59 that is located at the back end of the detent 58 . As one skilled in the art will appreciate, however, the detent 58 can be aligned differently such that, for example, the detent 58 is in the center of the closed end of the track 54 instead of at its top or the detent 58 is off-center instead of in the middle of the closed end.
[0047] To move the connector 50 shown in FIG. 4A to the attached position onto the web member 40 shown in FIG. 6, the bottom of the track 54 of the connector 50 is aligned with the top edge of a one attachment point 44 and slid vertically downwardly while the web member 40 is oriented in an upstanding position. Although not preferred or discussed further, the connector could alternatively be aligned with the bottom edge of the selected attachment point and slid upwardly. As the closed portion of track 54 of the connector 50 slides closer to the attachment point 44 while moving downwardly, the closed portion contacts the flexible tip 47 of the latching member 46 . That contact moves the tip 47 of the latching member 46 inwardly toward the end plate 42 of the web member 40 until the detent 58 is aligned with the tip 47 of the latching member 46 , at which time the latching member 46 extends outwardly away from the end plate 42 to its normal extended position to be complementarily received within the detent 58 . Thus, at that point (which preferably is reached when the attachment point 44 is fully received within the track 54 of the connector 50 ), the connector 50 is detachably locked into place by the tip 47 of the latching member 46 being positioned within the detent 58 so that the connector 50 cannot be freely removed from the attachment point 44 . In conjunction, the raised back 59 behind the detent 58 prevents the tip 47 from over extending beyond the detent 58 .
[0048] As one skilled in the art will appreciate, the locking means shown in FIGS. 4A and 6 allows the connector 50 to be easily slid down onto the attachment point 44 using very light downward force (i.e., with just two fingers) to latch the connector 50 to the attachment point 44 . That is, the preferred embodiment of the connector 50 shown in FIGS. 4A and 6 allows a construction worker to slide relatively “loosely” the end 52 of the connector 50 onto the attachment point 44 without significant frictional resistance. Such a design is advantageous because even mild frictional resistance may be burdensome given the number of connectors 50 involved in some construction projects, which may literally involve thousands of connectors 50 each attaching to two web members 40 in opposed side panels 20 . The scope of the connections made may be appreciated by considering FIG. 2, which shows the connections for one pair of opposed side panels 20 . As such, this less burdensome process may translate into a reduction in the amount of time necessary to attach the connectors 50 to the attachment points 44 .
[0049] To remove the connector 50 from the attachment point 44 back to the separated position (which is unusual to occur during a construction project), the flexible tip 47 of the latching member 46 must be pressed inwardly away from the detent 58 and toward the end plate 42 and, concurrently, the connector 50 must be slid upwardly toward the latching member 46 a sufficient distance so that the tip 47 of the latching member 46 is no longer aligned or in registry with the detent 58 . After this initial movement, the connector 50 can be removed from the attachment point 44 , either while still holding the tip 47 of the latching member 46 in the compressed position or releasing the latching member 46 so that its tip 47 contacts the closed portion of the track 54 .
[0050] Thus, although there is low frictional resistance moving the connector 50 to the attached position, the detachably locked connector 50 cannot easily be removed—even with strong upward force—unless the flexible tip 47 of the latching member 46 is compressed, which often requires a two-handed operation to separate the connector 50 from the web member 40 . This latching design further allows a construction worker or foreman to verify that a connector 50 is properly attached to the web members 40 by tapping on the bottom of the connector 50 and having the connector 50 remain in place, whereas other designs might result in the connector 50 “popping off” the attachment points 44 in response to such an upward tapping force. Further, the detachably locking design also more effectively resists the upward forces exerted by concrete to the connectors 50 as the fluid concrete is first placed, or pumped, into the cavity 38 of the concrete form. In so resisting the forces applied by the fluid concrete, the connectors 50 keep the side panels 20 in place and maintain the integrity of the structure when subjected to various forces or pressures.
[0051] Another embodiment of the locking means is shown referring to FIG. 4. As will be noted, the track 54 of the connector 50 forms a gap 56 into which a portion of the stem 48 is complementarily received when the connector 50 is moved to the attached position. The locking means in this embodiment comprises at least one barb 55 on the track 54 of the connector 50 that is oriented into the gap 56 and a corresponding indentation 49 on the stem 48 of the web member 40 (as shown in FIG. 6). As such, when the connector 50 is in the attached position, the barb 55 is complementarily received into the indentation 49 . FIG. 4 shows two spaced-apart barbs 55 extending toward each other in the gap and there would be two corresponding indentations 49 formed into the stem 48 . These barbs 55 provide a frictional fit between the connector 50 and the attachment point 44 of the web member 40 to hold the connector 50 at the attached position. However, the frictional resistance also exists when moving the connectors 50 to the attached position, which makes this embodiment of the locking means less desired.
[0052] One skilled in the art will appreciate that the locking means for the connectors 50 can also be used for the stanchions (some embodiments of which are discussed below and shown in FIG. 6). One skilled in the art will further appreciate that other locking means are possible, such as having the latching member 46 formed on the connector 50 and the detent 58 formed on the web member 40 .
[0053] Referring again to FIGS. 2, 4, and 4 A, the connectors 50 also preferably define an aperture 56 of a size to complementary receive a re-bar (not shown) therein. The rebar provides reinforcing strength to the formed wall. The diameter of the re-bar can be one quarter (¼) inch or other dimension as required for the necessary reinforcement, which depends on the thickness of the concrete wall and the design engineering requirements. The connectors 50 preferably have two or more apertures 56 and re-bar can be positioned in any of the apertures 56 before the concrete is poured into the cavity 38 . The apertures 56 can be designed so that the re-bar is securably snapped into place for ease of assembly.
[0054] To vary the width of the cavity 38 (i.e., the separation between the interior surfaces 34 of the opposed side panels 20 ), different connectors 50 can have varying lengths. The width of the cavity 38 can be two (2), four (4), six (6), eight (8) inches or greater separation. Different connectors 50 are sized accordingly to obtain the desired width of the cavity 38 . Also, as one skilled in the art will appreciate, the fire rating, sound insulation, and thermal insulation increase as the width of the cavity 38 , which is filled with concrete, increases. One skilled in the art will appreciate that the cavity 38 may only be partially filled with concrete, but such an embodiment is not preferred or desired.
[0055] The web members 40 and connectors 50 are preferably constructed of plastic, more preferably high-density plastic such as high-density polyethylene or high-density polypropylene, although other suitable polymers may be used. Other contemplated high-density plastics include acrylonitrile butadiene styrene (“ABS”) and glass-filled polyethylene or polypropylene, particularly for connectors and stanchions since they are more expensive materials. Factors used in choosing the material include the desired strength of the web member 40 and connector 50 and the compatibility with the material used to form side panels 20 and with the concrete. Another consideration is that the end plates 42 should be adapted to receive and frictionally hold a metal fastener, such as a nail or screw, therein, thus providing the “strapping” for a wall system that provides an attachment point for gypsum board (not shown), interior or exterior wall cladding (not shown), or other interior or exterior siding (not shown). Thus, the web members 40 function to align the side panels 20 , hold the side panels 20 in place during a concrete pour, and provide strapping to connect siding and the like to the formed concrete wall 10 .
[0056] Referring again to FIG. 1, one skilled in the art will appreciate that a plurality of side panels 20 can be longitudinally aligned to form a predetermined length and be vertically stacked to form a predetermined height. For example, as shown in FIG. 1, the first end 28 of one side panel 20 abuts the second end 30 of another side panel 20 and the bottom end 26 of one side panel 20 is disposed on the top end 24 of another side panel 20 . Thus, a series of side panels 20 can be aligned and stacked to form the concrete system 10 into which concrete C is poured to complete the construction of the wall 10 . One consideration, however, is that the side panels 20 are not vertically stacked too high and filled at once so that the pressure on the bottom side panel 20 is greater than the yield strength of the web members 40 or EPS side panels 20 . Instead, the stacked wall of panels 20 can be filled and cured in stages so that the static and dynamic pressures are not excessive on the lower side panels 20 .
[0057] To facilitate the stacking of the components, the side panels 20 are optionally provided with a series of projections 35 and indentations 37 that complementarily receive offset projections 35 and indentations 37 from another side panel 20 (i.e., a tongue-and-groove-type system). The projections 35 and indentations 37 in the adjacent side panels 20 mate with each other to form a tight seal that prevents leakage of concrete C during wall formation and prevents loss of energy through the formed wall.
[0058] Referring still to FIG. 1 for the first embodiment of the present invention, the present invention also uses corner sections 39 . Preferably, each corner section 39 forms a substantially right angle and concrete C is also poured into the corner section similar to the other sections of the concrete form system 10 . Forty-five degree angle corner sections can also be used. Thus, the formed concrete wall is contiguous for maximum strength, as opposed to being separately connected blocks. Still another embodiment of the present invention, which is not shown, uses non-linear side panels so that the formed wall has curvature instead of being straight.
[0059] The first embodiment of the present invention is an improvement over the prior art. Although other systems may use connector elements, the prior art lacks a web member 40 having an end plate 42 , which provides a nailing/screwing strip adjacent the exterior surface 32 of the side panel 20 , and has an attachment point 44 or similar connection projecting into the cavity 38 adjacent the interior surface 34 . Moreover, the present invention uses less plastic and is, therefore, less expensive to manufacture.
[0060] Furthermore, in prior art systems, the panels are made so that large, thick, plastic connector elements slide down in a “T” slot formed within the inside surface of the panel itself. These prior art designs are structurally weaker and the construction workers in the field have substantial difficulty avoiding breaking the panels while sliding the connector element into place. Additionally, the prior art panels can break off from the cured concrete if any “pulling” occurs while mounting sheetrock or other materials onto the outer side of the panel. The preferred embodiment of the present invention having the web member 40 integrally formed into the side panel 20 provides a stronger “interlocking” system among the side panels 20 , the web member 40 , and the connectors 50 , which are imbedded within concrete in the cavity 38 . Nonetheless, as mentioned above, it is contemplated within the scope of the present invention using web members 40 that are not integrally formed into the side panels 20 .
[0061] Now moving to the second embodiment of the present invention, as noted above, there are three methods of constructing the tilt-up walls 10 of the present invention: (1) pouring the concrete and then inserting the panel 20 into the poured concrete, which is also known as “wet-setting” and is shown in FIG. 7; (2) pouring the concrete onto a substantially horizontally-disposed side panel 20 , which is shown in FIG. 8; or (3) pouring the concrete onto a substantially horizontally-disposed side panel 20 and then inserting the panel 20 into the top surface of the poured concrete so that the concrete is “sandwiched” between two opposed side panels 20 and, when erected, appears the same as the wall 10 formed by the first embodiment shown in FIG. 2A. All of the walls 10 formed by these three methods or designs are known as tilt-up walls.
[0062] As noted, the first two designs of the second embodiment use a side panel 20 on only one side of the formed concrete structure 10 , unlike the third design that uses opposed side panels covering both faces of the concrete C. Thus, the walls 10 formed by the first two designs of this embodiment are insulated on one side, which may be either the interior or exterior of the wall. Leaving the external surface as a concrete surface without a side panel is advantageous for insect control, such as preventing termite infestation since termites cannot burrow through concrete C, but may attack and bore through EPS—the preferred material to form the side panels 20 . Alternatively, leaving the interior surface as a concrete surface is advantageous for warehouses in which fork lifts, for example, could potentially damage any interior finishes by forcefully contacting them, whereas a concrete surface subjected to the same contact will remain substantially unimpaired. The side panels 20 may extend the full or a partial height of the tilt-up wall and, as discussed above, provide both sound impedance and thermal insulation.
[0063] For the wet-setting method shown in FIG. 7, it is preferred that a concrete floor slab (not shown), which will serve as a casting base for the tilt-up walls, is formed on a prepared, well-compacted subbase. It has been found that a five-inch (5″) or thicker slab is desired. Also, instead of forming the entire floor during the initial pouring, the slab is typically held back several feet from its ultimate perimeter dimension (i.e., the interior boundaries of the building) to allow space for raising and setting the tilt-up walls after being formed on the floor slab. As discussed below, the gap that exists is subsequently filled in after the tilt-up walls are later erected.
[0064] After the floor slab cures, the perimeter foundations or forms (not shown) within which the concrete is poured for forming the tilt-up walls are next positioned and braced to form a substantially contained volume. The perimeter forms are often dimension lumber of sufficient width to allow the walls to be made the desired thickness. Once the periphery forms are in place, door and window openings are blocked out and set. One skilled in the art will also appreciate that reinforcement, typically re-bar, is also positioned within the perimeter forms to be contained within the interior of the tilt-up wall after the concrete is poured. Likewise, items to be embedded within the tilt-up wall, such as for attachments for the lifting cables (discussed below), are also positioned within the perimeter forms.
[0065] Concurrently, the side panels 20 are sized and interconnected to match (or, if desired, be smaller than) the length and width dimensions of the tilt-up sections to be cast. Specifically, the side panels 20 are joined together using the projections 35 and indentations 37 (i.e., tongue-and-groove-type connectors) so that a top end 24 of one panel 20 abuts a bottom end 26 of another panel 20 and/or a first end 28 of one panel 20 abuts a second end 30 of another. The side panels 20 are usually joined in a side-by-side configuration while they are horizontally oriented.
[0066] The assembled side panels 20 forming an array of panels are preferably fastened together using strongbacks (not shown), which are often a metal “C”-shaped channel or similar device that provides stiffness to the array. Screws are typically used to interconnect the end plates 42 of the web members 40 to the strongbacks, which run the entire height or length of the assembled array of panels 20 .
[0067] Either before or after fastening the array of panels together, the side panels 20 are cut not only for height and width dimensions, but also for any penetrations to be included within the tilt-up wall (i.e., windows and doorways), embedded items, and welding plates. The assembled panels with strongbacks are then staged to be “wet set” after consolidation and screeding of the concrete.
[0068] With the preliminary steps completed, a release agent is sprayed or poured onto the concrete floor slab or other surface used, if not completed earlier. The fluid concrete is then poured into the perimeter foundations (or other substantially contained volume) and leveled or screeded. The side panels 20 are then “wet set,” in which the interior surface 34 of the side panels 20 are oriented downwardly and pressed firmly into the wet concrete so that a portion of the interior surface 34 of the side panel 20 contacts or is adjacent to the upper surface of the poured concrete.
[0069] Two men can easily lift each array of panels, which may measure, in an example construction, four feet by twenty feet. In such an example, each array may be formed of panels abutting end to end 28 , 30 and five arrays of side panels 20 may be coupled together top end 24 to bottom end 26 to form a surface that is twenty feet by twenty feet. If necessary, small “fill-in” pieces of the side panels 20 are easily installed by hand after the arrays of panels are positioned. Compared to insulation mounted onto a tilt-up wall after the concrete slab C has cured, these contiguous, interlocked side panels 20 of the present invention provide superior insulation over systems that have breaks (i.e., at the location of a ferring member) and are significantly less expensive to install.
[0070] In the preferred embodiment, each side panel 20 in the array of panels measures sixteen inches by forty-eight inches (16″×48″) and has thirty (30) attachment points 44 that penetrate into the concrete C forming the tilt-up wall. Thus, there are 5.6 penetrations per square foot of wall surface area. If it is believed that the attachment points 44 will not provide a sufficient bond to the concrete C, then stanchions can be used, which are discussed below and some of which are shown in FIG. 6.
[0071] When the side panels 20 are firmly pressed into the wet cement, the attachment points 44 penetrate into the wet concrete. A stinger vibrator (not shown) or the like may also be used on the strongbacks or side panels 20 to aid in the consolidation of the concrete around the attachment points 44 . After setting the side panels 20 , the strongbacks are removed so that the tilt-up system 10 is complete and ready for curing. Once the poured concrete substantially cures and forms a concrete slab C, that slab maintains its relative position against the interior surface 34 of the side panel 20 by the attachment points 44 . That is, by projecting beyond the interior surface 34 of the side panel 20 , the web members 40 anchor the side panel 20 to the concrete slab C so that the concrete slab C and side panel 20 form the tilt-up concrete structure 10 of the present invention. After the concrete slab C is substantially cured, the formed concrete structure 10 is tilted up, as discussed below and shown generally in FIG. 11.
[0072] Referring again to FIG. 7 generally illustrating the wet-setting construction method of the tilt-up walls, one skilled in the art will appreciate that this process has specific benefits. First, the side panels 20 that are disposed over the concrete—which may be performed within ten minutes of pouring—can act as a barrier to the ambient environment. The less temperate the ambient conditions, the more beneficial the wet-setting method using the side panels 20 positioned over the wet concrete. For example, in hot conditions, the side panels 20 retard evaporation so that a slower “wet cure” of the concrete occurs and the formed tilt-up wall is stronger based on the curing process. Without using the side panels 20 of the present invention, either the moisture evaporates too quickly resulting in a structurally weaker concrete or, more typically, a sealing membrane or “retardant” is sprayed over the top of the fluid concrete after screeding and leveling—an expense that is not incurred using the wet-setting process of the present invention. Alternatively, if the ambient environment is cold (i.e., close to or below freezing conditions), the side panels 20 also facilitate curing by including an insulating layer. Without using the wet-setting process of the present invention, the prior art techniques have involved using tents with propane blowers, blanketing the top surface of the concrete, or heating the area around the poured tilt-up wall using other means known in the art. The present invention is advantageous because it avoids or reduces the labor, fuel, and equipment costs associated with heating the concrete as it cures. Another advantage of the wet-setting method is that irregularities in the upper surface of the concrete after pouring are acceptable. That is, the poured concrete should be leveled within plus or minus one quarter inch (±¼″) before placing the side panels 20 into the concrete. Accordingly, the process of using a power trowel, which is labor intensive and can be expensive, is most likely avoided. Therefore, the wet-setting method circumvents the need for curing compounds, power trowels or other surface finishing, and curing thermal blankets or other heating processes.
[0073] For the second method of forming the tilt-up walls shown generally in FIG. 8, the side panel 20 is horizontally-disposed so that the attachment points 44 extend upwardly (i.e., opposite to the orientation of the wet-setting embodiment). The interior surface 34 of the side panel 20 becomes the surface onto which concrete is poured. Perimeter forms (not shown) are placed around the of the periphery, namely, the top end 24 , bottom end 26 , first end 28 , and second end 30 of one side panel 20 or an array of side panels 20 , to prevent the fluid concrete from leaking off of the interior surface 34 . Furthermore, as discussed below if a connector 50 is used as a stanchion instead of other exemplary embodiments shown in FIG. 6, re-bar can be positioned within the apertures 56 to strengthen the tilt-up wall prior to pouring the concrete. Once the concrete is poured, leveled, and substantially cured, the forms are removed and the side panel 20 and substantially cured concrete slab C creates the tilt-up wall 10 . The second method of forming a tilt-up wall advantageously avoids use of a release agent. Also, one skilled in the art will appreciate that the term “a side panel” as used for the second and third designs may encompass multiple panels, including an array of panels discussed above for the first design.
[0074] The third method or design of forming the tilt-up wall repeats first steps used in the second design, namely, the side panel 20 is horizontally-disposed so that the attachment points 44 extend upwardly; perimeter forms are placed around the of the periphery of the side panel 20 ; and the concrete is poured. However, before the concrete cures to any substantial degree, another, second side panel 20 is wet set into the poured concrete, as occurs in the first design. Thus, the third method is a hybrid of the first two methods to create a wall 10 that, when substantially cured and tilted up, has the design shown in FIG. 2A. As will be appreciated, the interior surfaces 34 of the opposed side panels 20 and the web members 40 disposed therein are spaced apart in a non-contacting relationship with each other so that the first and second side panels are stationarily positioned relative to each other by only the concrete slab C disposed within the cavity 38 . That is, unlike the first embodiment shown in FIG. 2, there are no connectors 50 or other components interconnecting the opposed side panels 20 .
[0075] This third method of making a tilt-up wall 10 has many advantages. When considered to prior art tilt-up walls, it encompasses the same advantages of both the first and second methods of forming a tilt-up wall, such as avoiding the need for (1) curing thermal blankets or other heating processes, (2) curing compounds, (3) power trowels or other surface finishing, and (4) a release agent. This third design also has greater insulating value and sound impedance than either of the first two designs since there are side panels 20 on each side of the concrete slab C, instead on only on one side.
[0076] The third embodiment also has potential advantages over the first embodiment of the present invention, which is shown in FIGS. 1 and 2, particularly if the wall being formed is greater than one story high. Most obviously, this dual-panel tilt-up wall form using the third design does not use connectors so there is a cost savings both by avoiding the purchase of these components and by not requiring the labor to install the connectors to interconnect the side panels. In addition, for a wall greater than one story high, the cost of external bracing and scaffolding during the wall assembly and pouring of concrete is not required. Since the panels 20 are laid flat during pouring of the concrete, there are minimal hydrostatic pressures compared to the panels being erected before pouring. As one skilled in the art will further appreciate, the practice of forming a wall as shown in the first embodiment typically involves filling in the cavities in four foot vertical increments, called lifts. The process of forming each lift is more labor intensive than filling the cavity continuously at a single horizontal location. Furthermore, it is imprudent—and prohibited by some building codes—to drop concrete more than ten feet because the constituents of the concrete tend to separate from each other, resulting in a weak final product. Thus, the usual practice in vertical-wall formation is to cut holes into the side panels at different elevational positions and then patch the holes after they are used as a filling port between the source of concrete and the cavity. This process of using the holes in the side panels, obviously, increases the labor costs and time required to fill the cavity for a wall greater than one story in height. The third design of the tilt-up wall, in comparison, avoids these problems and, accordingly, is quicker and less expensive to construct than the first embodiment of the dual-panel wall for wall structures greater than one story in height.
[0077] Regardless of the method used to form the tilt-up walls of the present invention, the side panels 20 —either with or without the stanchions connected—forge a bond with the concrete as it cures. Once the concrete C obtains sufficient strength for lifting (usually 2,500-3,000 psi) that is typically reached in five to ten days (depending on ambient conditions), a crane (not shown) or other means connects to cables (not shown) attached to embedded inserts cast into the tilt-up wall. The crane sequentially lifts each tilt-up wall and sets it on a prepared foundation around the building perimeter. FIG. 11 shows a single concrete structure 10 having been tilted up. Before any of the tilt-up walls are released by the crane, temporary braces (not shown) are installed—at least two per tilt-up wall—to brace up the respective tilt-up walls until the roof structure is attached.
[0078] Next, connections between individual tilt-up walls are made, which usually entail welding splices of steel ledger angles (not shown), and then the joints between the tilt-up walls (typically three-quarter inch (¾″)) are caulked. Also, any necessary patching is made to repair blemishes. Approximately the same time, the closure strip between the tilt-up walls and the floor slab (usually a two-foot-wide strip) is filled with concrete and the bracing is removed when the roof has been permanently connected to the tilt-up walls.
[0079] One of the advantages of using tilt-up walls 10 of the present invention is the shortened construction time. All of the steps discussed above in forming a building frame, from pouring the floor slab to erecting the tilt-up walls that are ready to receive the roof structure, often require only four weeks. Tilt-up walls are also generally less labor intensive to construct, which results in a financial savings. Moreover, tilt-up walls 10 of the present invention may be used to form multi-story buildings.
[0080] When considering the benefits of using the side panels 20 with tilt-up walls, one skilled will appreciate the improved insulation and sound impedance that exists using the side panels 20 , which would be difficult and expensive to install on a conventional tilt-up wall once erected. Also, the web members 40 , when set into the concrete and substantially cured, insure a substantially permanent, worry-free connection for the side panels 20 and provide a solid attachment point that may be used to connect wallboard such as sheet rock, brick, or stone finishes. Moreover, electrical and plumbing runs are easily installed within the side panels 20 . That is, installing electrical and plumbing is accomplished by cutting the “run's” using a hot knife, router, or electric chain saw into the side panel 20 of preferred embodiment, which is made of EPS. Also, using the preferred side panels 20 removes any potential metal contact problems and makes it much easier to connect pipes and wires compared to achieving the same with conventional tilt-up walls.
[0081] The tilt-up wall concrete structure 10 using a side panel 20 on only one side of the concrete slab C can also be used as an insulated concrete floor, in which the panels are formed and raised upwardly to form a floor of the building. Likewise, the structure 10 can also be used to create roof panels. Thus, the present invention can be used to construct the majority of an entire building, namely, the walls, floors/ceilings, and roof panels. Also of note, the side panels 20 do not affect the engineered structural design of the formed tilt-up wall as compared to not using the panels.
[0082] If the concrete or “slump” is dry or if ambient conditions are cold, the attachment points 44 —being rectangular and substantially flat and extending eleven-sixteenths ({fraction (11/16)}) of an inch from the interior surface 34 of the side panel 20 in the preferred embodiment—may have difficulty penetrating into the fluid concrete. The present invention, as mentioned above, includes stanchions or extending devices that assist in bonding the side panels 20 to the wet concrete. The primary function of the stanchions is to form better bonds between the concrete C and the side panel 20 . As such, the side panels 20 are less likely to separate from the concrete slab C of the tilt-up wall or other wall of the present invention throughout its life. A secondary function of the stanchions is to give greater structural integrity to the side panels 20 and associated wallboard, brick, or stone finishes attached to the end plates 42 of the web members 40 . That is, by being more firmly anchored, the concrete slab C provides a better connection to the side panels 20 and a stronger foundation for any materials hung from the side panels 20 . The stanchions are discussed in the specific context of a tilt-up wall but, as one skilled in the art will appreciate, the stanchions, for example, may also be useful in a dual-panel wall discussed above to buttress the connection between the side panel 20 and the concrete poured into the cavity 38 .
[0083] One specific embodiment of the stanchion comprises a connector 50 , for example, coupled to one attachment point 44 to increase the surface area to which the concrete C bonds. If the connectors 50 are the incorrect length, then they can easily be cut to the proper dimension at the construction site. The connectors 50 , as discussed above, are best shown in FIGS. 4 and 4A.
[0084] Two additional such stanchions are shown in FIG. 6, namely, an extender 60 and a tilt-up anchor 70 . First addressing the extender 60 , it includes a tip end 62 , an opposed base end 64 , and a body 66 extending therebetween. Preferably, the tip end 62 is of a size to complementarily engage one end 52 of a connector 50 and the base end 64 is of a size to complementarily engage one attachment point 44 . Similar to the preferred designs discussed above, the tip end 62 is preferably rectangular in plan view—as is the attachment point 44 —and the base end 64 preferably defines a track of a size to slidably receive a selected one of the tip end 62 or the attachment point 44 therein—as does one end 52 of the connector 50 . The locking means is preferably also part of the extender 60 and other stanchions.
[0085] The body 66 of the extender 60 is preferably non-smooth, which assists in bonding to concrete C. In the preferred embodiment, the body 66 defines a passage 68 therethrough. As will be noted by FIGS. 6 and 12, the passage 68 has a substantially rectangular cross-section. In the preferred embodiment, the width of the sides of the passage 68 is between one-quarter (¼) and one (1) inch to have a cross-sectional area between approximately 0.125 and 1 square inches, and more preferably between one-half (½) inch and three-quarter (¾) inch to have a cross-sectional area between approximately 0.25 and 0.57 square inches. This range of widths allows a portion of a flexible linking member 90 (shown in FIG. 12) to be received therethrough (as discussed below) as well as being of a dimension to allow fluid concrete to at least partially flow into the passage 68 for better bonding. Of course, other dimensions are contemplated to achieve these same functions and, in fact, the minimal dimension to allow fluid concrete to flow partially therein may be a function of the viscosity of the fluid concrete and size of the aggregate stone used. Likewise, other cross-sectional shapes for the passage 68 are also contemplated, such as circular, elliptical, triangular, or other polygonal shapes. As one skilled in the art will also appreciate, the body 66 of the extender 60 can be manufactured in different lengths, depending on the use of the extender 60 ; however, the preferred length between the tip end 62 and the base end 64 is approximately one inch.
[0086] Three functions of the extender 60 of the present invention are addressed herein: (1) as a stanchion; (2) as an extension for the connectors 50 ; and (3) as part of a connection between side panels 20 or to buttress the connection between panels 20 . The first listed function of extender 60 is the same as the other stanchions, which is to provide an additional surface to which the concrete can bond while curing to form a stronger connection with the side panel 20 . The extender 60 connects to one respective attachment point 44 of the web member 40 and extends into the concrete C a greater distance than the attachment point 44 . This longer extension, in and of itself, strengthens the bond between the concrete C and the side panel 20 to which the extender 60 is connected since there is more surface area to which the concrete C may bond during curing. Moreover, this bond is further strengthened by the extender 60 in the preferred embodiment having a non-smooth surface and, in the preferred embodiment, the non-smooth surface resulting in part from the passage 68 extending therethrough. As mentioned above, the passage 68 is preferably of a dimension to allow fluid concrete to at least partially flow therein, which enhances the bond with concrete C.
[0087] The second listed function of the extender 60 is to extend the reach of the connectors 50 . As discussed above, it is preferred to make the connectors 50 having lengths so that the width of the cavity 38 is two (2), four (4), six (6), eight (8) inches or greater. If, however, it is desired to have the width of the cavity 38 be three (3), five (5), or seven (7) inches, then the preferred embodiment of the extender 60 could be used to obtain that extra inch of separation.
[0088] Assume, for example, that the connector 50 shown in FIGS. 4 and 4A connects to the two attachment points 44 of opposed side panels 20 in the dual-panel embodiment (which is discussed above and shown in FIGS. 1 and 2) to form a cavity 38 that is two inches wide. To increase the width of the cavity 38 to be three inches wide, the preferred extender 60 is used in conjunction with the connector 50 shown in FIG. 4 or FIG. 4A. That is, the tip end 62 of the extender 60 is preferably formed to be the same dimensions as an attachment point 44 of the web member 40 so that the tip end 62 can be slidably received into the track 54 at one end 52 of the connector 50 , similar to the attachment point 44 being slidably received into the end 52 of the connector 50 . The base end 64 of the extender 60 , in conjunction, preferably forms a track into which one attachment point 44 of a web member 40 is slidably received (i.e., the same dimension as the track 54 of the connector 50 shown in FIG. 4 or FIG. 4A). Accordingly, the connector 50 is coupled to the attachment point 44 of one side panel 20 , the base end 64 of the extender 60 is coupled to the attachment point 44 of the opposed side panel 20 , and the connector 50 is attached to the tip end 62 of the extender 60 so that a three-inch wide cavity 38 is formed between two opposed side panels 20 , instead of a two-inch cavity if the connector 50 shown in FIG. 4 or FIG. 4A was used alone. Thus, in the preferred embodiment, for each extender 60 added between the connector 50 and the attachment point 44 , the extender 60 advantageously allows the cavity 38 to be extended one inch in width. As such, the extender 60 can be used to meet this need to have an irregularly sized cavity without requiring the manufacturer to mold special new connectors, which would be an expensive endeavor. As one skilled in the art will appreciate, the extender 60 can have a length other than one inch, if desired.
[0089] The third potential function of the extender 60 is to establish or to buttress the connection between side panels 20 . One example in which the extender 60 is beneficial when one wall or panel is at a non-parallel angle to another wall or panel, often being disposed at right angles to form a T-wall in top plan view. Since concrete has to be poured into the cavity 38 defined by the side panels 20 that are not oriented parallel to each other (as exists in FIG. 2), the normally linear connectors 50 shown in FIGS. 4 and 4A cannot feasiblely be used. As one skilled in the art will appreciate, although within the scope of the present invention, manufacturing non-linear connectors would be expensive and often not be viable for a large percentage of construction projects.
[0090] In conjunction, one problem with constructing such a T-wall is that when the concrete is poured into the cavity 38 , pressures against the abutting side panel 20 (i.e., at the top of the “T”) forces the side panel outwardly. The prior art solution is to brace the wall on the exterior surface 32 of the side panel 20 using, for example, lumber braces. The braces, however, are difficult and labor intensive to construct, particularly when used on multistory building above the first or ground floor.
[0091] Referring now to FIG. 12, the extender 60 , used with a flexible linking member 90 , such as a zip-tie, plastic tie strap, tie wire, or other similar component, provides an easy and effective solution to buttress a connection between side panels 20 , particularly for situations in which the respective interior surfaces 34 are not parallel to each other. Although not required, it is preferred that the flexible linking member 90 be contiguous and connect to itself in by forming a closed loop, in which the looped linking member 90 interconnects the opposed side panels 20 .
[0092] For one design shown at the top of FIG. 12, respective extenders 60 are connected to attachment points 44 formed on different side panels 20 . That is, in this design there are two extenders: a first extender 60 connected to the attachment point 44 of one web member 40 partially disposed within a first panel 20 and a second extender 60 connected to the attachment point 44 of one web member 40 partially disposed within the opposed second panel 20 . A portion of the flexible linking member 90 , in conjunction, traverses through the passage of the first extender 60 and a portion of the flexible linking member 90 also traverses through the passage of the second extender 60 . The flexible linking member 90 is connected through the respective passages of two extenders 60 and tightened, thereby securely interconnecting the spaced-apart panels 20 .
[0093] In another embodiment, it is also contemplated that at least one of the two web members 40 defines a slot 41 extending therethrough. The slot 41 is preferably located adjacent the interior surface 34 of the first panel in which the web member 40 is disposed and preferably integrally formed with the web member 40 . The slot 41 is also preferably of a size to receive a portion of the flexible linking member 90 therein. Thus, as shown at the bottom of FIG. 12, a portion of the flexible linking member 90 traverses through the slot 41 of one web member 40 and also traverses through the extender 60 connected to the attachment point 44 of the other web member 40 to interconnect the spaced-apart panels 20 . In still another embodiment shown at the middle of FIG. 12, a portion of the flexible linking member 90 traverses through the slot 41 of one web member 40 and the slot 41 of the other web member 40 to interconnect the spaced-apart panels 20 . The three illustrated embodiments shown in FIG. 12, of course, may be used independently of each other.
[0094] Similarly, the extender 60 with the flexible linking members 90 can be used anywhere on the side panels 20 where there may be weakness in the structure. As an example, weakness may exist where a cut-up design is used or the wall zig-zags. As another example, weakness may also occur wherever quick turns are used in the layout of the side panel 20 . In these situations, the extenders 60 and interconnecting flexible linking members 90 may be used in lieu of external bracing. Although not preferred, it is also contemplated that the flexible linking member 90 —in concert with the passages 68 of extenders 60 or the slots 41 formed into the web members 40 —may interconnect opposed side panels 20 in the first embodiment (shown, for example, in FIGS. 1 and 2), instead of using connectors 50 to interconnect the side panels 20 .
[0095] In comparison to the extender 60 , another design of the stanchion, the anchor 70 , is also shown in FIG. 6 and is less broad in its potential functional uses. The primary purpose of the anchor 70 is to strengthen the bond between the side panel 20 and the adjacent concrete once that concrete has substantially cured. The preferred anchor 70 has a forward end 72 , an opposed back end 74 , and a body 76 extending therebetween. The back end 74 is preferably of a size to complementarily engage one attachment point 44 .
[0096] Also, it is preferred that the body 76 has at least one prong 78 extending from it and, more preferably, two prongs 78 oriented co-linearly to each other. However, as one skilled in the art will appreciate, other permutations also fall within the scope of the present invention, such as three or more prongs 78 or two prongs 78 not oriented co-linearly. The presently preferred prongs 78 have a length of a half (½) inch to one (1) inch and a generally round cross-sectional shape that has a diameter of one quarter (¼) inch. One skilled in the art, however, will appreciate that wider range of values are possible for the prongs 78 —the important consideration being that the prongs 78 not break when fluid concrete flows past the anchor 70 during the construction process or after substantial curing. Also, the prongs 78 can be integrally formed to the anchor 70 or coupled thereto using any means known in the art.
[0097] Returning to the presently preferred embodiment of two co-linear prongs 78 , it is preferred that when the anchor 70 is connected to the attachment point 44 , the two prongs 78 form an angle that is not perpendicular or normal to a plane formed by the interior surface 34 of the side panel 20 (and also the plane formed by the exterior surface of the concrete C on the tilt-up wall). In fact, it is most preferred that the two prongs 78 extend parallel to the plane formed by the interior surface 34 of the side panel 20 to which the anchor 70 is attached, an angle which is generally perpendicular to the direction that the anchor 70 extends between its forward and back ends 72 , 74 when connected to the attachment point 44 . This angular orientation of the prongs 78 provides increased bonding strength with the concrete C.
[0098] Although it is presently preferred that there is at least one prong 78 , the present invention contemplates that no prongs be included; instead, the body 76 of the anchor 70 can be of a non-smooth or non-linear shape to bond with the fluid concrete that flows around the body 76 . One contemplated design includes a generally mushroom shape that is narrow at the back end 74 and flares outwardly moving toward the forward end 72 . Other contemplated designs include the forward and back ends 72 , 74 being wider in side view than the intervening portion of the body 76 so that the body appears similar to a chef's hat or an hourglass in side view. Of course, symmetry is not required in any of these alternative embodiments. As one skilled in the art will appreciate, one important consideration is that the fluid concrete be able to flow around the anchor 70 to improve bonding after the concrete substantially cures.
[0099] Although the length of the connector 50 , extender 60 , or anchor 70 used as a stanchion between the interior surface 34 of the side panel 20 and the tip of the stanchion may be any dimension shorter than the thickness of the concrete portion of the tilt-up wall, the preferred embodiment uses a length of one inch (1″) or less. The reason for using a length shorter than the possible maximum length is that a longer stanchion would potentially interface with the re-bar or other structural support within the tilt-up wall. That is, either by convention or as required by applicable building code requirements, the re-bar is usually placed one inch or more away from either surface of the tilt-up wall so that the ends of the respective stanchions, extending the maximum of one inch, will not interface with or contact the re-bar, which could impede the proper setting of the side panels 20 into the fluid concrete.
[0100] As with the connectors 50 , the other embodiments of the stanchions are preferably formed of a high-density plastic, such as high-density polyethylene or polypropylene, although other polymers can be used as noted above. Advantages of the high-density plastics for the stanchions include cost of manufacturing, strength, rigidity when the component is sufficiently thick, and the like.
[0101] As one skilled in the art will also appreciate, the stanchions are not necessary for the present invention to function and, in fact, may not even be desired if the concrete is very “wet” or a plasticizer has been added to the concrete in the context of constructing tilt-up walls. If stanchions are used, it is contemplated using one stanchion per web member 40 connected to the center attachment point 44 (i.e., the middle attachment point 44 shown in FIG. 6); however, it is also contemplated using up to and including one stanchion on each attachment point 44 (i.e., five stanchions used on every web member in the embodiment shown in FIG. 6).
[0102] Referring now to FIGS. 9 and 9A, the third embodiment of the present invention is analogous to the first embodiment because a cavity is formed into which concrete is poured. However, instead of the formed concrete structure having opposed side panels 20 each connected to the concrete portion as in the first embodiment shown in FIGS. 2 and 2A, this embodiment preferably uses a side panel 20 on only one side of the formed concrete structure 10 . That is, the formed concrete structure 10 is similar to the tilt-up wall discussed above (i.e., a concrete slab C with side panels 20 positioned only on one side), but is made using a different construction process.
[0103] More specifically and as best shown in FIG. 9, the third embodiment uses a side panel 20 and an opposed sheet 80 to form the cavity 38 into which the concrete is poured. That is, in forming the wall 10 , the process involves positioning the side panel 20 and the sheet 80 substantially upright so that a portion of the interior surface 34 of the side panel 20 faces a portion of an inside surface 82 of the sheet 80 . The interior surface 34 and the inside surface 82 are laterally spaced apart from each other so that a cavity 38 is formed therebetween, just as occurs in the first embodiment using spaced-apart side panels 20 .
[0104] The sheet 80 is preferably plywood, but can be any solid material that can be coupled to either a web member 40 or a connector 50 and can withstand the forces exerted by the fluid concrete when poured into the cavity 38 without substantial bowing, warping, breaking, or other type of failure. Other contemplated materials include combined steel frame and plywood center, commonly known as a steel-ply panel. Accordingly, the sheet 80 functions as a form or barrier while the concrete is curing.
[0105] The process next involves attaching one end 52 (“the first end”) of the connector 50 to the attachment point 44 of the side panel 20 and connecting a portion of the inside surface 82 of the sheet 80 to the other end 52 (“the second end”) of the connector 50 . However, it may be a matter of preference for the order of construction so the first end of the connector 50 may be attached to the attachment point 44 before positioning the sheet 80 or the sheet may be positioned before the first end of the connector 50 is attached to the attachment point 44 .
[0106] The sheet 80 can be either directly or indirectly coupled to the connector 50 . That is, referring back to FIG. 3, there are two options for the second or “free end” of the connector 50 , which is the end not attached to the web member 40 located within the side panel 20 . First, for the indirect connection and as shown in FIG. 9, the free end can be connected to, for example, a stand-alone web member 40 ′, which is a web member that is not formed within a side panel 20 and is illustrated in FIGS. 3, 6, 9 , and 10 . The sheet 80 is then connected to the end plate 42 of the stand-alone web member 40 ′, instead of being directly connected to the second end of the connector. This indirect connection forms the preferred embodiment.
[0107] [0107]FIG. 3 shows only one stand-alone web member 40 ′ that is attached to the connectors 50 . As one skilled in the art will appreciate, however, multiple web members 40 are preferably used when preparing the wall structure 10 (i.e., between two and six stand-alone web members 40 ′ used for the side panel 20 shown in FIG. 3 based on there being six web members 40 located within the side panel 20 ). It is, of course, preferred to use a sufficient number of web members to withstand the dynamic and static forces that exist when the fluid concrete is poured into the cavity (i.e., preferably six for the side panel 20 shown in FIGS. 3 and 9).
[0108] Alternatively and less preferred, the sheet 80 may be connected directly to the second or free end of the connector 50 . Still referring to FIG. 3, four connectors 50 are shown in this configuration (i.e., connected to the web member 40 located within the side panel 20 but not connected to a stand-alone web member 40 ′). Thus, unlike the indirect connection having an intervening stand-alone web member 40 ′ or other component, the sheet 80 in this design is directly coupled to the second ends of the connectors 50 . The potential drawback with this design is that it is more difficult to attach or couple the sheet 80 to the connectors 50 at the construction site. However, if the free end of the connectors 50 is formed with more surface area than included in the illustrated embodiments, this potential drawback may be reduced.
[0109] It is also contemplated using connectors 50 that are integrally attached to or formed with the web members 40 located in the side panels 20 for the third embodiment (as well as other embodiments). Stated differently, the connectors 50 and web members 40 may be a unitary structure and, as such, the attachment points 44 in this contemplated design extend a distance from the interior surface 34 of the side panel 20 to the attachment points 44 that is substantially equivalent to the desired thickness of the cavity 38 for the direct connection process. Thus, the step of attaching the connectors 50 to the attachment points 44 of the web members 40 disposed within the side panels 20 is avoided because the inside surface 82 of the sheet 80 is attached directly to the attachment point 44 to form the cavity 38 . Alternatively, the extended attachment points 44 may be designed to connect to the stand-alone web member 40 ′ or similar structure is using the indirect connection method. However, this design of integrally forming the connectors 50 to the attachment points 44 has a potential drawback of the increased space needed to transport a given quantity of side panels 20 to the construction site if the web members 40 are integrally formed into the side panels 20 , as opposed to being inserted through precut slots at the construction site.
[0110] Regardless of the component to which the sheet 80 is connected, it is preferred that the sheet be detachably connected, or removably attached, to the second end of the connector 50 or stand-alone web member 40 ′. By being detachably connected, the present invention entails that the sheet 80 can be removed from the end plate 42 or connector 50 substantially intact, preferably so that the sheet can be reused to form another concrete structure. Many means are contemplated for detachably coupling the sheet 80 to the end plate 42 or connector 50 , such as using a nail or screw. One skilled in the art will appreciate that this list is not exhaustive and can include other coupling means such as chemical adhesives, rivets, tacks, nuts and bolts, and the like.
[0111] Once the sheet 80 and side panel 20 are interconnected and stationarily positioned relative to each other, the process of forming the structure 10 involves pouring fluid concrete into the cavity 38 and allowing the concrete to substantially cure to form a concrete slab C. The formed concrete structure 10 is shown in FIG. 9A. In the preferred embodiment, after the concrete substantially cures (which may take about three days depending on ambient conditions and the thickness of the cavity 38 ) the process involves removing the sheet 80 from the concrete slab C to expose a portion of the concrete slab C to atmosphere, which is shown in FIG. 11. That is, after substantially curing, the sheet 80 is preferably removed leaving a concrete structure 10 that has a side panel 20 disposed on one side and concrete C exposed to ambient or atmosphere on the other, opposed side. The sheet 80 is also preferably reusable for forming another wall. However, although not preferred, it is contemplated having the sheet 80 remain a permanent part of the tilt-up structure 10 as shown in FIG. 9A.
[0112] A potential aesthetic drawback with the above process is that when the sheet 80 is removed, the exposed surface will be predominately concrete C with the end plates 42 or the ends 52 of the connectors 50 recurrently showing on the exposed concrete surface. To avoid this non-contiguous appearance and as shown in FIG. 10, the present invention also contemplates using a spacer 84 attached or permanently affixed to the end plate 42 of the stand-alone web member 40 ′ or to one end 52 —the free or second end—of the connectors 50 . The spacer 84 is to be disposed in a contacting relationship with the inside surface 82 of the sheet 80 .
[0113] Referring now to FIG. 10, one embodiment of the spacer 84 is cone-shaped in side view, in which the narrow end is attached or coupled to the end plate 42 of the stand-alone web member 40 ′ or the end 52 of the connector 50 and preferably extends between a quarter and three-quarter (¼-¾) inches, more preferably one-half (½) inch. The cone-shaped spacers may also be inverted so that the wide end is attached to the end plate 42 . It is also contemplated that the cone-shaped spacer 84 has openings or slots extending between the narrow end and the wide end. Other shapes are contemplated for the spacer 84 , such as circular, elliptical, or rectangular shapes in plan view. It is also contemplated having the spacer 84 use a constant cross-sectional area along its length, instead of being cone shaped.
[0114] The sheet 80 is mounted to abut the wide end of the spacer 84 and the screw—if used as the coupling means—traverses through the sheet 80 , spacer 84 , and then into and through a portion of either the end plate 42 of the stand-alone web member 40 ′ or end 52 of the connector 50 . If the wide end of the spacer 84 is attached to the end plate 42 , then the coupling means need not traverse through the interior of the spacer, which may be easier at the construction site because less precise aligning is required. If the spacer 84 has openings, at least some concrete may enter into its internal volume when the cavity 38 is filled with concrete.
[0115] Using the spacers 84 , after the concrete substantially cures and the sheet 80 is removed, the interior volume of the spacer 84 is exposed so that there are only small portions of the concrete surface in which the concrete C is not contiguous on the face of the structure 10 . However, since the preferred spacer 84 is cone-shaped, a finish coat of cementitious material, including concrete, a parging coat, or stucco, can quickly be spread into the interior volume of the spacers so that when it cures, the exposed face of the concrete structure 10 appears as a uniform concrete surface, as opposed to having the ends 52 of the connectors 50 or the end plates 42 exposed.
[0116] One skilled in the art will appreciate that a uniform concrete appearance obtained using the spacers 84 is more aesthetically appealing if the exposed surface of the concrete structure remains exposed when the building is completed. However, if it is desired to mount materials such as drywall or masonry tiles directly onto the surface originally covered by the sheet 80 , not using the spacers 84 may be preferred. That is, the exposed end plates 42 of the stand-alone web members 40 ′ or the ends 52 of the connectors 50 facilitate attaching materials to the concrete surface because it is easier to connect materials to these members, compared to attaching the materials to the cured concrete C. Also, if the entire exposed concrete surface will be coated with stucco or the like, then depending on the bonding properties of the coating, it may be irrelevant whether the spacers 84 are used.
[0117] Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims. | A concrete structure formed using an extender that connects to a web member at least partially disposed within a side panel. The extender may be used to extend the length of a connector that interconnects opposed side panels, used to provide additional surface area to which concrete can bond if, for example, forming a tilt-up wall, or used as a strapping location with a flexible linking member. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. § 1.72(b). |
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to a material handling platform that may be installed on a material transport vehicle for carrying material on the platform and for rotating material relative to the longitudinal axis of the material transport vehicle. The material handling platform is particularly adapted for use in underground mining operations but the platform has applications other than for underground mining.
2. Description Of The Prior Art
Various types of vehicles have been provided with turntables on the vehicles for one purpose or another. U.S. Pat. No. 4,553,893 discloses a rotary turntable that may be placed in a production line to move the products to various locations.
U.S. Pat. No. 1,966,866 discloses a vehicle on endless tracks which has a turntable onto which a cement mixer may be driven. The turntable can be turned to permit the cement mixer to discharge cement to the sides of the vehicle.
U.S. Pat. Nos. 1,349,012 and 1,663,832 also show vehicles having turntables which may be utilized in paving and roadbed construction. U.S. Pat. No. 817,434 and U.S. Pat. No. 3,583,328 disclose turntables mounted on railway type vehicles. U.S. Pat. No. 3,830,385 discloses a baggage cart which has a turntable mounted on its top surface. U.S. Pat. No. 2,572,776, U.S. Pat. No. 3,190,475, U.S. Pat. No. 1,384,077 and U.S. Reissue Pat. No. 15,976 all show various types of portable turntables on vehicles.
None of the foregoing prior art shows a platform having a turntable wherein the platform may be both raised and lowered and also tilted and which may be readily secured to or removed from a material transport vehicle as the requirements of a particular job may require.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a material handling platform for a material transport vehicle wherein the platform has a forwardly extending base member with a top surface and a lower surface that is movably connected to a tilt frame so that the base member can be moved vertically relative to the tilt frame between a position at ground level and various positions substantially above ground level. First actuating means are connected to the base member and the tilt frame to move the base member vertically relative to the tilt frame upon actuation of the first actuating means and to maintain base member in a fixed position relative to the tilt frame when not actuated. A horizontal pivot is fixed to the material transport vehicle and the tilt frame is pivotally secured to the vehicle pivot means. A second actuating means connected to the vehicle and to the tilt frame pivots the tilt frame relative to the vehicle about the horizontal pivot means upon actuation of a second actuating means and maintains the tilt frame in a fixed position and relative to the vehicle when not actuated. A turntable which forms a portion of the area of the top surface of the base member is rotatably supported by the base member for movement with the base member and for rotation relative to the base member. A third actuating means is connected to the turntable and to the base member to turn the turntable relative to the base member when actuated and to maintain the turntable in a fixed position relative to the base member when not actuated.
Further, in accordance with the present invention, a material handling platform for a material transport vehicle is provided which has a forwardly extending base member that has a material handling top surface movably connected to a tilt frame. The base member may be moved vertically relative to the tilt frame between a position at ground level and positions substantially above ground level. A first actuating means which includes a double action hydraulic piston and cylinder is connected to the base member and to the tilt frame to move the base member vertically relative to the tilt frame upon actuation of the first actuating means and to maintain the base member in a fixed position relative to the tilt frame when not actuated. A horizontal pivot means is fixed to the front end of the vehicle to pivotally receive the tilt frame. A second actuating means, including a double action hydraulic piston and cylinder, is connected to the vehicle and to the tilt frame to pivot the tilt frame relative to the vehicle about the horizontal pivot means upon actuation of the second actuating means and to maintain the tilt frame in a fixed position relative to the vehicle when not actuated. A turntable forming more than fifty percent (50%) of the area of the material handling top surface of the base member is provided with the turntable being rotatably supported by the base member for movement with the base member and for rotation relative to the base member. A third actuating means, including a double action rotary vane hydraulic motor is connected to the turntable and to the base member to turn the turntable relative to the base member when actuated and to maintain the turntable in a fixed position relative to the base member when not actuated. A source of fluid under pressure is located on the material transport vehicle and hydraulic control lines and valves connect the hydraulic fluid source with the first actuating means, with the second actuating means, and with the third actuating means so that the actuating means may be selectively actuated to control the position of the base member and the turntable.
Still further in accordance with the present invention, there is provided a method of placing an additional roof support in position adjacent the long wall of an underground mine. The method includes placing a roof support to be transported on the material handling platform of a material transport vehicle having a device that enables the load on the platform to be rotated relative to the longitudinal axis of the vehicle. The roof support is rotated so that the longest dimension of the roof support is aligned with the longitudinal axis of the vehicle and the vehicle is moved along the long wall to the position where the transported roof support is to be placed. The roof support is then rotated on the material handling platform 90° so that the longest dimension of the roof support is at a right angle to the vehicle longitudinal axis and thereafter the transported roof support is removed from the vehicle material handling platform onto the floor of the underground mine.
Accordingly, a principal object of the present invention is to provide a material handling platform for a material transport vehicle which has a rotatable turntable on the top surface of the platform and wherein the platform may be lifted vertically relative to the vehicle and may be tilted relative to the vehicle.
Another object of the present invention is to provide a material handling platform for a material transport vehicle that may be readily controlled to perform a variety of tasks.
A further object of the present invention is to provide a method of placing an additional roof support in position adjacent to the long wall of an underground mine in an efficient manner.
These and other objects of the present invention will become apparent as this description proceeds in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the material handling platform of the present invention in position on a material transport vehicle.
FIG. 2 is a top plan view of the material handling platform.
FIG. 3 is a view in side elevation of the material handling platform of the present invention showing the platform in an elevated position in phantom lines.
FIG. 4 is an end elevation view of a material handling platform as viewed from the left side of FIG. 2.
FIG. 5 is a sectional view of the base member of the material handling platform taken along line 5--5 of FIG. 4.
FIG. 6 is an elevational view of the base member as viewed from the right side of FIG. 5.
FIG. 7 is an elevational view of the material handling platform as viewed from the right side of FIG. 3 with certain parts removed for clarity.
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7 showing details of the lifting actuator for the material handling platform base member.
FIG. 9 is a fragmentary sectional view showing details of the horizontal rollers and the ring guide for the turntable.
FIG. 10 is a fragmentary diagrammatic illustration of the tilt mechanism of the present invention showing the material handling platform in different tilted positions.
FIG. 11 is a side elevational view of the material handling platform of the present invention with a mine roof support being transported thereon.
FIG. 12 is a fragmentary top plan view of an underground mine with a long wall mining machine therein showing the material handling platform of the present invention being utilized in placing the roof supports.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and particularly to FIG. 1, there is shown a perspective view of a material handling platform indicated generally by the numeral 10 which is affixed to and carried by a material transport vehicle indicated generally by the numeral 12. The material transport vehicle 12 is preferably the type of vehicle disclosed in U.S. Pat. No. 4,199,299 and U.S. Pat. No. 4,411,583, both of which are assigned to the assignee herein. It should be understood that the vehicle disclosed in the aforesaid patents. is the preferred type of material transport vehicle 12 but that the material handling platform 10 of the present invention may be utilized with equal facility on other types of material transport vehicles such as back hoes, front end loaders, tractors and general utility vehicles. When utilized with the vehicles disclosed in U.S. Pat. No. 4,199,299 and U.S. Pat. No. 4,411,583, the material handling platform 10 is attached directly to the vehicle body and the boom arrangement shown in the aforesaid U.S. patents is removed from the vehicle body prior to installation of the material handling platform 10 of the present invention.
Referring to FIGS. 2, 3 and 4, the material handling platform 10 is formed from a base member 14 having a top wall 16 and a bottom wall 18 that are generally parallel to each other. The top wall 16 has an angled end portion 20 which permits material to slide up onto the top wall 16 of the platform. The base member 14 also has a vertical upstanding wall 22 that exterts upwardly from base member 14. Wall 22 has a rectangular opening 24 formed therein so that a winch cable 100 may be passed through opening 24 from a winch on the vehicle 12.
FIGS. 5 and 6 illustrate the base member 14 of the platform 10 in greater detail. As seen in FIGS. 2, 5 and 6 the base member 14 has a pair of guides 26 formed at the rear of upstanding vertical wall 22. The guides 26 guide the base member 14 for vertical movement relative to a pair of mating receiving guides 28 that are formed on tilt frame 30 (FIGS. 2 and 3).
As may best be seen in FIGS. 2, 3, 7 and 8, the tilt frame 30 slidingly receives guides 26 of base member 14 within receiving guides 28, respectively, so that base member 14 may be moved vertically relative to tilt frame 30. The tilt frame 30 has a pair of yokes 32 which extend to the rear of the tilt frame. The yokes 32 have pivot apertures or bores 34 formed therein to receive a pivot means (not shown) secured to the vehicle so that tilt frame 30 may pivot relative to the vehicle 12 about the pivot means that passes through pivot apertures 34 in yokes 32.
As best seen in FIGS. 7 and 8, a pair of piston brackets 36 are fixed to the tilt frame 30 within receiving guides 28. The pair of piston brackets 36 each receive a pin 40 that is attached to piston 38 of a piston-cylinder hydraulic actuator. The cylinder 42 of the hydraulic actuator is secured to a bracket 26a that is fixed to guides 26, as the case may be, that is part of base member 14. With such an arrangement, the double acting hydraulic actuator formed of piston 38 and cylinder 42 may raise and lower base member 14 relative to tilt frame 30 as illustrated in FIG. 3. With the double acting arrangement, the base member 14 may be stopped in any number of vertical positions relative to tilt frame 30 by closing all valves and trapping fluid at a specified level within the cylinder 42.
As shown in FIG. 7, the tilt frame 30 has an elongated opening 44 formed to admit the winch cable 100 (shown in FIG. 1) through the tilt frame 30. The opening 44 in tilt frame 30 registers with opening 24 in vertical wall 22 of base member 14. Because of the elongation of the openings, the winch cable 100 may readily pass through both the base member 14 and tilt frame 30 without being pinched no matter what vertical position the base member 14 is in relative to tilt frame 30. The winch cable 100 may be attached to a load to be carried on the platform 10 and the load may be pulled onto platform 10 over inclined end 20 of the base member 14 by actuating the winch (not shown) on the vehicle 12.
As best seen in FIGS. 2, 3 and 7, the tilt frame 30 has brackets 46 formed thereon so that pistons 48 may be pinned by pins 50 to the brackets 46. The pistons 48 are part of a double acting piston-cylinder actuator which includes cylinder 52. Cylinder 52 has a bracket with an aperture 54 which attaches to a pivot means (not shown) that is fixed to the material transport vehicle 12. As may be seen in FIG. 10, when the piston 48 and cylinder 52 are actuated they force the tilt frame 30 to pivot about pivot apertures 34 that are pivotally secured to vehicle 12. FIG. 10 shows, in phantom lines, an alternate position of the tilt frame 30. Shown in FIG. 10, tilt frame 30 may pivot about aperture 34 a total amount equal to angle A. In most cases, angle A will be a total of 12° so that the base number 14 may pivot 6° below the horizontal and 6° above the horizontal position shown in FIG. 3.
The piston 48 and cylinder 52 provide a double acting hydraulic piston-cylinder actuator which not only serves to tilt the tilt frame 30 relative to vehicle 12 but which also may fix the position of the tilt frame 30 relative to vehicle 12 while the piston 38 and cylinder 42 are not actuated.
As best seen in FIGS. 2 and 5, the top wall 16 of base member 14 has a turntable 56 positioned therein. Turntable 56 covers in excess of fifty percent (50%) of the total area of the top wall 16 of base member 14. The turntable 56 is supported by a center column 58 and by rollers 60 so that it may support heavy loads and be rotated relative to the base member 14 with the heavy weight thereon. The center column 58 is journaled for rotation relative to the base member 14. Rollers 60 are supported on brackets 62 fixed to base member 14. A circular flange 64 is fixed to the bottom of turntable 56 and extends around the periphery of turntable 56. Circular flange 64 rides upon the rollers 60 to support the weight of the turntable 56 and any material that is carried on turntable 56. As seen in FIGS. 3 and 5, the upper surface of turntable 56 extends above the top wall 16 of base member 14. A vane type hydraulic motor (not shown) is secured to center column 58 to rotate turntable 56 upon actuation of the hydraulic motor. The hydraulic motor is double acting so that it may be utilized to rotate the turntable in either direction and it may also be utilized to fix the turntable in a fixed position when the hydraulic motor is not actuated. The turntable 56 is constructed to rotate a total of 190° relative to base member 14.
The rollers 60 on brackets 62 are positioned in relatively closely spaced relation around the periphery of turntable 56. There are 12 sets of brackets 62 and rollers 60 to provide vertical support for the turntable, where desired, additional brackets 62 and rollers 60 may be utilized to provide additional support for the turntable 56. The turntable 56 is guided horizontally by horizontal rollers 66 that are rotatably journaled over posts 68 (FIG. 9). Posts 68 are fixed to bottom wall 18 of base member 14. A guide ring 70 is fixed to turntable 56 and rides against rollers 66 to maintain turntable 56 in proper horizontal position. There are four posts 68 and rollers 66 located around turntable 56. As seen in FIG. 2, access ports 72 provide access to rollers 66 through the top wall 16 of base member 14.
When positioned on a material transport vehicle 12, the material handling platform 10 of the present invention may be raised and lowered by actuating pistons 38 in cylinders 42 to raise and lower the base member 14 relative to the tilt frame 30 as shown in FIG. 3. When pistons 48 in cylinders 52 are actuated, the tilt frame may be pivoted about pivot aperture 34 relative to vehicle 12 through a total angle A as shown in FIG. 10. When the vane type motor actuator for turntable 56 is actuated, turntable 56 may be rotated through 190° relative to base member 14.
In the foregoing description, the actuators for the various elements of the material handling platform 10 have been described as hydraulic motor type actuators and hydraulic piston-cylinder type actuators. It will be appreciated that the actuators will have appropriate control lines and appropriate control valves to control the hydraulic fluid that actuates the various actuators. The control lines, control valves and actuators themselves are conventional units and form no part of the present invention. The control lines and control valves will pass through the operator's station located on the material handling transport vehicle so that the operator of the vehicle can control the various positions of the material handling platform. The typical material transport vehicle 12 will have a source of hydraulic fluid under pressure to operate the various actuators required for controlling the material handling platform 10.
While actuators for the positioning of the material handling platform 10 have been described as hydraulic type actuators, it will be appreciated that other types of actuators such as screw type actuators driven by electric motors could be substituted for piston-cylinder hydraulic type actuators and a worm gear drive powered by an electric motor could be utilized to drive the turntable of the present invention.
The material handling platform of the present invention has many uses in material handling and haulage. It is particularly useful, however, when utilized to position roof supports in an underground mine that is using long wall mining apparatus. In long wall mining, a shear is moved along the face of the mineral being mined and dislodges the mineral from the face. The mineral is deposited upon a conveyer belt immediately behind the face and is removed from the mine in a direction parallel to the face. Typically, hydraulically controlled roof supports are positioned to protect the long wall machine and the conveyer arrangement from the roof which collapses behind the face as the face advances into the seam. As shown in FIGS. 1 and 11, a long wall roof support or jack 74 is carried on the material handling platform 10 of the present invention. In FIG. 11, the roof support is positioned on the platform 10 so that the long dimension of the roof support is aligned with the longitudinal axis of the material transport vehicle 12. In FIG. 1, the roof support 74 for illustrative purposes is illustrated as positioned on platform 10 so that the long dimension of the roof support is perpendicular or at 90° to the longitudinal axis of the material transport vehicle 12.
FIG. 12 is a diagrammatic illustration of a portion of a mine in which the mineral is dislodged by a long wall type mining machine. In FIG. 12, roof supports 76, 78 and 80 are in position at a short distance from the face 82. The conveyer 84 conveys mineral which is mined from the face to an entry located at the end of the mine.
The material transport vehicle 12 with the material handling platform 10 has an additional roof support 74 on the turntable of material handling platform 10. Ordinarily, the vehicle 12 is driven under the roof supports 76, 78 and 80 that are already in position within the mine. As the material transport vehicle 12 is moved under the existing roof supports, the new roof support 74 is positioned on turntable 56 of material platform 10 so that the long dimension of support 74 is aligned with the longitudinal axis of vehicle 12. The roof support 74 is carried with the base member 14 of material handling platform 10 raised from the ground while the vehicle is in motion and the base member 14 is not tilted but is parallel to the ground
When the vehicle arrives at the place where roof support 74 is to be positioned, the turntable 56 of material handling platform 10 is rotated 90° so that the long dimension of the roof support 74 is at right angles to the longitudinal axis of vehicle 12. The base member 14 of material platform 10 is then tilted and lowered so that the front end of the base member 14 at the angled end 20 touches the ground. The roof support 74 is then slid from the material handling platform 10.
Prior to the use of the above-described method, it was difficult to position the roof support in its proper position within the long wall mining system since turning of the roof support was difficult. With the present method and the material handling platform of the present invention, placing a roof support within a long wall mine is greatly facilitated.
According to the provisions of the Patent Statutes, we have explained the principle, preferred construction and mode of operation of our invention and have illustrated and described what we now consider to represent its best embodiment. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described. | A material handling platform is pivotally attached to the front of the material transport vehicle. Actuator means raise and lower the platform. The platform is arranged to tilt relative to the vehicle about a horizontal pivot at the front of the vehicle. A turntable is mounted on the platform. The material handling platform positions roof supports in an underground mine adjacent a long wall mining machine. The roof supports are transported by the material transport vehicle carrying the material handling platform with the longest dimension of the roof support aligned with the longitudinal axis of the vehicle. After the roof support reaches the position where it is to be installed, the roof support is turned relative to the vehicle by turning the turntable of the material handling platform so that the longest dimension of the roof support is at right angles to the longitudinal axis of the vehicle. The roof support is then removed from the vehicle by lowering and tilting the platform relative to the vehicle. |
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PRIORITY
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/251,221, filed on Oct. 14, 2005 and published on Apr. 20, 2006, which in turn claims the benefit of U.S. Provisional Application No. 60/619,343, filed on Oct. 15, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of building construction. More particularly, the present invention provides a method and apparatus that prevents water intrusion into the walls of the building around a window, door, or other framed object.
BACKGROUND OF THE INVENTION
[0003] A typical window 100 of the prior art is shown in FIG. 1 . The window 100 may include one or more panes of glass 110 , which may be embedded in a single sash, or in an upper and lower sash such as in a double-hung window. The sash is secured in a frame 120 , which consists of two side jambs 130 , a top jamb 140 , and a sill 150 . The window frame 120 is typically made from wood, vinyl, aluminum, or fiberglass, but may be made from any durable, rigid material.
[0004] Typically, a window is installed into a rough opening 200 in a house or building, as shown in FIG. 2 . The rough opening 200 forms a window cavity 202 surrounded by a header 210 , two sides 220 , and a sill 230 . The header 210 must be constructed sufficiently sturdy to support the necessary roof loads, since these loads cannot be supported by the window unit 100 . This is especially important with large window units 100 , or when a “window wall” is created with multiple windows side-by-side. The rough opening 200 has an interior side 240 and an exterior side 250 relative to the building itself. The sill 230 is sloped toward the exterior side 250 to allow water that makes its way to the sill 230 to drain out the exterior of the building. The height and width of the window cavity 202 is constructed larger than the height and width of the window frame 120 ; typically about three-quarters of an inch (approximately two centimeters) larger in each direction. This leaves an approximately three-eighth inch space (about one centimeter) between the window 100 and the rough opening 200 on each of the four exterior faces 160 (the top 120 , sill 150 , and both sides 130 ) of the window 100 .
[0005] To hold the window unit 100 in place, the unit 100 is generally constructed with a nailing or installation flange 170 near the exterior edge on each of the four faces 160 of the window frame 120 . FIG. 3 shows the window 100 of FIG. 1 sectioned along line 3 - 3 , and shows the relationship of the nailing flange 170 versus the rest of the window frame 120 and the glass 110 . FIG. 4 shows the same section of window 100 , this time with the nailing flange 170 being used to secure the window frame 120 to one of the sides 220 of the rough opening 200 . The window 100 is installed so that the nailing flange 170 is on the building exterior 250 . Nails 300 are then placed through both the flange 170 and the side 220 of the rough opening 200 . These nails 300 are used around the circumference of the window 100 , preferably centering the window 100 in the opening 200 .
[0006] Because the opening 200 is deliberately sized larger than the window 100 , a space 310 is created between the opening 200 and the window. Modern construction techniques involve creating a vapor barrier between warm moist air inside a house and the outside, cooler air. To complete the vapor barrier, it is necessary to extend the vapor barrier from the rough opening 200 of the house framing to the window 100 itself. To accomplish this, foam 320 is inserted into space 310 around all four faces 160 of window 100 . This foam 320 also serves to insulate this gap 310 . Most window manufacturers carefully advise the window installers to take steps to prevent the expanding foam 320 from warping the window frame 120 . In most cases, installers are instructed to use low expanding foam 320 . In addition, installers are instructed to begin inserting the foam 320 at the nailing flange 170 , but to avoid filling the entire space 310 all the way to the interior 240 of the rough opening 200 and window frame 120 . This should allow the expansion of the foam 320 within space 310 without warping the window frame 120 .
[0007] To prevent water leakage under the nailing flange 170 , installers will generally place a sealant between the flange 170 and the exterior surface 250 of the rough opening 200 . Sill flashing is used on the sill 230 to provide a moisture barrier to prevent water that enters the window cavity 202 after installation of the window 100 from entering the wall under the sill 230 . Moisture in the window opening 202 will ideally pool on the sill flashing, where it will generally drain down the non-wood side of the exterior building paper. Any moisture that does not drain off the sill will remain on the sill flashing until it evaporates. Because of this, it is generally encouraged that sealant not be used on the bottom or sill nailing flange 170 , in order to allow for drainage and evaporation from outside.
[0008] Unfortunately, this prior art technique of window construction and installation has caused various moisture and mold problems in today's buildings. What is needed is an improved construction and installation method for windows the does not cause these problems.
SUMMARY OF THE INVENTION
[0009] The present invention prevents moisture that enters the window opening from entering the interior of the building by creating a channel behind the nailing flange of the window. Prior art windows and techniques encouraged foam insulation to be inserted between the window and the rough opening all the way to the nailing flange that is used to secure the window. This insulation prevented moisture from reaching the sill, from which it could drain or evaporate. Instead, the foam directed the water into the interior of the building. Alternatively, water that did reach the sill could become trapped behind the insulation and be prevented from draining or evaporating. In this case, the water may cause rotting inside the framing.
[0010] The present invention creates a barrier in the space between the window and the rough opening that prevents the foam from reaching the nailing flange. On the interior side of this barrier, the foam is installed normally. On the exterior side of this barrier a channel is created. This channel preferably runs around the circumference of the window. The channel allows water that enters behind the nailing flange the ability to drain down to the window sill where it can drain or evaporate.
[0011] To form the barrier, a gasket can be constructed around the perimeter of the window. This gasket is sized to engage the rough opening, such that it forms a barrier running from the window to the rough opening. Alternatively, the gasket can be sized to extend at least half way into the space between the window and the opening.
[0012] The gasket can be attached to the window during window manufacture. Alternatively, the gasket can be sold separately and attached to the window at the installation site. The gasket may also be directly attached to the rough opening itself, where it will then engage the window frame when the window is installed. The gasket can be relatively straight, extending perpendicularly from the window or rough opening and then bending during window installation. Alternatively, the gasket can be curved. The curved gasket can be sized large enough to span a large space between the window and the rough opening, and can be compressed easily to span a much smaller space. If designed to engage the rough opening, the gasket should be flexible so as to bend during the insertion of the window. If actual engagement is not anticipated, the gasket can be rigid. Finally, the barrier can be formed with a disintegrating object that disintegrates once the insulation has be installed, or a wicking object that remains in the channel to block the foam insulation while still allowing water to reach the sill.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a prior art window.
[0014] FIG. 2 is a perspective view of a rough opening for a window.
[0015] FIG. 3 is a sectional view of a portion of the window of FIG. 1 along line 3 - 3 .
[0016] FIG. 4 is a sectional view of the portion of the window shown in FIG. 3 attached to the rough opening of FIG. 2 .
[0017] FIG. 5 is a perspective view of a window of the present invention.
[0018] FIG. 6 is a sectional view of a portion of the present invention window of FIG. 5 taken along line 6 - 6 .
[0019] FIG. 7 is a sectional view of the portion of the present invention window shown in FIG. 6 attached to the rough opening of FIG. 2 .
[0020] FIG. 8 is a perspective view of a second embodiment of the present invention detached from a window.
[0021] FIG. 9 is a sectional view of the second embodiment being used on a window in a rough opening.
[0022] FIG. 10 is a sectional view of a third embodiment of the present invention being used in connection with a window in a rough opening.
[0023] FIG. 11 is a sectional view of a fourth embodiment of the present invention in which the gasket has a rounded shape that is easily compressed.
[0024] FIG. 12 is a sectional view of a fourth embodiment of the present invention showing a decomposing article being used in connection with a window in a rough opening.
[0025] FIG. 13 is a sectional view of the fourth embodiment after the decomposing article has decomposed.
[0026] FIG. 14 is a sectional view of a fifth embodiment of the present invention showing the use of a wicking article.
[0027] FIG. 15 is a sectional view of a sixth embodiment of the present invention showing the use of a wicking element attached to the nailing flange of the window.
[0028] FIG. 16 is a sectional view of the sixth embodiment of FIG. 15 being used in connection with a window in a rough opening.
[0029] FIG. 17 is a perspective view of a door frame of the present invention.
[0030] FIG. 18 is a sectional view of a seventh embodiment of the present invention being used on a window in a rough opening.
[0031] FIG. 19 is a section view showing the length of the seventh embodiment from FIG. 18 .
DETAILED DESCRIPTION OF THE INVENTION
[0000] Recognition of the Problem
[0032] The inventor of the present invention has discovered a significant problem with prior art windows and installation techniques as illustrated in FIGS. 1, 2 , 3 and 4 and described above. As explained above, the current thinking in window and building construction allows moisture that enters the window cavity to drain and evaporate at the sill. For this approach to function adequately, three requirements must be met. The moisture that enters the window cavity 202 must be able to flow down to the sill 230 . The sill 230 must be properly constructed to ensure a waterproof surface. And, the sill must be able to either drain the moisture to the outside 250 of the building, or must have enough ventilation to allow evaporation.
[0033] Unfortunately, the construction technique described above does not allow the first requirement to be met. Moisture will often enter into the window cavity 202 at the top 120 and sides 130 of the window 100 . Assuming that there is no failure in the window itself, the moisture enters at these locations under the nailing flange 170 . While the sealant applied under the flange 170 should help prevent this, gaps or cracks in the sealant are inevitable. The moisture that seeps under the nailing flange 170 will enter the space 310 between the window 100 and the rough opening 200 . At this point, the foam 320 that was installed all the way to the nailing flange 170 will interfere with the ability of the moisture to find its way down to the sill 230 . The problem is that the foam material 320 is permitted to fill the space 310 all the way to the nailing flange 170 . At some point, the foam 320 will form a blockage against the nailing flange 170 , and prevent any further downward movement of the moisture toward the sill 230 . In addition, since the foam insulation 320 is never perfectly formed, cracks and gaps in the foam 320 form passageways that permit the water to move toward the interior 240 of the rough opening 200 . In fact, once the foam insulation 320 has formed a blockage with the nailing flange 170 , the only place for the water to go is toward the interior of the building. There the water remains, leading to water damage and molding issues.
First Embodiment of the Solution
[0034] The present invention involves a plurality of techniques to ensure that the foam material 320 that is applied from the interior 240 of a building in the space 310 between the window 100 and the rough opening 200 is not allowed to reach the nailing flange 170 . By doing so, a channel or gap is created between the insulation 320 and the flange 170 that allows all moisture that enters anywhere around the edge of the window 100 to drain properly to the sill 230 .
[0035] The first such technique is shown in FIG. 5 . There a standard window 100 with a nailing flange 170 has been fitted with a gasket 400 around its circumference. This gasket 400 can be placed on each of the four peripheral faces 160 of the window frame 120 , and is positioned between the nailing flange 170 and the interior surface of the window 100 . While installing the gasket 400 around all four faces 160 of the window 100 is preferred, it is well within the scope of the present invention to install the gasket 400 on less than all of the circumference of the window. For instance, an installer or window manufacturer may refrain from installing the gasket 400 along the sill edge 150 of the window 100 to allow easier drainage at the sill 230 of the opening 200 . However, this is generally not preferred as foam material 320 that reaches the nailing flange 120 at the sill 230 can also prevent proper drainage of moisture. Modern building codes require the foam material 320 to complete the vapor barrier on all sides of a window 100 , and therefore the gasket 400 is preferably used on all sides as well.
[0036] As shown in the cross-sectional view in FIG. 6 , gasket 400 projects away from the window frame 120 , but does not extend as far as the nailing flange 170 . The purpose of the gasket 400 is to approach or engage the rough opening 200 when the window 100 is installed. The flexible gasket 400 can be formed and attached to the window frame in a variety of ways. In FIG. 6 , it is shown that the gasket 400 is formed with a tongue 410 that fits into a groove in the window frame 120 . This tongue-and-groove connection is designed to prevent the gasket 400 from moving or otherwise disengaging with the window frame 120 during the installation of the window 100 . Of course, other protrusion and channel combinations could be used equally as well as the tongue and groove shown in FIG. 6 , including protrusions on the window frame 120 that extend into channels or grooves on the gasket 400 .
[0037] In a first embodiment, the gasket 400 engages and flexes against the opening 200 when the window 100 is inserted into the window. To help assist the tongue-and-groove fitting in securing the gasket 400 , the gasket 400 is also formed with a base section 420 that abuts the window frame 200 . This base section helps keep the gasket 400 relatively perpendicular vis a vis the exterior surface of the window frame 200 . When designed to engage the opening 200 , it is important to manufacture the gasket 400 out of a significantly flexible material to allow the gasket 400 to bend during insertion.
[0038] One advantage of permanently attaching the gasket 400 on the peripheral faces 160 of the window 100 is that the gasket 400 can be added during the construction of the window 100 itself. In this way, the window manufacturer can be responsible for securely attaching the gasket 400 . The window 100 is then delivered to the construction site with the gasket attached, where the window installer can install the window 100 and gasket 400 combination in much the same as any ordinary window 100 . Window manufacturers may use any known technique to attach the gasket 400 to the window 100 , including protrusions and channels, or by nailing or stapling the gasket 400 directly to the window frame 120 . Alternatively, the gasket can be formed as an integral part of the window frame 120 itself.
[0039] As shown in FIG. 7 , the gasket 400 of this first embodiment will preferably contact the framing of the rough opening 200 , such as side 220 , thereby dividing the space 310 between the window 100 and the opening 200 in two. The portion of the space 310 closest the interior 240 of the building can be used for the foam material 320 . As the foam 320 is installed, it can be installed all the way up to the gasket 400 . This is similar enough to the prior art technique of installing the foam 320 all the way up to the nailing flange 170 so as to not require any significant change in foam installation techniques.
[0040] The other portion of the space 310 divided by the gasket 400 is the gap or channel 500 formed adjacent the nailing flange 170 . Because the gasket 400 is formed on at least the top 140 and sides 130 of the window frame 120 , the formed channel 500 is ensured of existing at these locations as well. In this way, the gasket 400 will allow for any moisture that penetrates the opening around a window 100 to have the proper channel 500 to continue its movement down toward the sill 150 and ultimately out to the exterior 250 of the building. In addition, the gasket 400 itself serves as a barrier to any water or moisture that enters the channel 500 , and helps to prevent that water from entering into the interior or framing of the building.
[0041] In this embodiment an entire width of the gasket structure 400 from one side 130 to the other side 130 of the window 100 is slightly larger than that of the largest recommended rough opening 200 , as defined by the window manufacturer. The gasket 400 should also be large enough to account for a non-centered window 100 , so that the gasket 400 will still engage the opening 200 . The gasket 400 should be rigid enough to hold its position in space 310 against insulation 320 , yet be flexible enough to handle a small space 310 that might be created in a non-centered window 100 . The flexibility should also be great enough so as not to hinder the simple installation of a window. In the preferred embodiment, the gasket 400 can be constructed of almost any material that can meet these basic properties, including open or closed cell foam plastics, natural or synthetic rubber, or the like. If a rigid gasket 400 is to be used, the choice of materials would be even broader, including wood, metal, and hard plastics.
[0042] FIG. 8 shows a second embodiment of the present invention gasket 410 . This gasket 410 can be manufactured in one piece and sized for a particular window 100 . The gasket 410 can then be applied to the window 100 at the installation site. Preferably, the gasket 400 is applied over the window frame 120 from the interior side. As shown in the cross-sectional view in FIG. 9 , the window 100 can be formed with a groove 412 for receiving the gasket 410 . Once the gasket 410 is installed in the groove 412 , it can either be nailed or stapled in place by the installer, or the elasticity of the gasket 410 can be relied to keep it in place. When installed, this second embodiment of the gasket 410 functions similar to gasket 400 , as can be seen by comparing FIG. 9 with FIG. 7 .
[0043] Alternatively, a gasket 420 can be created that is designed to be installed directly onto the rough opening 200 , as shown in FIG. 10 . In this Figure, the gasket 420 has been nailed to the opening 200 with a plurality of nails 422 , only one of which is shown in FIG. 10 . Alternatively, gasket 420 can be attached with staples or adhesive to the opening 200 . This gasket 420 can be provided to window installers in strips, which can then be cut to the size of the opening 200 . Once the gasket 420 has been attached to the opening, the window 100 can be inserted. The frame 120 of the window 100 will then engage the gasket 420 , much like how the rough opening 200 engaged gaskets 410 and 400 during the window insertion process described above. Like the other embodiments 410 , 400 , gasket 420 functions by forming a gap or channel 500 for the drainage of moisture and water. The gasket 420 further functions to prevent water from entering the interior of the house, and serves to prevent the insulation 320 from impeding the flow of moisture in the channel 500 .
[0044] FIG. 11 shows another embodiment of a gasket 430 that can be used to create channel 500 . In this case, the gasket 430 has a rounded shape that is easily compressed. This allows the gasket to fill a relatively large space 310 between the window and the rough opening 200 , while still being able to easily be compressed for a smaller space 310 . This shape is called rounded in this invention description, and is defined by having a gasket that forms at least 270 degrees of a complete circle.
[0045] FIG. 12 shows a fifth embodiment, in which a decomposing object 440 is placed adjacent to the nailing flange 170 after the window 100 is installed in the rough opening 200 . This object 440 has an interior face 442 , which servers to block the foam 320 from abutting the nailing flange 170 when the foam material 320 is injected into the space 310 between the window 100 and the rough opening 200 . To form channel 500 , the object 440 will then disintegrate, leaving only the channel 500 , as is shown in FIG. 13 . Such an object 440 can be created using an inflatable balloon. The balloon can be inserted into the space 310 either already inflated or deflated (which is then inflated in place). The size of the balloon will easily conform to the shape of the space 310 , and can be pressed to abut the nailing flange 170 . When the insulation 320 is injected into space 310 , the interior face 442 of the balloon 440 will prevent the foam 320 from reaching the nailing flange 170 . When the foam insulation 320 has firmed up, the balloon can be deflated using a long thin pin inserted through the insulation 320 . Alternatively, the balloon 440 can be design to deflate over time. Furthermore, a portion of the balloon 440 can be secured to the header 210 to prevent the deflated balloon from interfering with water flow in the channel 500 . Other disintegrating objects 440 can be used, either now known or hereinafter developed. Ideally, the disintegrating object 440 will have an interior face 442 that can impede the flow of injected insulation 320 , and will disintegrate completely soon after the insulation 320 has firmed or solidified.
[0046] Another embodiment of the present invention is to replace the disintegrating object 440 with a wicking object 450 , as shown in FIG. 14 . The wicking object would be placed in space 310 , and would impede the flow of the insulation 320 at face 452 , just like the disintegrating object 440 shown in FIG. 12 . However, the wicking object would not disintegrate after the foam 320 is installed, but would be designed to wick moisture around the window frame 120 toward the sill 230 of the rough opening 200 . In effect, the entire channel 500 would remain, but would stay filled with the wicking object 450 . The wicking object 450 would not impede the flow of moisture to the sill 230 , but would help wick the moisture to the sill 230 . The wicking object 450 could be made of a material that conveys the moisture via capillary action. Alternatively, the wicking object 450 could be formed of any material that would allow the flow of water while impeding the flow of foam 320 . For instance, the wicking object 450 could be formed of a porous, fibrous material that does not use capillary action but does allow water flow. One example of such a material is the Home Slicker® product sold by Benjamin Obdyke Incorporated, Horsham, Pa. Alternatively, traditional fiberglass insulation can be used since water is not absorbed by the glass fibers found in fiberglass insulation. Water that enters channel 500 would flow through the fiberglass fibers 450 down to the sill 230 .
[0047] FIG. 15 shows a sixth embodiment of the present invention in which a wicking strip 460 is attached directly to the window frame 120 . In the preferred embodiment, the wicking strip 460 abuts against both the nailing flange 170 and the main portion of the window frame 120 . Alternatively, the wicking strip 460 could be attached to only one of these portions 120 , 170 of the window 100 , so long as the strip 460 is positioned near both the nailing flange 170 and the window frame 120 . This wicking strip 460 will allow moisture to pass through it while impeding the progress of foam 320 , as shown in FIG. 16 . Notice that the strip 460 in FIG. 16 is not attached directly to the nailing flange 170 . The wicking strip 460 acts to stop the foam 320 at face 462 while partially filling gap 500 . As with the wicking object 450 that is positioned in the gap 500 , the wicking strip 460 that is pre-attached to the window 100 can move water through capillary action or by being a porous material that allows water to pass through. The moisture that enters gap 500 can flow down through the unfilled portion of the gap 500 or through the wicking strip 460 of the window frame 120 . The wicking strip 460 should be sized so as to position the barrier face 462 at a sufficient distance from the nailing flange so as to prevent the foam 320 from reaching the nailing flange 170 even when a portion of the gap 500 is not filled by the wicking strip 460 .
[0048] The present invention is not limited to window frames 120 , but would be equally applicable to any framed item that is inserted into an opening of a building. For instance, FIG. 17 shows a door 600 having a door frame 602 . This door 600 is also fitted with a nailing flange 604 , although such a flange would not be necessary for this invention. The gasket 470 of the present invention is attached to the periphery of the door frame 602 , preferably at least on the top and side of the door frame. This gasket 470 would function similar to the barriers 400 - 460 described above.
[0049] FIG. 18 shows yet another embodiment of the present invention in gasket 480 . As shown in this figure, gasket 480 does not completely extend from window 100 to frame 200 . Nonetheless, the gasket 480 serves as a sufficient barrier to foam material 320 so as to create the same gap 500 as was created in the other embodiments. In this case, the foam material 320 extends somewhat into the gap, but not significantly. The foam material 320 would be considered to extend significantly into the gap if the foam 320 came into contact with the nailing flange 170 . When the gasket 480 does not engage another surface, it is possible for the gasket 480 to be constructed of a rigid material. Preferably, this gasket 480 will extend at least half way across the space between the window 100 and the frame 200 .
[0050] Window frames 120 may be completely smooth on their exterior jamb surfaces, or they may have minor bumps and ridges 122 as shown in FIG. 19 . These irregularities 122 on the relatively planar 124 face of the window frame 120 do not significantly impede the flow of foam 320 that is inserted into gap 310 between the roughed opening 200 and the window frame 120 . To impede the foam 320 and serve as a barrier as described above, the barrier 480 should extend significantly into the gap 310 , which is not the case with irregularities 122 . Typically, window manufacturers require a minimum one-quarter to three-eighth of an inch between the window frame 120 and the roughed opening 200 . Because this distance might be greater, it is preferred that the barrier 480 extend away from the generally planar face 124 of the window frame by a distance 482 approximately equal to this minimum distance. Consequently, one way of measuring the size of the barrier 480 of the present invention is by this distance 482 , which ideally is at least 0.20 inches.
[0051] The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims. | A method and device are presented that creates a channel adjacent a nailing flange of a window in between the window and the rough opening that receives the window. The channel is created by establishing a barrier that prevents foam insulation inserted into the space between the window and the rough opening from reaching the nailing flange. The channel then ensures proper drainage of water that enters the window cavity down to the window sill. A gasket is presented that can be attached to the window or the rough opening to create the barrier. Alternatively, a disintegrating object or a wicking object can be used to impede the flow of insulation foam and to create the appropriate channel. The present invention is equally applicable to doors or other framed objects received into the exterior shell of a building. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to nipples utilized in subterranean wells and, in a preferred embodiment thereof, more particularly provides an improved full bore nipple and a lock mandrel for use therewith.
In a subterranean well, one or more nipples are typically installed as part of a tubing string positioned within the well. Such nipples may serve many purposes. For example, a nipple may serve as a positive positioning device, by providing an internal shoulder or other profile for landing equipment within the tubing string. As another example, a nipple may serve as a sealing device, by providing an internal seal surface which may be sealingly engaged by equipment disposed therein.
Where circumferential seals, such as packing or orings, are carried externally on equipment disposed within the nipple, it is common practice for such seals to have a smaller diameter than the tubing's internal drift diameter. In this way, the seals may easily pass axially through the tubing string to the nipple. Accordingly, internal seal surfaces of nipples typically have a smaller diameter than the tubing's drift diameter, so that the seal surfaces may sealingly engage the seals.
Unfortunately, a nipple seal surface which is smaller than the tubing drift diameter presents a restriction in the tubing string. Such restriction inhibits fluid flow through the tubing string, is quickly eroded by such fluid flow, restricts the diameter of equipment which may be passed axially therethrough, and otherwise inhibits operations in the well. For these reasons, it is generally desirable for all portions of the tubing string to have a minimum internal diameter which is at least as large as the tubing drift diameter. Those portions of a tubing string meeting this requirement are said to be "full bore".
Recently, full bore nipples have become available and are well known to those skilled in the art. For example, U.S. Pat. Nos. 5,348,087 and 5,390,735, each of which is assigned to the assignee of the present invention, disclose full bore nipples and lock mandrels therefor. The disclosures of these patents are hereby incorporated herein by this reference. In basic terms, such full bore nipples have a seal diameter at least as large as the tubing drift diameter, and the lock mandrels therefor have a seal which is radially outwardly extendable, so that the seal may pass through the tubing string when the seal is inwardly retracted, and the seal may sealingly engage the seal surface of the nipple when the seal is outwardly extended.
However, with the seal surface of a full bore nipple being generally aligned with the tubing drift diameter, several problems remain associated therewith. For example, the seal surface is still directly exposed to fluid flow through the tubing string. Where the fluid is abrasive, or carries abrasive particles therewith, the seal surface may become eroded, and weight loss corrosion may also result from the fluid flow. As another example, the seal surface may be damaged by equipment passing axially therethrough. As yet another example, the seal surface may be damaged by slickline, wireline, coiled tubing, etc., cutting into the seal surface as the slickline, etc., is axially reciprocated within the tubing string.
From the foregoing, it can be seen that it would be quite desirable to provide a full bore nipple which includes a recessed seal surface that is protected from fluid flow and equipment, slicklines, etc., passing through the nipple. Additionally, it would be desirable to provide a lock mandrel for such a full bore nipple, which is capable of locking to the nipple and sealingly engaging therewith. It is accordingly an object of the present invention to provide such a full bore nipple, lock mandrel therefor, and associated methods of configuring a tubing string within a subterranean well. Other objects, features, and benefits of the present invention will become apparent upon consideration of the detailed description hereinbelow.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, an improved full bore nipple is provided which has a recessed seal bore formed therein, utilization of which does not subject the seal bore directly to fluid flow and equipment passing through the nipple. A lock mandrel is also provided for the nipple, the lock mandrel being capable of expanding a seal outward to sealingly engage the recessed seal bore. For positioning the lock mandrel or other equipment within the nipple, a latching profile is formed internally on the nipple.
In broad terms, a nipple is provided for use in a subterranean well in conjunction with a well tool having a radially outwardly extendable seal carried thereon. The nipple includes a generally tubular housing. A generally cylindrical internal bore extends axially through the housing, the internal bore having a first diameter.
A shoulder is formed internally on the housing. The shoulder is capable of axially engaging the well tool when the well tool is inserted axially into the internal bore. A seal surface is formed internally on the housing, the seal surface being axially spaced apart from the shoulder. The seal surface has a second diameter greater than the first diameter of the internal bore, and is capable of sealing engagement with the seal when the seal is radially outwardly extended from the well tool.
In another aspect of the present invention, a full bore nipple is provided for use with a well tool having a generally tubular outer housing and a circumferential seal, the seal being radially outwardly extendable relative to the outer housing. The nipple includes a generally tubular body with first and second internal diameters. The body is configured for axial insertion of the well tool thereinto, and the first internal diameter is capable of receiving the outer housing axially therein.
The second internal diameter extends axially within the body. It is radially outwardly disposed relative to the first internal diameter, and is capable of engagement with the seal when the outer housing is received axially within the first internal diameter and the seal is radially outwardly extended relative to the outer housing.
Also provided is an apparatus for use in a subterranean well. The apparatus includes a generally tubular mandrel, a generally tubular expander sleeve, a circumferential seal, and a generally tubular outer sleeve. The expander sleeve is axially slidingly disposed externally on the mandrel and has first and second external diameters formed thereon. The second external diameter is larger than the first external diameter. The expander sleeve is selectively positionable in first and second axial positions relative to the mandrel, and the expander sleeve has an opening formed through a sidewall portion thereof.
The seal is disposed externally relative to the expander sleeve. It is disposed radially outward of the first external diameter when the expander sleeve is in the first position, and is disposed radially outward of the second external diameter when the expander sleeve is in the second position. The outer sleeve is axially slidingly disposed externally about the expander sleeve, and is releasably attached to the mandrel radially, through the expander sleeve opening.
In yet another aspect of the present invention, an apparatus for use in a subterranean well is provided. The apparatus includes generally tubular mandrel, housing, and expander sleeve, and a seal. The housing is radially outwardly disposed relative to the mandrel and at least partially radially spaced apart therefrom. One of the housing opposite ends is attached to one of the mandrel opposite ends.
The expander sleeve has an outer side surface, and is axially reciprocably disposed radially between the mandrel and the housing. The expander sleeve is positionable relative to the housing in a selected one of first and second axial positions, the first circumferential seal sealingly engaging the expander sleeve outer side surface and the housing when the expander sleeve is in the second axial position.
Additionally, apparatus for connection to a tubing string having an inner side surface and positionable within a subterranean well is also provided. The apparatus includes a generally tubular housing and expander sleeve, and first and second circumferential seals.
The housing has inner and outer side surfaces, and is axially displaceable through the tubing string. The expander sleeve has inner and outer side surfaces, and is axially positionable relative to the housing in a selected one of first and second positions. The expander sleeve outer side surface and the housing inner side surface are sealingly engaged by the first circumferential seal, and the second circumferential seal sealingly engages the expander sleeve outer side surface, when the expander sleeve is in the second position. The second circumferential seal is capable of sealingly engaging the tubing string inner side surface when the expander sleeve is in the second position.
A method of configuring a tubing string within a subterranean well is also provided, which method includes the steps of providing the tubing string having an internal drift diameter; providing a nipple, the nipple including a generally tubular housing having opposite ends, the opposite ends being configured for interconnection of the housing within the tubing string, an axially extending internal bore formed in the housing, the internal bore having a diameter at least as large as the tubing string drift diameter, and a seal surface formed in the housing axially between the internal bore and one of the opposite ends, the seal surface being radially outwardly disposed relative to the internal bore; interconnecting the nipple to the tubing string; and positioning the tubing string within the well.
The use of the present invention increases the economics, convenience, and efficiency of operations in subterranean wells involving nipples installed in tubing strings. The disclosed full bore nipple, and associated lock mandrel and methods, prevent damage to a seal bore within the nipple, thereby enabling prolonged use of the nipple without repair or replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C are partially elevational and partially cross-sectional views of a full bore nipple and lock mandrel therefor;
FIG. 2 is a cross-sectional view of an improved full bore nipple embodying principles of the present invention;
FIG. 3 is a cross-sectional view of a lock mandrel for use in association with the full bore nipple of FIG. 2, the lock mandrel embodying principles of the present invention;
FIG. 4 is a cross-sectional view of the lock mandrel of FIG. 3 operatively landed in the full bore nipple of FIG. 2;
FIG. 5 is a partially elevational and partially cross-sectional view of another lock mandrel for use in association with the full bore nipple of FIG. 2, the lock mandrel embodying principles of the present invention;
FIG. 6 is a cross-sectional view of an inner mandrel portion of the lock mandrel of FIG. 5;
FIG. 7 is a cross-sectional view of an expander sleeve portion of the lock mandrel of FIG. 5;
FIG. 8 is a cross-sectional view of an outer housing portion of the lock mandrel of FIG. 5; and
FIG. 9 is a cross-sectional view of the lock mandrel of FIG. 5, the view being taken along line 9--9 thereof.
DETAILED DESCRIPTION
Illustrated in FIGS. 1A-1C is a lock mandrel 10 and a full bore nipple 12. The lock mandrel 10 and nipple 12 are similar to those described in U.S. Pat. No. 5,390,735. As shown in FIGS. 1A-1C, the lock mandrel 10 has been inserted axially into the nipple 12, and has been set therein, that is, the lock mandrel is anchored to, and sealingly engages, the nipple.
Anchoring of the lock mandrel 10 to the nipple 12 is achieved by engagement of a series of circumferentially spaced apart keys 14 carried on the lock mandrel, with a circumferential groove 16 formed internally on the nipple. The keys 14 are displaced radially outward into engagement with the groove by an expander sleeve 18. The expander sleeve 18 is shown in FIG. 1B in a downwardly displaced configuration relative to the keys 14. When the expander sleeve 18 is in an upwardly displaced configuration relative to the keys 14, such as when the lock mandrel 10 is being transported downward through a tubing string (not shown) attached to the nipple 12, the keys are permitted to inwardly retract, since the expander sleeve does not radially inwardly contact the keys in that configuration.
The lock mandrel 10 is axially positioned for setting within the nipple 12 by engagement of a second set of keys 20 carried on the lock mandrel with a complementarily shaped latch profile 22 formed internally in the nipple. The keys 20 are resiliently biased radially outward by springs 24, so that, before the lock mandrel 10 is set in the nipple and as the lock mandrel is displaced downwardly through the tubing string, the keys are permitted to retract inwardly. However, when the keys engage the profile 22, an upwardly facing shoulder 26 of the profile prevents further downward displacement of the lock mandrel 10 relative to the nipple 12. A downwardly directed jarring force may then be applied to the lock mandrel 10 to shear shear pin 28 and thereby displace the expander sleeve 18 to its illustrated downwardly displaced configuration.
When displaced axially downward as shown in FIG. lB, the expander sleeve 18 forces a circumferential seal 30 radially outward to sealingly engage a seal bore 32 formed internally in the nipple 12. Such sealing engagement is typically required for proper operation of a safety valve or other equipment 34 suspended from the lock mandrel 10 below the seal 30. The seal bore 32 has a diameter which is approximately equal to the remainder of an internal bore 36 on which the groove 16 and profile 22 are formed.
Since the seal bore 32 and internal bore 36 have approximately equal diameters, the seal bore may be contacted by the lock mandrel 10, safety valve 34, or any other item of equipment which may pass axially through the nipple 12. Such contact between the seal bore 32 and various equipment passing through the nipple 12 may easily damage the seal bore, preventing the seal 30 from achieving proper sealing engagement therewith. In particular, a slickline, wireline, coiled tubing, etc., may lay against a lower side of the seal bore 32 and wear away a portion of the seal bore, thereby preventing sealing engagement of the seal 30 with the seal bore. The applicants have observed significant abrasion of a seal bore due to prolonged traversal of a slickline through a nipple, and it is quite common for appreciable abrasion to occur where extensive slickline jarring is performed on a single job.
The seal bore 32 is also exposed directly to fluids flowing axially through the nipple 12. The fluids, and/or abrasive particles carried by the fluids, may easily erode the seal bore 32, so that the seal 30 is prevented from sealingly engaging the seal bore. Additionally, weight loss corrosion of the seal bore 32 is aided by the exposure of the seal bore to the fluid flow axially through the nipple 12. Thus, it may be readily appreciated that the seal bore 32 is substantially unprotected in the nipple 12, even though the nipple is of the full bore type.
Note that, due to the configuration of the expander sleeve 18 relative to an outer housing 38 and inner mandrel 40, between which the expander sleeve slidingly reciprocates between its upwardly and downwardly displaced configurations, the inner mandrel carries circumferential seals 42, 44 thereon for sealing engagement with the expander sleeve and outer housing, respectively. These seals 42, 44 effectively reduce the cross-sectional area of the inner mandrel 40 and, thus, weaken the inner mandrel. To compensate for this, the inner mandrel 40 must be made thicker, thereby reducing the available radial thickness of the expander sleeve 18. Such reduced radial thickness of the expander sleeve 18 limits the radial displacement (i.e., the "throw") available to radially outwardly extend the seal 30 into contact with the seal bore 32 and to radially outwardly extend the keys 14 into engagement with the groove 16. It will be readily apparent that an increased radial throw is desirable for increased radial expansion of the seal 30 and radial displacement of the keys 14.
Turning now to FIG. 2, a full bore nipple 46 embodying principles of the present invention is representatively illustrated. In the following description of the nipple 46 and other embodiments of the present invention hereinbelow, directional terms, such as "above", "below", "upward", "downward", "upper", "lower", etc., are used for convenience to refer to the embodiments as they are illustrated in the accompanying drawings. Additionally, it is to be understood that the embodiments may be utilized in various orientations, such as, horizontal, vertical, inclined, inverted, etc., without departing from the principles of the present invention.
The nipple 46 has a generally tubular body or housing 48 with opposite ends 50, 52, each of which is externally threaded for attachment of the nipple within a tubing string for transport and positioning within a subterranean well. The body 48 has an interior side surface 54 defined in substantial part by an internal bore 56. The internal bore 56 has a diameter which is at least as great as the drift diameter of the tubing string to which it is attached, hence the nipple 46 is of the full bore type.
A latch profile 58 is formed on the interior side surface 54, extending generally radially outward from the internal bore 56. The profile 58 includes at least one upwardly facing shoulder 60. Above the profile 58, a seal bore 62 is formed on the interior side surface 54, extending radially outward from the internal bore 56. Note that, in the illustrated embodiment, the internal bore 56 has a first portion 64 above the seal bore 62, a second portion 66 axially between the seal bore 62 and the profile 58, and a third portion 68 below the profile 58. The seal bore 62 has a diameter which is greater than the diameter of either of the first and second portions 64, 66 of the internal bore 56.
It will be readily appreciated that, with the seal bore 62 axially straddled by the smaller diameter first and second portions 64, 66, the seal bore is substantially protected from contact with equipment, slicklines, etc., passing axially through the internal bore 56 of the nipple 46. It will also be readily appreciated that the seal bore 62 is protected from direct exposure to axial fluid flow through the internal bore 56, thereby preventing, or at least reducing, erosion and weight loss corrosion of the seal bore. The applicants prefer that the seal bore 62 diameter is approximately 0.05 inch greater than the diameter of either of the first and second portions 64, 66, but it is to be understood that other relative diameters may be utilized without departing from the principles of the present invention.
Referring additionally now to FIG. 3, a lock mandrel 70 embodying principles of the present invention is representatively illustrated. The lock mandrel 70 is configured for use with the nipple 46, but it is to be understood that, with suitable modification if necessary, the lock mandrel may be utilized with other nipples without departing from the principles of the present invention.
As shown in FIG. 3, the lock mandrel 70 is prepared for transport through the tubing string to which the nipple 46 is attached. At its upper end 72, the lock mandrel 70 may be attached to a conventional running tool. At its lower end 74, a safety valve or other equipment (not shown) may be attached according to conventional practice.
A generally tubular fishing head 76 at the upper end 72 is threadedly attached to a generally tubular expander sleeve 78. The expander sleeve 78 extends axially downward from the fishing head 76 and into a generally tubular outer housing 80. The expander sleeve 78 is slidingly received in the outer housing 80 which is threadedly and sealingly attached at its lower end to a generally tubular bottom head 82. The bottom head 82 is threadedly attached to a generally tubular inner mandrel 84, which extends axially upward from the bottom head, so that the inner mandrel substantially radially inwardly overlies the expander sleeve 78.
At its upper end, the inner mandrel 84 has two radially outwardly extending portions 86. Each of the portions 86 is axially slidingly received in an axially extending slot 88 formed through the expander sleeve 78. Note that such engagement of the portions 86 with the slots 88 prevents circumferential displacement of the inner mandrel 84 relative to the expander sleeve 78, while permitting axial displacement of the expander sleeve relative to the inner mandrel.
Attached to the portions 86 is a generally tubular outer sleeve 90. The outer sleeve 90 extends downwardly from the portions 86 and externally overlies a portion of the expander sleeve 78. A pair of shear pins 92 extend radially through the outer sleeve 90 and are biased inwardly into contact with the expander sleeve 78 by a pair of springs 94. The shear pins 92 and springs 94 are shown in FIG. 3 rotated about the expander sleeve 78 ninety degrees for illustrative clarity. When the expander sleeve 78 is displaced downwardly relative to the inner mandrel 84 as described more fully hereinbelow, the shear pins are permitted to displace radially inwardly to engage a pair of recesses (not visible in FIG. 3, see FIG. 9) formed on the expander sleeve. Thus, when the expander sleeve 78 is downwardly displaced relative to the inner mandrel 84, such that the shear pins 92 are permitted to radially inwardly displace, the expander sleeve and inner mandrel are releasably axially engaged. Thereafter, the shear pins 92 must be sheared to permit relative axial displacement between the expander sleeve 78 and the inner mandrel 84.
A fastener 96 releasably secures the outer sleeve 90 to the inner mandrel 84. A relatively thin cross-sectioned tubular C-shaped cover 98 is installed over the fastener 96 and about the outer sleeve 90 and portions 86.
Above the portions 86, and adjacent the threaded attachment of the fishing head 76 to the expander sleeve 78, a retainer ring 100 is installed radially outwardly overlying the expander sleeve. The retainer ring 100 prevents radially outward expansion of the expander sleeve 78 relative to the fishing head 76, thereby preventing detachment of the expander sleeve from the fishing head at the threaded connection. Depending upon the cross-sectional thickness of the expander sleeve 78, the width of the slots 88, and other factors, the expander sleeve may deflect radially outward at the threaded connection when axial tension is applied to the lock mandrel 70, but it is to be understood that other embodiments may be readily configured (e.g., by increasing the cross-sectional thickness of the expander sleeve, reducing the width of the slots 88, etc.), so that it is not necessary to radially inwardly restrain the expander sleeve 78 at the threaded connection.
The expander sleeve 78 has an outer side surface 102 formed thereon. A series of three axially spaced apart portions 104, 106, and 108 of the outer side surface 102 have substantially the same diameter. Two radially reduced portions 110, 112 axially separate the portions 104, 106, and 108. A circumferential seal 114 is carried externally on the portion 108, and a radially outwardly extendable circumferential seal 116 is disposed externally about the portion 110. Note that, with the seal 116 disposed about the portion 110, the seal 116 has an outer diameter that is somewhat less than the outer diameter of the outer housing 80. In this manner, the seal 116 is protected from damage while the lock mandrel 70 is being transported through the tubing string.
With the expander sleeve 78 in its axially upwardly disposed configuration as representatively illustrated in FIG. 3, the seal 116 is radially inwardly retracted and the seal 114 is radially inwardly disposed relative to a radially enlarged portion 118 of an inner side surface 120 of the outer housing 80. The seal 114 does not sealingly engage the inner side surface 120 at this point. When the expander sleeve 78 is displaced to its downwardly disposed configuration, however, the portion 108 is received within a seal bore 122 formed on the inner side surface 120 and is sealingly engaged therewith, and the seal 116 is disposed about the portion 104, thereby radially outwardly extending the seal 116 so that its outer diameter is greater than the outer diameter of the outer housing 80. It will be readily appreciated that, for a given cross-sectional thickness of the lock mandrel 70, a thinner inner mandrel 84 allows a thicker expander sleeve 78, and, thus, permits a greater radial separation between the portions 104, 110, thereby increasing the available expansion or throw of the seal 116.
A series of circumferentially spaced apart ports 124 formed radially through the inner mandrel 84 provide fluid communication between the interior of the lock mandrel 70 and an annular space 126 axially between the expander sleeve 78 and the bottom head 82, and radially between the outer housing 80 and the inner mandrel. A circumferential seal 128 carried externally on the bottom head 82 sealingly engages the seal bore 122 adjacent the threaded connection between the bottom head and the outer housing 80.
A series of circumferentially spaced apart keys 130 are carried on the outer housing 80. Each of the keys 130 is radially slidingly received in an opening 132 formed through the outer housing 80. The keys 130 are resiliently biased radially outward by a series of springs 134 carried on the outer housing 80. Each of the keys 130 has at least one downwardly facing shoulder 136 formed externally thereon for axial engagement with the shoulder 60 of the nipple 46. In general, each of the keys 130 is complementarily shaped relative to the profile 58 formed on the interior side surface 54 of the nipple 46.
With the expander sleeve 78 in its upwardly disposed configuration as shown in FIG. 3, the keys 130 radially outwardly overly the portion 112 of the expander sleeve. In this configuration, the keys 130 are permitted to radially inwardly displace relative to the outer housing 80. In this manner, the keys 130 may inwardly retract while the lock mandrel 70 is transported through the tubing string. When, however, the expander sleeve 78 is positioned in its downwardly disposed configuration, the keys 130 will radially outwardly overly the portion 106, and the keys will be prevented from radially inwardly retracting due to radial contact between the keys and the portion 106.
Referring additionally now to FIG. 4, the lock mandrel 70 is representatively illustrated inserted axially downwardly into the nipple 46. The keys 130 are radially outwardly received in the profile 58, such that the shoulders 60 of the profile axially engage the shoulders 136 of the keys. The lock mandrel 70 is, thus, positioned within the nipple 46 properly for being set therein. Note that the seal 116 is positioned radially inward from the recessed seal bore 62 of the nipple 46.
As shown in FIG. 4, the expander sleeve 78 remains in its axially upwardly disposed position relative to the inner mandrel 84 and outer housing 80. Therefore, the seal 116 is radially inwardly retracted and the seal 114 is axially spaced apart from the seal bore 122. When the expander sleeve 78 is displaced axially downward to its downwardly disposed position relative to the inner mandrel 84 and outer housing 80, the seal 116 will radially outwardly overly and sealingly engage the portion 104 of the expander sleeve and will be radially outwardly extended into sealing engagement with the seal bore 62, the seal 114 will sealingly- engage the seal bore 122, and the keys 130 will be prevented from disengaging from the profile 58 by radial contact with the portion 106.
Referring additionally now to FIG. 5, a lock mandrel 138 embodying principles of the present invention is representatively illustrated. The lock mandrel 138 is substantially similar to the previously described lock mandrel 70. Elements of the lock mandrel 138 which are similar to elements of the lock mandrel 70 described hereinabove are indicated using the same reference numerals, with an added suffix "a".
As shown in FIG. 5, the expander sleeve 78a is positioned in its downwardly disposed configuration. The expander sleeve 78a may be displaced from its upwardly disposed configuration to its downwardly disposed configuration by, for example, applying a downwardly directed force to the fishing head 76a while the keys 130a are engaged with the profile 58 of the nipple 46. For example, a conventional running tool may be utilized to exert a downwardly directed force to the fishing head 76a.
When positioned in its downwardly, disposed configuration, the expander sleeve 78a radially outwardly extends the seal 116a, radially outwardly retains the keys 130a, and positions the seal 114a so that it sealingly engages the seal bore 122a. Note that, at this point, the seal 116a has a greater outside diameter than does the outer housing 80a, so that the seal 116a may sealingly engage the seal bore 62 of the nipple 46. Note that each of the shear pins 92a is now received in a recess 140 formed externally on the expander sleeve 78a. When it is desired to remove the lock mandrel 138 from the nipple 46, an upwardly directed force may be applied to the fishing head 76a to thereby shear the shear pins 92a and axially upwardly displace the expander sleeve 78a from its downwardly, disposed configuration to its upwardly disposed configuration. The lock mandrel 138 may then be transported upwardly through the tubing string to the earth's surface.
One benefit of the unique design of the lock mandrel 138 is that the inner mandrel 84a is subjected to very limited forces during operation of the lock mandrel and may, therefore, be relatively thin in cross-section. With a relatively thin inner mandrel 84a, the expander sleeve 78a may be made relatively thick in cross-section, thus permitting a greater throw of the seal 116 radially outward. Preferably, the seal 116a, expander sleeve 78a, seal bore 62, etc., are designed so that the seal 116a is squeezed approximately 7% when the expander sleeve is in its downwardly disposed configuration and the seal 116a sealingly engages the seal bore 62.
A feature of the lock mandrel 138 which allows the inner mandrel 84a to have a relatively thin cross-section is the manner in which the seal 114a sealingly engages the seal bore 122a when the expander sleeve 78a is in its downwardly disposed configuration. Since the seal 114a seals at substantially the same diameter as the seal 116a sealingly engages the portion 104a of the expander sleeve 78a, the expander sleeve is axially, balanced with regard to fluid pressure applied radially inward of the portions 104a, 108a. The inner mandrel 84a is exposed on all of its external surfaces to the fluid pressure in the interior of the lock mandrel 138 and, therefore, is subjected to no significant forces due to fluid pressure applied thereto.
With the lock mandrel 138 set in the nipple 46, when fluid pressure above the seal 116a (e.g., in the interior of the tubing string above the nipple) is greater than fluid pressure below the seal 116a (e.g., in the interior of the tubing string below the nipple when the bottom head 82a is sealingly connected to a safety valve or other equipment, thereby isolating the interior of the lock mandrel 138 from the interior of the tubing string below the nipple), a downwardly directed axial force resulting from the fluid pressure differential applied to the cross-sectional area of the seal 116a is applied to the seal 116a, which abuts the outer housing 80a. The downwardly directed axial force is transferred to the keys 130a from the outer housing 80a (due to axial contact between the keys and the openings 132a), and the force is then transmitted to the nipple 46 via the axial contact between the shoulders 136a, 60.
Referring additionally now to FIGS. 6, 7, 8, and 9, various elements of the lock mandrel 138 are representatively illustrated. FIGS. 6, 7, and 8 show the inner mandrel 84a, expander sleeve 78a, and outer housing 80a, respectively, apart from the remainder of the lock mandrel 138 and enlarged for illustrative clarity. FIG. 9 shows a cross-sectional view of the lock mandrel 138, taken along line 9--9 of FIG. 5, in which various elements of the lock mandrel may be viewed in relation to other elements thereof.
In FIG. 9, the manner in which the portions 86a of the inner mandrel axially slidingly engage the slots 88a of the expander sleeve 78a is clearly visible. Additionally, the spatial relationship of the shear pins 92a, springs 94a, and recesses 140 relative to the portions 86a may also be clearly seen. In FIG. 8, it may be seen that a recess 142, adjacent radially reduced portion 144, and adjacent opening 146 formed on the outer housing 80a cooperates with an aligned axially extending slot 148 to retain each of the springs 134a. Each of the slots 148 extends to a corresponding one of the openings 132a.
It will be readily appreciated by one of ordinary skill in the art that the unique configuration of the inner mandrel 84a, expander sleeve 78a, and outer housing 80a, along with other elements of the lock mandrel 138, greatly reduce the complexity, number of elements, assembly difficulties, inventory, etc., associated therewith. For example, compare the number of elements in the lock mandrel 138 or 70 with the number of elements in the lock mandrel 10 shown in FIGS. 1A-1D.
Of course, modifications may be made to the lock mandrels 70, 138 and nipple 46, such as those that would be obvious to one ordinarily skilled in the art, without departing from the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims. | An improved full bore nipple and associated lock mandrel provides enhanced sealing capability in tubing strings positioned in subterranean wells. In a described embodiment of the full bore nipple, a nipple body has a recessed seal surface and a latch profile formed on an internal bore of the body. In a described embodiment of the lock mandrel, an expander sleeve radially outwardly expands a circumferential seal to sealingly engage the recessed seal surface, locks a series of keys into the latch profile, and displaces another seal to sealingly engage an outer housing, when the expander sleeve is displaced axially downward relative to an inner mandrel of the lock mandrel. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to a device which can be attached to an all terrain vehicle (“ATV”) and used for clearing away loose granular material, such as snow, sand, earth, and crushed stones.
BACKGROUND OF THE INVENTION
All terrain vehicles are popularly used by consumers as recreational vehicles. However, given their ability to manoeuvre on a variety of terrains, ATVs have the potential to be adapted for practical applications such as the removal of snow. Accordingly, there is consumer demand for an ATV attachment which enables the ATV to be used for clearing snow and other loose granular material, such as sand, earth and crushed stones.
It is desirable that the attachment be easily installed and removed, so that the vehicle does not carry any unnecessary weight when the attachment is not in use. However, the devices found in the prior art are relatively cumbersome to install and remove, or have limited applications. Typically, the attachment points for these devices are situated on the underside of the ATV, so that they are not readily accessible to the user. U.S. Pat. No. 3,688,847 teaches a frame assembly which requires the removal of the front wheels of the vehicle in order to initially install the attachment piece for hooking up the frame assembly. U.S. Pat. No. 4,615,130 teaches a frame assembly suitable only for ATV's having a trailer—type hitch on the rear—end of the vehicle. Accordingly, there is a need for an assembly which can be quickly and easily attached and detached from ATV's.
In certain situations it may be desirable to change the angle of the blade on the attachment, for example, when clearing snow adjacent to a wall or fence. However, the prior art suffers from the disadvantage that it can be relatively cumbersome to adjust the angle of the blade. For example, U.S. Pat. No. 4,615,130 teaches the use of retractable pins as a means for locking the blade at a desired angle. However, the removal and insertion of pins requires a certain degree of manual dexterity and maybe difficult to accomplish under cold-weather conditions, when the driver of the ATV is likely to be wearing gloves. Accordingly, there is a need for a device equipped with means for quickly and conveniently adjusting the angle of the blade.
In certain situations, it may also be desirable to raise the blade, for example when travelling to a destination which needs to be cleared. Accordingly, it is desirable to have an attachment that can be easily raised and lowered by the driver while seated on the MV.
Finally, the prior an does not teach a blade with a detachable liner, which would allow the liner to be inexpensively replaced if it becomes damaged, and which would also allow the liner to be inexpensively colour coordinated with the customer's ATV.
SUMMARY OF THE INVENTION
The disadvantages of the prior at are obviated and mitigated by the present invention which provides an attachment for use in shoveling snow and other loose granular material, which can be quickly and easily attached and detached from an ATV; which enables the operator of the MV to easily and quickly adjust the blade to a desired angle; and easily raise or lower the blade of the ATV while seated on the ATV.
In a preferred embodiment, the snow blade has a coloured liner detachably secured to the blade frame, which may be colour coordinated with the body of the ATV.
In a preferred embodiment, the invention provides an apparatus which may be attached to an all terrain vehicle for use in clearing loose granular material; said apparatus comprising a frame assembly adapted to fit beneath the all terrain vehicle in a spaced apart relationship thereto, and to be releasably connected to the outer sides of the all terrain vehicle by a mounting means; blade means for use in clearing loose granular material; said blade means attached to the frame assembly at the front-end of the all terrain vehicle; angle adjustment means for adjusting the angle of the blade means relative to the longitudinal axis of the all terrain vehicle; and vertical adjustment means for raising and lowering said blade means and said frame assembly.
A further embodiment provides a kit comprising a frame assembly adapted to fit beneath the all terrain vehicle in a spaced apart relationship thereto, and to be releasably connected to the outer sides of the all, terrain vehicle by a mounting means; blade means for use in clearing loose granular material; said blade means attached to the frame assembly at the front-end of the all terrain vehicle; angle adjustment means for adjusting the angle of the blade means relative to the longitudinal axis of the all terrain vehicle; and vertical adjustment means for raising and lowering said blade means and said frame assembly.
Additionally, the invention provides an attachment means for releasably securing a frame assembly and blade means to an all terrain vehicles comprising angle adjustment means for adjusting the angle of the blade means relative to the longitudinal axis of the all terrain vehicle; and vertical adjustment means for raising and lowering said blade means and said frame assembly.
An advantage of the present invention is that the attachment points for the frame assembly are easily accessible on the outer sides of the ATV, and therefore the frame assembly can be attached and detached quickly and easily.
Preferably, the vertical adjustment means comprises a dual-handed lever which enables the operator to easily adjust the angle of the blade from either side of the ATV. Because the angle of the blade is adjusted using a simple lifting and turning motion, it is possible to adjust the angle of the blade even while wearing gloves.
A further advantage of this invention is that the driver can easily raise or lower the blade and frame assembly while seated on the ATV, through the use of an over-centering mechanism which enables the blade to stay locked in the up position without the use of latch pins or extra brackets.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention will be obtained by considering the detailed description below, with reference to the following drawings of embodiments of the present invention in which:
FIG. 1 is a side view showing an ATV incorporating the present invention
FIG. 2 is a perspective view of the lift attachment apparatus of the present invention, shown in combination with a blade assembly
FIG. 3 is a top elevated view of the lift attachment apparatus of the present invention, shown in combination with a blade assembly
FIG. 4 is a side perspective view of the lift attachment apparatus of the present invention
FIG. 4A is a side exploded view of the lift attachment apparatus of the present invention
FIG. 5 is a perspective view of the locking means of the lift attachment apparatus
FIG. 5A is an exploded view of the locking means of the lift attachment apparatus
FIG. 6 shows an exploded view of a blade assembly
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the lift attachment apparatus of the present invention, generally designated as 2 , is shown mounted to an all terrain vehicle (ATV) 4 , and a blade assembly 6 .
Referring to FIGS. 2 and 3, lift attachment apparatus 2 comprises a frame assembly 10 , a locking device 18 and over centering lift handle assembly 30 .
Frame assembly 10 is of substantially A-shaped design, consisting of diverging arms 12 , 13 that are connected by cross members 14 , 15 for reinforcement. The posterior end of the frame assembly 10 is defined by attachment means such as lug 16 disposed at one end of each of arms 12 , 13 . The frame assembly may accordingly be conveniently mounted to the frame of ATV 4 , as shown by FIG. 1 .
Locking device 18 is mounted to the anterior end of frame assembly 10 . As more particularly shown in FIG. 4A, locking device 18 comprises a base plate 19 , and frame member 20 which may be secured to blade assembly 6 by means by of a pivot bolt 21 or other similar securement means. Lock pin assembly 22 comprises dual lock handle 24 which is operatively connected to latch lever means 26 by means of lugs 28 and pivot bolts 29 , and to lock spring 27 .
Frame member 20 is secured to blade assembly 6 by means of bolts or other mechanically equivalent attachment means and is preferably pivotally connected to base plate 19 at attachment point 25 . Spring means 23 acts to bias the blade assembly 6 as against the frame member 20 .
Over center lift handle assembly means 30 comprises handle member 32 which is pivotally connected to base bracket 34 , connecting link 40 , lever 36 and over center pivot arm 38 . Lock spring 41 is secured to pivot arm 38 and to support member 37 . Pivot arm 38 is rotatable along vertical axis A, and may be a first, second, or third class lever. Pivot arm 38 is attached to a lift cable 42 . Lift cable 42 runs along the longitudinal axis of the frame assembly 10 and is received by pulley 44 which is operatively connected to locking device 18 . The free end of lift cable 42 is fitted with attachment means 46 that enables the cable to be secured to the front bumper, or other suitable attachment point on the ATV.
Referring to FIG. 6, blade assembly 6 includes a blade frame 62 which may optionally be fitted with a replaceable blade liner 64 . Blade liner 64 may be detachably secured to blade assembly by means of bolts 66 or similar connection means. Blade frame 62 is rotatably connected to the anterior end of the frame assembly 10 , as described above. The detachable liner enables a damaged liner to be inexpensively replaced. It also enables a dealer to stock fewer blade frames, while providing the consumer with a variety of colour options for the liner. Optionally, a blade guard 67 may be incorporated within the blade assembly.
As will be understood by those skilled in the art, the blade assembly 6 may define a single direction, tapered speed blade, or a bidirectional, conventional blade. All conventional blades and blade frames adapted for use for an all terrain vehicle or similar device are within the scope of the present invention.
The orientation of the locking device 18 relative to the frame assembly 20 means that the blade assembly 6 may be attached to the all terrain vehicle, and the relative angle of the blade may be adjusted, from either side of the all terrain vehicle.
The present invention defines an over centering lift system with significant mechanical advantage that enables the operator of the ATV to easily and conveniently raise and lower the blade assembly without undue manipulation. By pulling back on the handle 32 , the driver can quickly and easily raise the blade assembly 6 . When handle 32 is pulled toward the back of the ATV, the handle lever 36 is pulled toward the front of the ATV which causes the pivot arm 38 to pivot about its axis A, by means of connecting link 40 thereby tightening the lift cable 42 which pulls up on the pulley 44 . This motion is translated to frame member 19 and causes blade assembly 6 to move lo vertically, relative to the ground (“up position”). Once the lift cable 42 has passed over the axis A of the pivot arm 38 , the weight of the blade assembly 6 would tend to cause the pivot arm 38 to continue pivoting about its axis A thereby urging blade assembly 36 to a downward position. However, a pivot am stop 34 is situated so as to block further movement of the pivot arm 38 . This over-centering mechanism holds blade assembly 36 in an up position without the use of pins and extra brackets. The frame assembly 10 and blade assembly 36 remain in the up position by virtue of the over-centering mechanism, described above, until the driver returns the handle 32 to an upright position.
When the handle 32 is in an upright position, the pivot arm 38 is oriented approximately 90 degrees to the longitudinal axis of the ATV, the lift cable 42 is relatively slack and the blade assembly is in a down position, i.e. substantially tangential to the ground surface.
The action of lock spring 41 (attached between the base of the handle 32 and the end of the pivot arm 38 that is attached to the support member 37 ) reduces the manual effort required to lift the blade assembly and ensures that pivot arm 38 achieves a positive lock in the up or down position, thereby preventing blade assembly 6 from dropping to the ground as the ATV travels over rough terrain.
The angle of the blade assembly 6 relative to the ground surface may be adjusted by pulling up on either side of the dual-handed lock handle 24 to release the latch lever 26 , then rotating the frame member 20 about the blade angle pivot attachment point 25 until the blade assembly 6 is at a desired angle relative to the longitudinal axis of the ATV whereupon the latch lever is realigned with a suitable notch 29 on the frame member 20 , and then releasing the dual-handed lock handle 24 so that the latch lever 26 matingly engages with the desired notch. Return spring 27 urges the latch lever 26 against the notch 27 , and thereby serves to lock the blade assembly 6 into the desired angular orientation, relative the longitudinal axis of the frame assembly 10 .
Optionally, the relative mechanical advantage of the over centering lift system may be adjusted by altering the point at which cable 42 is connected to pivot am 38 . This may be accomplished by the provision of one or more additional connection points That may take the form of apertures, eyelets or other similar structures that may be used to secure cable 42 to pivot arm 38 . | An attachment for an all terrain vehicle (ATV) which enables the ATV to be used for clearing away snow and other loose granular material, such as sand, earth, and crushed stones. The apparatus includes a blade with a detachable liner, and a frame which fits beneath the ATV and is releasably connected to the outer sides of the ATV by a mounting device. The angle of the blade may be adjusted using a dual-handed lever. The blade may be raised and lowered by the driver while seated at the ATV using a handle which actuates a lever and a cable and pulley apparatus. |
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 method and apparatus for the drilling of the curved borehole portion of a horizontal or directional well. More specifically, but not by way of limitation, this invention relates to the drilling of short radius curved boreholes.
2. The Prior Art
It is generally known that the final portion of a rotary drilling string (the so-called drilling collar) or the like is under compressive loads and torque during drilling, while the upper portion of the drilling string is under tension. As such, the weight of the drill collar below the point of last contact with the borehole wall may be thought of as being divided into two components; one acting along the axis of the collars and the second acting normal to the first, perpendicular to the borehole.
It is also generally known that, in principle, if the downhole orientation and magnitude of the normal force could be controlled during drilling, the drill bit could essentially be steered to any desired subsurface location or strata. Although theoretically possible and highly desirable, such a process and corresponding drilling equipment to achieve such a goal have not yet been developed. However, various processes and associated equipment have been employed that generally achieve varying degrees of what is recognized in the art as directional drilling. For example, it is common practice in oil and gas well drilling to use a so-called "whipstock" (a sloped plug inserted below the drill bit) to intentionally deflect the drill bit in a desired direction, thus creating a deviation in the direction of drilling.
It is also common practice in oil and gas well drilling to employ equipment and methods to minimize or eliminate the effect of the force normal to the bore hole such as to maintain the drilling in a vertical line. Thus, various types of drilling collars, stabilizers and the like have been proposed to keep the drilling process proceeding uniformly in one direction. For example, U.S. Pat. Nos. 3,145,758 and 4,319,649 disclose drill collar stabilizers to maintain the drilling in a straight line.
In U.S. Pat. No. 4,220,213 an eccentric member having a heavy, thick walled side and a lighter, thin walled side is placed concentrically about the drill bit collar or a rigid drill string with an offset projection on the outside of the eccentric member positioned usually 90 degrees to the right of the heavy, thick walled portion. In this manner, gravity will cause the heavy, thick walled portion of the eccentric collar to rotate to the underside or low side of a deviating drill string, thus positioning the projection such as to alleviate or compensate for the undesirable "walking" of the drill bit. In other words, an eccentric tumbler member rotatably supported on the drill string is used to prevent the drill bit from moving laterally and the resulting normal force continuously restores the hole to vertical.
Various types of drilling collar stabilizers have also been proposed to alter the direction of drilling. For example, U.S. Pat. Nos. 4,305,474 and 4,465,147 disclose stabilizers that create a deflecting force perpendicular to the drill string in order to control and guide the drill bit along a desired course of direction. Also, the use of an eccentric stabilizer has been proposed in U.S. Pat. No. 4,076,084 to drill a directionally oriented hole such as commonly practiced when drilling from an offshore platform or the like.
One particularly difficult type of drilling process to control is the so-called lateral or horizontal drilling. Unlike the concept of directional drilling wherein radii in terms of hundreds of feet and deviations up to one to two miles are to be achieved relative to the surface location of the drilling platform or drilling rig, the concept of lateral drilling involves creating a highly curved well bore usually as an offshoot from a pre-drilled well bore. Thus, for example, in U.S. Pat. No. 4,402,551 a whipstock is employed to drill short radius horizontal holes below a vertical cased well bore. It is acknowledged in this patent that current, state-of-the-art techniques limit the smallest radius of curvature for surface drilling to 19 feet (i.e., 3 degrees of deflection per foot over 30 feet of linear drilling) to produce a horizontal drainhole at depths greater than 2,000 feet.
Part of the difficulty in lateral drilling was the elimination or reduction in the spiral effect that was caused by the drill bit turning to the right. This problem was first fully addressed in U.S. Pat. No. 2,712,434 whereby a non-rotating eccentric sleeve was used in conjunction with a bushing latch type mechanism which allowed the orientation back to the desired position after the drill bit had wandered off the desired track. In an attempt to maintain a constant heading, U.S. Pat. Nos. 4,739,843 and 4,699,224 addressed the problem of poor orientation control by using the aforementioned non-rotating eccentric sleeve and adding spring-loaded blades attached in order to grip the wellbore and to maintain orientation as the drilling assembly is advanced. It was advocated in these patents that periodic repositioning of the blades be accomplished so that a planar curve could be drilled.
Although the prior art has achieved some degree of success in drilling a tight radius or curvature, the failure to develop a commercial apparatus to date has been: (1) the radius of curvature is inconsistent, (2) the ball/pin flexible joint is weak and could fail under normal operating conditions, (3) maintaining the desired orientation of deflection is difficult, (4) the constant engagement of spring-loaded blades can cause multiple problems ranging from mis-orientation to sticking in the hole. In spite of previous efforts in the prior art, an acceptable method for drilling a tight radius of curvature without unacceptable deviation out of the plane of rotation has yet to be achieved. The present invention is viewed as being an improvement over the prior art methods and apparatus in that the control over the azimuth and inclination of a curved wellbore has been achieved and the inherent problems associated with the prior art have been eliminated.
SUMMARY OF THE INVENTION
It is a feature of the present invention to provide for a short-radius lateral drilling system that is capable of drilling a consistent radius of curvature and drilling the curve in the desired direction. The present invention is designed to overcome the problems associated with the prior art methods and apparatus for lateral drainhole drilling; i.e., the tendency for the prior art to drill inconsistent radius of curvatures; the tendency for the prior art to lose the desired orientation of the deflection sleeve and the inability to accurately determine said direction and correct for errors; and the weakness of the flexible joint with the associated tendency of this joint to fail under normal operating conditions.
The present invention employs at least one novel eccentric member with retractable sidewall engaging means that attaches to the downhole end of the flexible drilling string directly over the flexible joint leading to the drill bit collar. The presence of the eccentric member or collar forces the drill bit string passing therethrough to one side of the well bore, thus lever arming the drill bit to the other side of the well bore by pivoting of the drill bit. The presence of the retractable sidewall engaging means prevents the eccentric collar from rotating (in conjunction with the grooved and arched sleeve opposite the compression pad) in the well bore, thus resulting in a tightly curved well bore or short radius of curvature with essentially no change in the azimuth; i.e., resulting in a consistent radius of curvature without substantial doglegs.
Thus, the present invention provides a drilling apparatus for lateral drilling comprising:
(a) a flexible drilling string consisting of limber drilling pipe constructed of various composite materials or other standard industry flexible drill pipe;
(b) an eccentric cylindrical collar having a cylindrical hole passing therethrough wherein the central axis of the cylindrical hole is collinear with and displaced radially to one side relative to the central axis of the eccentric collar and wherein the outer surface of the eccentric collar opposite the side toward which the cylindrical hole is displaced is further equipped with a surface activated, pressure controlled, grooved compression pad that extends from its chamber to engage the borehole and in conjunction with the grooved sleeve on the opposite side of the pressure activated compression pad, engages the borehole during rotary drilling, thus preventing the eccentric collar from rotating during drilling and wherein the eccentric collar operatively surrounds a portion of a drill stem section at the lower end of the flexible drilling string, thus allowing the flexible drilling string and drill stem section to revolve in the cylindrical hole during rotary drilling;
(c) a ball and socket joint utilizing four keys and four keyways to connect the eccentric collar rotatably to the drill collar;
(d) a drill bit collar with rotary drill bit operatively attached to the flexible joint.
It is an objective of the present invention to provide a method of consistently and reliably drilling lateral, horizontal drainholes in environmental, oil, gas and injection wells and the like. It is a further object that the lateral drilling be characterized by a relatively short radius of curvature as well as the absence of significant angular or axial deviation (spiral rotation) of the curved portion of the laterally drilled drainhole. It is another object of the present invention to provide a means for maintaining said curved portion of a laterally drilled drainhole without continuous contact between the well bore and the drill string. Fulfillment of the objects and the presence and fulfillment of additional objects will become apparent upon complete reading of the attached specification and Claims taken in view of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B together represent a partial longitudinal sectional view through the lower portion of a drill string showing certain details of the present invention.
FIG. 2 is a semi-diagrammatic representation of a drill string employing the present invention on the lower portion thereof, showing the lower end of a plugged up well bore and showing the device of the present invention as it commences to drill on a deviant path from the original well bore.
FIG. 3 is a transverse sectional view taken along section line 3--3 of FIG. 1A.
FIG. 4 is a transverse sectional view taken along section line 4--4 of FIG. 1A.
FIG. 5 is a partial side elevational view, as it would appear looking along line 5--5 of FIG. 1A, of the retractable compression pad and its means of attachment to the eccentric collar
FIG. 6 is a partial side elevation looking at the eccentric collar from the opposite side as compared to FIG. 5 and showing the vertical grooves opposite from the compression pad.
FIG. 7 is a partial longitudinal section view taken along section line 7--7 of FIG. 1B, on a slightly enlarged scale, showing further details of the ball and socket arrangement including the keys mounted in the keyways.
FIG. 8 is a transverse sectional view taken along section line 8--8 of FIG. 7.
FIG. 9 is a partial longitudinal sectional view similar to FIG. 7 but taken along a section line 9--9 of FIG. 1B.
FIG. 10 is a partial longitudinal sectional view taken along section line 10--10 of FIG. 9.
FIG. 11 is a front elevation of one of the keys shown in FIG. 7.
FIG. 12 is an end view of the key shown in FIG. 11.
FIG. 13 is a partial longitudinal section view, on an enlarged scale, from the bottom portion of FIG. 1A and showing details of the connections involving the retractable compression pad and associated structure with remaining elements on the lower drill string section.
FIGS. 14A, 14B and 14C together represent an exploded view of the device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail, FIGS. 1A and 1B show a drill pipe sub 10 which has been modified and ported in a manner later to be described. The drill sub 10 is provided with female threads 12 which mate with male threads 14 on the lower end of a piece of flexible drill pipe 16. The flexible drill pipe 16 is made of composite materials and is one of a plurality of vertical drill pipes which have been connected together to make a flexible drill string. Below the threaded portion 12, the drill pipe sub 10 is provided with a portion 18 of reduced diameter, but having an outer cylindrical surface on which is received an eccentric cylindrical collar or sleeve 20. The collar 20 has an outer diameter which exceeds the diameter of the upper portion of the drill pipe sub 10, but which has a hole or bore 22 which is offset from the central cylindrical axis of the cylindrical collar 20 itself. The hole 22, however, has a diameter equal to the outer diameter of the reduced portion 18 of the pipe sub 10. Thus, the eccentric collar 20 can rotate around the portion 18 of the pipe sub 10 in a manner similar to that of a cam. Bronze bushings 24 are located at the upper and lower ends of the eccentric collar 20. In this regard, the upper and lower ends of the bore 22 of the collar 20 are provided with cylindrical recesses 26. The bushings 24 are provided with sleeve projections 28 which are received in recesses 26. The bushings 24 are shaped to correspond with the shape of the ends of the eccentric collar 20; that is, the outer circumferences of the bushings 24 are the same as the outer circumference of the eccentric collar 20; likewise, the bushings 24 have central bores therethrough which are offset from the outer diameters of the bushings 24 in the same manner that the bore 22 is offset with respect to the central cylindrical axis of the collar 20. In any event, the internal bores or surfaces of the bronze bushings 24 provide bearing surfaces for the drill pipe sub 10 to rotate inside the eccentric collar 20.
The drill pipe sub 10 is provided with a central bore which is in communication with a central bore (not shown) in the flexible drill pipe 16; all of the drill pipes of the drill pipe string have central bores which are connected to each other and, therefore, the central bore 30 of the drill pipe sub 10 is in communication with the surface for a purpose which will hereinafter appear. The central bore 30 of the drill pipe sub 10 is provided with a radial port 32 which extends horizontally through the reduced portion 18 and is in communication with the eccentric collar 20 for a purpose which will hereinafter appear. Also, the lower portion of the bore 30 is provided with an inwardly radially projecting key 34 for the purpose of aligning and triggering a survey tool (not shown). The key 34 is aligned with engaging locks (not shown) for the purpose of tool face orientation.
As indicated heretofore, the eccentric collar 20, when it rotates relative to the drill pipe sub 10, behaves as a cam. It is further noted that the bore 22 in the eccentric collar 20 is offset from the vertical cylindrical axis of this member. Referring to FIG. 1A, the collar 20, in cross-section, shows a thin portion at the left and a fat or thick portion at the right; the thick portion can also be referred to as the cam portion. The outer left hand portion of the collar 20 appears in FIG. 6 and this portion is provided with vertical grooves 40 which will assist in preventing rotation of the collar 20 in a manner later to be described. The right central (thick) portion of the eccentric collar 20 (as it appears in FIG. 1A) is cut out to form a central boss 42 which projects outwardly between a pair of flat recesses or tracks 44. The boss 42 is provided with a horizontal cylindrical chamber or bore 46 which is in communication with the port 32. The cylindrical chamber 46 is coaxial with the port 32 but somewhat larger than the port 32.
Within the cylindrical chamber 36 is mounted a piston 48. The piston is adapted to slide outwardly and inwardly within the bore 46 in a manner later to be described. The curved exterior of the piston 48 is maintained in sealing relation with the chamber 46 by means of an O-ring 50. A compression pad 52 is mounted over the boss 42 and the piston 48. The compression pad is provided with a pair of horizontal legs 54 which are received in the recesses or tracks 44. The legs 54 are provided with horizontal slots 56 which extend for the full length of the legs parallel to the slots 44. Each interior slot 56 will receive a spring 58, and a restraining strap 60 is positioned in the outer right hand portion of each slot 56 so as to overlie the springs 58.
As shown in FIGS. 3 and 5 the ends of the straps 60 are received in recesses 62 and held firmly in place by means of screws 64. Also, as best shown in FIG. 5, the exterior surface of the compression pad 52 is provided with grooves 66 similar to the grooves 40 shown in FIG. 6.
The compression pad 52 is mounted to the exterior of the eccentric collar 20 by means of the boss 42 and the slots or recesses 44 above and below the boss 42. The compression pad 52 has legs 54 that are received in the recesses 44. The outer curved surface of the compression pad 52 conforms generally to the shape of the collar 20. The boss 42 and the recesses 44 and associated structure on the collar 20 can be generally considered as a compression pad chamber to which, or in which, the compression pad 52 is mounted. As best shown in FIG. 4, the outer surface of the compression pad 52 is provided with grooves 66 which, in the solid line position shown in FIG. 4, fall within the normal curvature of the collar 20 if the cut out portion above the boss and the recesses 44 had not been provided. When the drilling string is pressurized so that the piston 48 forces the compression pad 52 outwardly, the outer periphery of the compression pad 52 then travels beyond the outer periphery of the eccentric collar 20 as shown in dotted lines in FIG. 4. The piston 48 is open at its left hand end so as to be in communication with the horizontal port 32. The right hand end of the piston 48 is closed and bears against the underside of the compression pad 52 between the two legs 54. The straps 60 overlie the recesses 56 in the compression pad 52 as shown in FIG. 1A and 14B. The ends of the strap 60 are secured in the outer surface of the collar 20 by means of screws 64. Springs 58 are received in the slots 56 under the straps 60. Thus, when the drill string is pressurized so as to cause the piston 48 to move outwardly in the cylindrical chamber 46, the piston will move the compression pad 52 radially outward against the action of the springs 58. However, when the pressure in the drill string is released, the springs 58 will force the compression pad and the cylinder 48 back to the solid line position shown in FIG. 4.
The lower end of the drill pipe sub 10 is provided with female threads 70 which mate with male threads 72 on the upper portion 74 of a ball shaft 76. The upper portion 74 is of reduced diameter with respect to the main part of the ball shaft 76 and is separated therefrom by means of a flange 78 which projects outwardly so as to be of essentially the same size as the upper portion of the drill pipe sub 10. Thus, the collar 20 is confined between the flange 78 at the lower end and the lip at the upper end which separates the reduced portion 18 from the main portion of the drill pipe sub 10 as best shown in FIG. 13.
Turning now to consideration of FIG. 1B, the ball shaft 76 has a central bore 82 which extends all the way through and communicates at its upper end with the bore 30 of the drill pipe sub 10. The lower end of the ball shaft 76 is provided with a ball 84 which cooperates with a socket, later to be described, at the upper end of a cylindrical adapter 86 which is similar in some respects to the drill pipe sub 10 in that it has a central bore 88 which communicates at its upper end with the bore 82 of the ball shaft 76. The lower end of the adapter 86 is provided with female threads 90 which mate with male threads 92 of a drill bit 94. The drill bit 94 can be a conventional drill bit or any other drill bit which is applicable to the device of the present invention. The drill bit 94 is provided with a bore (not shown) extending through the drill bit and into the area of the cutting teeth for the purpose of introducing a drilling mud, etc.
The ball 84 is provided with four radially outwardly projecting keys 96 which are snugly received (pressure fit) in four keyways 98. The upper internal portion of the adapter 86 is shaped to correspond with the outer shape of the ball 84 and the outwardly projecting keys 96. In order to provide this shape, the adapter 86 is split into two longitudinal sections 100 and 102. As best shown in FIG. 14A, the member 100 is provided with a plurality of recesses 104 in which holes 106 are drilled. Opposite the holes 106, the lower member 102 is provided with threaded openings (not shown). Six threaded screws 108 are adapted to be received in the holes 106 of the recesses 104 and can be screwed down to engage the threaded openings (not shown) in the member 102. Thus, tightening the screws 108 will bring the two parts of the adapter 86 snugly together.
The upper end of the bore 88 is enlarged to permit the ball 84 to move from side to side. Also, the interior upper end of the bore 88 is provided with curved portions 110 and 112 so as to conform with the outer shape of the ball 84. Between the curved portions 110 and 112, the adapter 86 is provided with four keyways or recesses 114 (see also FIG. 8) which, as shown in FIGS. 1B, 7, 9 and 10, have a vertical dimension which is greater than the vertical dimension of the keys 96 to permit tilting of the ball 84 in relation to the adapter 86.
Each key 96 (see FIGS. 11 and 12) has an outer curvature 116. The part of the key which is inserted into the keyway 98 of the ball 84 is tapered convergingly upward, as best shown in FIG. 12, to provide two surfaces 118 and 120 which are tapered approximately 6° each with respect to the vertical. The keyways 114 in the adapter 86 are shaped in the form of a trapezoid, as best shown in FIG. 7. Below the curved portion 112 there is a recess 122 for receiving therein an O-ring 124.
FIG. 1B shows the adapter 86 tilted to the right with respect to the ball shaft 76; that is, the lower end of the adapter upon which the drill bit 94 is mounted is moved to the right with respect to the upper end of the adapter 86. With respect to the right hand key shown in FIG. 1B, this has now moved to the bottom of the keyway 114 to the right in the adapter 86; conversely, the left hand key 96 has moved to the upper end of the left hand keyway 114 in the adapter 86. FIG. 7 is a sectional view, on a slightly larger scale, taken along section line 7--7 of FIG. 1B and the right hand key 96 shown in FIG. 1B is now in dotted lines in the center of the figure. The key 96 to the right in FIG. 7 would be the key that is closest to the reader in FIG. 1B and the key 96 which is to the left in FIG. 7 would be the key to the rear for the reader of FIG. 1B. Since the adapter 86 is tilted in one direction only, the two keys 96 shown in FIG. 7 are located midway in the recesses 114 of FIG. 7.
FIG. 9 is a view taken along section line 9--9 of FIG. 1B opposite to the direction of FIG. 7. In FIG. 9, the key 96 and keyway 114 shown in dotted lines in the center of the Figure represent the key 96 and the keyway 114 shown to the left in FIG. 1B; this Figure confirms the fact that the key 96 is at its uppermost position in the slot 114 as shown in FIG. 1B. FIG. 10 is a view taken along section line 10--10 of FIG. 9 and shows the exact opposite of what is shown in FIG. 1B; for example, the key 96 shown to the right in FIG. 10 is the same as the key 96 shown at the left of FIG. 1B.
Turning briefly to FIG. 4, this is a representation of what happens when pressure is exerted through the channel or port 32 against the piston 48 which rides against the compression pad 66. Absent any pressure, the compression pad will occupy the solid line position shown in FIG. 4; however, when pressure is exerted through the port 32, the compression pad will move to the dotted line position shown in this figure.
Turning now to FIG. 3, this figure shows a means whereby the eccentric collar 20 can be turned when the drill string is rotated in a counter-clockwise direction or, conversely, why the collar does not turn when the drill string is rotated in a clockwise direction. The reduced portion 18 of the drill pipe sub 10 is provided with a rectangular recess 126 in which a pawl or lug 128 is received. The end of the pawl is pivotally mounted on a pin 130 which is received in a suitable slot 131 and held in place by screws 133 (see FIG. 14C). A wire spring 132 is received on the pin 130. A portion of the spring 132 bears against the inside portion of the recess 126, as shown in FIG. 3, and the other part of the spring bears against the pawl 128 to urge the pawl radially outward around the pin 130. The collar 120 is provided with a tapered recess 134, one end of which ends in a shoulder 136. When the drill string is rotating in a clockwise direction, as would be normally the case, the member 18 shown in FIG. 3 would be also rotating in a clockwise direction so as to carry the pawl 128 in a clockwise direction out of the recess 134 and continuing around until it again falls into the recess 134, but continued rotation of the member 18 in a clockwise direction will cause the pawl 128 to alternately drop into the recess 134 and alternately be pulled out of it as the member 18 rotates. However, if the drill string should be rotated in a counter-clockwise direction, referring to FIG. 3, the member 18 would also be moving in a counter-clockwise direction so that the pawl 128 would now be received fully within the recess 134 and the end of the pawl would bear against the shoulder 136 so as to attempt to turn the eccentric collar 20 in a counter-clockwise direction.
The bronze bearings 24 seated at the top and bottom of the eccentric collar support the sleeve on the drill pipe sub 10 and provide a bearing surface for the eccentric collar on which to rotate when secured to the drill pipe sub. The eccentric collar however is able to resist the rotational torque during the drilling of the rotatable drill sub in a clockwise direction as the sleeve is held stationary in part by the compression pad while the compression pad engages the well bore. The O-ring 80 inserted in the bronze bearings provides a seal to prevent leakage of the drilling fluid between the drill pipe sub and the eccentric collar.
The thin side of the eccentric collar (opposite from the compression pad) is shaped and grooved as in FIG. 3 and as also shown in FIG. 6. This side has vertical grooves 40 in order to stabilize and prevent the eccentric collar from rotating when the compression pad is activated causing the opposite side and the compression pad (thick) side to be compressed against the sides of the bore hole. The vertical grooves 40 engage the back side of the well bore thus helping to prevent rotation of the eccentric collar while the drill pipe sub is rotating within. However, grooves 66 on the compression pad as seen in FIG. 5 provide an essential element which prevents rotation of the eccentric collar. It is the combination of the two sets of grooves 40 and 66, working together, which prevents the eccentric collar from rotating when fluid pump pressure is applied to the compression pad. This causes the compression pad to be forced against the side of the hole and in turn forces the drill pipe sub and eccentric collar to the opposite side of the well bore. The two sets of grooves 40 and 66 on the eccentric collar and compression pad then dig into each side and prevent the eccentric collar from rotating.
The compression pad 52 is unique over the prior art because of the amount of grooved surface available to engage the side of the well bore. The grooved face of the compression pad of this invention has been found to be the most efficient device for grabbing the side of a well bore. The grooves 66 and 40 are oriented in a vertical direction and slighted canted to the left (see FIG. 6 where the lower ends of the grooved 40 are canted to the left in relation to the tops of these grooves). The canting of the grooves, in effect, counters the rotational effect of the drill pipe sub because of the compression pad's left hand spiral. The purpose of this is to maintain a cleaner curve while drilling by offsetting the tendency of the eccentric collar to pull to the right because of the friction between the bearings in the eccentric collar and the surface of the drill pipe sub whereupon they rotate. In addition to the vertical grooves on the face of the pad, there is a second set of vertical grooves on the back side or side of the eccentric collar opposite from the compression pad. These grooves are also canted to the left, also helping to pull the cam sleeve to the left as it follows the bit down the hole during the drilling process. By grooving both the compression pad face and the back side of the eccentric collar, the drilling tool is better able to secure itself to the well bore when the compression pad is activated, thus drilling a more planar curve.
FIG. 2 shows the tool 10 of the present invention at the lower end of a well bore where curved drilling has already commenced. The curved borehole has an outside radius Ro and inside radius Ri. When the compression pad 52 is expanded it contacts the borehole at the inside radius Ri and forces the drill pipe sub 10 towards the outside radius Ro. This causes the drill bit 14 and the adapter 86 to pivot around the ball joint.
When drilling a well bore with the tool of the present invention, it will be first assumed that the eccentric cylindrical collar has been previously positioned in the proper location and that the drilling assembly is pressurized and rotating clockwise in the drilling mode. It would be further assumed that weight is on the drill bit so that the bit can do its job of drilling. Since the eccentric cylindrical collar will be pushing against one side of the well bore, the upper end of the adapter will be moved towards the opposite side of the well bore and the drill bit and adapter will be tilted slightly such that the drill bit is drilling along a curved path. As the drill bit continues to drill downwardly, the eccentric collar will move downwardly in sliding relation to the side of the well bore. The grooves on the compression pad and on the opposite side of the eccentric collar will prevent the collar from rotating.
Later, if it is desired to reposition the drilling assembly within the borehole, the drill bit is first lifted off the bottom of the borehole, the pump pressure is increased to insure that the compression pad is pushed against the side of the borehole, the drilling assembly is then rotated in the nondrilling mode until the lug in the drilling pipe sub engages the shoulder in the eccentric collar. When the lug is in engagement with the eccentric collar, the pump pressure is decreased so as to retract the piston and the compression pad. The drilling assembly is now rotated in the nondrilling direction until the compression pad is pointed in the desired orientation. Thereafter, the drilling apparatus is lowered to place the drill bit on the bottom of the borehole. At this time, the pump pressure is increased to activate the piston and the compression pad so as to urge the latter into contact with the side of the well bore. Thereafter, the drilling apparatus can be rotated in the drilling direction and the drilling will proceed as before.
Whereas, the present invention has been described in particular relation to the drawings attached hereto, other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. | A method and apparatus for the drilling of the curved borehole portion of a horizontal or directional well. A tight radius of curvature is rotary drilled by use of flexible composite drilling pipe or other flexible pipe common to the industry which terminate within an eccentric collar on the final drill string section. The eccentric collar is equipped with a retractable and grooved compression pad which expands outwardly to hold the eccentric collar (which is also grooved on its opposite side) against the side of the well bore to prevent the eccentric collar from rotating during the rotary drilling process. The final drill string section connects to a lower drill bit collar and rotary drill bit through a driving ball and socket connection. The eccentric collar on the final drill string section that engages the well bore forces the deflection of the drill bit about the ball and socket connection and holds this orientation as the rotating drill proceeds forward. Such a technique can achieve a radius of curvature of less than twenty feet. |
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This invention relates to a large-surface, sound-procting machine-cladding panels and to booths producable from such panels.
BACKGROUND OF THE INVENTION
Machines often have a frame as a stand. The space which is available between the frame legs and which is usually limited rectangularly is clad with metal plating. Such plate-metal claddings are in terms of their area of the order of 0.5 m 2 to 5.0 m 2, but can also be more or less than this. The plate-metal claddings have several purposes:
a) They perform an aesthetic function and an attempt is made to ensure that the machine has an agreeable appearance.
b) Spatial delimitation between the machine interior and the machine exterior is obtained. This is advantageous, for example, for safety reasons, so that no one can reach into the machine, or so that no articles fall into the machine. Very often, however, the machine-cladding panels also have the function of damping the sound which the machine generates within the stand. Examples of this are vibration-grinding machines or other types of special machines. The panels are arranged essentially vertically. They consist of metal plating which first has to be surface-treated such as, for example, lacquered or otherwise color-treated.
For sound insulation, anti-drumming material is adhesively bonded to the plates from the rear. This performs merely the function of removing the drumming of the plating, since foam material is additionally added to the anti-drumming material.
The sound insulation becomes the more difficult, the longer the sound wave. At low frequencies, heavy-duty sheeting is bonded on. At especially low frequencies, it may also be necessary to include a thin lead plate. The panels thereby become even heavier. Where large panels are concerned, three men are even needed for handling them.
When the metal plates are canted off so that no injuries from cuts are caused at the edges, and so that the plates become even more rigid, this is reflected in the price. Moreover, the panels can then be fitted into the machine stands only with much more difficulty. Another disadvantage of the state of the art is that the metal plates have to be screwed on, and this necessitates a high accuracy of fit between the passage hole in the plate and the threaded screw hole on the machine stand. Tools are also needed. Threads are destroyed in the course of time and have to be recut. Furthermore, a screw fastening, since it is essentially rigid, is an undesirably efficient sound bridge. These sound bridges are precisely what nullifies the excellent insulation elsewhere. Such plates can also easily be warped during operation if, for example, a fork-lift truck bumps against them, and they can even be warped to the extent that they become useless. The plates have to be surface-treated, i.e. galvanized or lacquered.
When the plates are removed, they have to be arranged in an orderly fashion in the plant and it is necessary to ensure that they do not fall over, because they would otherwise be damaged.
Subsequent changes are very difficult to make, because in practice, new plates then have to be manufactured again or they have to be reconstructed at a very high outlay. Such reconstruction is necessary when an inspection window has to be built into such a plate.
As is known, metal plating has good heat conduction and consequently it has not been possible for the metal plates to be used for thermal insulation in addition to sound insulation.
If the metal plates have a slight oversize they cannot be pressed into the orifices to be closed, because, of course, plate-metal does not yield. High precision manufacture is therefore necessary.
Sometimes the entire surface has to be composed of two individual surfaces for reasons of weight. In this case a reinforcing post is employed where there is a gap between the individual plate-metal panels, so that the two plate end regions cannot vibrate. This is a solution involving a high outlay.
OBJECTS AND STATEMENT OF THE INVENTION
The objects of the invention are to provide large surface, sound-proofing, machine-cladding panels and booths produced from such panels that avoid the disadvantages mentioned above. In particular, it is to be possible, at a substantially lower outlay, to have a capacity for at least equal, if not better insulation, specifically at least against sound. At the same time, it is to be possible to manufacture the machine stands in the known way. There will therefore be no need to change the construction of the machines for the sake of better sound-proofing.
Panels of the kind described have a first layer of sound-proofing material extending in the form of a panel, a second layer connected to said first layer over a common large surface, and a first half of a connecting device on said panel for fastening said panel to a machine or the like by means of a second half of said connecting device.
The objects of the invention are achieved by means of the following features:
a) said sound-proofing material is a foam material having a thickness of at least approximately 10 cm, a plane front face, a rear face spaced from said front face by the thickness of said foam material, and circumferential faces connecting said front face and said rear face;
b) said second layer is a thin sheet in relation to said foam material thickness, is connected materially on its rear face to said front face of said foam material over a large surface, has wrap-around portions that extend around said circumferential faces of said foam material at least as far as said rear face of said foam material and is materially connected to said rear face of said foam material over a large surface; and
c) said first half of said connecting device is one half of a mutiply reusable surface fastener that is releasable by manual force.
As used in this specification, the term "thin sheet" means a plastic foil. Advantageously, the plastic foil is reinforced with fabric.
The invention has at least the following advantages:
a) Even very large panels can be handled by only one man. The storage of the panels presents no problems. The sound-proofing is substantially better than hitherto, despite a simpler technology. Although the panels can be larger, they are more rigid than plate-metal panels of equal size. No screws and no tools are required. Accuracies of fit are not involved. There are no sound bridges. Screws cannot fall into the machine. Anyone will immediately understand the operations of assembly and removal. The aesthetic appearance is excellent, since the sheet is already on the market in many colors and patterns for other purposes, such as, for example, for tarpaulins.
The embodiment described includes the following additional advantageous features.
The foam material is of the type of the cores used for sports mats. It is possible to use cores which are already on the market for other purposes, the properties of which have been known for a long time and which, as is known, are capable of absorbing the worst shocks without damage.
The foam material is continuous in one piece at least over the width and height of the panel. This ensures high rigidities without discontinuities which would occur if the core were glued together from several pieces of foam.
The foam material is composed of regenerated foam. It has been shown that such foam material is fully satisfactory, and therefore a new field of use for regenerated foam has been found.
The foam material is selected from the group consisting of composite foam, polyethylene foam and polyether/polyester foam. Foam materials of these types have proved highly appropriate in practice, and this of course also applies to foam materials of a similar type.
The foam material is chosen to contain an air fraction that is smaller when a frequency to be damped is lower. As a result, it is possible to adapt to the different frequencies which mainly occur.
The front face and the rear face of the foam material are parallel to one another. The rigidity of the device remains the same everywhere. If, for example, the core were thicker in the middle region, then the rigidity conditions over its length would also be different.
The circumferential faces of the foam material are perpendicular relative to said front face of said foam material. By virtue of this feature, the slits between the frame legs of the machine and circumferential faces become very long and narrow, so that no sound can escape outwards through them. If the device is made a little oversize, there is even a slit of "zero" width over the breadth of the circumferential faces.
The foam material is in the form of a flat rectangle. This feature makes it possible to ensure that the core can be cut by means of simple cuts perpendicular relative to one another.
The thin sheet is reinforced with a fabric. Devices especially resistant to bending are obtained as a result of this feature, and the device becomes substantially more rigid than either of the two components in itself, but also more rigid than plate-metal when the dimensions are large. The structure of the fabric largely results in a roughening of the surface of the sheet, so that better adhesive bonding is also possible.
The thin sheet is of low extensibility, and the fabric is of low extensibility. By means of these features, the low extensibility can be transmitted to the fabric, this leading to better results, and the filling material of the sheet can then perform other functions and need not be of such high quality.
The fabric has a high resistance to tear propagation. This feature maintains the rigidity and protective function of the sheet for the core, even if a tear were to form anywhere.
The thin sheet is adhesively bonded over a large surface to the circumferential faces of the foam material. This feature further stiffens the device.
The first half of the surface fastening is attached to the thin sheet on circumferential faces thereof. This feature makes it possible to couple devices to one another in a simple way, without having to provide intermediate carriers.
The thin sheet has wrap-around portions laid back onto the rear face of the foam material, which carry the first half of the surface fastening. As a result, the surface fastening cannot be torn off from the core, and moreover the wrap-round providing rigidity is itself stiffened further.
The first half of the surface fastening is hookvelvet. An especially simple form of a surface fastening with known properties is the result, wherein an acoustic decoupling also takes place within the hookvelvet, because of course it is resilient in acoustic terms.
The first half is the hook part of the hookvelvet. This feature provides the more rigid part of the hookvelvet on the device, thus further stiffening the latter.
The surface fastening consists of individual pads that are small in relation to the surface of the panel. By virtue of this feature, the force for opening the surface fastening becomes very low and also only a little material is needed for the surface fastening.
At least one pad is provided in four corner regions of approximately flat rectangular panels of the wrap-around portions of the thin sheet. A fastening having this feature is sufficient even for large-surface devices.
The other half of the surface fastening is provided on a tab which extends from an interior of a machine stand frame into a space to be filled by the panel. This feature ensures a simple counterface which is easy to produce and can easily be attached to the frame and also does not cause any obstruction.
The foam material consists of at least two sandwich layers with at least one stiffening insert, which are connected to one another materially and over their entire surface. As a result, extremely large devices can be stiffened so that they do not buckle when handled. If the stiffening inserts are made of plastic, the weight scarcely changes at all. Furthermore, the stiffening inserts have even better properties when they are included in the bonding operation.
A booth is comprised of walls produced at least partially from panels according to the invention. It is possible to produce such booths with the best possible sound insulation properties, even though they are substantially less expensive than the booths known hitherto. Because of their very low weight, they can also easily be transported or stored in a dismantled state.
A panel forms a door, and door-hinge sockets are embedded into a door edge of said panel forming said door and into a panel forming an associated wall. As a result, doors can also be provided without the need to resort to metal technology for these.
DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is now described. In the drawings:
FIG. 1 shows a front view of a machine-stand frame filled with a device according to the invention shown truncated;
FIG. 2 shows a section along the line 2--2 of FIG. 1, but partially not in section;
FIG. 3 shows a blank of the sheet with a foam core laid on it;
FIG. 4 shows the rear view of a device according to the invention shown truncated;
FIG. 5 shows an enlarged view of the top right region of FIG. 4;
FIG. 6 shows a cross-section through a device according to the invention with inserted stiffening bars;
FIG. 7 shows a perspective inner view of a soundproof booth with the door removed;
FIG. 8 shows a diagrammatical representation of a somewhat different arrangement of the panels for a soundproof booth.
DETAILED DESCRIPTION
A machine otherwise not shown has a frame 11 consisting of four frame legs 12, 13, 14, 16, forming a rectangular frame, in which the frame legs 12 and 14 are parallel to one another and frame legs 13 and 16 are in turn parallel to one another and perpendicular relative to those first mentioned. They are produced from a rectangular raw section and are made of steel. Three metal tabs 17, 18, 19 are welded to the rear face of the frame leg 12, there being here a flat iron section. The tabs 17, 19 are provided in the corner region and the tab 18 is provided in the middle region. They project a few centimeters downwards and are of equal size and equal length. Tabs 21, 22, 23 extend upwards from the frame leg 14 in an exactly corresponding way, as seen from above. A coating strip 26 of a hookvelvet 27 is adhesively bonded to each tab 17 to 23 on its face 24 directed outwards. The area of each coating strip 26 is in the range of 5 to 15 cm 2.
A core 28 of foam material is cut in the form of a flat rectangle so that it just fits into the compartment 29. It is 6 cm thick and is therefore essentially as thick as the frame legs 12 to 16 are wide. The core 28 has a plane front face 31, a plane rear face 32 parallel to this and plane circumferential faces 33, 34, 36, 37, perpendicular relative to these.
A foil 38 is reinforced in a linen weave by means of fabric 39. The foil 38 has a blank according to FIG. 3.
Sheet 38 has on one end a wing 41, which has faces 43, 44, 46 and 47. Sheet 38 has on its opposite end a wing 42 which has corresponding faces, e.g. face 39. At top and bottom in FIG. 3, sheet 38 has a wing 48, which has faces 49, 51 and a wing 52, which includes corresponding faces. The core 28, on its front face 31, is adhesively bonded over its entire surface (i.e. not only over part regions) to the correspondingly large rectangular face of the foil 38. All the other faces visible in FIG. 3 are also subsequently bonded adhesively to the core 28. For this, appropriately first, the left and right wings 41, 42 are swung up. For the wing 41 the face 43 then rests bonded against the circumferential face 37. The face 44 rests against the rear face 32 of the core in its left edge region and is likewise adhesively bonded over its entire surface. In the view of FIG. 3, the faces 46, 47, turned down, rest bonded against the circumferential face 33, 36 over their entire surface.
The same applies analogously to wing 42. Accordingly, the wing 48 is adhesively bonded over its entire surface, the face 49 resting on the faces 46 and on the circumferential face 33, and the face 51 resting bonded over its entire surface externally on the faces 44 and otherwise on the rear face 32 of the core 28.
The same applies analogously to the wing 52.
According to the FIGS. 4 and 5, hookstrips 53 are glued in an overlapping manner onto the faces 44 and 51, where corner regions are concerned, as shown clearly in FIG. 5. In the middle region of the device according to FIG. 4, the hookstrips 53 are glued to the faces 51 only from outside. The hookstrips 53 are cut longer than the tabs 17, 18, 19, 21, 22, 23 are wide so hookstrip 53 always meets a coating strip 26.
The procedure for cutting the core 28 to size can also be such that the device according to the invention fits into the compartment 29 under a slight internal compression, that is to say has a certain oversize in the untensioned state so that no gaps 54 at all are formed. The device then to a considerable extent holds itself in the compartment 29 and the surface fastening 26, 53 then perform only a certain auxiliary function.
FIG. 6 shows 2 core halves 56, 57 which are adhesively bonded to one another over the entire surface along their inner faces 58 confronting one another, plastic bars 59 being glued in between them and serving for further stiffening. The foil 38 is represented by dot-dashed lines.
Such panels formed from core 28 and foil 38 can also be used to produce a soundproof booth 60 in a simple way (FIG. 7). The rear wall is formed by a panel 61, the ceiling by a panel 62 and the two side walls by panels 63 and 64. So that these can be connected removably to one another, mutually abutting faces 66 are provided with surface fastenings in the manner of hookvelvet. In this case, the hookvelvet must be provided on four faces 66, so that the panels 61 to 64 can be connected to one another.
Set into the end face 67 of the panel 64 are two hinge halves 68 which are embedded in the foam material, for example by the use of heat, and which project from the end face 67 with their hinge part only. A fifth panel which covers the panels 61 to 64, as seen from the front, is used as a door 69. The door can likewise be provided with surface fastening means. For aesthetic reasons, but also for the sake of greater rigidity and easier cleaning, perforated sheeting 71 is glued to the panels from inside over their entire surface.
FIG. 8 shows that the upper panel can also be placed on top of the two panels perpendicular to it, thus obtaining an even better connection.
Both the foam material and the adhesive can be ordered, for example, from Messrs. Dunlop Deutschland. The desired relative density must be given for the foam material.
At extremely low frequencies, it may be necessary to glue in lead sheeting in a foam/lead sheeting/foam sandwich. However, a heavy-duty sheet is usually sufficient. | A sound-proofing panel for the cladding of machine tools consists of a foam board (28) of a thickness of at least approximately 10 cm., over which is glued a tear-resistant plastic sheet (38). The connection to the frame (12, 14) of the machine is made by means of self-catching strip fastenings (27). |
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BACKGROUND OF THE INVENTION
This invention relates to emergency shelters for protection against tornados, hurricanes, floods, fire, earthquakes, burglary, bombs and other hazards.
A variety of emergency shelters previously have been site-constructed of cement, steel, fiberglass and other materials for particular uses. Others have been manufactured in an assembled condition for particular applications. None are known to be site-assembled from matching parts as taught by this invention.
Examples of different but related emergency shelters are described in the following patent documents. U.S. Pat. No. 5,611,178, issued to Aubert on Mar. 18, 1997, described a tunnel-like structure made of corrugated metallic half shells. U.S. Pat. No. 4,955,166, issued to Qualline, et al. on Sep. 11, 1990, described a tornado underground shelter having a truncated spherical form. U.S. Pat. No. 4,805,360, issued to Kuehnl on Feb. 21, 1989, described an underground supply room for supplying goods and services to vendors in a retail outlet above it in a parking lot. U.S. Pat. No. 4,660,334, issued to McCarthy on Apr. 28, 1987, described a blast shelter with a separate command station. U.S. Pat. No. 4,615,158, issued to Thornton on Oct. 7, 1986, described a mobile-home tornado shelter with a ladder leading from a trailer lot. U.S. Pat. No. 4,534,144, issued to Gustafsson, et al. on Aug. 13, 1985, described an underground bomb shelter with cellular storage compartments. U.S. Pat. No. 3,212,220, issued to Boniecki, et al. on Oct. 19, 1965, described an "ovaloid" or egg-shaped shelter. U.S. Pat. No. 288,354, issued to Mileham on Nov. 13, 1883, described a cylindrical cyclone refuge.
Regardless of catastrophic damages that occur from tornados, hurricanes, floods, fire, earthquakes, burglary, bombs and other hazards, relatively little protection against them is provided because of variously prohibitive problems with present protection alternatives. The most expensive alternative is insurance which is designed for replacement compensation instead of prevention of irreplaceable losses from major hazards.
SUMMARY OF THE INVENTION
In light of these problems, objects of patentable novelty and utility taught by this invention are to provide a site-assembled emergency shelter which:
Can be produced at sufficiently low cost to merit its unlikely but perilous need;
Can be structured for protection against a wide selection of hazards;
Can be marketed either assembled or unassembled;
Can be packaged for low-bulk, inexpensive and convenient transport;
Is relatively easy for an inexperienced person to assemble;
Can be made in sizes to meet different use requirements;
Can be positioned underground for protection against such hazards as tornados, hurricanes, fire, bombs and fallout;
Can be positioned partially underground and partially above ground for protection against hurricanes, floods and earthquakes;
Can be positioned underfloor for protection against burglary in addition to all of the above;
Can be used for storage of food and water to meet disaster needs; and
Can be used as an annex to a building.
This invention accomplishes these and other objectives with a site-assembled emergency shelter having matching shelter portions that can be juxtaposed adjacently for low-volume packaging for shipment and then assembled on site. A wide selection of sizes and shapes are included. For different shelter uses, objectives and preferences, different structural materials such as fiberglass, some aluminum alloys, some stainless-steel alloys and other materials can be selected for appearance, endurance, weight, strength, cost and other factors. Installation components such as ground anchors, air circulators, accesses, handling members, flotation ballasts and communications are provided.
The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are described briefly as follows:
FIG. 1 is a partially cutaway perspective view of a domed cylindrical shelter partially in the ground;
FIG. 2 is a partially cutaway perspective view of a domed cylindrical shelter underground except for an entrance hatch;
FIG. 3 is a partially cutaway perspective view of a domed cylindrical shelter partially having a tie-down line and a ballast tank for floating in the event of floods;
FIG. 4 is a partially cutaway perspective view of a domed cubical or rectangularly domed shelter having a tie-down line and a ballast tank for floating protection from flooding;
FIG. 5 is a top view of a cubically domed shelter;
FIG. 6 is a front view of the FIG. 5 illustration;
FIG. 7 is a top view of a rectangularly domed shelter;
FIG. 8 is a side view of the FIG. 7 illustration underground;
FIG. 9 is a partially cutaway side view of a cubically domed shelter in pieces for packaging and transportation before being site-assembled;
FIG. 10 is an end view of a cylindrically domed shelter in pieces for packaging and transportation before being site-assembled;
FIG. 11 is an end view of a cubical shelter in pieces for packaging and transportation before being site-assembled;
FIG. 12 is a partially cutaway side view of a cylindrically domed shelter in pieces for packaging and transportation before being site-assembled;
FIG. 13 is a partially cutaway side view of a cubically domed shelter in pieces for packaging and transportation before being site-assembled;
FIG. 14 is a partially cutaway side view of a curve joiner;
FIG. 15 is a cross-sectional view of the cylindrical joint taken through line 14--14 of FIG. 14;
FIG. 16 is a partially cutaway side view of a plane joiner;
FIG. 17 is a cross-sectional view of the angle joint taken through line 16--16 of FIG. 16;
FIG. 18 is a partially cutaway side view of a pole ladder for shelter hatchways;
FIG. 19 is a side view of an under-building shelter and a partially underground shelter in relationship to a building; and
FIG. 20 is a partially cutaway perspective view of a rectangular shelter with a slanted door.
DESCRIPTION OF PREFERRED EMBODIMENT
Terms used to describe features of this invention are listed below with numbering in the order of their initial use with reference to the drawings. These terms and numbers assigned to them designate the same features wherever used throughout this description.
______________________________________1. Base portion 15. Escape hatch2. Wall portion 16. Slide pole3. Roof portion 17. Rungs4. Door 18. Ground5. Hatchway 19. Building6. Hatchway closure 20. Curved joining edges7. Hinges 21. Site-assembly portions8. Lift-hook attachments 22. Straight joining edges9. Air conveyance 23. Curve joiner10. Anchor line 24. Plane joiner11. Land anchor 25. Joiner walls12. Ballast tank 26. Joiner bolts13. Ariel 27. Shipping containers14. Under-building safe room 28. Transom______________________________________
Referring first to FIGS. 1 and 9-14, a site-assembled emergency shelter has a base portion 1, a wall portion 2 and a roof portion 3 with site-assembly portions that fit together juxtaposed adjacently in an unassembled mode, as shown in FIGS. 9-13, for transportation.
Referring to FIGS. 1-8, 19, and 20, the wall portion 2 can be vertically cylindrical with preferably but not necessarily a slight taper and the base portion 1 correspondingly circular as depicted in FIGS. 1-3. Optionally as desired, the wall portion 2 can be vertically rectangular with or without a slight taper and the base portion 1 square as indicated in FIGS. 4-6. Further optionally, the wall portion 2 can be horizontally rectangular and the base portion 1 correspondingly rectangular as depicted in FIGS. 7-8. As shown in FIG. 20, the wall portion 2 and the base portion 1 both can be rectangular.
Tapering of the wall portion 2 provides not only structural rigidity but also a positioning means by being wedged under ground as shown in FIGS. 1 and 19. A positioning means also is provided by structural capacity to support ground overburden on the roof portion 3 as shown in FIGS. 2, 8 and 19.
At least one securable access to an inside periphery of the site-assembled emergency shelter is provided by optionally a door 4 as shown in FIGS. 1, 3-6 and 19-20 or a hatchway 5 with a hatchway closure 6 as shown in FIGS. 2, 7-8, and 19. The door 4 is preferably a flotation member that can be removed from its hinges 7.
Lift-hook attachments 8, as depicted in FIGS. 1-8 and 19-20, are provided to aid on-site assembly and mobility after assembly.
An air conveyance 9 as indicated in FIGS. 1-8 and 19-20 is preferably a telescopic tube in securable communication with an outside source of clean air and an inside periphery of the site-assembled emergency shelter. Securement of the air supply can be with an air conveyance 9 that is telescopic as shown in FIGS. 1-8 and 19-20 but also can be positioned permanently in a secure position such as indicated also in FIG. 19.
An anchor line 10 attached to a land anchor 11, as shown in FIGS. 3-4 is a positioning means for sheltering protection against floods. The anchor line 10 is preferably sufficiently long to anchor in flood water as deep as probable for a particular area. The anchor line 10 also is preferably releasable.
To aid verticality of buoyance, a ballast tank 12 shown in FIGS. 3-4 can be provided in a bottom of site-assembled emergency shelters that are intended for positioning on the ground or partially in the ground. The ballast tank 12 is preferably for potable water or other fluid that is stored in the ballast tank 12 for emergencies. Flood water also can be used for ballast as shown by outside connections.
Two stories as shown in FIGS. 1-4, 19 and 20 can be provided not only for people capacity but also for storage of food, water, communications equipment, flotation devices and survival equipment such as fishing and hunting implements. The horizontally rectangular site-assembled emergency shelter underground with a fast-entry hatchway as shown in FIGS. 7-8 is preferable for some conditions such as near schools.
An ariel 13 shown in FIG. 19 can be provided in the event of failure or unavailability of satellite communications.
An under-building safe room 14 with a hatchway closure 6 as shown in FIG. 19 can shelter against a plurality of hazards such as burglary, tornados, hurricanes, flood, fire, earthquakes and bombs. For maximum protection, the hatchway closure 6 is optionally sealable from the inside, has a plurality of particularly secure air conveyances 9 and has an alternate escape route through an escape hatch 15 such as oil-well casing that is made of steel and extends high enough to prevent entry of burglars or flood water. Preferably, the escape hatch 15 also has an inside-sealable hatchway closure 6.
For convenience in vertical access through hatchways, through the escape hatch 15 and from-floor-to-floor of a multiple-storied shelter, a pole ladder having a slide pole 16 and positional rungs 17 as shown in FIGS. 18-20 can be used. The rungs 17 can be left off for sliding down the slide pole 16 for fast entrance and then hand-positioned conveniently for going up the pole ladder. This is a particularly convenient and space-saving use of oil-well casing or other tubing for the escape hatch 15. A burglar coming down it if possible to enter it, could be stopped and trapped by a closure entrance into the site-assembled emergency shelter.
An annex of shelter rooms as conveniently positioned in relation to a dwelling as indicated in FIG. 19 can be used for common purposes such as a quiet room, a study, a bedroom or a storage room in addition to use for sheltering against intended hazards. They can also have access to air conditioning or heating if needed under ground 18 proximate a building 19.
Referring to FIGS. 9-17, curved joining edges 20 that are side-joining edges of site-assembly portions 21 can be joined and sealed with any of a selection of known means for joining metal if metal is used or for joining fiberglass if fiberglass or other plastic material is used for construction of an intended emergency shelter. Similarly, straight joining edges 22 that are side-joining edges of site-assembly portions 21 can be joined and sealed with any of a selection of known means for joining metal if metal is used or for joining fiberglass if fiberglass or other plastic material is used for construction of an intended emergency shelter.
Regardless of which type of material is used for construction of intended emergency shelters, a preferred means for joining curved joining edges 20 is with a curve joiner 23 shown in FIGS. 14-15 and a preferred means for joining straight joining edges 22 is with a plane joiner 24 as shown in FIGS. 16-17. Both have length approximately equal to lengths of material to be joined. Both have material channels between joiner walls 25 and both have joiner bolts 26 that are used to force the joiner walls 25 together against opposite sides of material 20 and 22 positioned between the joiner walls 25. A cement for some relatively plastic materials and a gasket for relatively hard structural materials can be positioned on opposite sides of the structural materials 20 and 22 to aid tightness of sealing. Angles between oppositely disposed channels having joiner walls 25 can be structured for particular shelter designs.
As shown in FIGS. 9-13, the site-assembly portions 21 of intended emergency shelters or of the base portion 1, the wall portion 2 or the roof portion 3 thereof are made to fit juxtaposed adjacently for transportation in shipping containers 27 that are represented generally by dashed lines. Site-assembly portions 21 of rectangularly shaped emergency shelters can be single sides 2 stacked for shipment as shown in FIG. 9 with a dome-shaped top portion 3 and peripheral components packaged on top of them. Circular or cylindrical site-assembly portions 21 or optionally, rectangular site-assembly portions 21 can be structured as enclosure portions as shown in FIGS. 10-13 and juxtaposed adjacently for shipment.
As shown in FIGS. 1, 3-4 and 20, doors 4 of intended emergency shelters having them instead of hatchways 5 can have transoms 28 that provide structural integrity.
A new and useful site-assembled emergency shelter having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention. | A site-assembled emergency shelter has matching site-assembly portions (21) that can be juxtaposed adjacently for low-volume packaging for shipment and then assembled on site. A wide selection of sizes and shapes are included. For different shelter uses, objectives and preferences, different structural materials such as fiberglass, some aluminum alloys, some stainless-steel alloys and other materials can be selected for appearance, endurance, weight, strength, cost and other factors. Installation components such as ground anchors (10, 11, 18), air circulators (9), accesses (4, 5), handling members (8), flotation ballasts (12) and communications (13) are provided. |
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention is in the field of portable safes or strong boxes. It relates mainly to a portable safe which when locked is secured against removal from a drawer or a similar structure.
Portable safes are a convenience for use at home or when traveling, to protect valuables such as money and jewelry. Since portable safes by their nature are easy to carry off they need to be protected not only against unauthorized opening but also against unauthorized removal of the entire safe. For this reason it has been suggested with respect to some prior art portable safes to use some mechanism to secure the safe to a larger object such as a drawer. Some prior art portable safes of this type have been referred to in British Pat. No. 392,557 and in U.S. Pat. Nos. 4,029,370 and 4,030,426. One disadvantage of the prior art portable safes referred to in these patents is that the particular technique used to secure them to a larger object reduces the amount of interior space available to store valuables and that one must reach inside the safe in order to unlock the mechanism for securing it to a larger object. A similar prior art portable safe is referred to in U.S. Pat. No. 3,166,364. It is also designed to be secured to a larger object, in this case a drawer, but the restraining mechanism is released automatically with the unlocking of the safe. This prior art safe is secured to a larger object by placing it in a drawer of a chest or the like and by pivoting up a part of the safe so as to increase the height of the safe and make it difficult to remove it from the drawer. The part that can be pivoted up for that purpose uses a ratchet and pawl mechanism and other parts which must be manufactured to close tolerances, which makes it expensive to manufacture. In addition, the lid which closes off the interior of this prior art safe is not completely detachable from it, which makes it necessary to include in the safe a removable inner tray so that this tray can be taken completely out from the safe to provide convenient access to the valuables kept in it.
This invention is also directed to a portable safe which can be secured to a larger object, to thus make it more difficult for an unauthorized person to remove the entire safe. Unlike the prior art devices referred to above the invention is directed to a portable safe which is effective but is at the same time simple and inexpensive. More particularly the invention is directed to a portable safe which works by wedging itself in a drawer and resists being either opened or moved from the drawer without first unlocking it. Moreover, the invention is directed to a safe which has a completely detachable lid, so as to provide convenient access to the interior of the safe, and a safe which requires no precision parts and can be made almost entirely of inexpensive molded plastic components which can be easily assembled by hand or with minimal use of tools.
A portable safe embodying this invention includes an open-top container which has a bottom, side walls, a front wall and a back wall which define an interior for storing valuables. An inner lid fits over the container to enclose its interior and bar access to it. This inner lid can be easily removed from the container in its entirety so as to provide convenient access to the valuables stored in the container. There is a substantially rigid outer lid which fits over the container and the inner lid and has a back end pivoted on the container. This outer lid can be pivoted up or down relative to the container to thereby increase or decrease the vertical dimension of the safe. Thus, when the safe is put in a drawer this outer lid can be pivoted up to wedge the safe between the bottom and the top of the drawer.
There is a substantially rigid prop which is pivoted on and extends through the outer lid such that its top end is above the outer lid and its bottom end is below it.
The inner lid has means for engaging the bottom end of the prop during movement of the outer lid and the prop relative to the inner lid, and a locking plate is provided which is coupled to the inner lid and is movable relative to it between a locking position and a released position. In its locking position the locking plate concurrently engages the container to lock the inner lid to it and engages the bottom end of the prop to lock it to the inner lid. In its released position the locking plate does not engage the container and does not lock the prop to the inner lid. Thus, when the locking plate is in its released position the outer lid may be manually moved up to wedge the safe in a drawer or down to unwedge the safe and permit its removal from the drawer. In addition, in the released position of the locking plate the inner lid may be manually lifted completely from the container to permit easy access to its interior. Conversely, when the locking plate is in its locking position the inner lid of the container is kept closed and the outer lid is kept wedged in the drawer, since the prop keeps it from being unwedged. There is a lock, such as a combination lock, coupled with the locking plate. The lock can be locked only when the locking plate is in its locking position. When the lock is so locked the locking plate cannot be moved from its locking position. Conversely, when the lock is not locked the locking plate can move back and forth between its locking and released positions. The locking plate is so moved through a pair of slide pushers which are accessible from outside the safe and can be moved manually.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portable safe embodying the invention.
FIG. 2 is a side sectional view through a drawer in which the portable safe has been wedged.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a partly sectional and partly side view of the safe without its outer lid.
FIG. 5 is a partial sectional view along line 5--5 of FIG. 4.
FIG. 6 is a perspective view of a back portion of the safe.
FIG. 7 is a sectional view of a part of the safe showing it in the unlocked position.
FIG. 8 is a partial sectional view along line 8--8 of FIG. 3.
FIG. 9 is a partial sectional view along line 9--9 of FIG. 7
FIG. 10 is a view similar to that of FIG. 7 but showing the safe in its locked position.
FIG. 11 is a sectional view along line 11--11 of FIG. 10.
FIG. 12 is an exploded perspective view of a part of a combination lock of the safe.
FIG. 13 is a perspective view of a tool for resetting the combination lock.
FIG. 14 is a partial sectional view along line 14--14 of FIG. 10.
DETAILED DESCRIPTION
The illustrated embodiment of a portable safe embodying the invention includes an open-top container 20 which has a bottom 22, right side wall 24, left side wall 26, back wall 28 and front wall 30 which define an interior for storing valuables. An inner lid 32 fits over the container 20 to enclose its interior and bar access to it. A substantially rigid outer lid 34 fits over the container 20 and the inner lid 32 and has a back end pivoted on the container 20 at 36 and 38 to pivot up or down relative to the container 20 to thereby increase or decrease the vertical dimension of the safe. A substantially rigid prop 40 passes through a suitable opening 42 in the outer lid 34 and is pivoted on the outer lid 34 at 43. The prop 40 has a top end 40a which extends above the outer lid 34 and a bottom end which is below the outer lid 34. The inner lid 32 has means for engaging this bottom end 40b of the prop during movement of the prop relative to the inner lid 32. This means includes a slot in the inner lid 32 which has a wider front part 32a and a narrower rear part 32b. The bottom end 40b of the prop has a pair of feet 40b' and 40b" which extend toward the respective side walls 24 and 26 of the container. These feet can pass through the wider but not through the narrower part of the slot. When the outer lid 34 is all the way down against the inner lid 32 the feet of the prop are lined up with the wider part 32a of the slot in the inner lid 32 and can go through that part of the slot. Thereafter, when the outer lid 34 is manually pivoted up the feet at the bottom end of the prop 40 ride along the underside of the inner lid 32 along the narrower part 32b of the slot in the inner lid, as best seen in FIG. 3. The relevant dimensions are such that if the outer lid 34 is pressed down against the inner lid 32 when the feet at the bottom end of the prop 40 are above the inner lid 32 these feet snap in through the wider part 32a of the slot in the inner lid 32 and ride along the underside of the inner lid 32 when the outer lid 34 is thereafter manually pivoted up. To release the feet at the bottom of the prop 40 from engagement with the inner lid 32 the outer lid 34 must be pressed down against the inner lid 32 and concurrently the top end 40a of the prop 40 must be pressed down against the outer lid 34 to snap the feet of the prop 40 out of the inner lid 32 through the wider part 32a of the slot in it.
The inner lid 32 is locked to the container 20 and the outer lid 34 is locked in a position to wedge the safe in a drawer with the help of a locking plate 44 which is coupled to the inner lid 32 and is movable between a locking position and a released position. In its locking position the locking plate 44 concurrently engages the container 20 to lock the inner lid 32 to it and engages the bottom end 40b of the prop to lock it to the inner lid 32. This locked position is illustrated in FIGS. 2 and 10. In its released position the locking plate 44 does not engage the container 20 and does not lock the prop 40 to the inner lid 32. This released position is illustrated in FIGS. 7 (in solid lines) and 11. Thus when the locking plate 44 is in its released position the outer lid 34 may be manually pivoted up to wedge the safe in a drawer or down to unwedge the safe, and the inner lid 32 may be manually lifted completely from the container 20 to provide convenient access to the valuables stored in the interior of the container. When the locking plate 44 is in its locking position the inner lid 32 keeps the container closed and, if the outer lid 34 is wedged in a drawer, the prop 40 keeps that outer lid 34 from being unwedged. The safe is illustrated in FIG. 2 as wedged in an exemplary drawer which has a bottom 46 and front 48 and opens to the right by sliding relative to the drawer top 50. In this exemplary drawer there is a bead 52 depending from the top 50 and in line with the drawer front 48 when the drawer is closed. Note that this bead 52 keeps the safe from being taken out of the drawer without first bringing down the outer lid 34.
A combination lock generally indicated at 45 is coupled with the locking plate 44 and has a locked position to which it can be moved only when the locking plate 44 is in its locking position. When the lock 45 is in its locked position it keeps the locking plate 44 from moving out of its locking position. The lock 45 also has an unlocked position in which it does not interfere with movement of the locking plate 44 between its locking and released positions. The locking plate 44 can be manually moved between its locking and released positions (of course only when the lock 46 is in its unlocked position) through slide pushers 56 and 58 which are easily accessible from outside the safe.
The outer lid 34 includes a pair of upwardly extending projections 34a and 34b which are adjacent to but spaced from the front end of the outer lid, which are designed to make it more difficult to remove the safe from a drawer without first unlocking it and bringing down its outer lid 34. More specifically, these projections make it more difficult to turn the safe, in the case illustrated in FIG. 2, with its back end toward the front of the drawer, partly opening the drawer and then trying to remove the safe from the drawer by lifting up its back end and pivoting it about its front end.
Referring in greater detail to the mechanism for locking the inner lid 32 to the container 20 note, as best seen in FIGS. 7 and 10, that the front wall 30 of the container and the front end of the inner lid 32 have interlocking means engaging each other when the inner lid is fitted in place over the container so as to prevent lifting the front end of the inner lid from the container but to permit lifting the back end of the inner lid. These interlocking means include, in this particular example, a rearwardly facing lip 30a along the top end of the front wall 30 and a forward projection 32c at the front end of the inner lid 32 which fits under the lip 30a. The engagement of the lip 30a and projection 32c keeps the front end of the inner lid 32 from being picked up from the container 20 even when the locking plate 44 is in its released position shown in solid lines in FIG. 7. However, the inner lid 32 and all elements attached to it can be completely removed from the container 20 by lifting the rear part of the inner lid 32 up from the container and pivoting it about its front end until the projection 32c clears the lip 30a, at which time the entire inner lid 32 and its attachments can be completely removed from the container 20 to permit easy access to its interior. The back wall 28 of the container and the back end of the locking plate 44 similarly have aligned interlocking means which engage each other when the locking plate 44 is in its locking position, shown in FIG. 10, to keep the back end of the inner lid from being moved away from the container. These interlocking means comprise, in this particular example, several openings 28a in the back wall 28 of the container 20 and matching rearwardly extending projections 44a at the back end of the locking plate 44 which fit within the openings 28a when the locking plate 44 is in its locking position shown in FIG. 10.
The locking plate 44 is coupled with the inner lid 32 by being within the space between the underside of the inner lid 32 and the top side of a tray 54 which is affixed to the inner lid 32 as by screws 55. To assist in locking the prop 40 to the inner lid 32, the locking plate 44 has a row of ridges facing the path of each of the feet of the prop 40 along the underside of the inner lid 32. Thus, there is a row of ridges 44b facing the path of the foot 40b' and a row of ridges 44c facing the path of the foot 40b". The spaces between the underside of the inner lid 32 and these rows of ridges from respective tracks 59 and 60 for the prop feet. In the released position of the locking plate 44 illustrated in FIGS. 7 and 11 the tracks 59 and 60 have sufficient vertical dimension to permit rearward or forward movement of the prop feet along the tracks. However, when the locking plate 44 is in its locking position, as illustrated in FIG. 10, the vertical dimension of the tracks 59 and 60, i.e. the distance between the tops of the ridges 44b and 44c and the undersides of depending beads 32d and 32e of the inner lid 32, is less than the vertical dimension of the feet 40b' and 40b" of the prop 40, and the prop feet must fit in the spaces between adjacent ridges.
In order to help wedge the safe tighter in a drawer when the safe is locked the locking plate 44 not only moves backwardly to lock the inner lid 32 to the container 20 but also moves slightly upwardly to thereby pivot up the outer lid 34 a bit more as the safe is locked. More specifically, the tray 54 includes cam surfaces 54a and the locking plate 44 includes cam followers 44d which ride up the cam surfaces 54a as the locking plate 44 moves rearwardly. The locking plate 44 is moved manually back and forth through slide pushers 56 and 58 which are at the opposite side ends of a bar 61 which extends across the width of the container 20 and interlocks with the front end of the locking plate 44 so as to move forwardly or rearwardly with it. The bar 61 fits in suitable openings 63 and 65 in the side walls 24 and 26 of the container 20.
In order to assist smooth movement of the prop feet within the tracks 59 and 60 the bottom end of the prop may be biased upwardly, as by an extension spring 64 connecting the bottom end of the prop 40 to a point at the forward part of the underside of the outer lid 34. Then, in order to keep the lid 32 fitted in place over the container 20 while the locking plate 44 is in its released position and the prop feet are riding within the tracks 59 and 60, a latch 66 may be provided to slide along a suitable track 68 and the back end of the inner lid 32 and to engage, when in its back position, a suitable opening 28b in the back wall 28 of the container with a projection 66a.
The combination lock generally indicated at 45 includes a shaft 70 and several number dials 72 (a total of three in the illustrated example) which are mounted next to each other to rotate on the shaft 70. Each number wheel includes an integrally formed lug slot wheel 74 which has a number of radially extending lug slots 76. A lug wheel 78 is mounted coaxially with the number dial 72 to rotate about a tubular shaft 77 which is integrally formed with the number dial 72. The lug wheel 78 has a lug 78a and a radial slot 78b. Once the combination lock 45 is set the lug 78 is in a particular one of the lug slots 76 and the lug wheel 78 and the number dial 72 rotate as a unit. However, each of the several number dials 72 rotates about the main shaft 70 independently of the other number wheels. When the proper combination of number indicia on the periphery of the several number wheels 72 is aligned with a center mark 80 on respective bars 82 which separate the number wheels from each other the slots 78b of all of the slot wheels 78 point rearwardly and are aligned with the fingers 61a of the bar 61 which serve as a locking latch and must move into the slots 78b for the locking plate 44 to move to its released position. Thus for the lock 45 to be in its locked position all of the number wheels 72 must be in the position which corresponds to the slot 78b being as illustrated in FIG. 7. The lock 45 is in a locked position if any of its number wheels 72 has the associated slot 78b out of alignment with the respective projection 61a of the bar 61, as in the position illustrated in FIG. 10.
The lock 45 is affixed to the inner lid 32 by brackets 84 which, together with studs 32f and 32g extending downwardly from the inner lid 32, to which they are affixed by screws 86, form a bearing for the main shaft 70 of the lock 45. The lug wheels 78 are kept pressed against the respective slot wheels 74 by respective compression springs 88.
The lock combination can be conveniently changed with the help of a special tool 90 illustrated in FIG. 13. To do this the inner lid and the parts attached to it are removed completely from the container 20 and a snap cover 92 which encloses the underside of the lock 45 is removed to expose the underside of the lock. The forked end of the tool 90 is then inserted between a slot wheel 74 and the associated lug wheel 78, to move the lug wheel to the right as seen in FIG. 12 and disengage the lug 78a from its respective slot 76. The associated number wheel 72 may then be manually rotated relative to the lug wheel 78 to a new position, and the tool 90 may then be withdrawn to permit the lug 78 to go into a different slot 76, to thereby reset the lock 45 to a different combination.
In operation, valuables are placed in the safe while the inner lid 32 is away from the container and the outer lid 34 is pivoted up to provide an unobstructed access to the container interior. The front end of the inner lid 32 is then slid into the front portion of the container 20 so as to engage the projection 32c under the lip 30a of the front wall of the container. At this time the outer lid 34 is pivoted all the way up, the lock 45 is in its unlocked position and the slide pushers 56 and 58 have been moved all the way forward to thereby place the locking plate 44 in its released poisition, and the latch 66 has been slid all the way forward. Once the front end of the inner lid 32 is in place against the front wall 30 of the container the back end of the inner lid 32 is pivoted down to also fit in place over the container 20 so as to align the projections 44a with the openings 28, and to align the projection 66a of the latch 66 with the opening 28b in the back wall of the container. The latch 66 is then slid back to engage the projection 66a with the opening 28b. The outer lid 34 is then pivoted down and pressed down against the inner lid 32 to snap the feet 40b' and 40b" through the wider part 32a of the slot in the inner lid 32, then the outer lid 34 is pivoted up while the feet of the prop 40 enter the tracks 59 and 60. This entry is facilitated by suitably dimensioning the relevant parts of the safe and by providing runways 44e aligned with the rows of ridges on the locking plate 44 so as to lead the prop feet into the tracks 59 and 60 at the height of the tops of the ridges and by also bevelling the forward ends of the beads 32d which define the upper surface of the tracks 59, 60 for the same purpose. This getting of the prop feet into the tracks may be done while the safe is in a drawer or the safe may be placed in a drawer once the prop feet are in the tracks. With the safe in the drawer the outer lid 34 is pivoted up until it presses against the top of the drawer, and at this time the slide pushers 56 and 58 are pushed back to move the locking plate 44 toward and into its locking position. This makes the locking plate 44 move backwardly and rearwardly while the prop feet are in the spaces between adjacent ridges, and this wedges the safe in the drawer even tighter. Note that the spring 64 helps keep the prop feet against the beads 32d and 32e while the locking plate is in its released position and thus keeps the prop feet from jamming into the spaces between the ridges of the locking plate. With the locking plate 44 in its locking position the number wheels 72 of the combination lock 45 are turned to new positions. At this time the safe is locked and is wedged in a drawer. To gain access to the interior of the safe the number wheels 72 of the combination lock 45 are rotated to align the proper numerals with the center marks 80 on the bars 82. The slide pushers 56 and 58 are then moved forwardly to thereby move the locking plate 44 to its released position. Once it is in the released position the prop feet can move within the tracks 59 and 60, while being kept riding against the beads 32d and 32e by the spring 64, and the outer lid 34 may be pivoted down so that the safe can be removed from the drawer. Then the outer lid 34 is brought all the way down against the inner lid 32 and pressed down against it while concurrently pressing down on the top end 40a of the prop 40 to snap the prop feet out of the inner lid 32 through the wider part 32a of the slot in the inner lid. Note that the latch 66, which at this time is still in the position to which it was slid back, keeps the back end of the inner lid 32 from being lifted up by the action of the spring 64 or by the pressing down of the top end of the prop 40. With the prop feet out of the slot in the inner lid 32 the outer lid 34 is pivoted all the way up, the latch 66 is slid forward and the inner lid 32 may be removed from the container 20 by picking up the rear part of the inner lid 32 and pivoting the inner lid about its front end and then removing it completely from the container to gain unimpeded access to the container interior.
Note that the bar 61 serves both as a means for moving the locking plate 44 rearwardly and forwardly through the slide pushers 56 and 58 and also serves as a locking latch for the lock 45 by virtue of its projections 61a which fit in the slots of the lug wheels 78.
The portable safe illustrated above is made almost entirely from inexpensive molded plastic components. The only parts which are not made out of molded plastic material in the particular embodiment described above are the spring 64, the prop feet 40b' and 40b", the screws 55 and 86 and the compression springs 88. The pivots at 36 and 38 are molded plastic slugs which snap into suitable openings through the outer lid 34 and side walls 24 and 26 of the container. The plastic parts may be assembled without the use of tools or with minimal use of tools. | Disclosed is a portable safe which when locked wedges itself in a drawer to resist being either opened or removed from the drawer without first being unlocked. |
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PRIORITY AND RELATED APPLICATIONS STATEMENT
This application claims priority under 35 U.S.C. §120 and is a continuation of U.S. patent application Ser. No. 11/906,372, filed on Oct. 2, 2007 and entitled, “METHOD FOR PLACING REINFORED CONCRETE PILING WITHOUT UTILIZING A PILE DRIVER OR AN AUGER,” and now U.S. Pat. No. 7,731,454 issued on Jun. 8, 2010, the entire contents of which are hereby incorporated by reference.
BACKGROUND
The present invention relates generally to apparatus and methods for placing or installing reinforced concrete piles into the ground.
Pilings are often used to support buildings, bridges, antenna structures, or other structures, for example. Conventionally, reinforced concrete piles are placed in the ground by one of two methods. The first method places a precast reinforced concrete pile into the ground by using a pile driver and hammering the pile into the ground. The second method places a reinforced concrete pile into the ground by drilling a circular hole using an auger, removing the soil, placing a pre assembled circular, for example, steel reinforcing rod cage into the hole and pouring wet concrete into the hole to encase the steel reinforcing rod cage.
More particularly, conventional helical pilings typically include one or more helical screw(s) or helices. The shaft is rotated to force the helical screw downwardly into the earth. The piling is screwed downwardly until the screw is seated in a region of soil sufficiently strong to support the load from the structure that it is to support. An additional piling is attached or spliced to a previously screwed piling to increase the depth of the overall piling. To accomplish this, adjacent round or circular ends of the pilings are reconfigured to have a generally square shape with rounded corners. The adjacent ends are configured to have male and female cross-sections so that the piles slide together forming a telescoping joint and are spliced to make a continuous piling.
U.S. Pat. No. 6,814,525 issued to Whitsett discloses conventional piling apparatus and installation methods. The Whitsett patent discloses in its Abstract, for example, that an “in-situ pile apparatus includes a helical anchor to which a plurality of elongated generally cylindrically shaped sections can be added. Each of the sections has a specially shaped end portion for connecting to another section. An internal drive is positioned in sections inside the bore of each of the connectable pile sections. The internal drive includes enlarged sections that fit at the joint between pile sections. In one embodiment, the internal drive can be removed to leave a rod behind that defines reinforcement for an added material such as concrete. The rod also allows for a tension rod connection from the anchor tip to an upper portion attachment point.”
Conventional composite helical pipe piling apparatus is distributed by MacLean Dixie HFS. This piling apparatus could include reinforcing rods and a concrete core within the steel pipe piles hollow inside, however, the steel pipe piling would remain in the ground.
It would be desirable to have a reinforced concrete piling apparatus that may be installed in the ground without requiring a pile driver or an auger.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features, functionalities and practical advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 is an elevational view of exemplary piling apparatus;
FIG. 2 is an enlarged view of a coupler assembly used in the apparatus shown in FIG. 1 ;
FIG. 3 is a plan view of the coupler assembly shown in FIG. 2 with shear pins not engaged;
FIG. 4 is a sectional view of the coupler assembly shown in FIG. 2 taken along the lines 4 - 4 ;
FIG. 5 is a plan view of the coupler assembly shown in FIG. 2 with shear pins engaged;
FIG. 6 is a sectional view of the coupler assembly shown in FIG. 5 taken along the lines 5 - 5 ;
FIGS. 7-9 illustrate installation of exemplary piling apparatus;
FIG. 10 illustrates an installed piling comprising j-shaped bolts; and
FIG. 11 is an enlarged view of a portion of FIG. 10 showing the j-shaped bolts in more detail.
DETAILED DESCRIPTION
Disclosed are piling apparatus and methods for installing piling apparatus into the ground without the use of a pile driver or an auger. In accordance with the teachings disclosed herein, a helical screw anchor and coupling device are used to pull pipe sections down into the ground. A preassembled circular, for example, steel reinforcing rod cage is placed into the pipe sections in the ground. Wet concrete is poured into the pipe sections in the ground to encase the steel reinforcing rod cage. The pipe sections are then removed. Removal of the pipe sections from the helical screw anchor is accomplished using the coupling device.
Referring to the drawing figures, FIGS. 1-6 illustrate various views of exemplary piling apparatus 10 . More particularly, FIG. 1 is an elevational view of exemplary piling apparatus 10 . FIG. 2 is an enlarged view of a coupler section 20 of the apparatus 10 . FIG. 3 is a plan view of the coupler section 20 shown in FIG. 2 with shear pins 44 not engaged. FIG. 4 is a sectional view of the coupler section 20 shown in FIG. 2 taken along the lines 4 - 4 . FIG. 5 is a plan view of the coupler section 20 shown in FIG. 2 with shear pins 44 engaged. FIG. 6 is a sectional view of the coupler section 20 shown in FIG. 5 taken along the lines 5 - 5 .
As shown in FIG. 1 , the exemplary piling apparatus 10 comprises an anchor assembly 11 that includes a helical screw anchor 12 having a plurality of helices ( 12 a ), an extension shaft 13 , a tapered reducer section 14 , and a lower pipe section 15 having a plurality of shear pin holes 16 disposed around its periphery. During use, the anchor assembly 11 is screwed into the ground to a depth such that the shear pin holes 16 are several inches above ground level.
The piling apparatus 10 also comprises a coupler section 20 , shown in detail in FIGS. 2-6 , that includes a coupler pipe section 21 with an inner splice ring 22 attached to the coupler pipe section 21 , and a helical flange 23 attached at its upper end of the coupler pipe section 21 . A coupler 25 is disposed within the coupler pipe section 21 . A short square shaft bar 24 extends from an upper end of the coupler 25 above the helical flange 23 . The short square shaft bar 24 is coupled to the coupler 25 as will be described below. Details of the coupler section 20 are provided with reference to FIGS. 3-6 .
The coupler pipe section 21 is coupled to a pipe section 30 with the standard width helices 32 . The short square shaft bar 24 is coupled to a section of square shaft bar 33 that extends through the pipe section 30 . Additional pipe sections 30 are coupled to the previous pipe section 30 as required. A final pipe section 34 without the intermediate helices is disposed at the upper end of the apparatus 10 .
As is shown in FIGS. 3 and 4 , the coupler pipe section 21 is welded 49 to the splice ring 22 . The coupler 25 comprises a plurality of thrust plate guide plates 41 that are attached to a lower coupler plate 42 . A thrust plate 43 is disposed within the plurality of thrust plate guide plates 41 . A plurality of transversely slidable shear pins 44 are slidably attached to the lower coupler plate 42 . The shear pins 44 are aligned with a corresponding plurality of shear pin holes 45 in the inner splice ring 22 . In addition, the shear pin holes 45 in the inner splice ring 22 align with the shear pin holes 16 in the lower pipe section 15 . Note that any number of shear pins 44 and corresponding shear pin holes 45 , 16 may be employed. The actual number of shear pins 44 and shear pin holes 45 , 16 may vary depending on the overall design.
The short square shaft bar 24 is attached to a threaded rod 48 that extends through a nut 47 welded to an upper coupler plate 46 . The threaded rod 48 extends through the lower coupler plate 42 and is attached to the thrust plate 43 . A plurality of shear pin slide guides 51 are attached to the lower coupler plate 42 through which the shear pins 44 slide. The shear pins 44 are attached to the upper coupler plate 46 by way of a plurality of shear pin position arms 52 .
The coupler pipe section 20 with the coupler 25 and splice ring 22 are placed into the lower pipe section 15 and oriented such that the shear pins 44 in the coupler 25 are aligned with the shear pin holes 45 in the inner splice ring 22 and shear pin holes 16 in the lower pipe section 15 . Horizontal movement of the shear pins 44 is controlled by rotating the threaded rod 48 , which causes the upper coupler plate to lower toward the lower coupler plate and force the shear pins 44 outward, and vice versa. This is illustrated in FIGS. 3 , 4 , 5 and 6 .
FIGS. 7-9 illustrate installation of exemplary piling apparatus 10 . FIG. 10 illustrates installed piling apparatus 10 comprising j-shaped bolts 61 . FIG. 11 is an enlarged view of a portion of FIG. 10 showing the j-shaped bolts 61 in more detail. The j-shaped bolts 61 are attached by way of nuts to an extension shaft plate 62 disposed in the reducer section 14 .
Details regarding an exemplary procedure or method for installing the reinforced concrete piling apparatus 10 without utilizing a pile driver or an auger is as follows. An assembly comprising the helical screw anchor 12 , extension shaft 13 , reducer section 14 and lower pipe section 15 having a plurality of shear pin holes 16 disposed around its periphery are screwed into the ground to a depth such that the shear pin holes 16 are several inches above ground level. Next the coupler pipe section 20 with the coupler 25 and the splice ring 22 are placed into the lower pipe section 15 and oriented such that the shear pins 44 in the coupler 25 are aligned with the shear pin holes 16 in the lower pipe section 15 .
The short square shaft bar 24 , which is welded to the threaded rod 48 , is bolted to a short square shaft female end 33 . The short square shaft bar 24 is then rotated counterclockwise. The counterclockwise rotation of the threaded rod 48 forces the upper coupler plate 46 and welded nut 47 downward which in turn causes the shear pin positioning arms 52 to push the shear pins 44 through the shear pin holes 45 , 16 . Once the shear pins 44 protrude through the shear pin holes 45 , 16 , torque may be transmitted through the coupler pipe section 20 .
A long section of square shaft bar 33 is then bolted to the short section of square shaft bar 33 and a pipe section 30 with the standard width helices 32 is bolted to the coupling pipe section 20 containing the coupling device 25 . All of the pipe sections 20 , 30 have helical flanges 23 . This serves two purposes. The first is for splicing of the two pipe sections 20 , 30 . The second is when the pipe sections 20 , 30 are required to be removed, counterclockwise torque can be applied to the helical flanges 23 and the pipe sections will “unscrew” themselves out of the ground.
The torque required for installation and removal is always applied to the pipe sections 20 , 30 . Because the helical flanges 23 are typically narrow, approximately 2 inches in width; standard width helices 32 may be required for the removal of the pipe sections 20 , 30 . The bottom one or two pipe sections 30 may require standard width helices to assist with the surface area needed to back out all of the pipe sections 20 , 30 being removed.
Once all of the square shaft bars 13 , 24 , 33 and all of the pipe sections 15 , 20 , 30 have been screwed into the ground to a desired depth (see FIG. 7 ) the square shaft bar 33 , 24 is rotated clockwise. The clockwise rotation of the threaded rod 48 in the coupling device 25 forces the upper coupler plate 46 and welded nut 47 upward which in turn causes the shear pin positioning arms 52 to pull the shear pins 44 out of the shear pin holes 45 , 16 , thus releasing all of the pipe sections 30 from the lower pipe section 15 , which is left permanently in the ground. The square shaft bars 33 , 24 and the coupling device 25 are then pulled up through the pipe sections 30 and set aside.
Steel reinforcing rods 65 are then placed into the pipe sections 30 (see FIG. 8 ). Concrete 66 is then poured into the pipe sections 30 in volumes approximating the length of one or more pipe sections 30 . The pipe sections 30 are removed by “unscrewing” them one-by-one, making certain that the top surface of the wet concrete is always above the bottom helical flange 23 of the bottommost pipe section 30 . This may be done by intermittently adding more concrete until all of the pipe sections 30 have been removed so that the hole previously occupied by the pipe sections is completely filled with wet concrete (see FIG. 9 ).
The resulting concrete piling has a capacity in compression that is based on the friction between the soil and the concrete 66 along the length of the concrete piling plus the bearing capacity of the soil below the helical screw anchor 12 . The concrete piling tension capacity, however, is limited to the friction between the soil and the concrete 66 along the length of the concrete piling. Without an apparatus to provide a tension connection between the helical screw anchor 12 and the concrete piling, there would be no method for transferring the bearing capacity of the soil above the helical screw anchor 12 .
An exemplary way to transfer tension from the helical screw anchor 12 to the concrete piling is accomplished by attaching j-shaped bolts to the top side of the welded extension shaft plate. FIG. 10 illustrates a piling comprising j-shaped bolts, and FIG. 11 is an enlarged view of a portion of FIG. 10 showing the j-shaped bolts in more detail. The j-shaped bolts transfer the tension from the concrete piling into a welded extension shaft plate 62 and through the extension shaft 13 into helices 12 a of the helical screw anchor 12 .
Thus, apparatus and methods for placing reinforced concrete piles into the ground without utilizing a pile driver or an auger have been disclosed.
It is to be understood that the above-described embodiments are merely illustrative of some of the many specific embodiments that represent applications of the principles discussed above. Clearly, numerous other arrangements can be readily devised by those skilled in the art without departing from the scope of the invention. | Piling, apparatus and methods for pouring a concrete piling in situ around pre-positioned reinforcing rods inside removable hollow pipe sections that have been screwed into the ground. A final coupler pipe section including a removable coupler device is releasably attached to a reducer section and helical screw anchor that are left in the ground. The pipe sections are connected end to end by helical flanges and are screwed into the ground using the helical screw anchor. Once the pipe sections are screwed into the ground to a desired depth, the coupler device is operated to release the coupler section from the reducer section and the coupler device is extracted from the pipe sections. Reinforcing rods are disposed inside the pipe sections and reducer section. Concrete is poured into the pipe sections and reducer section to encase the reinforcing rods. The pipe sections including the coupler section are then removed from the ground and reused. |