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This application claims priority on provisional Application No. 60/304,794 filed on Jul. 13, 2001, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to a synthetic grass turf to provide a game playing surface, and more particularly relates to a drainage system for a synthetic grass turf assembly for installation on a supporting substrate to provide a game playing surface.
BACKGROUND OF THE INVENTION
Synthetic grass sport surfaces are well known. They are used to replace natural grass surfaces which do not stand up well to wear and which require a great deal of maintenance. Also, natural grass surfaces do not grow well in partly or fully enclosed sport stadiums. The synthetic grass surfaces stand up to wear much better than the natural grass surfaces, do not require as much maintenance, and can be used in closed stadiums. Some synthetic grass surfaces comprise rows of strips or ribbons of a synthetic material, extending vertically from a backing mat with particulate material in-filled in between the ribbons on the mat. The ribbons of synthetic material usually extend a short distance above the layer of particulate material and represent blades of grass.
In order to reduce the abrasive nature of the synthetic grass infills and stabilize the top surface of the infills to retain a resilient grass-like surface that does not deteriorate in quality, or compact over time through use, a unique infilled layer of multiple distinct courses of a particulate material, for example, is disclosed in U.S. Pat. No. 5,958,527 which issued to Prevost on Sep. 28, 1999 and was assigned to the Assignee of this application. In Assignee's Canadian patent application No. 2,218,314, filed Oct. 16, 1997 and published on Sep. 10, 1998, the Assignee discloses a synthetic grass turf assembly.
When the synthetic grass turf assembly is installed on a sport field, however, an efficient drainage system under the grass turf assembly is needed because the water permeable backing cannot function well without a drainage system underneath to prevent water from accumulating on the turf surface. With certain infill materials, slow water evacuation could cause the infill material to float off of the surface, thereby creating an additional maintenance cost issue.
For example, U.S. Pat. No. 5,976,645, issued to Daluise et al on Nov. 2, 1999, discloses a vertical drainage system for a rubber-filled synthetic turf. The drainage system disclosed in this patent is deployed below a fabric backing layer of a synthetic turf and incorporates a porous geotextile membrane between an open graded aggregate layer and a sand layer above the aggregate layer to prevent the movement of one aggregate layer into the other. The drainage passages are generally formed with the 2-inch thick porous layer of sand and the 6-inch thick layer of sand and stone mixture. The draining rate depends on the particulate sizes and compact conditions of those layers. The porous geotextile membrane is used only for separating those two different layers.
A multiple-layer net structure for fluid drainage, particularly for geotechnical use, is well known in the art. A triplanar net, described in U.S. Pat. No. 5,255,998, which issued to Beretta on Oct. 26, 1993, for example, includes a first layer of mutually parallel wires which is rigidly associated with a second or intermediate layer of substantially mutually parallel wires, which are inclined with respect to the wires of the first layer. A third layer of wires is rigidly associated with the intermediate layer, on the opposite side thereof with respect to the first layer, and has substantially mutually parallel wires which are inclined with respect to the wires of the second or intermediate layer. In general and geotechnical use, such multiple-layer nets are buried and inclined with respect to the horizontal plane, so as to allow the drainage of any liquids to be eliminated from the region in which the drainage nets are located.
However, those multiple layer nets have not been suggested to be used in a drainage system for a synthetic grass turf assembly. Unlike other environments in which the multiple layer nets are used for drainage, a synthetic grass turf assembly for providing a game playing surface is a dynamic system continuously in movement under the influence of bouncing balls, vibration, and impacts from the feet and bodies of players in contact with the top surface of the turf. The more rigid grids do not alleviate the resilience of the synthetic turf. Many efforts have so far been made for improving such dynamic properties of synthetic grass turf assemblies.
Another problem with regard to the use of multiple layer nets in synthetic grass turf assembly is deformation resulting from radiant heat from the sun. A deformed multiple layer net not only statically affects the formation of a planar game playing surface but also jeopardizes the dynamic property thereof. For instance, the synthetic grass surface weight with an infill will not always correct the deformations caused by the curling of the edges of the net caused by absorbing heat from the sun. The net itself can form undulations by heat absorption both prior to and after the installation of the artificial grass system.
Therefore, there exists a need for a more efficient drainage system for a synthetic grass turf assembly, which meets the dynamic requirements for a game playing surface.
SUMMARY OF THE INVENTION
It is one object of the invention to provide a drainage system for a synthetic grass turf assembly for installation on a supporting substrate to provide a game playing surface.
It is another object of the invention to provide an improved drainage system for a synthetic grass turf assembly using a spacing device to provide additional draining capacity to the system to facilitate drainage.
It is a further object of the invention to provide a synthetic grass turf assembly for installation on a supporting substrate to provide a game playing surface, which includes an efficient drainage system to prevent water from accumulating on the turf surface.
It is also contemplated to use the drainage system embodying drainage tiles. Such drainage tiles are in the form of one-foot square, or more, interlocking tiles of molded plastic with vertical through openings.
A drainage system for a synthetic grass turf assembly having a flexible and water permeable sheet backing for installation on a supporting substrate to provide a game playing surface generally comprises a flexible, three-dimensional spacing device positioned between the backing and the supporting substrate, supporting the undersurface of the backing and having the backing spaced apart from the supporting substrate to form draining passages in both vertical and substantially horizontal directions.
The spacing device may be an assembly of interconnecting tiles preferably selected from plastics materials, having a plurality of elongated channels preferably parallel to each other, on at least one surface of the tile as well as through openings extending from one surface of the tile to the other, in a manner such that water is enabled to flow through the tile in a direction perpendicular to a major plane defined by the tile, and also in another direction from one edge of the tile to another edge such that the water to be drained can flow throughout the interconnected tile assembly. It is desirable to have the supporting substrate sloped to facilitate drainage.
The spacing device may alternatively be a grid preferably selected from geotextile materials, having a plurality of elongated grid members preferably parallel to each other, bonded with link elements in a manner such that water is enabled to flow through the grid in a direction perpendicular to a major plane defined by the grid, and also in another direction from one edge of the grid to an opposite edge. It is desirable to have the supporting substrate sloped downwardly from a field centerline to two opposed edges to facilitate drainage.
In one embodiment, it is desirable that the support substrate has a non-porous and stable crushed stone base directly under the spacing grid or tiles. This stone is readily available and is lower in cost than specially graded stone. This method would reduce the cost of the substrate construction by allowing the water to drain horizontally to the edges, thus reducing the need for a more complicated and costlier drainage system under the support substrate. This in effect simulates the characteristics of having a nonporous asphalt or concrete base. A geotextile fabric or impermeable liner could be placed directly on the stone base to prevent the water from percolating through the stone base.
The latter drainage device is a grid type of plastics material which preferably comprises a plurality of longitudinal grid members in a base layer to form the substantially horizontal drainage passages therebetween when the grid is positioned between the backing and the supporting substrate. A plurality of link elements in two outer layers associated with two opposite sides of the base layer bond the grid members in position to form the grid without blocking either the vertical draining passages or the substantially horizontal draining passages. The spacing grid is preferably made of an extruded triplanar plastic structure having adequate properties in regard to flexibility, firmness, and resilience. White colour is preferred to reduce heat absorption and, therefore, to prevent or minimize deformation of the spacing grid from the heat of the sun.
It may also be desirable to place a porous aggregate layer, preferably formed with selectively sized crushed rocks, between the supporting substrate and the spacing device so that water is enabled to be drained through the spacing device into the porous aggregate layer.
An additional advantage of using the spacing device relates to the property of the adequate combination of resilience and firmness of the material. The resilience yet firmness of the spacing grid will further improve the impact absorption capability of the synthetic grass turf assembly which is an important property of a game playing surface especially in shorter pile infilled synthetic grasses.
Other features and advantages will be better understood with reference to a preferred embodiment described below.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference is now given to drawings by way of examples only illustrating a preferred embodiment in which:
FIG. 1 a is a cross-sectional view of an installed synthetic grass turf assembly with a drainage system according to a preferred embodiment of the invention;
FIG. 1 b is a cross-sectional view of an installed synthetic grass turf assembly with a drainage system according to an alternate embodiment of the invention;
FIG. 2 is a plan view of a spacing grid used in the embodiment shown in FIG. 1 ;
FIG. 3 is a plan view of a layer of drainage tiles;
FIG. 4 is a perspective view taken from the bottom of another embodiment of a drainage tile;
FIG. 5 is a perspective view taken from the top of still another embodiment of a drainage tile; and
FIG. 6 is a perspective view, taken from the side, of the embodiment shown in FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 , a synthetic grass turf assembly, generally indicated at numeral 10 , is installed on a supporting soil substrate to provide a game playing surface. The synthetic grass turf assembly 10 has a pile fabric including a flexible sheet backing 14 that in the embodiment shown is a two-ply open weave fabric. Extending upwardly from an upper surface of the backing 14 is a large number of upstanding synthetic ribbons 16 . As indicated in FIG. 1 , the ribbons 16 are tufted through the backing 14 spaced apart in rows by a distance W and of a length L. The length is selected depending upon the depth of an infill 18 and the desired resilience of the completed synthetic grass turf assembly.
The ribbons 16 may include a mixture of multiple fibers and the single ribbons fibrillated when manufactured, or fibrillated on site or left in their original state. The on-site fibrillation can be done by passing over the turf surface with a wire brush, for example, or other brushing means after installation of the infill 18 . Generally, thin fibers cannot be easily top-dressed on site since they are more fragile and fall more easily than thicker fibers, especially in high heat environments. The mix of thick and thin fibers on the ribbons can cause a ball to roll in a more predictable manner depending on the resistance of the fibers to the moving ball. Modification of the ribbon width and density in the turf will also modify the ball-rolling characteristics.
The ribbons 16 are made from suitable synthetic plastic material which is extruded in a strip that is relatively wide and thin. The details of the synthetic ribbons 16 and the porous sheet backing 14 as well as the method for attaching the ribbons 16 to the sheet backing 14 are described in Canadian Patent Application 2,218,314 which is incorporated herein by reference.
Deposited interstitially between the upstanding ribbons 16 upon the upper surface of the backing 14 is the infill layer 18 of particulate matter. The particulate matter may be selected from any number of commonly available hard granules, such as sand, small rocks or other graded particulate matter, and resilient granular, such as crumb rubber.
The infill layer 18 is made up of a base course 20 , a middle course 22 , and a top course 24 . The base course 20 is substantially exclusively of hard sand granules disposed immediately upon the top surface of the backing 14 . The middle course 22 is of intermixed hard sand granules and resilient rubber granules. The mix is selected on the basis of a weight ratio greater than 2 to 1 of hard and resilient granules respectively. The top course 24 is substantially exclusively of resilient rubber granules. It is noted that the infill can be all rubber.
An upper portion 26 of the synthetic ribbons 16 extends upwardly from a top surface 28 of the top course 24 . The resulting artificial turf surface can be adapted for several indoor and outdoor uses, such as athletic playing fields, horse racing, and recreational areas. The detailed characteristics of the infill layer 18 and the selection, in particular, of the particulate sizes and unit weights of the respective courses are described in U.S. Pat. No. 5,958,527 which is incorporated herein by reference.
The supporting soil substrate 12 is formed, for example, by removing turf, loam, etc., and grading and compacting the earth. Excavation of materials is necessary to establish a proper grade of the supporting soil substrate 12 to a tolerance of about 1-inch per 10 feet. The supporting soil substrate 12 is compacted to about 95% Proctor density, if possible, to form a firm and stable surface. Then a layer of concrete or asphalt is placed on the compacted earth, in order to ensure the grade and to provide an impervious barrier to the water being drained. Instead of the concrete or asphalt, a layer of non-porous stone may be provided which is compacted to form a stone base 31 . This stone base may be relatively inexpensive, as it need not be graded. An impermeable membrane 33 can then be placed on the stone base 31 to complete the water barrier, as seen in FIG. 1 b . Preferably, the slope of the supporting substrate 12 is 0.5% to about 1%, depending on the IDF rainfall curves for specific areas, from the field center line downwards to opposed edges of the field in order to facilitate drainage.
Situated over the support substrate 12 , in one embodiment, is a spacing grid 32 , preferably made of extruded triplanar polypropylene or polyethylene material. The spacing grid 32 directly supports the undersurface of the backing 14 , and as a result, the backing 14 is spaced apart from the supporting substrate 12 .
The spacing grid 32 , more clearly shown in FIGS. 1 and 2 , includes a plurality of longitudinal grid members 34 which are parallel to each other and form a base layer of the grid, and a plurality of link elements 36 at one side and link members 38 at the other side of the spacing grid 32 which form two respective outer layers of the grid to bond the longitudinal grid members 34 in position. The link elements 36 and 38 are elongated and extend diagonally with respect to the longitudinal grid members 34 according to this embodiment of the invention. The diagonal directions of the respective link elements 36 and 38 at the opposite sides of the spacing grid are angularly crossed, preferably perpendicular to each other, as shown in FIG. 2 . The spacing grid has a thickness that can be from ⅕ inch (5.08 mm) to 1½ inch (38.1 mm) in accordance with this embodiment to provide an adequate draining space between the backing 14 and the porous aggregate layer 30 . The thickness of the spacing device is inversely proportional to the degree of slope of the field.
The spacing grid 32 with such a structure provides a plurality of draining apertures 40 defined by the longitudinal grid members 34 and the diagonal link elements 36 and 38 to permit water drained vertically from the grass turf through the spacing grid 32 in which water is drained toward the field edges.
The spacing grid 32 provides substantially horizontal draining passages defined between adjacent longitudinal grid members 34 , as indicated by numeral 42 in FIG. 1 , which permits water to flow freely along the passage 42 , horizontally through the spacing grid 32 when water is accumulated in the porous aggregate layer 30 and is enabled to be drained promptly through the layer 30 . For this purpose, the thickness of the base layer formed by the grid members 34 should be much greater than the thickness of the outer layers formed by the link elements 36 and 38 . The spacing grid 32 is preferably positioned in a direction such that the longitudinal grid members extend from the field center line to the opposed edges, aligning with the slope direction of the supporting soil substrate to achieve the best drainage result.
The spacing grid 32 is preferably manufactured in a light colour such as white because a dark coloured plastic spacing grid, installed outdoors, absorbs more heat energy which results in deformation thereof.
In high rainfall areas, a geotextile, that is, a non-woven porous membrane made of needle-punch poly-propylene, may be placed immediately over the spacing grid 32 . In fact, the geotextile membrane could be attached directly to the spacing grid 32 at the manufacturing plant. The membrane could also be woven.
The geotextile membrane prevents sand or other infill material from entering the interstices formed in the grid 32 which would tend to block the passages so formed in the grid 32 . This, however, would reduce the function between the grass surface and the geogrid and could cause movement of the grass surface which may result in line deformation unless the backing material has a non-slip characteristic that does not allow the grass to slide on it.
In a preferred embodiment, the backing 14 is made in accordance with Canadian patent application 2,218,314 and U.S. Pat. No. 5,958,927, herewith incorporated by reference. This backing prevents the infill from passing through the backing into the spacing grid 32 , thereby preventing blocking of the drainage passages.
Another preferred embodiment is illustrated in FIG. 3 . In this embodiment, the drainage device is in the form of interconnecting tiles 50 made up of individual tiles 52 . The tiles 52 are generally square but could be made up of various shapes. The tiles 52 include intersecting grooves or channels 53 defining square lugs 54 . The opposite surface of the tile 52 would have similar channels 53 and lugs 54 . Through openings 55 extend from one surface to the other and provide drainage passages for the vertical flow of the water, and communicate with the channels 53 in order to evacuate the water horizontally. The interconnected tiles would normally sit on the support substrate 12 and would be in direct contact with the backing 14 in order to allow the water to pass through the backing 14 and then along the channels 53 , on the top of the tiles 52 , or through the openings 55 to access the channels 53 on the bottom of tiles 50 .
FIG. 4 shows another embodiment of the tile 152 , in accordance with the present invention, having a bottom surface 152 a and a plurality of lugs 154 extending from the bottom surface 152 a . The lugs 154 define channels 153 to provide the necessary drainage from edge to edge. Through openings 155 are provided to allow drainage perpendicular to the tile 152 . Nails 156 are provided for anchoring the tiles to the support substrate 12 .
In yet another embodiment, the tiles 252 shown in FIGS. 5 and 6 show the through openings 255 as a pattern of openings defined by links 257 . Lugs 254 are provided on the bottom surface 252 a to define the channels 253 .
Although the above description and accompanying drawings relate to a specific preferred embodiment as presently contemplated by the inventor, it will be understood that the invention in its broad aspect includes mechanical and functional equivalents of the elements described and illustrated. Modifications and improvements to the above-described embodiment of the invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the invention is intended to be limited solely by the scope of the appended claims. | A drainage system is provided for a synthetic grass turf assembly having a flexible and water permeable sheet backing for installation on a supporting soil substrate to provide a game playing surface. The draining system of the present invention prevents water from accumulating on the turf surface, which could cause the top-dressing layer to “float” and be moved by inundation. The draining system of the present invention includes a spacing grid disposed between the backing of the turf. The spacing grid is structured to permit water not only to be drained vertically through the spacing grid, but also to be drained horizontally through the spacing grid to the edges of the field. The spacing grid is made from one or more types of geotextile or plastics material with an adequate flexibility to improve the impact absorption capabilities and resilience of the synthetic grass turf assembly. |
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates generally to electrically operated door access systems in which the door is either unlocked or opened, or both unlocked and opened, by accessing an electronic control system, and more particularly to an improved pressure-actuated control bar or handle which may be located on a door through which access is controlled by the electrically operated door access system, whereby the pressure-actuated control bar is used to trigger unlocking or opening, or both unlocking and opening, of the door following pressure being exerted on the pressure-actuated control bar by an individual desiring access or egress through the door.
Hardware and systems for controlling egress and access through doors may predominantly be classified into one of two categories. The first category is that of hardware and systems which are designed to limit and control access and egress through doors. Devices falling into this classification are generally utilized for theft-prevention or to establish a secured area into which (or from which) entry is limited. The second category is that of hardware and systems which are designed to facilitate access through doors by opening the doors in a manner not requiring great strength or facility by the person desiring access.. Devices falling into this second classification are used to automate the opening of a door in an easy, yet controlled, manner suitable for use by handicapped individuals, for example.
The first of these two categories includes controlled access security doors and operating systems for such doors. Such doors and systems have evolved over the years from simple doors having heavy duty mechanical locks thereon to sophisticated egress and access control devices. In bygone times, heavy duty chains and locks were the norm on security doors which were not generally used, or which were used to prevent theft or vandalism. However, fire codes have made such relatively simple door locking systems obsolete, at least in most developed countries. Emergency exit doors are required by law to be provided in all commercial buildings, and such doors must be operative in the event of a fire, earthquake, or other emergency.
These exit doors are typically provided with heavy horizontal push bars which unlock the door upon actuation and which may provide an alarm of some sort. The early alarms on such doors were either mechanical in nature, such as wind-up alarms contained on the push bar mechanism, or completely separate electrical circuits actuated by a switch opened as the door was opened. Accordingly, egress from such doors was immediate, and, although egress was accompanied by an alarm, typically the person leaving through the door was long gone by the time security personnel arrived.
Many stores suffer great losses through emergency doors, with thieves escaping cleanly through the emergency doors with valuable merchandise. In addition, industrial companies also suffer pilferage of valuable equipment and merchandise through such emergency exit doors. While one solution is to have a greater number of security personnel patrolling the emergency exit doors, to do so is also an expensive solution.
As might be expected, the art reflects a number of emergency exit access activation devices which attempt to solve this problem. A first type of device is found in U.S. Pat. No. 4,257,631, to Logan, Jr., which describes a system activated by a push bar which, upon depression, moves a switch carried by the door to sound an alarm and start a timer delay. After the delay, the door is unlocked.
This type of device in which a push bar containing an electrical switch therein is used to initiate a request for access or egress is by far the most common. It has not always been viewed as the optimum solution, however, due to the difficulty in making it durable and long lasting in addition to being relatively simple and inexpensive. Several other types of systems have been proposed, and, although none of these systems has found great acceptance, a brief discussion of them is in order.
U.S. Pat. No. 4,328,985 and U.S. Pat. No. 4,354,699, both also to Logan, teach a hydraulic system for accomplishing the delay prior to unlocking the door, and a retrofit locking device of the same type which is usable with any door latching system, respectively. These two systems are thus mechanical rather than electrical in nature.
U.S. Pat. No. 4,652,028 and U.S. Pat. No. 4,720,128, to Logan et al. and to Logan, Jr., et al., respectively, teach an electromagnet mounted on a door jamb, an armature on the door held by the electromagnet to retain the door in the closed position, and a switch mounted near the electromagnet which is used to indicate when the door is being opened or tampered with. The Logan, Jr. et al. '128 patent also adds a set of contacts to confirm that the armature properly contacts the electromagnet. These systems have no switch located in a door access bar.
As mentioned above, the second category of hardware and systems includes devices and systems which are designed to facilitate access through doors by opening the doors in a manner not requiring great strength or facility by the person desiring access. One example of such a device is the type of door commonly found in supermarkets, which is typically radar controlled. Another example is a power actuated door in a hospital corridor, wherein when a wall switch is depressed the door automatically opens.
Both of the two categories of devices discussed above are beneficial, yet both categories of devices still possess several disadvantages and are illustrative of problems inherent in the art. For example, the preferred type of door access bar, the type containing an electrical switch therein, has several disadvantages. First, in order for the switching mechanism to operate, there must be a minimal amount of free movement in the bar. The use of a limit switch in the bar requires the switch to be precisely adjusted to operate properly. In addition, one or more springs must be utilized in order to keep the switches in the open position when the door access bar is not being depressed. In addition, the presently known electrical switch type door access bar is mechanically fairly complex, and not inexpensive to manufacture.
Referring now to the automatic door opening mechanisms discussed above, there are also problems in the implementation insofar as these devices may be used by handicapped persons. This is because the types of automatic doors discussed above do not automatically stop once they begin to open. In addition, such devices do not comply with safety regulations such as those found in The Americans With Disabilities Act, and thus are no longer be commercially competitive. This Act and related requirements direct that the doors must be stoppable in an intermediate position upon the exertion of a minimal force.
It is accordingly the primary objective of the present invention that it present a door access bar which has a greatly improved electromechanical mechanism through which mechanical contact by a user with the door access bar is translated into an electrical output which may be utilized to initiate the process of unlocking the door on which the door access bar is located. In this regard, it is a closely related objective of the present invention that the conventional limit switch mechanism be entirely replaced with a different type of switch mechanism which is more dependable and long lasting than conventional limit switches, and which also requires no adjustment throughout its lifetime.
It is a further objective of the door access bar of the present invention that it require only minimal movement of the door access bar to initiate the electrical output indicating a desire for access or egress. In addition, it is desired that the conventional coiled springs used in door access bars be eliminated in favor of an improved mechanical design. It is a related objective that only a slight degree of force need be applied to the door access bar in order to obtain its electrical output. It is a further objective of the present invention that the minimum amount of force required to initiate the electrical output required to indicate a desire for access or egress be fully adjustable over an appreciable range of force.
It is another principal objective of the improved door access bar mechanism of the present invention that it be adaptable for use as a control mechanism for operating an automatically opening door of the type used by handicapped individuals. It is a closely related objective that the switch mechanism contained in the door access bar of the present invention be adaptable as a push/pull door access handle to control both the opening of a door when the door access handle is pulled, as well as the stopping, in an intermediate position, of the door when the door access handle is pushed. The adapted door access handle must require only a minimal force to actuate it in either the pushing movement or the pulling movement thereof in order to safely meet the needs of the handicapped, as well as to meet the requirements of The Americans With Disabilities Act.
The door access bar or handle of the present invention must also be of a construction which is both durable and long lasting, and it should also require little or no maintenance to be provided by the user. In order to enhance the market appeal of the door access bar or handle of the present invention, it should also be of inexpensive construction to thereby afford it the broadest possible market. Finally, it is also an objective that all of the aforesaid advantages and objectives of the present invention be achieved without incurring any substantial relative disadvantage.
SUMMARY OF THE INVENTION
The disadvantages and limitations of the background art discussed above are overcome by the present invention. With this invention, a novel electromechanical switch element is utilized in a door access bar or handle to replace the conventional limit switch. This electromechanical switch element is a force sensing resistor, which has a resistance which drops when a compressive force exerted across the force sensing resistor increases.
The force sensing resistor is placed in series with a reference resistor having a fixed resistance, with an essentially constant voltage placed across the force sensing resistor and the reference resistor. The voltage between the force sensing resistor and the reference resistor will thus increase as force is applied to the force sensing resistor, since its resistance will drop and leave a larger portion of the voltage across the reference resistor.
The voltage between the force sensing resistor and the reference resistor may be applied to a comparator having a predetermined reference voltage. When the voltage between the force sensing resistor and the reference resistor reaches the reference voltage, the comparator provides an electrical output which is used to indicate a desire for access or egress through a door on which the door access bar is mounted. The amount of force needed to be applied to the sensor bar to trigger an output from the comparator may be adjusted by varying the reference voltage. Various other components known in the art may be involved in actually operating the door.
In the preferred embodiment, a hollow sensor bar is supported at the ends thereof above two mounting members mounted on a door. A force sensing resistor is located between each end of the sensor bar and the mounting member located at that end of the sensor bar. In the preferred embodiment, a resilient silicone rubber disc is used between one side of each of the force sensing resistors and either the sensor bar or the mounting member which is adjacent that side of the relevant force sensing resistor.
A circuit board may desirably be located within the sensor bar, the circuit board being electrically connected to the two force sensing resistors and a source of power. The comparator circuit mentioned above is present on the circuit board. In addition, if desired, provision may be made on the circuit board for adjusting the reference voltage supplied to the comparator, thus enabling the amount of force required to produce an output from the comparator to be adjusted. An electrical output from the circuit board is supplied to the door lock operational system, which is not a part of the present invention, and which is well known in the art.
When the sensor bar is depressed, one or both of the force sensing resistors will have a compressive force placed thereon, which force will change its or their resistance. If sufficient pressure is placed on the sensor bar, the comparator will be caused to provide an electrical output indicating a desire for access or egress through the door on which the door access bar is located.
In a related but different implementation, a door access handle is used instead of the door access bar. A sensor handle is connected to and spaced away from a flat sensor plate with cylindrical posts or the like. The sensor plate is mounted within a housing having a front side and a back side, with the back side of the housing being mounted on a door. The cylindrical posts extend through apertures in the front side of the housing.
One or more force sensing resistors are mounted on the back side of the sensor plate facing the back side of the housing. Similarly, one or more force sensing resistors are mounted on the front side of the sensor plate facing the front side of the housing. Silicone rubber discs are placed between one side of each of the force sensing resistors and the housing.
It will be appreciated by those skilled in the art that when the sensor handle is pushed, the one or more force sensing resistors mounted on the back side of the sensor plate facing the back side of the housing will change in resistance. Similarly, when the sensor handle is pulled, the one or more force sensing resistors mounted on the front side of the sensor plate facing the front side of the housing will change in resistance.
Thus, the door access handle may be used with a pair of comparators to provide electrical indications when the door access handle is pushed or pulled using a minimal amount of force. By coupling the output of the comparator indicating that the door access handle is being pulled to an opening actuator, the door on which the door access handle is mounted can be opened when the door access handle is pulled. By coupling the output of the comparator indicating that the door access handle is being pushed to a kill circuit, the opening movement of the door can be stopped when the door access handle is pushed.
It may therefore be seen that the present invention teaches a door access bar which has a greatly improved electromechanical mechanism through which mechanical contact by a user with the door access bar is translated into an electrical output which may be utilized to initiate the process of unlocking the door on which the door access bar is located. In this regard, in the door access bar of the present invention, the conventional limit switch mechanism has been replaced with a different type of switch mechanism which is more dependable and long lasting than conventional limit switches, and which also requires no adjustment throughout its lifetime.
The door access bar of the present invention also requires only minimal movement to initiate the electrical output indicating a desire for access or egress. In addition, the coiled springs conventionally used in door access bars have been eliminated in favor of an improved minimal movement mechanical design. Only a slight degree of force need be applied to the door access bar in order to obtain its electrical output. The minimum amount of force required to initiate the electrical output required to indicate a desire for access or egress is also fully adjustable over an appreciable range.
In another significant characteristic, the improved door access bar mechanism of the present invention is adaptable for use as a control mechanism for operating an automatically opening door of the type used by handicapped individuals. The switch mechanism contained in the door access bar is adaptable to manufacture as a push/pull door access handle which controls both the opening of a door when the door access handle is pulled, as well as the stopping, in an intermediate position, of the door when the door access handle is pushed. The adapted door access handle requires only a minimal force to actuate it in either the pushing movement or the pulling movement thereof, thereby safely meeting the needs of the handicapped, as well as meeting the requirements of The Americans With Disabilities Act.
Both door access bar or handle of the present invention also is of a construction which is both durable and long lasting, and it also requires little or no maintenance to be provided by the user. It is of inexpensive construction, thereby affording it significant economic advantage and access to the broadest possible market. Finally, all of the aforesaid advantages and objectives of the present invention are achieved without incurring any substantial relative disadvantage.
DESCRIPTION OF THE DRAWINGS
These and other advantages of the present invention are best understood with reference to the drawings, in which:
FIG. 1 is a front plan view of a mounting member for installation onto a door, one of which mounting members will be used to support a sensor bar (not shown) at each end thereof, showing a cylindrical recess located therein and a slot extending therethrough;
FIG. 2 is a cross-sectional view of the mounting member illustrated in FIG. 1, showing the cylindrical recess therein and the slot extending therethrough;
FIG. 3 is a rear plan view of the mounting member illustrated in FIGS. 1 and 2, showing a slot extending therethrough;
FIG. 4 is a top end view of the mounting member illustrated in FIG. 3;
FIG. 5 is a side view of the mounting member illustrated in FIGS. 2 and 4, showing a pair of bracket ends extending orthogonally from the side of the mounting member illustrated in FIGS. 1 and 2, the bracket ends each having a threaded aperture therein;
FIG. 6 is a front plan view of a trigger coverplate which will be mounted over the mounting member illustrated in FIGS. 3 through 5, showing a cylindrical aperture located therein and a Slot located in one side thereof;
FIG. 7 is a plan view of a trigger button formed of three concentric, adjacent cylinders having different diameters;
FIG. 8 is a side view of the trigger button illustrated in FIG. 7;
FIG. 9 is a is a plan view of a disc-shaped force sensing resistor having a pair of leads and a connector extending therefrom;
FIG. 10 is a side view of the force sensing resistor illustrated in FIG. 9;
FIG. 11 is an end view of a bar end cap, showing two apertures therein which will be used to mount the bar end cap to the mounting member illustrated in FIGS. 1 through 5;
FIG. 12 is a back view of the bar end cap illustrated in FIG. 11;
FIG. 13 is an isometric view of the components illustrated in FIGS. 1 through 12 and a silicone rubber disc being assembled together to form a sensor bar mounting assembly, which is used to support one end of a sensor bar;
FIG. 14 is a perspective view of a door and a door frame, showing a door access bar consisting of the sensor bar mounted between two of the sensor bar mounting assemblies illustrated in FIG. 13 and installed on the door, and also showing a push bar electromagnetic locking system known in the art;
FIG. 15 is a functional schematic block diagram of an electromagnetic locking system using the force sensing resistors located in each of the mounting assemblies illustrated in FIG. 14 as inputs to trigger the unlocking of the lock retaining the door illustrated in FIG. 14 in the closed position;
FIG. 16 is an electrical schematic of the electromagnetic locking system illustrated in functional schematic form in FIG. 15;
FIG. 17 is a front plan view of a flat sensor plate for use in a push/pull door access handle, showing a pair of force sensing resistors mounted on the front side of the sensor plate;
FIG. 18 is a back plan view of the sensor plate illustrated in FIG. 17, showing a pair of force sensing resistors mounted on the back side of the sensor plate;
FIG. 19 is a front plan view of a front housing member showing four countersunk apertures and two larger apertures located therein;
FIG. 20 is a back plan view of the front housing member illustrated in FIG. 19, showing the sides of the front housing member as well as the location of a pair of protrusions located on the back side of the front housing member;
FIG. 21 is a cross-sectional view of the front housing member illustrated in FIGS. 19 and 20;
FIG. 22 is a front plan view of a back housing member, showing the sides of the back housing member, four forwardly-extending cylindrical posts having tapped apertures located therein, as well as the location of a pair of protrusions located on the front side of the back housing member;
FIG. 23 is a back plan view of the back housing member illustrated in FIG. 22, showing the location of a pair of mounting apertures located therein, as well as the location of a larger aperture located therein;
FIG. 24 is a cross-sectional view of the back housing member illustrated in FIGS. 22 and 23;
FIG. 25 is a front plan view of a sensor handle for use in a push/pull door access handle;
FIG. 26 is a side view of the sensor handle illustrated in FIG. 25, showing a pair of cylindrical posts extending from the back side thereof;
FIG. 27 is a back plan view of the sensor handle illustrated in FIGS. 25 and 26, showing threaded apertures located in the cylindrical posts;
FIG. 28 is a front plan view of an alternate configuration sensor handle for use in a push/pull door access handle;
FIG. 29 is a top side view of the alternate configuration sensor handle illustrated in FIG. 28, showing a pair of cylindrical posts extending from the back side thereof;
FIG. 30 is a back plan view of the alternate configuration sensor handle illustrated in FIGS. 28 and 29, showing threaded apertures located in the cylindrical posts;
FIG. 31 is an isometric view of the components illustrated in FIGS. 17 through 27 being assembled into a push/pull door access handle; and
FIG. 32 is a functional schematic block diagram for a control system for operating an automatically opening door of the type used by handicapped individuals using the force sensing resistors located in the push/pull door access handle illustrated in FIG. 31 as inputs to control the operation of the automatically opening door.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is embodied in a door access bar illustrated in FIGS. 1 through 16. This door access bar may be used as the means to request access or egress through a door on which the door access bar is located, which door is locked by an electrically-operated lock of conventional design. When the door access bar is pressed, control circuitry connected to the door access bar provides an electrical output signal indicating that access or egress through the door is being requested.
Referring first to FIGS. 1 and 2, a mounting member 50 is illustrated. The mounting member 50 has a cylindrical recess 52 located in the front side thereof, which cylindrical recess 52 does not extend through the mounting member 50. The mounting member 50 has a slot 54 which does extend entirely through the mounting member 50. The slot 54 is in communication with the side of the cylindrical recess 52 in the mounting member 50, as better shown in FIG. 2.
Also located in the mounting member 50 are four tapped apertures 56, 58, 60, and 62. The tapped apertures 56, 58, 60, and 62 will be used to align two other components to be discussed below in the proper position with respect to the mounting member 50.
Referrring now to FIGS. 3 through 5, other views of the member 50 (FIG. 1) are illustrated. The mounting member 90 is L-shaped in cross-section, as shown in FIG. 4, and is sized to fit over the mounting member 50 as best shown in FIG. 3. The mounting member 50 has four apertures 56, 58, 60, and 72 located therein and extending therethrough.
A slot 76 is located in the mounting member 50. The slot 76 entirely divides the side of the L forming the mounting member 50 away from the cylindrical aperture 74 into two bracket ends 78 and 80, as shown in FIG. 5. A threaded aperture 82 is located in the bracket end 78 of the mounting member 50, as shown in FIG. 5. Similarly, a threaded aperture 84 is located in the bracket end 80 of the mounting member 50.
Referring next to FIG. 6, a trigger coverplate 86 is illustrated. The trigger coverplate 86 is essentially flat, and is sized to fit over the front side of the mounting member 50 (FIG. 1), covering the front side of the mounting member 56 adjacent to the bracket ends 78 and 80 of the mounting member 50. The trigger coverplate 86 has four countersunk apertures 88, 90, 92, and 94 located therein and extending therethrough. When the trigger coverplate 86 is placed over the front of the mounting member 50, the countersunk aperture 88 in the trigger coverplate 86 will be axially aligned with the aperture 50 in the mounting member 50, the countersunk aperture 90 in the trigger coverplate 86 will be axially aligned with the aperture 58 in the mounting member 50, the countersunk aperture 92 in the trigger coverplate 86 will be axially aligned with the aperture 60 in the mounting member 50, and the countersunk aperture 94 in the trigger coverplate 86 will be axially aligned with the aperture 62 in the mounting member 50.
A cylindrical aperture 96 extends through the trigger coverplate 86. The cylindrical aperture 96 is of a smaller diameter than the diameter of the cylindrical recess 52 of the mounting member 50 (FIG. 1). When the trigger coverplate 86 is aligned with the mounting bracket 64, the cylindrical aperture 96 in the trigger coverplate 86 will be concentric with the cylindrical recess 52 in the mounting member 50.
A slot 98 is located in the trigger coverplate 86, which slot 98 is in communication with the edge of the trigger coverplate 86, but is not in communication with the side of the cylindrical aperture 96 in the trigger coverplate 86. When the trigger coverplate 86 is aligned with the mounting member 50 (FIG. 1), the slot 98 in the trigger coverplate 86 will be aligned with the slot 76 in the mounting member 50.
Referring now to FIGS. 7 and 8, a trigger button 100 is illustrated. The trigger button 100 is formed of three concentric, adjacent cylinders having different diameters. A larger diameter cylinder 102 is located behind a smaller diameter cylinder 104and a smaller diameter cylinder 105 is located behind cylinder 102. The diameter of the larger diameter cylinder 102 is slightly smaller than the diameter of the cylindrical aperture 52 in the mounting member 50 (FIG. 1). The diameter of the smaller diameter cylinder 104 is slightly smaller than the diameter of the cylindrical aperture 96 in the trigger coverplate 86 (FIG. 6).
Referring next to FIGS. 9 and 10, a disc-shaped force sensing resistor 106 is illustrated. The force sensing resistor 106 has a pair of leads 108 and 110 extending therefrom, which leads 108 and 110 are also connected to a connector 112. The force sensing resistor 106 is one of the key components of the present invention, and is a device which changes its resistance when a compressive force is applied to it. The resistance of the force sensing resistor 106 decreases as the compressive force exerted upon it increases. The force sensing resistor 106 is preferably a device such as the model number 302B force sensing resistor, which is available from Interlink Electronics.
Referring now to FIGS. 11 and 12, a bar end cap 114 is illustrated. The bar end cap 114 may be viewed as being a six-rectangular-sided shape with two adjacent sides being open, as better shown in FIG. 12. The bar end cap 114 has two countersunk apertures 116 and 118 located on the side illustrated in FIG. 11, which countersunk apertures 116 and 118 will be used to mount the bar end cap 114 to the mounting member 50 to retain a sensor bar (not shown) is position. When the bar end cap 114 is mounted onto the mounting member 50, the countersunk aperture 116 in the bar end cap 114 will be axially aligned with the threaded aperture 82 in the bracket end 78 of the mounting member 60, and the countersunk aperture 118 in the bar end cap 114 will be axially aligned with the threaded aperture 84 in the bracket end 80 of the mounting member 50.
Referring next to FIG. 13, a sensor bar mounting assembly 120 for supporting one end of a hollow, rectangular cross-section sensor bar 122 is illustrated. The components illustrated in FIGS. 1 through 12 together with a silicone rubber disc 124 may be assembled into the sensor bar mounting assembly 120 as shown. The function of the sensor bar mounting assembly 120 is to support one end of the hollow, rectangular cross-section sensor bar 122 in a manner whereby when the sensor bar 122 is pushed, it will cause the force sensing resistor 106 to have a compressive force exerted on it, changing its resistance.
The assembly of the components into the sensor bar mounting assembly 120 may now be described. The force sensing resistor 106 is placed into the cylindrical recess 52 in the mounting member 50, where it may, if desired, be adhesively secured in place.
The silicone rubber disc 124 is then placed into the cylindrical recess 52 in the mounting member 50, on top of the force sensing resistor 106. The silicone rubber disc 124 is made of resilient silicone rubber, which is in the preferred embodiment approximately one-sixteenth of an inch in thickness. The silicone rubber disc 124 functions as a spring.
The larger diameter cylinder 102 and smaller cylinder 105 of the trigger button 100 is then placed into the cylindrical recess 52 in the mounting member 50, on top of the silicone rubber disc 124. The trigger coverplate 86 is then placed against the mounting member 50, with the smaller diameter cylinder 104 of the trigger button 100 extending through the cylindrical aperture 96 in the trigger coverplate 86.
A flat head bolt 126 is inserted through the countersunk aperture 88 in the trigger coverplate 86, into the aperture 56 in the mounting member 50, where it is secured. A flat head bolt 128 is inserted through the countersunk aperture 90 in the trigger coverplate 86, into the aperture 58 in the mounting member 50, where it is secured.
A flat head bolt 130 is inserted through the countersunk aperture 92 in the trigger coverplate 86, and into the aperture 60 in the mounting member 50, where it is secured. A flat head bolt 132 is inserted through the countersunk aperture 94 in the trigger coverplate 86 into the tapped aperture 62 in the mounting member 50, where it is secured.
In this manner assembled, and when the larger diameter cylinder 102 of the trigger button 100, the silicone rubber disc 124, and the force sensing resistor 106 are all in contact and inserted fully into the cylindrical recess 52 in the mounting member 50, the smaller diameter cylinder 105 of the trigger button 100 will be spaced away from the trigger coverplate 86, and the smaller diameter cylinder 104 will extend out of the cylindrical aperture 96 in the trigger coverplate 86.
Thus, it will be appreciated that when the end of the sensor bar 122 is placed over the trigger coverplate 86, when the sensor bar 122 is pushed it will tend to depress the smaller diameter cylinder 104 of the trigger button 100, urging the smaller diameter cylinder 105 of the trigger button 100 into the silicone rubber disc 124, tending to exert a compressive force on the force sensing resistor 106 and thereby cause the force sensing resistor 106 to change its resistance.
With the sensor bar 122 so placed over the trigger coverplate 86, the bar end cap 114 is placed over the end of the sensor bar 122, in contact with the smaller diameter cylinder 104 of the trigger button 100. A flat head bolt 134 is inserted through the countersunk aperture 116 in the bar end cap 114, and into the threaded aperture 82 in the bracket end 78 of the mounting member 50, where it is secured. A flat head bolt 136 is inserted through the countersunk aperture 118 in the bar end cap 114, and into the threaded aperture 84 in the bracket end 78 of the mounting member 50, where it is secured. The bar end cap 114 thereby will retain the end of the sensor bar 122 in position on top of the trigger coverplate 86, and in contact with the smaller diameter cylinder 104 of the trigger button 100.
Note that a two conductor wire 138 having a connector 140 at one end thereof extends through the sensor bar 122. The connector 140 extends out of the end of the sensor bar 122 which is placed over the trigger coverplate 86. The connector 140 is connected to the connector 112, thereby connecting the electrical output of the force sensing resistor 106 to the two conductor wire 138. The two conductor wire 138 will supply the electrical output of the force sensing resistor 106 to a circuit board 142, which may be located inside the sensor bar 122.
It will be appreciated by those skilled in the art that two of the sensor bar mounting assemblies 120 are needed--one at each end of the sensor bar 122. Thus, when the sensor bar 122 is pushed, one or the other, or possibly both, of the force sensing resistors 106 located in the sensor bar mounting assemblies 120 at the opposite ends of the sensor bar 122 will provide an electrical output to the circuit board 142 which will cause the circuit board 142 to provide an output causing the door lock (not shown) on which the sensor bar mounting assemblies 120 and the sensor bar 122 are mounted to be unlocked.
Referring now to FIG. 14, a door 144 is shown mounted in a door frame 146. An electromagnetic coil assembly 148 is mounted in the door frame 146, and a door switch actuator 150 may be mounted on the door frame 146. An armature 152 is mounted on the top of the door 144, and a door position switch 154 may be mounted on the door 144. The sensor bar 122 is shown mounted on the door 144 using two of the sensor bar mounting assemblies 120. Except for the sensor bar mounting assemblies 120 and the sensor bar 122 of the present invention, all of the components shown in FIG. 14 are conventional.
Referring next to FIG. 15, a functional schematic block diagram of the electrical system operating the door lock shown in FIG. 14 is illustrated. The blocks shown in FIG. 15 all represent major system elements, some of which may be components discussed above. Before pointing out which of the elements in FIG. 15 are which of the components discussed above, the function of the system shown in FIG. 15 will be described.
A power supply 160 supplies electrical power to a comparator electronics 164. Typically, the power is low voltage DC, such as, for example 12 Volts DC. At least a first sensor 166 is used to provide an electrical input to the comparator electronics 164, which electrical input is indicative of force being placed on the sensor bar 122 (FIG. 14). When the comparator electronics 164 determines that the electrical input from the first sensor 166 is indicative of access or egress being requested.
A relay 168 normally functions to energize a lock 170, which, when energized, keeps the door locked. As such, the relay 168 is normally operated by the comparator electronics 164 to keep the lock 170 energized. However, when the relay 168 is actuated by the comparator electronics 164 to open the door, it deenergizes the lock 170, allowing the door to open.
Optionally, a second sensor 172 may be used by the system in addition to the first sensor 166. When either (or both) of the sensors 166 or 172 provide an electrical input to the comparator electronics 164 indicative of force being placed on the sensor bar 122 (FIG. 14), the comparator electronics 164 will cause the relay 168 to deenergize the lock 170.
Several other features may also optionally be included in the system. First, a sensor adjustment 174 may be added to control just how much (or, looking at it differently, just how little) force need be exerted on the sensors 166 and 172 in order to cause the comparator electronics 164 to operate the relay 168 to deenergize the lock 170, opening the door. Secondly, an output monitor 176 may be utilized to provide an indication at a remote location as to whether and when the comparator electronics 164 actuated the relay 168 to deenergize the lock 170, unlocking the door. The output monitor 176 may provide either a visual alarm or an audible alarm, or both.
In the above description, the comparator electronics 164, the relay 168, and the sensor adjustment 174 together comprise the circuit board 142, mentioned above in conjunction with FIG. 13. The sensors 166 and 172 each comprise one of the force sensing resistors 106, described above in conjunction with FIGS. 9, 10, and 13. The lock 170 comprises the electromagnetic coil assembly 148, described above in conjunction with FIG. 14.
Referring now to FIG. 16, one possible electrical schematic is given for the system illustrated functionally in FIG. 15. The key elements of the system shown in FIG. 16 are the two sensors 166 and 172, which each comprise one of the force sensing resistors 106, and the circuit board 142, which comprises the comparator electronics 164, the relay 168, and the sensor adjustment 174, all of which are used to operate the lock 170, which comprises the electromagnetic coil assembly 148. Also shown in FIG. 16 as connected to the circuit board 142 is the power supply 160.
The circuit board 142 includes five pairs of terminal blocks 178, 180, 182, 184, and 186, which are used to connect the circuit board 142 to external components. The terminal blocks 178 are used to supply power to the system. One of the terminal blocks 178 is connected to the negative side of the power supply 160, and the other of the terminal blocks 178 is connected to the positive side of the power supply 160. The terminal blocks 180 are connected to the lock 170. The terminal blocks 182 are connected to the first sensor 166, and the terminal blocks 184 are connected to the second sensor 172.
Finally, one of the terminal blocks 186 is connected to one side of a monitor power source 188. The other of the terminal blocks 186 is connected to one side of a visual output indicator 190 and to one side of an audible output indicator 192. The other side of the monitor power source 188 is connected to the other side of the visual output indicator 190 and to the other side of the audible output indicator 192. The monitor power source 188, the visual output indicator 190, and the audible output indicator 192 together comprise the output monitor 176 of FIG. 15.
One of the terminal blocks 178 is the system ground of the circuit board 142. The other of the terminal blocks 178 is connected to the anode of a diode 194. The cathode of the diode 194 is connected to the cathode of a diode 196, to the input side of a voltage regulator 198, and to one side of a capacitor 200. The other side of the capacitor 200 and the ground connection of the voltage regulator 198 are both connected to the system ground of the circuit board 142. The anode of the diode 196 is connected to the output side of the voltage regulator 198, which is also connected to one side of a capacitor 202. The other side of the capacitor 202 is connected to the system ground of the circuit board 142.
The output side of the voltage regulator 198 and the system ground provide power for the other electronic components of the circuit illustrated in FIG. 16. These components used may be, for example, as follows. The diodes 194 and 196 may be 1N4002, 1 Amp diodes, the voltage regulator 198 may be a 5 Volt regulator such as an LM340-T5 regulator, the capacitor 200 may be a 47 microfarad, 50 Volt capacitor, and the capacitor 202 may be a 0.1 microfarad, 100 Volt capacitor.
The output side of the voltage regulator 198 and the system ground are connected to power a comparator 204. The comparator 204 may be an LM311N comparator. The inverting input of the comparator 204 will be connected to a variable reference voltage, which comprises the sensor adjustment 174 for the circuit. The noninverting input to the comparator 204 will be connected to accept the inputs from the first sensor 166 and the second sensor 172.
The sensor adjustment 174 utilizes a potentiometer 206 which is connected in series with a resistor 208. One side of the potentiometer 206 is connected to the system ground, and the other side of the potentiometer 206 is connected to one side of the resistor 208. The other side of the resistor 208 is connected to the output side of the voltage regulator 198. The center tap of the potentiometer 206 is connected to the inverting input of the comparator 204. By way of example, the potentiometer 206 may be a 500K Ohm potentiometer, and the resistor 208 may be a a 100K Ohm, 1/4 Watt resistor.
A resistor 210 is connected between the noninverting input to the comparator 204 and the system ground. A resistor 212 is connected on one side thereof to the output side of the voltage regulator 198, and on the other side thereof to one side of the first sensor 166 via one of the terminal blocks 182. Similarly, a resistor 214 is connected on one side thereof to the output side of the voltage regulator 198, and on the other side thereof to one side of the second sensor 172 via one of the terminal blocks 184.
The anode of a diode 216 is connected to the other side of the first sensor 166 via the other of the terminal blocks 182. The anode of a diode 218 is connected to the other side of the second sensor 172 via the other of the terminal blocks 184. The cathodes of the diode 216 and the diode 218 are both connected to the noninverting input of the comparator 204. Thus, the first sensor 166 and the second sensor 172 will each be able to trigger the comparator 204 independently.
By way of example, the resistor 210 may be a 33K Ohm, 1/4 Watt resistor, the diodes 216 and 218 may be 1N4002, 1 Amp diodes, and the resistors 212 and 214 may be 1K Ohm, 1/4 Watt resistors.
The output of the comparator 204 is connected to one side of a resistor 220, the other side of which is connected to the base of an NPN transistor 222. The collector of the transistor 222 is connected to the output side of the voltage regulator 198. The emitter of the transistor 222 is connected to the cathode of a diode 224, and to one side of a coil 226, which is the coil of the relay 168. The anode of the diode 224 and the other side of the coil 226 are connected to the system ground.
The relay 168 is a double pole, single throw relay, with one normally closed switch 228 and one normally open switch 230, as shown in FIG. 16. Thus, when the coil 226 is energized, the normally closed switch 228 will be opened, and the normally open switch 230 will be closed. One side of the normally closed switch 228 is connected to the other of the terminal blocks 17S, which in turn is connected to the positive side of the power supply 160.
The other side of the normally closed switch 228 is connected to one side of the lock 170, (which comprises the electromagnetic coil assembly 148) via one of the terminal blocks 180. The other side of the lock 170 is connected to the system ground via the other of the terminal blocks 180. Thus, when the normally closed switch 228 is opened by energizing the coil 226 of the relay 168, the lock 170 will be deenergized, and will allow the door to be opened,
By way of example, the resistor 220 may be a 470 Ohm, 1/4 Watt resistor, the transistor 222 may be a 2N2222A NPN transistor, the diode 224 may be a 1N4002, 1 Amp diode, and the relay 168 may be a G6C-2114P 5 Volt relay.
The normally open switch 230 of the relay 168 is connected to components which together comprise the output monitor 176. One side of the normally open switch 230 is connected to the one of the terminal blocks 186, and the other side of the normally open switch 230 is connected to the other one of the terminal blocks 186. Thus, when the normally open switch 230 is closed by energizing the coil 226 of the relay 168, the visual output indicator 190 will provide a visual output, and the audible output indicator 192 will provide an audible output.
The operation of the circuit of FIG. 16 is quite simple. By adjusting the potentiometer 206, a reference voltage is set which is supplied to the inverting input of the comparator 204. When force is applied to either the first sensor 166 or the second sensor 172 (or to both of the sensors 166 and 172), the resistance across that sensor (or those sensors) drops. This causes the voltage across the resistor 210, which is applied to the noninverting input of the comparator 204, to increase.
When the voltage applied to the noninverting input of the comparator 204 reaches or exceeds the voltage applied to the inverting input of the comparator 204, the comparator 204 will provide an output which drives the transistor 222 to conduct, energizing the coil 226 in the relay 168. This causes the normally closed switch 228 to open, deenergizing the lock 170 and allowing the door to be opened. It also causes the normally open switch 230 to close, energizing the visual output indicator 190 and the audible output indicator 192 and thereby providing both a visual indication and an audible indication that the lock 170 has been deenergized, thereby allowing the door to be opened.
An alternate embodiment of the present invention is embodied in a push/pull door access handle illustrated in FIGS. 18 through 32. This door access handle may be used as the means to control the operation of an automatically opening door of the type used by handicapped individuals. When the door access handle is pulled, control circuitry connected to the door access handle provides a first electrical output signal indicating that a user is requesting that the door be opened. When the door access handle is pushed, the control circuitry connected to the door access handle provides a second electrical output signal indicating that the user is requesting that the opening of the door be stopped.
Referring first to FIGS. 17 and 18, a flat sensor plate 300 is illustrated which is essentially rectangular in configuration. The sensor plate 300 is relatively thin but rigid, and has apertures 302, 304, 306, and 308 located near the four corners thereof, each of which apertures 302, 304, 306, and 308 extend through the sensor plate 300. Located in the center of the sensor plate 300 is an aperture 310, which extends therethrough. Located along the vertical axis of the sensor plate 300 are two countersunk apertures 312 and 314, which are countersunk on the back side of the sensor plate 300 as shown in FIG. 18. The countersunk aperture 312 is located intermediate the aperture 310 and the top edge of the sensor plate 300, and the countersunk aperture 314 is located intermediate the aperture 310 and the bottom edge of the sensor plate 300.
Mounted on the sensor plate 300 by means of adhesive are four of the force sensing resistors 106 illustrated in FIGS. 9 and 10. For purposes of reference herein, they are referred to as the force sensing resistor 106A, the force sensing resistor 106B, the force sensing resistor 106C, and the force sensing resistor 106D. The force sensing resistor 106A is located on the front side and nearer the top than the bottom of the sensor plate 300. The force sensing resistor 106B is located on the front side and nearer the bottom than the top of the sensor plate 300. The force sensing resistor 106C is located on the back side and nearer the top than the bottom of the sensor plate 300. The force sensing resistor 106D is located on the back side and nearer the bottom than the top of the sensor plate 300.
The connector 112A of the force sensing resistor 106A is connected via the connector 140A to the two conductor wire 138A. The connector 112B of the force sensing resistor 106B is connected via the connector 140B to the two conductor wires 138A and 138B. The two conductor wires 138A and 138B extend through the aperture 310 in the sensor plate 300 to the back side of the sensor plate 300. The connector 112C of the force sensing resistor 106C is connected via the connector 140C to the two conductor wire 138C. The connector 112D of the force sensing resistor 106D is connected via the connector 140D to the two conductor wire 138D.
Referring next to FIGS. 19 through 21, a front housing member 316 is illustrated. The front housing member 316 has rearwardly projecting side walls about the outer periphery thereof, as best shown in FIGS. 20 and 21. The front housing member 316 has countersunk apertures 318, 320, 322, and 324 located near the side walls at the four corners thereof, each of which countersunk apertures 318, 320, 322, and 324 extend through the front housing member 316, and each of which countersunk apertures 318, 320, 322, and 324 are countersunk on the front side of the front housing member 316 as shown in FIG. 19. The countersunk apertures 318, 320, 322, and 324 are located to correspond in coaxial fashion with the apertures 302, 304, 306, and 308, respectively, in the sensor plate 300, which will be capable of fitting freely within the rearwardly projecting side walls of the front housing member 316.
Located along the vertical axis of the sensor plate 300 are two larger apertures 326 and 328. The larger aperture 326 is located intermediate the middle and the top edge of the front housing member 316, and the larger aperture 328 is located intermediate the middle and the bottom edge of the front housing member 316. The larger apertures 326 and 328 are located to correspond in coaxial fashion with the countersunk apertures 312 and 314, respectively, in the sensor plate 300.
Located on the back side of the front housing member 316 are two protrusions 330 and 332. The protrusion 330 is located to correspond in coaxial fashion with the center of the force sensing resistor 106A on the front side of the sensor plate 300 (FIG. 17) when the sensor plate 300 is located within the rearwardly projecting side walls of the front housing member 316. Similarly, the protrusion 332 is located to correspond in coaxial fashion with the center of the force sensing resistor 106B on the front side of the sensor plate 300 when the sensor plate 300 is located within the rearwardly projecting side walls of the front housing member 316. The protrusions 330 and 332 may be cylindrical projections extending rearwardly from the back face of the front housing member 316.
Referring now to FIGS. 22 through 24, a back housing member 334 is illustrated. The back housing member 334 has frontwardly projecting side walls about the outer periphery thereof, as best shown in FIGS. 22 and 24. The back housing member 334 has four forwardly-extending cylindrical posts 336, 338, 340, and 342 located near the side walls at the four corners thereof. The cylindrical posts 336, 338, 340, and 342 are located to correspond in coaxial fashion with the apertures 302, 304, 306, and 308, respectively, in the sensor plate 300, which will be capable of fitting freely within the rearwardly projecting side walls of the back housing member 334. The cylindrical posts 336, 338, 340, and 342 have tapped apertures 344, 346, 348, and 350, respectively, located therein.
Located in the center of the back housing member 334 is an aperture 352, which extends therethrough. Located along the vertical axis of the back housing member 334 are two tapped apertures 354 and 356. The tapped aperture 354 is located just below the level of the cylindrical posts 336 and 338 in the back housing member 334, and the tapped aperture 356 is located just above the level of the cylindrical posts 340 and 342 in the back housing member 334. The tapped apertures 354 and 356 will be used to mount the back housing member 334 onto a door (not shown).
Located on the front side of the back housing member 334 are two protrusions 358 and 360. The protrusion 358 is located to correspond in coaxial fashion with the center of the force sensing resistor 106C on the back side of the sensor plate 300 (FIG. 18) when the sensor plate 300 is located within the frontwardly projecting side walls of the back housing member 334. Similarly, the protrusion 360 is located to correspond in coaxial fashion with the center of the force sensing resistor 106D on the back side of the sensor plate 300 when the sensor plate 300 is located within the frontwardly projecting side walls of the back housing member 334. The protrusions 358 and 360 may be cylindrical projections extending frontwardly out from the front face of the back housing member 334.
Referring next to FIGS. 25 through 27, a sensor handle 362 is illustrated which consists of a plate member 364 having two cylindrical posts 366 and 368 extending from the back side thereof. The cylindrical posts 366 and 368 are located to correspond in coaxial fashion with the countersunk apertures 312 and 314 in the sensor plate 300 (FIG. 17). The cylindrical posts 366 and 368 have tapped apertures 370 and 372, respectively, located therein.
Referring now to FIGS. 28 through 30, an alternate embodiment sensor handle 374 is illustrated which consists of a three segment zigzag-shaped plate member 376 having two cylindrical posts 378 and 380 extending from the back side thereof. The cylindrical posts 378 and 380 are located to correspond in coaxial fashion with the countersunk apertures 312 and 314 in the sensor plate 300 (FIG. 17). The cylindrical posts 378 and 380 have tapped apertures 382 and 384, respectively, located therein.
Referring next to FIG. 31, the assembly of the components illustrated in FIGS. 17 through 27 is illustrated. It should be noted that the sensor handle 362 of FIGS. 28 through 30 may be used instead of the sensor handle 362 illustrated in FIGS. 25 through 27, if desired. Four silicone rubber discs 124A, 124B, 124C, and 124D are adhesively mounted onto the four force sensing resistors 106A, 106B, 106C, and 106D, respectively.
The cylindrical posts 366 and 368 of the sensor handle 362 are extended through the larger apertures 326 and 328, respectively, in the front housing member 316, and into place against the front side of the sensor plate 300 adjacent the countersunk apertures 312 and 314, respectively. Note that the outer diameters of each of the cylindrical posts 366 and 368 of the sensor handle 362 are slightly smaller than the diameters of the larger apertures 326 and 328 in the front housing member 316.
A flat head bolt 386 is inserted from the back side of the sensor plate 300 through the countersunk aperture 312, and into the tapped aperture 370 (FIG. 27) in the cylindrical post 366 of the sensor handle 362. A flat head bolt 388 is inserted from the back side of the sensor plate 300 through the countersunk aperture 314, and into the tapped aperture 372 (FIG. 27) in the cylindrical post 368 of the sensor handle 362. The sensor handle 362 is thus fixedly attached to the sensor plate 300.
Next, the two conductor wires 138A, 138B, 138C, and 138D are fed through the aperture 352 in the back housing member 334 from the front side to the back side thereof. The four cylindrical posts 336, 338, 340, and 342 of the back housing member 334 are inserted through the four apertures 302, 304, 306, and 306, respectively, in the sensor plate 300 from the back side to the front side thereof. Note that the outer diameters of each of the cylindrical posts 336, 338, 340, and 342 of the back housing member 334 are slightly smaller than the diameters of the apertures 302, 304, 306, and 306 in the sensor plate 300.
The four cylindrical posts 336, 338, 340, and 342 of the back housing member 334 are then placed against the back side of the front housing member 316 adjacent the countersunk apertures 318, 320, 322, and 324, respectively. A flat head bolt 390 is inserted from the front side of the front housing member 316 through the countersunk aperture 318, and into the tapped aperture 344 (FIG. 22) in the cylindrical post 336 of the back housing member 334. A flat head bolt 392 is inserted from the front side of the front housing member 316 through the countersunk aperture 320, and into the tapped aperture 346 (FIG. 22) in the cylindrical post 338 of the back housing member 334.
A flat head bolt 394 is inserted from the front side of the front housing member 316 through the countersunk aperture 322, and into the tapped aperture 348 (FIG. 22) in the cylindrical post 340 of the back housing member 334. A flat head bolt 396 is inserted from the front side of the front housing member 316 through the countersunk aperture 324, and into the tapped aperture 350 (FIG. 22) in the cylindrical post 342 of the back housing member 334.
This completes the assembly of a door access handle 398 as illustrated in FIG. 31. A pair of bolts 400 and 402 may be used to retain the door access handle 398 in place on a door (not shown) through use of the tapped apertures 354 and 356. When assembled the silicone rubber discs 124A and 124B will just contact the protrusions 330 and 332, respectively, on the back side of the front housing member 316. Similarly, the silicone rubber discs 124C and 124D will just contact the protrusions 358 and 360, respectively, on the front side of the back housing member 334.
When the plate member 364 is not being pulled away from the rest of the door access handle 398, the silicone rubber discs 124A and 124B will not be compressed against the protrusions 330 and 332, respectively, in the front housing member 316, and will not exert pressure on the force sensing resistors 106A and 106B, respectively. Similarly, when the plate member 364 is not being pushed toward the rest of the door access handle 398, the silicone rubber discs 124C and 124D will not be compressed against the protrusions 358 and 360, respectively, in the back housing member 334, and will not exert pressure on the force sensing resistors 106A and 106B, respectively.
When the plate member 364 is being pulled away from the rest of the door access handle 398, the silicone rubber discs 124A and 124B will be compressed against the protrusions 330 and 332, respectively, in the front housing member 316, and will exert pressure on the force sensing resistors 106A and 106B, respectively, causing the resistance of the force sensing resistors 106A and 106B to change. Similarly, when the plate member 364 is being pushed toward the rest of the door access handle 398, the silicone rubber discs 124C and 124D will be compressed against the protrusions 358 and 360, respectively, in the back housing member 334, and will exert pressure on the force sensing resistors 106A and 106B, respectively, causing the resistance of the force sensing resistors 106C and 106D to change.
Referring finally to FIG. 32, a functional schematic block diagram is shown for a control system which may be used to operate an automatically opening door of the type used by handicapped individuals. The control system uses the force sensing resistors 106A, 106B, 106C, and 106D located in the door access handle 398 illustrated in FIG. 31 as inputs to control the operation of the automatically opening door. The force sensing resistor 106A is shown in FIG. 32 as a first pull sensor 404, the force sensing resistor 106B is shown as a second pull sensor 406, the force sensing resistor 106C is shown as a first push sensor 408, and the force sensing resistor 106D is shown as a second push sensor 410.
The first pull sensor 404 and the second pull sensor 406 provide inputs to a door open comparator electronics 412, and the first push sensor 408 and the second push sensor 410 provide inputs to a door kill comparator electronics 414. Power is supplied to the door open comparator electronics 412 and the door kill comparator electronics 414 by a power supply 416. The power is typically low voltage DC, such as, for example 12 Volts DC.
A pull sensor adjustment 418 is used to control just how much (or, looking at it differently, just how little) pulling force need be exerted on the sensors 404 and 406 in order to cause the door open comparator electronics 412 to provide an output which will cause a door to be opened. Similarly, a push sensor adjustment 420 is used to control just mow much (or, looking at it differently, just how little) pushing force need be exerted on the sensors 408 and 410 in order to cause the door kill comparator electronics 414 to provide an output which will cause the opening of the door to be immediately ceased.
The output from the door open comparator electronics 412 is supplied to a timed open relay 422, which, when it receives the output from the door open comparator electronics 412, will cause an opening motor 424 to open a door 426. The door 426 may use a door closing mechanism 428 to close the door 426 whenever power is not being supplied by the timed open relay 422 to the opening motor 424.
The timed open relay 422 may advantageously have a timing period, during which it will supply power to the opening motor 424 to cause the door 426 to be opened and to remain open. After the timing period times out, power is no longer supplied from the timed open relay 422 to the opening motor 424, allowing the door closing mechanism 428 to close the door 426.
The timed open relay 422 may also drive a door position monitor 430 to provide an indication at a remote location as to whether and when the timed open relay 422 is supplying power to the opening motor 424 to cause the opening motor 424 to open the door 426. The door position monitor 430 may provide either a visual alarm or an audible alarm, or both.
The output from the door kill comparator electronics 414 is an indication that the user of the door access handle 398 (FIG. 31) desires to stop movement of the door 416. Accordingly, the output from the door kill comparator electronics 414 is supplied to a kill relay 432, which in turn will provide a signal to the timed open relay 422 causing it to immediately cease supplying power to the opening motor 424, even if the timed open relay 422 timing period has not timed out. This will immediately allow the door closing mechanism 428 to begin closing the door 426.
By adjusting the pull sensor adjustment 418 and the push sensor adjustment 420, the door access handle 398 (FIG. 31) can be made to be quite sensitive, requiring as little as two pounds of force to cause the door 426 to be opened, or to stop the opening of the door 426. This embodiment of the present invention thus provides an advantageous door control for use by handicapped individuals.
It may therefore be appreciated from the above detailed description of the preferred embodiment of the present invention that it teaches a door access bar which has a greatly improved electromechanical mechanism through which mechanical contact by a user with the door access bar is translated into an electrical output which may be utilized to initiate the process of unlocking the door on which the door access bar is located. In this regard, in the door access bar of the present invention, the Conventional limit switch mechanism has been replaced with a different type of switch mechanism which is more dependable and long lasting than conventional limit switches, and which also requires no adjustment throughout its lifetime.
The door access bar of the present invention also requires only minimal movement to initiate the electrical output indicating a desire for access or egress. In addition, the coiled springs conventionally used in door access bars have been eliminated in favor of an improved minimal movement mechanical design. Only a slight degree of force need be applied to the door access bar in order to obtain its electrical output. The minimum amount of force required to initiate the electrical output required to indicate a desire for access or egress is also fully adjustable over an appreciable range.
In another significant characteristic, the improved door access bar mechanism of the present invention is adaptable for use as a control mechanism for operating an automatically opening door of the type used by handicapped individuals. The switch mechanism contained in the door access bar is adaptable to manufacture as a push/pull door access handle which controls both the opening of a door when the door access handle is pulled, as well as the stopping, in an intermediate position, of the door when the door access handle is pushed. The adapted door access handle requires only a minimal force to actuate it in either the pushing movement or the pulling movement thereof, thereby safely meeting the needs of the handicapped, as well as meeting the requirements of The Americans With Disabilities Act.
The door access bar or handle of the present invention also is of a construction which is both durable and long lasting, and it also requires little or no maintenance to be provided by the user. It is of inexpensive construction, thereby affording it significant economic advantage and access to the broadest possible market. Finally, all of the aforesaid advantages and objectives of the present invention are achieved without incurring any substantial relative disadvantage.
Although an exemplary embodiment of the present invention has been shown and described with reference to particular embodiments and applications thereof, it will be apparent to those having ordinary skill in the art that a number of changes, modifications, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. All such changes, modifications, and alterations should therefore be seen as being within the scope of the present invention. | An improved pressure-actuated control bar is disclosed which may be located on a door to control access or egress through the door, whereby the control bar is used to trigger unlocking or opening, or both unlocking and opening, of the door following pressure being exerted on the control bar by an individual desiring access or egress through the door. A comparator is used to determine whether pressure exerted on the control bar and sensed by a pressure-sensitive component with no moving parts is sufficient to trigger unlocking or opening, or both unlocking and opening, of the door. A second embodiment describes a push/pull door access handle which may be used on a handicapped-accessible door to initiate powered opening of the door when the handle is pulled, and to cause immediate cessation of the opening of the door when the handle is pushed. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/441,504, filed Feb. 10, 2011, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] A staircase is typically one of the first parts of a building to be constructed. After the stairs are constructed, they are often used by construction workers while the remainder of the building is constructed and finished. This period of time after the stairs are constructed and before the building is finished can expose stairs, and particularly front nosings of the stairs, to significant damage, wear, contamination, etc. For example, the exposed features of the stair nosings can be scratched, dented or splashed with paint or other material while the building is being finished.
[0003] To protect the stair nosings after they are constructed, construction works often place a layer of tape over the upper surfaces of the nosings and then remove the tape after construction of the building is complete.
SUMMARY
[0004] Embodiments of stair nosing assemblies are disclosed herein that come pre-assembled with a protective cover layer that can remain covering the nosing after construction of the stairs while the remainder of the building is constructed and finished. The cover can then be quickly, easily, and accurately removed by lifting a front lip and thereby breaking the front and upper portions of the cover apart from an embedded rear lip.
[0005] One exemplary stair nosing assembly can comprise an elongated polymeric base, an elongated metal plate adhered to the base, and an elongated polymeric cover temporarily covering the base and the plate. The base can comprise at least one anchor portion extending downwardly from the upper portion for attaching the assembly to a rearward projecting lip of a tread pan and/or for embedding in a concrete tread. The plate can have various features to enhance traction and visibility. The cover can comprise front and rear lips that engage with front and rear edges of the base to temporarily secure the cover over upper surfaces of the base and the plate. The cover can further comprise a horizontally extending weakened region adjacent to or in the rear lip. When lower portions of the assembly are embedded in a concrete tread, the cover is configured to fracture along the weakened region when the front lip of the cover is lifted upward from the base, leaving the rear lip of the cover remaining embedded in the concrete and allowing the rest of the cover to be removed to expose upper surfaces of the base and plate.
[0006] The foregoing and other objects, features, and advantages of the disclosure will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an exploded cross-sectional end view of an exemplary stair nosing assembly, shown in the context of other portions of a stair.
[0008] FIG. 2 is a perspective view of the assembly of FIG. 1 , with various components of the assembly cut away at different lengths for illustrative purposes.
[0009] FIG. 3 is a cross-sectional perspective view of another exemplary stair nosing assembly shown coupled to a metal tread pan, with various components of the assembly cut away at different lengths for illustrative purposes.
[0010] FIG. 4 is a cross-sectional perspective view of a finished concrete and metal stair with the stair nosing assembly of FIGS. 1 and 2 installed, after a cover layer has been removed.
[0011] FIG. 5 is a cross-sectional end view of a finished concrete stair with an alternative embodiment of the nosing assembly installed, prior to the cover layer being removed.
DETAILED DESCRIPTION
[0012] Described herein are embodiments of a nosing assembly, components thereof, and methods related thereto. The following description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Various changes to the described embodiment may be made in the function and arrangement of the elements described herein without departing from the scope of the invention.
[0013] The nosing assembly and components described herein are primarily intended for use with stair construction, but can also be used to form a nosing for other similar structures or objects, such as curbs, sidewalks, ledges, edges, and the like. Thus, although this disclosure proceeds with reference mainly to stairs, one of ordinary skill will understand that the inventive features disclosed herein can similarly be applied to these analogous fields of endeavor.
[0014] As shown in FIGS. 1 and 2 , a nosing assembly 10 can comprise a plurality of components. These components can include a base 12 , a plate 14 , an adhesive 16 , a cover 18 , and/or other optional components. The nosing assembly can be pre-assembled and installed as a unit during the construction of a stair or a stair case. The base 12 can couple the nosing assembly 10 to a stair. The adhesive 16 can couple the plate 14 to the base 12 . The cover 18 can cover and protect the base 12 and plate 14 from damage and/or contamination, such as during transportation and construction, and can be removed to expose the base 12 and plate 14 (see FIG. 4 ), such as after construction of the stair case is complete.
[0015] The nosing assembly 10 can be elongated and have a generally constant cross-section transverse to the elongated direction, or length. The length of the nosing assembly 10 can be selected to correspond to the width of the stair on which it is installed. The base 12 , plate 14 , adhesive 16 and cover 18 can each have the same or similar length. The nosing assembly 10 can be any width (measured from the front edge to the rear edge), and in some embodiments is approximately two inches wide.
[0016] The base, or tread portion, 12 can be comprised of a durable polymeric material, such as PVC. As shown in FIG. 1 , the base 12 can comprise a tread portion 20 that forms a generally horizontal upper portion 22 and curves downwardly at a front side to form a generally vertical front lip 24 . The tread portion 20 can further comprise a recessed area between a front rib 28 and a rear rib 26 . This recessed area can be sized and shaped to receive the adhesive 16 and the plate 14 between the ribs 26 and 28 .
[0017] The rear of the upper portion 22 can terminate in a rear edge 30 and the bottom of the front lip 24 can terminate in a bottom edge 32 . The rear edge 30 and bottom edge 32 can engage with the cover 18 , as described below.
[0018] The base 12 can comprise a downwardly projecting rear flange 34 extending from the rear of the upper portion 22 . The rear flange 34 can comprise a rearwardly opening recess, or cavity, 35 adjacent the upper portion 22 and an expanded bottom end portion 38 . The cavity 35 can extend horizontally along the base and can be configured to receive another component in a snap-fit connection. The cavity 35 can alternatively be filled with concrete during installation and help retain the nosing 10 to the step.
[0019] The base 12 can further comprise a downwardly projecting anchor portion 36 extending from the lower surface of the upper portion 22 between the rear flange 34 and the front lip 24 . The anchor portion 36 of the base 12 can comprise a forwardly extending lip 40 and/or a downwardly extending flange 42 that terminates in an expanded bottom end portion 44 . The lip 40 can be used to couple the base 12 to a rearwardly projecting lip of a tread pan, as shown in FIG. 4 , or to an anchor 80 mounted in the concrete, as shown in FIG. 5 .
[0020] The plate 14 can be comprised of durable material, such as a suitable metal (e.g., aluminum or steel) and/or polymeric material. The plate 14 can comprise a variety of upper surface features designed to provide foot traction, illumination, aesthetic appearance, and/or other functions. For example, the plate 14 can comprise one or more ribs 50 extending lengthwise of the plate, as shown in FIGS. 1-4 . The plate 14 can further comprise a friction-enhancing material and/or a textured pattern 52 on the upper surface, such as knurling, to provide grip and/or an aesthetic appearance. One or more surfaces of the plate 14 can further comprise a photoluminescent, or “glow-in-the-dark,” material, such as the photoluminescent strips 54 shown in FIGS. 1 and 4 . One or more surfaces of the plate 14 can also comprise a friction-enhancing material, such as the strips 56 shown in FIGS. 1 and 4 . The photoluminescent material and/or the friction-enhancing material can comprise strips of material inserted into mating receptacles in the plate 14 between the ribs 50 . These materials can comprise a spray-on substance, adhesive strips, or other materials coupled to the plate. In addition, various surfaces of the plate 14 can be coated or painted to provide desirable properties, such as aesthetic appearance.
[0021] On some exemplary embodiments, the upper and/or lower surfaces of the plate 14 are painted, such as black or yellow. Yellow paint, for example, can provide a visual alert and/or contrast with other materials to signify the edge of a step. In one example, an aluminum plate is first painted black, and then portions of the black paint are removed, such as the top edges of the ribs 50 and/or the front and rear edges of the plate, to expose the shiny, silvery color of the metal, creating a contrasting silver and black contrast. In this example, the black can be replaced with any other color, such as yellow, to provide a similar effect.
[0022] The plate 14 can be coupled to the base 12 using an adhesive 16 , such as a double-sided tape, a layer of adhesive applied in fluid form, or the like. The adhesive 16 can be releasable in order to allow removal and replacement of the plate 14 , such as if the plate is worn or damaged or if a plate with different surface features is desired. To remove and replace the plate 14 , the plate can simply be peeled off, the adhesive 16 can be removed, and a plate can be attached with a new adhesive.
[0023] The cover 18 can be comprised of a flexible, durable material, such as PVC or other polymeric material. The cover 18 can comprise an elongated sheet of material having curled or hooked front 62 and rear 60 portions that engage with the front edge 32 and rear edge 30 , respectively, of the base 12 to hold the cover 18 in place over the base 12 and plate 14 , as shown in FIGS. 3 and 5 .
[0024] As shown in FIGS. 1 and 5 , the cover 18 can comprise a horizontal nick, or weakened region, 64 adjacent to the rear portion 60 that extends lengthwise of the cover 18 and allows the cover to easily fracture along the nick 64 to facilitate removal of the exposed portion of the cover 18 from the nosing assembly 10 . The nick 64 can comprise one or more slots, grooves, perforations, apertures, weakened regions, and/or other structural features that facilitate the separation of the rear portion 60 from the remainder of the cover when the cover is lifted upwardly from the stair. The structural features that comprise the nick 64 can be located at one or both of the inner and outer, or forward-facing and rear-facing, surfaces of the cover between the rear portion 60 and the remainder of the cover. The nick 64 can furthermore be pre-stressed or pre-weakened prior to assembly with the base 12 to further facilitate fracturing.
[0025] The nosing assembly 10 can be installed on different types of stair frames. As a first example, the nosing assembly 10 can be installed on a stair frame as shown in FIGS. 3 and 4 . This exemplary stair system can comprise a generally vertical metal plate 100 and a generally horizontal metal plate 102 . The front plate 100 can have a rearwardly extending, horizontally disposed upper lip 104 that engages with the lip 40 of the base 12 . The lip 104 can extend into a gap formed between the upper surface of the lip 40 and the lower surface of the upper portion 20 . The lip 40 can resiliently flex to expand the gap and receive the metal lip 104 in the gap. The upper surface of the lip 104 can contact the upper portion 20 while the front lip 24 of the base 12 can contact the front surface of the plate 100 to hold the nosing assembly 10 on the metal stair frame. The anchor portion 36 and rear flange 34 of the base can hang freely behind the lip 104 . Concrete can then be poured into the pan formed by the plates 100 , 102 . The concrete can fill the pan up to the level of the top surface of the cover 18 , or slightly lower, such as up to the level of the upper surface of the plate 16 . The rear portion 60 of the cover can be submerged in the concrete and pinned between the rear edge 30 of the base 12 and the concrete. The anchor portion 36 and the rear flange 34 of the base can also be submerged in the concrete. The expanded lower end portions 38 and 44 and the cavity 35 assist in physically retaining the base 12 in the concrete.
[0026] After the concrete cures (see FIG. 4 ) and/or after construction of the stair case is complete, the cover 18 can be removed. The front portion 62 of the cover can be pulled forwardly away from the lower edge 32 of the front lip 24 of the base 12 to free the front of the cover 18 from the stair. The front portion 62 can then be lifted upwardly until the rear portion 60 of the cover 18 fractures apart from the rest of the cover at the nick 64 . As the majority of the cover 18 is separated from the stair, the rear portion 60 of the cover can remain buried in the concrete beneath and behind the rear edge 30 of the base 12 . The nick 64 can be positioned in the cover 18 such that the rear portion 60 of the cover that remains in the concrete can have an upper surface that is flush with the level of the concrete and/or the rear edge 30 of the base 12 .
[0027] In other embodiments, such as shown in FIG. 5 , the nosing assembly 10 can be installed with a stair system that lacks a vertical plate and rearwardly projecting metal lip for the nosing assembly for attachment. In one such stair system, a temporary mold, or framework can be constructed and concrete can be poured into the mold to form the stair tread. As the concrete cures, the nosing assembly 10 can be pressed into the concrete such that the front lip 24 rests against the front of the concrete stair and the upper surface of the cover 18 is flush with or slightly above the level of the concrete. The anchor portion 36 and the rear flange 34 of the base 12 can be submerged in the concrete such that the expanded portions 44 , 38 fix the base 12 in the concrete. After curing, the framework can be removed, leaving the nosing assembly 10 at the upper front edge of the concrete tread. After construction, the cover 18 can be removed, as described above, exposing the front and upper portions of the base 12 and the plate 14 .
[0028] In some embodiments of the nosing assembly 10 , the anchor portion 36 of the base 12 can comprise a hooked lip portion 40 without a downwardly projecting flange 42 , as shown in FIGS. 3 and 5 , for examples. The downwardly projecting flange 42 may not be needed to secure the base 12 to the concrete, such as when the lip portion 40 is clipped onto a rearwardly extending lip 104 of the stair frame, as in FIG. 3 .
[0029] In an alternative embodiment, an additional component can be included in the nosing assembly 10 , as shown in FIG. 5 , that engages the lip portion 40 and provides a downwardly projecting flange for embedding in the concrete. For example, an adapter, or anchor, 80 (see FIG. 5 ) can be provided that comprises an upper lip 82 that engages with the lip 40 of the base 12 . The adapter 80 can further comprise a downwardly extending flange portion 84 terminating in an expanded lower edge 86 that serves the same purpose as the lower edge 44 shown in FIG. 1 . The adapter 80 can have a cross-sectional shape generally in the form of a question mark, as shown in FIG. 5 . The adapter 80 can comprise a single elongated strip or it can comprise a plurality of separate pieces that can be spaced apart along the length of the base 12 . The adapter 80 can be used, for example, to convert a base 12 that was designed to be used with a stair frame having metal lip 104 that engages the lip 40 , as in FIG. 3 , to be used with a stair frame that does not have such a lip.
[0030] In other embodiments, an additional component can be added to the rear of the base 12 , such as adapter 90 shown in FIG. 5 . The adapter 90 can have an upper rib 92 that engages, such as with a snap or friction fit, within the cavity 35 at the rear of the base 12 . The adapter 90 can extend below the level of the rear flange 34 and can comprise an expanded lower edge 94 . The adapter 90 can, in effect, extend the height of the rear flange 34 as desired. In some embodiments, (not shown) the lower edge 94 can contact a lower surface of the concrete stair, such as the bottom of a metal tread pan, to create a rear support for the nosing. This feature can help keep the upper surface of the nosing level and at a desired height relative to the concrete. The adapter 90 can comprise a single elongated strip or can comprise a plurality of separate pieces that can be spaced apart along the length of the base 12 . In some embodiments, both adapters 80 and 90 can be used.
[0031] One benefit of the nosing assemblies 10 described herein is that the cover 18 can protect the exposed surfaces of the base 12 and plate 14 during the installation of the stair and for an additional period of time after installation is complete, until the cover is removed. For example, after the installation of the nosing on a stair, the stair may be used by construction workers while the remainder of the building is constructed and finished. This period of time after the stairs are constructed and before the building is finished can expose the base 12 and plate 14 to significant damage, wear, contamination, etc. For example, the upper features of the plate can be scratched, dented or splashed with paint or other material while the building is being finished. The cover 18 can prevent and/or reduce these undesirable and unnecessary exposures. When the building is complete and ready for normal use, the covers 18 can be removed leaving a pristine nosing. The removable cover 18 described herein can obviate the alternative use of duct tape covering or other ad hoc protective devices used by construction workers to cover the stair nosing. These ad hoc attempts to protect the nosing can furthermore be less effective, less accurate, more time consuming and/or more expensive that using the nosing assemblies described herein. The cover 18 can be very tough and durable, can precisely cover the areas of the nosing that need to be protected, can come pre-installed with the rest of the nosing, and can be removed in one quick motion without leaving any residue or markings behind. The cover 18 can furthermore comprise upper surface features that provide functional benefits, such as traction and illumination, to the construction workers prior to removal.
[0032] The nosing assembly 10 can be pre-assembled with the base 12 , plate 14 and cover 18 engaged together. The adapter 80 and/or the adapter 90 can also be pre-engaged with the bottom of the base 12 . Thus, the installer merely needs to remove the nosing assembly 10 from its packaging and either clip it onto a flange of a stair frame, as shown in FIG. 3 , or press the nosing assembly into wet concrete. After the concrete cures, the installer simply lifts and breaks the cover off and the stair nosing is ready for use. Later, if desirable, the plate 14 can be peeled off and replaced with another plate without removing or damaging any other portion of the nosing other than the adhesive 16 .
[0033] In some embodiments, the base 12 and/or the cover 18 can be made of a material that is photoluminescent and/or emits light in the dark. Portions of the base 12 can be exposed below and behind the plate 14 , such that the nosing can be easily recognized by a person moving up or down the stairs.
[0034] As used herein, the terms “a”, “an” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element. As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C” or “A, B and C.” As used herein, the term “coupled” generally means physically (e.g., mechanically, chemically, magnetically, etc.) coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.
[0035] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples and should not be taken as limiting the scope of the disclosure. Rather, the scope of the disclosure is defined by the following claims. I therefore claim all that comes within the scope of these claims. | An exemplary stair nosing assembly comprises an elongated base, a plate adhered to the base, and a cover temporarily covering the base and the plate. The base has at least one anchor portion extending downwardly from the upper portion for attaching to a lip of a tread pan and/or embedding in a concrete tread. The plate can have various features to enhance traction and visibility. The cover has front and rear lips that engage with front and rear edges of the base, and a weakened region adjacent the rear lip. When the assembly is embedded in a concrete tread, the cover is configured to fracture at the weakened region when the front lip of the cover is lifted upward from the base, leaving the rear lip remaining embedded in the concrete and allowing the rest of the cover to be removed to expose upper surfaces of the base and plate. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to window coverings, and more specifically, to a pleated shade.
[0003] 2. Description of the Related Art
[0004] Pleated window shades are well known in the industry. Typically, the pleats in the shade are introduced by heat-treating the material to form the pleats. Alternatively, the pleats can be sewn into the material using an independent segment of thread. Both of these methods of forming pleats are expensive and time-consuming. Undesirably, when pleats are placed in a vertical orientation, they often are not uniform in appearance. In addition, in the case of heat-treated pleats, over time fabric may return to its original, unpleated shape and not maintain the desired pleated appearance.
[0005] Although horizontal pleated shades and vertical blinds have been well known for many hears, recently consumers have requested the appearance of pleats in a vertical shade. Many windows and transparent doors in connection with which vertical shades are used run from the floor of a room to close to the ceiling. Thus, the distance over which the shade must be pleated is typically much longer than the distance required for pleats in horizontal shades. In the prior art, pleats were normally made along the width of a roll of fabric. However, this width often is not long enough to cover the entire window or door in the vertical direction. Thus, a method of pleating fabric along the length of a roll of fabric is needed. Moreover, with regard to prior art pleats, the length of the pleat to be made was often limited by the length of the pleating machine used. Again, this length often is not long enough to cover the entire vertical distance needed by the shade. As a result, an improved method of pleating fabric along the length of a roll of fabric is needed.
[0006] In view of the fact that the length of a roll of fabric is typically much longer than any window or door, by placing the pleats in a vertical orientation along the length of the fabric roll, a shade for vertical windows and doors can be manufactured from a single piece of fabric. As a result, two segments of fabric do not need to be sewn together in order to be long enough to cover the window or door.
[0007] Moreover, many prior art pleats tend to have an inherent bias toward the packed together or closed state. That is, when open, a shade may not uniformly lie flat across a window or door. This may result in the shade not uniformly draping, creating an unappealing look to the shade. Thus, an improved method of making pleats is needed in order to improve the appearance of pleats in either the horizontal or vertical direction. An improved pleated window shade is also needed in the industry.
SUMMARY OF THE INVENTION
[0008] A pleated vertical window shade is disclosed having pleats that are uniform in appearance, that maintains its pleated shape over time, and is easy and inexpensive to manufacture. The shade comprises a fabric formed of woven yarn fibers, having a predetermined number of fibers cut along an axis, such that a fold along a hinge line provided by the uncut fibers is created, forming a pleat. Preferably, five of every eight fibers are cut to form the pleat. The yarn fibers are preferably vinyl coated, polyester and anti-microbial and anti-bacterial. Alternatively, the material used for the pleated shade may be a coated fabric, laminated fabric, plastic sheet or any other material known to those skilled in the art. A plurality of identical pleats can be formed in the fabric, using a serrated cutting wheel. To form multiple pleats in the fabric or other material, a plurality of cutting wheels arranged in parallel are used to make the cuts in the yarn fibers or to make indentations or perforations in whatever material is used. The fabric is preferably provided in a roll and the fabric is pleated along the length of the roll.
[0009] The shade can be provided in a single section, or alternatively, in two matching sections, that cover a window when in an uncollapsed position. Hangers can be attached between each pleat of the shade, which are then attached to support means. Control means, such as a pull rod or cord can be used to move the shade between a collapsed and an uncollapsed position.
[0010] In accordance with another embodiment of the invention, there is provided a method of creating a pleat in a fabric or other material. The method comprises cutting a predetermined number of yarn fibers, holes or perforations along an axis, such that a fold along a hinge line provided by the uncut fibers is created, forming a pleat in the fabric. Preferably, the cutting comprises cutting five of every eight yarn fibers, and uses a serrated cutting wheel. Multiple cutting wheels are used to create a plurality of pleats in the fabric. In addition, the number of yarn fibers cut can be varied dramatically as will be understood by those of skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a partial perspective view of the vertical pleated shade disclosed herein.
[0012] [0012]FIG. 2 is an enlarged view of the vertical pleated shade of FIG. 1, showing the cuts made in the fabric to form the vertical pleats.
[0013] [0013]FIG. 3A is a perspective view of the cuts being made in the fabric of the shade.
[0014] [0014]FIG. 3B is a perspective view of multiple cutting wheels arranged in parallel to form multiple vertical pleats in a piece of fabric.
[0015] [0015]FIG. 4 is a perspective view of a vertical pleated shade of the present invention in two matching sections in an uncollapsed position.
[0016] [0016]FIG. 5 is a perspective view of a vertical pleated shade of the present invention having a single section in a collapsed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Turning now to FIG. 1, there is shown a partial perspective view of a vertical pleated window shade 10 . The shade 10 is made of light filtering fabric, with fabric made of flame-resistant, vinyl coated yarns being preferred. The yarns are preferably polyester, but other known materials can also be used. The yarns are also preferably anti-microbial, anti-bacterial, and washable. The fabric can be of variable opacity to achieve a desired amount of room darkening when the shade 10 is closed. The pleated fabric of the shade 10 has strong, permanently set vertical pleats 12 a, 12 b, 12 c which are capable of packing together tightly.
[0018] As an alternative to fabric, as will be understood by those skilled in the art, the present invention may be used with coated fabrics, laminated fabrics, plastic sheets or other materials. In the event that an alternative material is used, holes or perforations may be made in the material as opposed to cuts in yarn fibers.
[0019] In order to form the vertical pleats 12 a, 12 b, 12 c in the shade material, a preselected number of yarn fibers are cut in a vertical direction 20 a, 20 b, 20 c throughout the full height of the fabric from the top of the shade 14 to the bottom of the shade 16 . By cutting a select number of yarn segments, the material maintains structural integrity but folds along the vertical axis 22 of the cuts, resulting in a plurality of pleats 12 a, 12 b, 12 c. The cuts 20 a, 20 b, 20 c create a sharp fold along a narrow hinge line provided by the remaining threads.
[0020] In a preferred embodiment, illustrated in FIG. 2, five of every eight yarn fibers are cut 24 . This number can be varied of course. For example, three or four of every eight yam fibers, five or six of every ten yarn fibers, etc. can be cut, so long as the structural integrity of the material is maintained, and the cuts are sufficient to cause the material to fold along the vertical axis of the cuts 22 . As will be understood by those of skill in the art, any percent of yarn fibers may be cut to accomplish the goal of the present invention.
[0021] In a preferred embodiment, the cuts are made in the fabric by running a segment of the material 26 under a serrated cutting wheel 28 , as illustrated in FIG. 3A. The blades 27 on the wheel 28 are sized and spaced apart so as to produce the desired length of cut in the desired spacing pattern. For example, the blades are long enough to cut five yarn fibers, and are spaced apart by a width of three fibers. As a result, five of every eighth fibers are cut as the wheel travels along the fabric.
[0022] As shown in FIG. 3B, multiple cutting wheels 28 can be positioned adjacent one another in parallel, and the fabric 26 run under the adjacent wheels, to produce a piece of fabric 26 that is cut along its vertical length in several parallel lines. The cutting wheels 28 are spaced apart from one another at widths that correspond to the distance between pleats desired in the final product. For example, two- or four-inch segments between pleats are common. To achieve the desired spacing, the cutting wheels 28 are spaced two or four inches apart.
[0023] The vertical pleated window shade can be produced to fit a variety of different window sizes. The desired width of the pleats are determined, and the fabric cut accordingly. Advantageously, when creating pleats in vertical shades, the pleats can be cut along the length of the fabric roll. Thus, the length of the shade is not restricted by the width of the fabric roll. As a result, shades of any desired length can be manufactured to cover windows and/or doors running from the floor to the ceiling of a room without the need for sewing two pieces of fabric together, as will be understood by those of skill in the art. For example, if pleats were cut along the width of a fabric roll and the width of the roll or the width of the pleating machine was 48 ″, but the window to be covered was 70 ″ from top to bottom, in order to obtain vertical pleats, two segments of the fabric would need to be sewn together to achieve vertical pleating. By cutting pleats along the length of the roll, the fabric roll far exceeds 70 ″ in length and a unitary piece of fabric can be used for the shade for the vertical window or door.
[0024] Of course, the present invention can be used to cut standard, horizontal pleats as well along the width of a fabric roll to quickly and easily create pleats without using the heat or sewing methods of the prior art. Thus, the method of creating pleats of the present invention is intended to be used for both horizontal and vertical pleats.
[0025] Turning now to FIGS. 4 and 5, there is shown a vertical pleated shade 30 as it would appear installed in an interior window. The shade 30 is sized so as to cover the window glass completely in its uncollapsed position (FIG. 4), yet in its collapsed position (FIG. 5), leave the window glass substantially uncovered. The shade 30 is collapsed by folding the pleats 32 a, 32 b, 32 c accordion-fashion. When the shade 30 is drawn to a retracted position, the pleats 32 a, 32 b, 32 c move to a tightly packed configuration 44 , wherein the pleats 32 a, 32 b, 32 c lie substantially flat against each other. Of course, shades are often used to cover a wide variety of things other than doors and windows. The pleated shades of the present invention may be used in many different applications including, but not limited to, shades which cover a section of a wall, shades which are used to divide a room and shades which are used as screens.
[0026] Conventional control means 34 , such as a pull rod or cord can be used to extend the shade 30 fully across the window and to collapse it into its fully folded or stacked configuration 44 . When the shade 30 is in the stacked position 44 , it occupies a minimum of space along the side of the window to allow the widest possible view.
[0027] The window shade 30 can be provided in a single section (FIG. 5), or in two matching sections 36 a, 36 b as shown in FIG. 4, if desired. The two sections 36 a, 36 b cover the window when uncollapsed, and leave the window substantially uncovered when collapsed. Again, the sections 36 a, 36 b, are collapsed by folding the pleats 32 a, 32 b, 32 c accordion-fashion to form a stack 44 .
[0028] The window shade 30 can be installed in the window using any of a number of known methods. For example, as illustrated, conventional hangers 38 a, 38 b are attached to each segment of the shade 30 which is then attached to support means 40 which traverse the width of the window. Alternatively, a curtain rod (not shown) can be used. The rod extends between the vertical sides of the window above the top edge. A plurality of moveable support members, such a curtain rings, are carried thereon. The rings, in turn, support the window shade. The shade is attached to the curtain rings by any of a number of known methods, including conventional hangers. If desired, as shown in FIG. 4, a valence 42 can be formed around the support means 40 , to hide it from view and make the window shade 30 more visually appealing. The improved shade of the present invention may be mounted by grommets or any other means known to those of skill in the art.
[0029] While the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the invention illustrated may be made by those skilled in the art without departing from the spirit of the invention. | A pleated window shade is disclosed having pleats that are uniform in appearance, that maintains its pleated shape over time in either a vertical or horizontal orientation, and is easy and inexpensive to manufacture. The shade is produced by running a flat segment of material over a serrated cutting wheel, which cuts a predetermined number of yarn segments at regular intervals. The cuts cause the material to fold or pleat along the axis of the cuts, resulting in a uniform, neat pleated appearance. The pleats may be made along the length of a roll of fabric to easily manufacture shades to cover large vertical spaces. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. patent application Ser. No. 14/037,170, filed Sep. 25, 2013, which is a divisional of U.S. patent application Ser. No. 13/168,089, filed Jun. 24, 2011 and issued on Oct. 1, 2013 as U.S. Pat. No. 8,544,239, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/398,461, filed on Jun. 25, 2010. The disclosures of all of the above-referenced prior applications, publications, and patents are considered part of the disclosure of this application, and are incorporated by reference herein in their entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The field of the invention relates to roofing materials, and more particularly to methods and systems for spacing panels on roofs.
[0004] 2. Description of the Related Art
[0005] Roofs cover the uppermost part of a space or building, protecting the space or building interior from rain, snow, wind, cold, heat, sunlight, and other weather effects. Many roofs are pitched or sloped to provide additional protection against the weather, allowing rain or snow to run off the angled sides of the roof. Roofs generally include a supporting structure and an outer skin, which can be an uppermost weatherproof layer. The supporting structure of a roof typically includes beams of a strong, rigid material such as timber, cast iron, or steel. The outer layer of a roof can comprise panels or boards constructed of timber, metal, plastic, vegetation such as bamboo stems, or other suitable materials.
[0006] In some cases, a pitched roof is desired to shield a space against elements such as rain or snow, while still admitting light into the space and allowing air to freely circulate through the roof and into the space. Thus, methods and systems to efficiently and reliably attach an outer skin to the supporting structure of a roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation are desired and remain a significant challenge in the design of roofing systems.
SUMMARY OF CERTAIN EMBODIMENTS
[0007] The systems, methods, and devices of the invention each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description” one will understand how the features of this invention provide advantages over other roofing systems.
[0008] Methods and devices for spacing panels on a roof are provided. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface; a top surface inclined at an angle α relative to the bottom surface; and an integral support structure connecting the top surface and the bottom surface. The support structure includes a plurality of support ribs and a plurality of nail boxes.
[0009] Another embodiment provides a method of installing roof panels on roof support beams. The method includes fastening a plurality of wedge-shaped spacers to a top surface of one or more roof support beams; and fastening a bottom surface of one or more roof panels to the spacers.
[0010] In yet another embodiment, a roof panel spacer system for constructing a roof is provided. The system includes a plurality of support beams; a plurality of spacers fastened to at least some of said support beams; and a plurality of roof panels fastened to the plurality of spacers. Each spacer orients each roof panel substantially horizontal to the ground. Each spacer is positioned to create a space between adjacent roof panels allowing air and light to pass through the roof. Each spacer is also positioned to create an overlap between adjacent roof panels, inhibiting rain and other weather elements from passing through the roof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a top perspective view of an embodiment of a roof panel spacer device.
[0012] FIG. 1B is a bottom perspective view of the device of FIG. 1A .
[0013] FIG. 1C is a bottom elevational view of the device of FIG. 1A .
[0014] FIGS. 2-7 illustrate the device of FIG. 1A in use on a roof.
[0015] FIG. 8 is a top elevational view of the device of FIG. 1A .
[0016] FIG. 9A is a side elevational view of the device of FIG. 1A .
[0017] FIG. 9B is a side elevational view of the device of FIG. 1A showing additional internal features.
[0018] FIG. 10A is a back elevational view of the device of FIG. 1A .
[0019] FIG. 10B is a back elevational view of the device of FIG. 1A showing additional internal features.
[0020] FIG. 11A is a bottom perspective view of another embodiment of a roof panel spacer device.
[0021] FIG. 11B is a bottom elevational view of the device of FIG. 11A .
[0022] FIG. 11C is a cross-sectional view of the device of FIG. 11A taken along line 11 C- 11 C of FIG. 11B .
[0023] FIG. 11D is a cross sectional view of the device of FIG. 11A taken along line 11 D- 11 D of FIG. 11B .
[0024] FIGS. 12-15 illustrate the device of FIG. 11A in use on a roof.
DETAILED DESCRIPTION
[0025] Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this description, and the knowledge of one skilled in the art. In addition, any feature or combination of features may be specifically excluded from any embodiment of the present invention. For purposes of summarizing the present invention, certain aspects, advantages, and novel features of the present invention are described herein. Of course, it is to be understood that not necessarily all such aspects, advantages, or features will be present in any particular embodiment of the present invention.
[0026] It is to be understood that embodiments presented herein are by way of example and not by way of limitation. The intent of the following detailed description, although discussing exemplary embodiments, is to be construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the spirit and scope of the invention.
Roof Panel Spacer for Two-Sided Roof
[0027] FIG. 1A is a top perspective view of an embodiment of a roof panel spacer 100 according to the present invention. FIG. 1B is a bottom perspective view of the spacer 100 . FIG. 1C is a bottom elevational view of the spacer 100 . The spacer 100 generally has a width W measured along an x-axis of the spacer 100 , a length L measured along a y-axis of the spacer 100 , and a height H measured along a z-axis of the spacer 100 . The spacer 100 includes a top surface 102 ; a bottom surface 104 ; sides 106 , 108 ; a back 110 ; and a front 112 .
[0028] The height H of the spacer 100 can be measured at different locations along the spacer 100 . For example, the height of the spacer 100 at the back 110 can be H BACK , while the height of the spacer 100 at the front 112 can be H FRONT . Embodiments of the spacer 100 can be wedge-shaped. For example, the top surface 102 can be inclined at an angle α relative to the bottom surface 104 . Additionally, the bottom surface 104 can be inclined at an angle β relative to the back 110 . In some aspects, the top surface 102 is oriented at an angle of 90° or about 90° relative to the back 110 .
[0029] The spacer 100 can include an integral support structure connecting the top surface 102 and the bottom surface 104 . The support structure can include a plurality of support ribs. For example, the spacer 100 includes width ribs 130 , 132 extending along the width W of the spacer 100 between the sides 106 , 108 . The spacer 100 can also comprise a length rib 134 extending along the length L of the spacer 100 between the back 110 and the front 112 . Bottom surfaces of the ribs 130 , 132 , 134 can form all or a portion of the bottom surface 104 of the spacer 100 .
[0030] In some aspects, the support structure also includes a plurality of nail boxes. For example, the spacer 100 includes nail boxes 150 , 152 , 154 , 156 , which will be described in greater detail below with reference to FIGS. 8-10B . The nail boxes can be configured to accept nails or other fasteners. Some embodiments of the nail boxes 150 , 152 , 154 , 156 comprise a hollow tube extending from the top surface 102 and the bottom surface 104 . The nail boxes can be connected to the width ribs 130 , 132 via flanges 160 , 162 , 164 , 166 , respectively. The spacer 100 may also comprise a nail box 168 disposed in the length rib 134 . Other configurations are possible. For example, in some aspects, the spacer 100 may not comprise one or more of width ribs, length ribs, nail boxes, and/or flanges.
[0031] FIGS. 2-7 illustrate one embodiment of a spacer according to the present invention in use on a roof 268 . Referring now to FIG. 2 , a first spacer 200 according to one embodiment is positioned between a first support beam 270 and a roofing panel or board 275 . The support beam 270 includes a top surface 272 . The panel 275 comprises a top surface 276 and a bottom surface 278 . A second spacer 200 is also positioned between a second support beam 280 and the panel 275 . The support beams 270 , 280 can comprise portions of the support structure of a roofing system, and the panel 275 can comprise a portion of the outer skin of the roofing system.
[0032] A top surface 202 of the spacers 200 are adjacent to and contact the bottom surface 278 of the panel 275 , while a bottom surface 204 of the spacers 200 are adjacent to and contact the top surfaces 272 of the support beams 270 , 280 . Other configurations are possible. For example, in another embodiment, the top surface 202 of the spacers 200 may be adjacent to the support beams 270 , 280 and the bottom surface 204 of the spacers 200 may be adjacent to the panel 275 .
[0033] FIGS. 3 and 4 illustrate embodiments of the spacers 200 in use. The support beams 270 , 280 are inclined relative to a horizontal axis x of the roof 268 by an angle ABEAM. The panel 275 is inclined relative to the horizontal axis x of the roof 268 by an angle θ PANEL . As described above, the spacers 200 are positioned between the panel 275 and the support beams 270 , 280 . Additional spacers 200 (not illustrated in FIGS. 3 and 4 , but illustrated in FIG. 5 ) are positioned between a panel 282 and the support beams 270 , 280 . An “n” number of panels can be positioned on the support beams 270 , 280 using the spacers 200 . Additionally, the panels 275 , 282 can be positioned on “n” number of support beams using the spacers 200 in order to construct the roof 268 .
[0034] In some embodiments, the spacers 200 are positioned on the support beams 270 , 280 such that the panels 275 , 282 are horizontal or substantially horizontal to the ground and θ PANEL is 0° or about 0°. The spacers 200 may be positioned on the support beams 270 , 280 such that a vertical space 284 separates the panels 275 , 282 . In the embodiment illustrated in FIG. 3 , for example, each of the adjacent panels on the roof 268 are separated by the vertical space 284 . The spacers 200 can be positioned along the support beam 270 at the same or substantially the same distance intervals, such that the vertical spaces 284 separating adjacent panels are the same or substantially the same. It will be understood, however, that the vertical space 284 separating adjacent panels of the roof 268 need not be the same or substantially the same across the entire roof 268 . The vertical spaces 284 can advantageously allow for air to enter the space underneath the roof 268 and circulate within the space. Advantageously, the vertical spaces 284 can also allow light to enter the space underneath the roof 268 .
[0035] In some aspects, the top surface 276 of the panel 275 and the bottom surface 278 of the panel 282 overlap in a region 286 . This overlap between adjacent panels 275 , 282 can advantageously restrict rain and other weather elements from passing through the vertical space 284 and entering the space underneath the roof 268 . For example, embodiments of spacers described herein can shield the interior of a building or other space below a roof from light rain and/or rain without horizontal wind.
[0036] Persons of skill in the art will understand that the spacers 200 can be used with roofs 268 of varying slope or pitch. For example, the support beams 270 , 280 may be less sloped relative to the horizontal axis x of the roof 268 (corresponding to a smaller beam angle θ BEAM than that illustrated in FIGS. 2-7 ), in which case the angle α of the spacer 200 may be decreased. Similarly, the support beams 270 , 280 may be more sloped relative to the horizontal axis x of the roof 268 (corresponding to a greater beam angle θ BEAM than that illustrated in FIGS. 2-7 ). In such cases, the angle α of the spacer 200 can be increased accordingly. Of course, it will be understood that beam angle θ BEAM may not be equal to the angle α of the spacer 200 .
[0037] FIG. 5 illustrates a plurality of spacers 200 in use on adjacent panels 275 , 282 . For example, the panel 275 is spaced from the support beam 270 by a first spacer 200 , from the support beam 280 by a second spacer 200 , and from a support beam θ BEAM by a third spacer 200 . The panel 282 is spaced from the support beam 270 by a fourth spacer 200 , from the support beam 280 by a fifth spacer 200 , and from the support beam θ BEAM by a sixth spacer 200 . Each of the panels of the roof 268 can be spaced from the support beams in a similar manner.
[0038] FIG. 6 illustrates the vertical spaces 284 that can be provided between adjacent panels 275 , 282 according to some embodiments of the present invention. As described above with reference to FIGS. 3 and 4 , the vertical spaces 284 between adjacent panels of the roof 268 can allow air and light to enter through the roof 268 , while also preventing weather elements such as rain from entering the space below the roof 268 .
[0039] FIG. 7 illustrates a plurality of spacers 200 in use on the roof 268 . A spacer is provided at the interface between each panel and each supporting beam. As described above with reference to FIG. 3 , the top surface of a first panel and the bottom surface of a second, higher panel are horizontally overlapped such that rain and other weather elements falling in a vertical direction do not enter the vertical spaces 284 and penetrate the space below the roof 268 .
[0040] Embodiments of the spacers 200 can advantageously be used to construct two-sided roofing structures. For example, the roof 268 illustrated in FIGS. 2-9 comprises a first side 288 and a second side 290 . The spacers 200 are positioned between support beams and panels on the first side 288 , as well as between support beams and panels on the second side 290 .
[0041] FIG. 8 is a top elevational view of the spacer 100 . FIG. 9A is an elevational view of the side 106 of the spacer 100 , illustrating internal features in dashed lines. FIG. 9B is an elevational view of the side 106 showing additional internal features such as the width ribs 130 , 132 . FIG. 10A is an elevational view of the back 110 of the spacer 100 , illustrating internal features in dashed lines. FIG. 10B is an elevational view of the back 110 illustrating additional internal features, including ribs and nail box features.
[0042] As described above with reference to FIGS. 1A-1C , the spacer 100 can include nail boxes 150 , 152 , 154 , 156 , and 168 . In one embodiment, the nail box 150 comprises a recessed area 151 and the nail box 152 comprises a recessed area 153 . The recessed areas 151 , 153 can accommodate the head of a nail or other fastener disposed in nail boxes 150 , 152 , respectively. It will be understood that other nail boxes of the spacer 100 can comprise recessed areas, and that the spacer 100 need not comprise any recessed areas around the nail boxes.
[0043] Referring now to FIG. 9A , the bottom surface 104 of the spacer 100 may be inclined at an angle α relative to the top surface 102 . The angle α can be between about 10° and about 25°. In one embodiment, the angle α corresponds to the angle θ BEAM of the support beams of the roof relative to a horizontal axis x of the roof. Where a equals θ BEAM , the top surface 276 of the panels of the roof may lie substantially horizontally on the spacers, such that the angle θ PANEL of the panels relative to the horizontal axis x of the roof is 0° or about 0°.
[0044] Additionally, the bottom surface 104 can be inclined at an angle β relative to the back 110 . The angle β can be between about 80° and about 65°. In the embodiment illustrated in FIG. 9A , angle α is about 18° and the angle β is about 72°. Other configurations are possible. For example, for a roof comprising support beams disposed at an angle θ BEAM of 20°, the spacer 100 can be modified such that the angle α is 20° and the angle β is 70°.
[0045] FIGS. 10A and 10B show additional views of the spacer 100 . FIG. 10A illustrates nail boxes 150 , 152 , 154 , 156 , 168 , as well as recessed areas 151 , 153 in dashed lines. FIG. 10B illustrates rib 134 in dashed lines.
[0046] FIG. 1A illustrates advantageous dimensions of certain specific embodiments of the spacer 100 . For example, the top surface of the spacer 100 is about 6 inches by about 4 inches; and the back 110 is about 4 inches by about 2 inches. Persons of skill in the art will understand that other dimensions are possible, and embodiments of the spacer 100 are not limited to the number or configuration of nail boxes shown, or the dimensions of spacer 100 .
[0000] Roof Panel Spacer for Roof with Three or More Sides
[0047] FIG. 11A is a bottom perspective view of an embodiment of a roof panel spacer 1300 according to the present invention. FIG. 11B is a bottom elevational view of the spacer 1300 . FIG. 11C is a cross-sectional view taken along line 11 C- 11 C of FIG. 11B . FIG. 11D is a cross-sectional view taken along line 11 D- 11 D of FIG. 11B . Embodiments of the spacer 1300 can be used to construct roofing structures with three or more sides.
[0048] The spacer 1300 generally has a width W measured along an x-axis of the spacer 1300 , a length L measured along a y-axis of the spacer 1300 , and a height H measured along a z-axis of the spacer 1300 . The spacer 1300 includes a first top surface 1302 A; a second top surface 1302 B; a bottom surface 1304 ; and sides 1306 , 1308 , 1310 , 1311 , 1312 , and 1313 . In some aspects, the spacer 1300 includes a peaked top surface.
[0049] The height H of the spacer 1300 can be measured at different locations along the spacer 1300 . For example, the height of the spacer 1300 where the sides 1310 , 1311 meet can be H MAX , while the height of the spacer 1300 where the sides 1308 , 1311 meet can be H MID . Embodiments of the spacer 1300 can be wedge-shaped. For example, the top surface 1302 of the spacer 1300 may be inclined at an angle α relative to the bottom surface 1304 . The bottom surface 1304 can also be inclined by an angle β 1 relative to the intersection of the sides 1308 , 1311 . Additionally, the bottom surface 1304 can be inclined at an angle β 2 relative to the intersection of the sides 1310 , 1311 .
[0050] The spacer 1300 can include an integral support structure connecting the top surface 1302 and the bottom surface 1304 . The support structure can include a plurality of support ribs. For example, the spacer 1300 includes width ribs 1330 , 1332 extending along the width W of the spacer 1300 between the sides 1306 , 1308 . The spacer 100 can also comprise a length rib 1334 extending along the length L of the spacer 1300 between the sides 1310 , 1311 and the sides 1312 , 1313 . Bottom surfaces of the ribs 1330 , 1332 , 1334 can form a portion of the bottom surface 1304 of the spacer 1300 .
[0051] In some aspects, the support structure includes a plurality of nail boxes. For example, the spacer 1300 comprises nail boxes 1350 , 1352 , 1354 , 1355 , 1356 , and 1357 . Some embodiments of the nail boxes 1350 , 1352 , 1354 , 1355 , 1356 , and 1356 comprise a hollow tube extending from the top surface 1302 and the bottom surface 1304 . The nail boxes 1354 , 1355 can be connected to the width rib 1331 via flanges 1360 and 1362 . Other configurations are possible. For example, in some aspects, the spacer 1300 may not comprise width ribs, length ribs, nail boxes, and/or flanges.
[0052] In some aspects, the nail box 1354 comprises a recessed area 1351 and the nail box 1355 comprises a recessed area 1353 (not illustrated). The recessed areas 1351 , 1353 can accommodate the head of a nail or other fastener disposed in nail boxes 1354 , 1355 , respectively. It will be understood that other nail boxes of the spacer 1300 can comprise recessed areas, and that the spacer 1300 need not comprise any recessed areas around the nail boxes.
[0053] FIGS. 12-15 illustrate this embodiment of a spacer according to the present invention in use on a roof 1468 that has three or more sides. Referring now to FIG. 12 , a spacer 1400 according to one embodiment is positioned between a support beam 1470 and a first roofing panel or board 1475 . The roof 1468 also comprises a second spacer 1400 positioned between the support beam 1470 and a second panel 1482 . The support beam 1470 includes a top surface 1472 . The panels 1475 , 1482 each include a top surface 1476 and a bottom surface 1478 . The support beam 1470 can comprise a portion of the support structure of a roofing system, and the panels 1475 , 1482 can comprise a portion of the outer skin of the roofing system.
[0054] A top surface 1402 of the spacers 1400 are adjacent to and contact the bottom surfaces 1478 of the panels 1475 , 1482 , while a bottom surface 1404 of the spacers 1400 are adjacent to and contact the top surface 1472 of the support beam 1470 . Other configurations are possible.
[0055] In one embodiment of the present invention, the spacers 1400 are positioned on the support beam 1470 such that a vertical space 1484 separates the panels 1475 , 1482 . In some aspects, each of the adjacent panels on the roof 1468 are separated by a vertical space 1484 . As described above with reference to FIG. 3 , the vertical spaces 1484 can advantageously allow for air to enter the space underneath the roof 1468 and circulate within the space. Advantageously, the vertical spaces 1484 can also allow light to enter the space underneath the roof 1468 .
[0056] In some aspects, the top surface 1476 of the panel 1475 and the bottom surface 1478 of the panel 1482 overlap in a region 1486 . This overlap between adjacent panels 1475 , 1482 can advantageously restrict rain and other weather elements from passing through the spaces 1484 and entering the space underneath the roof 1468 .
[0057] FIGS. 13-15 illustrate a plurality of panels spaced from the support beam 1470 by the spacers 1400 . The panel 1475 and a panel 1492 are positioned on a first spacer 1400 (not illustrated), and the panel 1482 and a panel 1494 are positioned on a second spacer 1400 (not illustrated). A third spacer 1400 is also positioned on the support beam 1470 , ready to receive panels. As described above, the spacers 1400 allow the panels 1492 , 1494 to be advantageously separated by a vertical space 1484 .
Installation of Roofing Spacers
[0058] Embodiments of the roofing spacers described herein can be installed using fasteners such as nails. In one embodiment, a spacer according to the present invention is first positioned on a support beam. Nails are driven into one or more nail boxes of the spacer. The nails may be driven into nail boxes comprising recessed areas, for example. These nails may initially restrict movement of the spacer relative to the support beam until additional nails are driven into the spacer. Next, a panel is positioned over the spacer, and additional nails are driven through the panel into the spacer. In some aspects, the installer is aware of the general location of the nail boxes which remain empty, but is not able to see the precise location of the empty nail boxes through the panel. The installer can estimate the location of the empty nail boxes and aim the nails so that they enter the spacer at or near the empty nail boxes.
[0059] It will be understood by those of skill in the art that positioning nails precisely in the nail boxes is not required to install embodiments of spacers described herein. Nails and other fasteners can effectively secure the spacers to support beams, and panels to the spacers, if they are driven into the nail boxes, the ribs, and/or the flanges described herein. It will also be understood that a nail need not be driven into each nail box provided on the spacers in order to secure the spacer to a support beam, or to secure a panel to the spacer.
Materials for a Roofing Spacer
[0060] Embodiments of the spacers described herein can be made of any suitable material, including plastic or metal. In one embodiment, spacers according to the present invention are made of polypropylene copolymer. In some aspects, the comonomer of the polypropylene copolymer is ethylene. Polypropylene copolymer is characterized as having high impact resistance strength. Polypropylene copolymer also has slightly increased elongation at break, and is thus more pliable, compared to unmodified polypropylene homopolymer. Typical material properties of polypropylene copolymer are provided in Table 1 below.
[0000]
TABLE 1
Property
Yield Point
24
MPa
Elongation at Yield
10-12%
Tensile Break
33
MPa
Elongation at Break
650%
Tensile Modulus
1050
MPa
Flexural Modulus
1270
MPa
Flexural Strength
25-26
MPa
Tensile Impact
800
kJ/m2
[0061] Spacers described herein need not be made of polypropylene copolymer, and can be made of any suitable material, including but not limited to materials exhibiting material properties similar to that of polypropylene copolymer. Spacers made of polypropylene copolymer can advantageously accept fasteners without shattering or suffering other adverse structural effects which may result when a nail or other fastener is driven into the spacer.
[0062] Embodiments of the spacers described herein can be molded from one piece of injection-molded plastic, such that the spacer is monolithic. The spacers described herein can also be manufactured by connecting together separate components, such as the top surface, the bottom surface, the back, and the integral support structure, to form one spacer.
[0063] The above-described embodiments have been provided by way of example, and the present invention is not limited to these examples. Multiple variations and modifications to the disclosed embodiments will occur, to the extent not mutually exclusive, to those skilled in the art upon consideration of the foregoing description. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the disclosed embodiments. | Devices, methods, and systems are provided herein for spacing an outer skin of a roof from the supporting structure of the roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface, a top surface inclined at an angle relative to the bottom surface, and an integral support structure connecting the top surface and the bottom surface, the support structure including a plurality of ribs and a plurality of nail boxes. |
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This application is a continuation of our copending U.S. application Ser. No. 08/776,881, filed Feb. 4, 1997, now U.S. Pat. No. 5,953,862, which is based on PCT application Ser. No. PCT/US95/09498 filed Aug. 3, 1995 which in turn is a continuation-in-part of U.S. application Ser. No. 08/286,866 filed Aug. 5, 1994.
FIELD OF INVENTION
This invention pertains to plastic workpieces and particularly to plastic shims and to a sheet of such shims or like workpieces.
BACKGROUND
In the construction of buildings, tapered workpieces, such as shims, are commonly used. Shims are used to fill gaps; to level items such as doors, windows, cabinets; or to adjust such items to fit properly. In the past, shims have traditionally been made of wood, sometimes simply from scrap pieces found on the job site and fashioned by the craftsman to suit the task. In order to provide a ready supply and to overcome the inconvenience of manually creating them, manufacturers have produced wooden shims and sold them in bundles. Experience shows, however, that such manufactured shims are often not useable because of knots and cracks inherent in the secondary wood used to create them. In fact, as much as one-half of a bundle of manufactured wooden shims is generally unusable because of such defects.
Moreover, the wood used to manufacture shims is not subjected to the same quality control or care as are the better grades of wood. Although the moisture content of Grade A lumber is maintained by soaking it in water up until delivery, secondary wood usually does not receive such care and thus becomes exceedingly brittle and dry by the time it is ready for use. Shims made of such secondary wood will often split or disintegrate upon the slight impression of force needed to hammer them into a shim space.
After shims are set in a door frame or window jamb, their excess lengths must be broken off so as to allow for a uniform substrate against which to install drywall. The wooden shims in common use must be scored with a razor knife and then broken off with a hammer tap. This procedure often results in disintegration or breakage of the shims because of the poor and inconsistent quality of the wood used.
Not only does the described practice waste wood, it would be better if shims and the like were made from other materials. There are ever-increasing concerns for the preservation of forests, and thus the availability of manufactured shims and other wood products is uncertain. Still, it has not previously been recognized that conventionally shaped shims need not be made of wood but could be made of recyclable materials while improving the characteristics of the shims.
Furthermore, the handling and storing of wooden shims prior to use has not been convenient or efficient. Even manufactured bundles are cumbersome to handle and do not lend themselves to compact storage and transport, particularly after unbundling. Again, because of the quality of the wood used, wooden shims are more prone to damage while being transported and stored.
The U.S. Pat. No. 5,163,255 to Gamba provides a wooden block which is saw-cut into a plurality of wooden shims. The Gamba shims are still wood and have the disadvantages of wooden shims, as discussed above. In addition, each shim has a burr or remnant on its working face because of the wood breakage which prevents intimate mating contact with the surface or item to be leveled or adjusted. The U.S. Pat. No. 5,0554,250 to Foss provides a plastic shim, thereby avoiding the disadvantages of wood, but it is not the shape and design of the common shim which is the accepted standard for conventional construction. The U.S. patent to Trussell discloses a metal shim for use in alignment of automobile front ends, but such a shim would not be an acceptable shim for a carpenter to carry, store or use in the building trades.
SUMMARY
The present invention provides an improved plastic shim or other workpiece useful in the construction industry. Each workpiece is a tapered hard plastic body with a thicker section and a thinner section and has special characteristics for its intended purpose. Thus, the workpieces are manufactured to be of uniform size and shape, of homogeneous consistency, and of dependable quality so that they do not split or break easily or unintentionally. Moreover, they are of such dimensions, hardness, nailability, durability, surface friction and other characteristics as are especially suited for use as a shim or other workpiece and which overcome the disadvantages of wooden shims. Each shim has transverse breakable lines on both the thicker and the thinner sections and on opposite surfaces of such sections and may have nailing pockets in the thicker section which facilitate nailing of the shims without breakage. Further, a plurality of such workpieces are molded in a sheet with adjacent workpieces being spaced from each other along their thinner sections but being separably joined in the sheet by longitudinal, manually breakable lines extending along their thicker sections, whereby the workpieces can be readily detached from the sheet along said longitudinal breakable lines and whereby in the case of shims, segments of each shim can be readily broken off therefrom along their transverse breakable lines.
Accordingly, an object of this invention is to provide an improved plastic workpiece, such as a shim, having a tapered configuration for use in the building trades.
Another object is to provide a shim which is of uniform size and shape, of homogeneous consistency, of dependable quality so that it does not split or break easily or unintentionally, and of such dimensions, hardness, nailability, durability, surface friction and other characteristics as are especially suited for use as a shim or other workpiece and which overcome the disadvantages of wooden shims.
A further object is to provide sheets of plastic shims or other workpieces wherein the sheets are convenient and durable for transport, storage and handling and can be neatly, cleanly, and easily separated into individual workpieces when ready for use and so that their work surfaces are flat and unencumbered with break-off fragments.
Still another object is to enable segments of a plastic shim to be neatly and cleanly broken or snapped off manually or with a hammer to enable the shim to be shortened to a desired length.
Another object is to provide a shim which can be tapered to a feathered, nearly sharp edge, while retaining sufficient strength to maintain its integrity in during transport, storage and use.
An additional object is to provide a sheet of plastic shims which can readily be broken lengthwise of the shims for separating the shims from the sheet and transversely of the shims for shortening the shims to a desired length, and yet to provide shims that are solid and durable and do not splinter or break in their intended uses.
Another object is to provide a sheet of plastic workpieces, such as shims, which can be broken off in single units if single narrower workpieces are needed or in multiple units if wider workpieces are needed.
A still further object is to provide transverse break lines in opposite surfaces of shims so that the shims can be paired and cleanly broken as a pair.
Another object is to prevent the flat working surfaces of a plastic shims from slipping in place before being nailed.
Another object is to provide shims which can operate efficiently in pairs in that they are of uniform size and shape and have complementary flat surfaces with the appropriate degree of friction in contact each other and with items being shimmed to allow necessary sliding and avoid unacceptable slippage.
Yet another object is to provide a plastic shim through which a nail can be driven into wood and subsequently removed without damaging the shim or the wood.
A further object is to provide shims and like workpieces which are not made of wood but of recyclable material and thereby help to preserve the forests.
These and other objects will become apparent from the accompanying drawings and the description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the back surface of a shim in accordance with the present invention.
FIG. 2 is a plan view of the front surface of the shim shown in FIG. 1.
FIG. 3 is a side elevation of a shim of the shim shown in FIG. 1.
FIG. 4 is a plan view of the back surface of a sheet of the shims of the type shown in FIGS. 1-3 but with the individual shims being shown on a reduced scale from FIGS. 1-3.
FIG. 5 is a plan view of the front surface of the sheet shown in FIG. 4.
FIG. 6 is an enlarged fragmentary view of the rearward edge of the sheet of FIGS. 4 and 5.
FIG. 7 is an enlarged fragmentary view of a side edge of the shim of FIGS. 1-3.
FIG. 8 is a fragmentary isometric of a pair of shims of the present invention in use.
FIG. 9 is a top view of the structure shown in FIG. 8 but showing how the shims accommodate nailing and how the shims are broken in pairs.
DETAILED DESCRIPTION
Referring to FIGS. 1-3, the principles of the present invention are incorporated in a shim which is shown and identified by the numeral 20. The shim is molded of plastic material such as polystyrene, impact polystyrene or polypropylene and is hard, durable, of high strength and impact resistance, and of homogeneous consistency. The shim has opposite flat, rectangular front and back shimming surfaces 22 and 24, side edges 26, a rearward hammer end 28, and a forward insertion end 30. Short and long rib fragments 32 and 33 project almost imperceptibly from the side edges, for a reason to be described.
With particular reference to FIG. 3, the shim 20 is gradually and uniformly, linearly tapered from the rearward end 28 to the forward end 30, the later being referred to as a feathered end because of its thinness and nearly sharp edge. It is descriptively convenient to refer to the shim as having a thicker rearward section 34 and a thinner forward section 36. There is no discrete boundary between such sections but a short "overlap", it being understood that the shim is molded in one piece. The rearward section 34 extends from the rearward end 28 past the center of the shim (approximately 5/8th of the length of the shim in the preferred embodiment). The forward section 36 slightly overlaps the rearward section and extends therefrom to the forward end 30 (approximately 3/8th of the length of the shim in this preferred embodiment). Although proportions very close to those stated are preferred, the exact division between these sections is not critical.
It is significant, however, that the forward section 36 is very thin and yet exhibits high strength and resilient flexibility. As an example, in the preferred embodiment, the shim is 1.170 in (2.97 cm) in width, the forward section is 2.950 in (7.49 cm) long and tapers from about 0.11 in ( 0.28 cm) at the 5/8th-3/8th border to 0.032 in (0.08 cm) at the forward end 30. With these dimensions, the forward section can be flexed relative to the rearward section 34, like a cantilever, in both directions out of its normal coplanar relation with the rearward section by more than 1 in (2.54 cm) and return to such coplanar relation without breaking and with no deformity. Notwithstanding this strength, such thinness allows the shim to fit into narrow shim spaces and facilitates the controlled breaking described below.
The rearward section 34 has a plurality of U-shaped grooves 40 (FIGS. 2, 3 and 7) in the front surface 22. These grooves are equally spaced lengthwise of the shim 20 and extend transversely thereof. As best shown in FIGS. 3 and 7, the depth of these grooves gradually varies from a maximum (about 0.050 in or, 0.013 cm in the preferred embodiment) at the rearward end 28 to a minimum at the forward end of the rearward section. Also, the forward section 30 has a plurality of U-shaped grooves 42 (FIGS. 1 and 3) in the back surface 24, and these grooves are equally spaced lengthwise of the shim and extend transversely thereof. The depth of these grooves varies from a maximum at the rearward end of the forward section to a minimum adjacent to the forward end 30. The spacing of all of the grooves in each section is uniform, as shown.
The forward and rearward grooves 40 and 42 (FIGS. 1 and 2) thus define or create a pattern in their respective surfaces 22 and 24 of a plurality of small rectangular segments 38 most of which are of uniform length and width except for the forwardmost segment on each surface. The narrower forwardmost segment 44 on the back surface 24 is not grooved because of the thinness of the shim at that location, whereas the front surface 22 of the forward section 36 is not grooved so as to provide an area for a logo, advertising material, or other indicia. With reference to FIG. 3, it will be noted that where the forward and rearward sections "overlap," there is an absence of grooves on both the front and back surfaces. Stated otherwise, the spacing between the forwardmost groove of the rearward section and the rearwardmost groove of the forward section is approximately three times the spacing between the other grooves, thereby maintaining the strength of this "overlap" area.
The forward and rearward grooves 40 and 42 (FIG. 3) also define breakable portions 46 which are weakened areas or lines in the shim 20 to enable the segments 38 to be snapped or broken off from the remainder of the shim. As noted above, the forward section 36 is so thin that the shim can easily be manually broken off at any of its forward grooves, particularly when the entire forward section is present for leverage. This allows the craftsman to make a preliminary break if desired before inserting the shim in place. Normally, however, segments of the shim are snapped off by hammer after the shims are inserted.
As stated, the rearward grooves 40 (FIGS. 1 and 2) are uniformly spaced along the length of the front surface 22 of the rearward section 34 and the forward grooves are uniformly spaced along the back surface 24 of the forward section 36, and this spacing is the same in both places. Since the shims are normally used in pairs, as shown in FIGS. 8 and 9, this spacing allows alignment of opposing grooves and breakable portions 46 so that the shims can be cleanly broken as a pair.
Also in accordance with this invention, the back surface 24 (FIG. 1) of the rearward section 34 provides a plurality of oblong nailing pockets, cavities or depressions 50 which are uniformly spaced lengthwise of the shim 20 and which extend transversely thereof. With reference to FIG. 3, it will be noted that the pockets are located generally between the rearward grooves 40 on the front surface 22. In other words, each rearward segment 38 has a back pocket. Like the grooves, the pockets vary in depth from a maximum depth at the rearward end 28 to a minimum depth at the forward end of the rearward section. No pockets are provided in the forward section 36.
The purpose of these pockets 50 is to allow nails to be driven through the shim 20 and the wood parts being shimmed and then be pulled out without splintering or otherwise damaging the shim or the wood. Without the pockets, the plastic grasps the nail so tightly that in removing it during adjustment of the shims and the work being shimmed, the shim may splinter and the adjacent wood be damaged in the process. The pockets thus provide each rearward segment 38 with a nailing portion 52 (FIG. 3) of reduced thickness, that is, with less material than the full thickness of the shim. When a nail extends through a pocket and penetrates the associated nailing portion, the latter does not grasp the nail as tightly as would the full thickness of the shim.
Still further, the front and back surfaces 22 and 24 of the shim 20 (FIGS. 1 and 2) are chemically etched or striated, preferably to a depth of about 0.003 inch (about 1.18 mil), as represented at 60. It is to be understood that this etching preferably covers the full extent of the front and back surfaces, except for the logo area, but is shown only at certain locations for illustrative clarity. The purpose of this etching is provide the surfaces with a moderate degree of friction so that in use, the shims are prevented from slipping out of position while still retaining the ability to be readily and controllably slid against each other and adjacent shimmed surfaces. Because the plastic imparts such a hard, smooth finish to the shim, such etching is especially useful to achieve better control of the shims as they fit against each other in pairs or against wood.
With reference now to FIGS. 4 and 5, an important aspect of the present invention is a plastic sheet 70 of the shims 20. This sheet has opposite, flat, rectangular front and back shimming surfaces 72 and 74 which are defined by the coplanar front and back shimming surfaces 22 and 24 of the shims in the sheet. The sheet also has side edges 76, which are defined by the outer side edges 26 of the outside shims, a rearward edge 78 which is defined by the aligned rearward edges 28 of the shims, and a forward edge 80 which is defined by the aligned forward edges 80 of the shims.
Adjacent shims 20 in the sheet 70 are separably, breakably joined by short and long plastic ribs 84 and 86 (FIGS. 2-4 and 5) which are spaced from each other lengthwise of the shims. That is, each short rib is in adjacent spaced relation to the rearward edge 78, interconnects adjacent rearward sections 34 of adjacent shims, and extends from about the centerline of the rearwardmost segment 38 to about the centerline of the next adjacent segment. Each long rib extends preferably from about the sixth segment from the rearward end to the so-called overlap area of the rearward and forward sections and is thus longer than the short rib.
Between the short and long ribs 84 and 86 (FIGS. 2-4 and 5) and between adjacent forward sections 36, adjacent shims 20 in the sheet 70 are closely spaced but are not connected. Such spacing facilitates breakability of the shims from the sheet while the ribs maintain sheet rigidity. Also in this regard, the thickness of each rib is less than the thickness of the shim at the place where the rib attaches, it being understood that the rib thickness tapers like the shim. In fact, to further facilitate breakability, it is preferred that the rib thickness be less than about half the thickness of the shim at the place of attachment and that the ribs be located closer to the front surface 22 than to the back surface 24, as shown in FIG. 6.
Interconnection of adjacent shims 20 by the spaced dual ribs 84 and 86 thus has several advantages. These ribs of course maintain the relatively rigid integrity of the sheet and its coplanar condition for handling, transporting, and storing of the sheets. The ribs are sufficiently strong to maintain such integrity but are weak enough to be readily broken with the application of moderate finger pressure. No ribs exist between the forward sections because of the thinness of these sections and because such absence facilitates manual break-off of the shims from the sheet. If ribs were to be provided between the forward sections, they would have be about the same thickness as the forward section so that a clean break-off line could not be established and risk of unintentional breakage of the forward section might occur.
Further, it is noted that after a shim 20 is broken off from the sheet 70 (FIGS. 4 and 5), the break along each side edge 26 is clean and neat (FIG. 2), with no splitting, splintering, or rough burrs. All that remains are the short and long rib fragments 32 and 33 which are smooth and almost unnoticeable. In any event, these rib fragments are on the side edges which do not contact the working surfaces of the items being shimmed.
Although exact dimensions are not critical to the principles of the present invention, a few of the preferred dimensions of the described embodiment have been given above and a few more are set forth below to enable a better understanding of the invention.
______________________________________Part Dimension______________________________________L (length of sheet 70 and each shim 20) 7.875 in (20 cm)W (width of each sheet 70 of ten shims) 11.812 in (30 cm)w (width of each shim 20 including rib fragments 1.170 in (2.97 cm)32 and 33)t (thickness at rearward end) 0.312 in (.79 cm)t' (thickness at forward end) 0.032 in (.08 cm)r1 (length of long rib) 3.315 in (8.42 cm)r2 (length of short rib 84) 0.500 in (1.27 cm)s (spacing between adjacent shims in sheet) 0.050 in (.13 cm)______________________________________
With reference to FIGS. 8 and 9, a pair of shims 20 is shown back-to-back between studs 90 and finish wood 92 of a door frame. As the craftsman is hanging the door, he works his way around the frame, driving a few nails 94 part way in as he goes. As shown in FIG. 9, these nails fit into the pockets 50 and through the reduced portions 52 of the shims. If he has to pull out one or more nails, they slide out of the reduced portions without splitting or splintering the shim and avoid damage to the wood, especially the finish wood. Also FIG. 9 shows how the opposed grooves allow the shims to be cleanly broken as a pair.
From the foregoing, it will be understood that a plastic shim 20 has been provided which is of uniform size and shape, of homogeneous consistency, and of dependable quality so that it does not split or break easily or unintentionally. The shim is of such dimensions, hardness, nailablity, durability, surface friction and other characteristics as are especially suited for use as a shim and which overcome the disadvantages of wooden shims. Segments 38 of the shim can be neatly and cleanly broken or snapped off manually or with a hammer to enable the shim to be shortened to a desired length.
Moreover, a sheet 70 of plastic shims 20 has been disclosed which is convenient for transport, storage and handling of the shims. The sheet can be neatly and cleanly separated into individual shims when ready for use and so that the work surfaces of the shims are flat and unencumbered with break-off fragments. The joining of only the thicker sections of the shims in the sheet by the spaced ribs 84 and 86 maintains the sheet configuration while facilitating breakability. The sheet construction allows the sheet to be readily broken lengthwise of the shims for separating the shims from the sheet and allows the shims to be readily broken transversely thereof for shortening the shims to a desired length. Yet, both the sheet and the shims are solid and durable, and the latter does not splinter or break in its intended use. The sheet also provides a very convenient way of breaking off a single shim if only one is needed or multiple shims if a wider shim is needed. The entire sheet is even available as a shim if that is desired.
The invention has been disclosed in the embodiment of a plastic shim, but there are other workpieces, especially tapered ones like a stake, and other items particularly those suited for the building industry, that could equally as well incorporate the same principles. Thus, although preferred embodiments of the present invention have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A plastic shim or other workpiece useful in the construction industry. The shim or workpiece is an elongated tapered hard plastic body incorporating qualities of a shim lacking in wooden shims. Each shim has transverse break lines so that segments can be broken off to adjust its length. For handling, a plurality of such shims are molded in a sheet with adjacent shims being spaced along their thinner sections but separably joined by longitudinal, break lines extending along their thicker sections, whereby the shims can be detached from the sheet either individually or in multiples. The shims may have pockets defining nailing portions of reduced thickness which minimize the grasp of nails by the shim and allow removal of nails without damage to the shim or adjacent wood and etching to avoid uncontrolled slippage. |
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This application is a continuation of application Ser. No. 07/716,989, filed on Jun. 18, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a human private parts washing apparatus installed to a toilet bowl.
2. Description of the Related Art
A human private parts washing apparatus disclosed in Japanese Utility Model Laid-Open No. 26778/1986 has been known as one of the human private parts washing apparatus of this type. This apparatus has two washing nozzles arranged to extend up and down in a case, and each nozzle is used for washing an anus region (hereinafter denoted simply first position) and for washing a bidet (hereinafter denoted simply second position). Each nozzle has a wire means driven by a motor. When a user puts on a switch in order to wash the first position, the nozzles are extend from an opening of the case to the first position by the motor. A fine adjustment of the washing position is controlled by moving the wire.
The above mentioned appratus makes it possible to splash an amount of washing water from the nozzle at a center of a lavatory seat because each nozzle is arranged to extend up and down. However the opening of the case becomes vertical so that filthy water and a detergent and the like enter to the opening easily on using or cleaning of this apparatus. It causes a short circuit and breakdown. Moreover the length of the whole apparatus from top to bottom becomes long so that the height of the lavatory seat becomes high. It is not useful for children and the user who is of a short height. And further, this apparatus needs many parts such as pulleys because the wires are used for driving, and the motor which drives two nozzles by using the wires and pulley needs high torque because of produced mechanical friction. It has drawbacks that the parts which comprise a driving machine of the nozzles become large in number.
In order to solve the above problem, a washing apparatus disclosed in Japanese Patent Laid-Open No. 242030/1987 has been known as the other private parts washing apparatus. This apparatus has one nozzle which washes both the first position and the second position, and a rack which meshes with a pinion is installed under the nozzle. A shaft of the pinion is mounted to a motor. The nozzle is extended to the washing position by driving the motor. However, this apparatus has a problem that the nozzle can't keep clean. This is caused by the following reason. The nozzle has two kinds of splashing openings, one is opened on a position end of the nozzle for washing the second position and the other is opened at the back of said openings for washing the second position. So that it may occur that filth adheres on the nozzle on washing the second position.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a human private parts washing apparatus which obviates the above conventional drawbacks.
It is another object of the invention to provide an improved human private parts washing apparatus in which filth and a detergent don't enter the opening of the case.
It is the third object of this invention to keep the nozzle clean.
It is the forth object of this invention to wash the first position and the second position correctly.
In order to attain the foregoing objects, a human private parts washing apparatus according to this invention comprises a case mounted in proximity to the toilet bowl, a stand movably mounted to the case for movement between a stand retracted position and at least one stand advanced position, drive means for driving the stand between the stand retracted position and at least one stand advanced position, two nozzle holders mounted to the stand for movement with the stand between the retracted and the at least one advanced position, first and second nozzles having first and second splashing openings and being respectively mounted in the nozzle holders for movement from nozzle retracted positions to nozzle advanced positions in which the splash openings are positioned for splashing water onto the respective human private parts, together with means for independently moving the first and second nozzles between the retracted and advanced positioned thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent and more readilly appreciated from the following detailed description of preferred exemplarly embodiments of the present invention, taken in connection with the accompanying drawings, in which;
FIG. 1 is a view illustrating a human private parts washing apparatus according to this invention;
FIG. 2 is a plan view showing a nozzle unit of a preferred embodiment according to this invention;
FIG. 3 is a cross sectional view taken along line A--A line of FIG. 2;
FIG. 4 is a plan view illustrated an action of second nozzle which washes the second position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated a human private parts washing apparatus which includes a case 40 and a lavatory seat 41. The case 40 holds a rear end portion of the lavatory seat 41 rotatable to a toilet bowl. The case 40 is formed by a case cover 42 and a base cover 43, and holds a first switch 44 for washing a first position, a second switch 45 for washing a second position, a thermo control sensor 46, a first nozzle 7 for washing the first position, a second nozzle 8 for washing the second position, and other equipment needed for the washing.
As illustrated in FIGS. 2 and 3, a rest 18 which supports a motor 33 is installed on the base cover 43 fasten by screws 47, 48, 49 and 50 at the corner thereof. The rest 18 has rails 19, 20, 21 installed at its center portion and a stand 13 is put on the rails 19, 20, 21. The stand 13 has a rack 31 at its under side thereof in parallel with a the moving of the stand 13. The rack 31 meshes with a pinion 32 installed on a shaft of the motor 33. The stand 13 has a boss 22, 23 out of the rail 19, 20 and a boss 24, 25 out of the rail 21 in order to securely fit to the rest 18. The stand 13 has fixed thereon a first nozzle supporter 2 and a second nozzle supporter 3 via screws 16, 17 and 14, 15 respectively. The first nozzle supporter 2 is fixed as to keep an angle α, and the second nozzle supporter 3 is fixed to keep an angle β with respect to center-lines S, i.e., the direction of movement of the stand 13 by the rack 31 (shown in FIG. 2). As seen in FIG. 2, the angle α may be about 5° and the angle β may be about 12°. Above the first and second nozzle supporters 2 and 3, a plate 27 is fixed, by screws 28, 29, 30, to bosses (not shown) on the rest 18. The plate 27 allows the first and second nozzle supporter 2, 3 not to totter. The first nozzle supporter 2 has an opening 1 to which a water is supplied, and the second nozzle supporter 3 has an opening 9 to which a water is supplied.
A first nozzle 7 is supported in the first nozzle supporter 2 slidably back and forth in a forward inclining manner toward an inner space of a toilet bowl, and has a few first splashing openings 10 at one end thereof for washing the first position. The first nozzle 7 is pushed into the first nozzle supporter 2 by a spring(not shown). A second nozzle 8 is supported in the second nozzle supporter 3, and has a few splashing openings 11 at one end thereof for washing the second position. The second nozzle 8 is similar to the first nozzle 7 except that the second nozzle 8 is longer than the first nozzle 7.
An interrupting plate 35 is installed under the stand 13, and a sensor 34 which detects a location of the stand 13 is installed on the rest 18. The sensor 34 has an emitting part 34a and a receptive part 34b. When the stand 13 is advanced, the interrupting plate 35 passes between the emitting part 34a and the receptive part 34b, so that a light emitted from the emitting part 34a is interrupted and the location of the stand 13 is detected. The sensor 34 is installed to be able to detect any location of the stand 13.
The operation of this embodiment will be described hereinafter. At first, a case to wash the first position is described. When a user pushes the first switch 44, water is supplied into the opening 1 resulting in that the first nozzle 7 extends to the first nozzle advanced position by the resulting water under pressure against the spring pressure. At the same time the motor 33 moves the stand 13 ahead. So the interrupting plate 35 goes through the sensor 34, and interrupts infrared rays radiated from the emitting part 34a. The sensor 34 detects that the interrupting plate 35 is in the first nozzle advanced position and provides a signal to a control means (not shown) to stop the motor 33. Thus the first nozzle 7 is placed at the first washing position. The water supplied to the opening 1 flows into the nozzle supporter 2, a gate 5 and the water-way 6 in the nozzle and at last splashes from the splashing opening 10 toward the first washing position. At this time, the nozzle 7 is extended to a position "A" after a stroke of (L1+L2). "L1" shows a stroke of the first nozzle 7, and "L2" shows a stroke of the nozzle supporter 2.
When the user wants to wash in front of the position A, the user can select "Front switch" which makes the motor 33 to drive to the left in FIG. 3, and the nozzle 7 moves to "B". When the user wants to wash behind the position A, the user can select "Back switch" which makes the motor 33 to drive to the right in FIG. 3, and the nozzle 7 moves to "C". And further when the user wants to wash the first position with optional waving, the user can select "Wave switch" which makes the motor 33 to drive to the left and right, and the nozzle 7 moves to the back and forth. Thus, the first position is washed correctly and effectively.
To stop washing, the user pushes "Stop switch" and the motor 33 rotates to the right in FIG. 3. The nozzle supporter 2 returns to the retracted position. At the same time supplying the water is stopped, and as a result of that the nozzle 7 is retracted into the case 40 by the spring pressure.
In the case of the second nozzle 8, as shown in FIG. 4, the splashing water is usually splashed from the splashing opening 11 of the second nozzle at the standard position "D", and the second nozzle is driven by the motor 33 and the water pressure similar to the first nozzle. Especially, the second nozzle can be moved from a position "E" to a position "F" in FIG. 4.
As mentioned above, according to the present invention, not only the standard position but also the wide position around the standard position can be washed easily and correctly for the abovementioned reason. The difference between the position where the user wants to wash and the standard position of the apparatus can be adjusted by controlling the advanced position of the stand 13 which is moved by the motor 33.
In addition, the opening of the case becomes narrow because each nozzle extends horizontally. Thus filthy water and a detergent and the like do not enter the opening easily on using or cleaning of this apparatus.
Obviously numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A human private parts washing apparatus includes a first nozzle device having a first splashing opening for washing the first position, a second nozzle device having a second splashing opening that is opened on a position end thereof for washing the second position, a case having the first nozzle device and the second nozzle device therein, a stand for mounting thereon the first nozzle device and the second nozzle device, and a driving device for driving the stand back and forth. |
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[0001] This claims the benefit of German Patent Application DE 10 2010 002 214.4 filed Feb. 23, 2010 and hereby incorporated by reference herein.
[0002] The present invention relates to a reinforcement and/or anchor bolt, to a method for reinforcing and/or anchoring bedrock in mining and/or tunnel construction, and to the use of a reinforcement and/or anchor bolt in mining and/or tunnel construction.
BACKGROUND
[0003] Anchor systems are used in mining and tunnel construction to prevent ground movement of the bedrock or to slow it down or to secure large spalls of the bedrock so as to allow safe operation. Here, two functional principles are known which are, at times, also combined with each other. In mechanical systems, the anchor is secured by frictional engagement, whereby mechanical rock anchors generally also have an expansion shell. In chemical systems, reinforcement rods with a curing mortar are connected to the substrate or bedrock by means of adhesion. Here, the anchors are installed with or without pre-tensioning in the bedrock. The drawbacks of these two different anchor systems are that chemical anchor systems are expensive and that, with so-called expansion anchors, a punctual load is applied into the bedrock. Moreover, with chemical anchor systems, the curing is temperature-dependent, so that a long curing time has to be expected at low temperatures. The anchors cannot be dismantled, which is especially disadvantageous when they are used in coal mining.
[0004] European patent application EP 0 623 759 B1 describes a thread-forming bolt that can be screwed directly into concrete masonry or the like and that comprises a bolt head, a bolt shaft and a thread.
[0005] U.S. Pat. No. 5,114,278 discloses a mining bolt with a thread and a conical tip.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention is to provide a reinforcement and/or anchor bolt, a method for reinforcing and/or anchoring bedrock in mining and/or tunnel construction, and the use of a reinforcement and/or anchor bolt in mining and/or tunnel construction, whereby the reinforcement and/or anchor bolt can be attached inexpensively and reliably to the bedrock with little technical effort.
[0007] The present invention provides a reinforcement and/or anchor bolt that can be used in mining and/or tunnel construction and that can be screwed into bedrock, comprising a bolt head, a bolt end, a bolt shaft and a thread that is at least partially configured on the bolt shaft, whereby the ratio of the length of the reinforcement and/or anchor bolt to the outer diameter of the reinforcement and/or anchor bolt is greater than 20, 30, 50 or 70.
[0008] In particular, the ratio of the of the length of the reinforcement and/or anchor bolt to the outer diameter of the reinforcement and/or anchor bolt may be between 20 and 150, preferably between 30 and 120, especially between 40 and 100.
[0009] In another embodiment, the pitch of the thread corresponds to the product of the outer diameter of the reinforcement and/or anchor bolt and of a factor between 0.2 and 1.2, especially between 0.4 and 0.9.
[0010] In another embodiment, between the bolt head and the bolt end, the thread is configured on the bolt shaft only in the area of the bolt end of the bolt shaft, in particular, the thread is configured on the bolt end only at a distance from the bolt end of less than 80%, 70% or 50% of the length of the reinforcement and/or anchor bolt, and preferably, the core diameter of the bolt shaft without the thread in the area of the bolt head is smaller, preferably by less than 15%, 10%, 5% or 2%, than the core diameter of the bolt shaft with the thread in the area of the bolt end.
[0011] Preferably, the ratio of the outer diameter to the core diameter is between 0.8 and 1.6, preferably between 1.0 and 1.4, especially between 1.1 and 1.2, and/or the ratio of the outer diameter to the pitch of the thread is between 1.0 and 3.0, preferably between 1.5 and 2.5, especially between 1.7 and 2.2, and/or the flank angle is in the range from 50° to 90°. The above-mentioned geometric configuration of the reinforcement and/or anchor bolt allows a reliable positive connection between the reinforcement and/or anchor bolt and the bedrock, especially between the thread of the reinforcement and/or anchor bolt and the bedrock. In this manner, the reinforcement and/or anchor bolt can be reliably connected with a positive fit to the bedrock simply by being screwed into a bore hole in the bedrock. Thus, in an advantageous manner, no chemical systems, for example, curing mortar, are needed to attach the reinforcement and/or anchor bolt to the bedrock, and furthermore, essentially no frictional connection is needed between the reinforcement and/or anchor bolt and the bedrock either, because the reinforcement and/or anchor bolt is attached to the bedrock essentially by means of a positive connection.
[0012] In one variant, the bolt end is configured as a conical tip. The conical tip can be partially or completely shaped onto the bolt end of the reinforcement and/or anchor bolt.
[0013] Advantageously, the bolt end, especially the conical tip, is made at least partially, especially completely, of a material—e.g. metal, especially tempered steel, for example, also as a coating, e.g. made of quartz sand or corundum, or in the form of a ceramic coating—that differs from that of the rest of the reinforcement and/or anchor bolt aside from the bolt end.
[0014] In coal mining (underground mining), so-called longwall mining methods are used more and more often. In this case, the coal seam is mined between longwall panels using a large milling head or plow over the entire length. Before the mining can begin, the panels to be mined have to be secured with the reinforcement and/or anchor bolts, as a result of which the reinforcement and/or anchor bolt is situated in the coal seam that is to be mined. The milling head pulls out the reinforcement and/or anchor bolt together with the coal. Reinforcement and/or anchor bolts made of steel can cause problems when the coal is being conveyed and processed. For this reason, when reinforcement and/or anchor bolts are used in coal mining, they are made, preferably at least partially, of plastic, especially of fiber-reinforced plastic, so that the reinforcement and/or anchor bolt is chopped up by the milling head and cannot damage the conveyor belts. However, in order for the reinforcement and/or anchor bolt to be nevertheless screwed into the bedrock, the bolt end, especially in a configuration as a conical tip, is made of a material that is different from that of the rest of the reinforcement and/or anchor bolt, which is made of plastic. Consequently, the bolt end, especially the conical tip, is made of metal or by means of a coating on the plastic. Moreover, the thread can also be configured as a cutting profile consisting of a hard, wear-resistant layer, for example, the same coating as that on the bolt end.
[0015] In another embodiment, the air-side bolt head is connected, for example, with a positive fit, to the rest of the bolt shaft, and it is made of a material that is different from that of the rest of the bolt shaft. For instance, the bolt head is made of metal, especially steel, and the rest of the bolt shaft is made of plastic. Here, the air-side bolt head preferably has a special geometry, e.g. a hexagonal shape, so that the torque needed to screw in the reinforcement and/or anchor bolt can be applied to the bolt head.
[0016] In an additional embodiment, the diameter of the bolt head is essentially the same size as the core diameter of the bolt shaft or else larger, e.g. by 10%, 20% or 50%, than the core diameter of the bolt shaft.
[0017] In another variant, a thread is present on the bolt head, and a nut, especially an anchor nut, is screwed onto this thread on the bolt head, so that this nut allows the reinforcement and/or anchor bolt to be screwed in as well as tightened, and the force on the anchor head can be transmitted to a head plate or to an anchor head construction.
[0018] Advantageously, the reinforcement and/or anchor bolt, especially aside from the bolt end, can be made at least partially of metal, e.g. steel, or preferably fiber-reinforced plastic, e.g. GFP. Particularly when the reinforcement and/or anchor bolt is used in coal mining, it is made at least partially of plastic.
[0019] In another embodiment, the bolt shaft has a solid or hollow cross section. Particularly in bedrock having a low compressive strength, the bolt shaft can be made with a hollow cross section.
[0020] The invention also relates to a method for reinforcing and/or anchoring bedrock in mining and/or tunnel construction in that a reinforcement and/or anchor bolt, especially a reinforcement and/or anchor bolt described in this patent application, is inserted into the bedrock, whereby a bore hole is drilled into the bedrock and subsequently, the reinforcement and/or anchor bolt is screwed into the bore hole, so that preferably the bedrock is reinforced, and/or preferably an anchor is attached to the bedrock.
[0021] In another embodiment, the thread of the reinforcement and/or anchor bolt cuts its way into the bedrock when the reinforcement and/or anchor bolt is screwed in, and/or a positive connection is created between the thread and the bedrock, and/or a bore hole is drilled whose diameter is smaller, especially by at least 10%, 20% or 30%, than the outer diameter of the reinforcement and/or anchor bolt, and/or a bore hole having a constant diameter is drilled and/or a reinforcement and/or anchor bolt is provided so that the pitch of the thread of the reinforcement and/or anchor bolt is between 0.3 and 1.5, preferably between 0.4 and 1.2, especially between 0.5 and 0.8, times the diameter of the bore hole, and/or a bore hole is drilled and/or a reinforcement and/or anchor bolt is provided so that the core diameter of the thread is smaller, especially by less than 15%, 12% or 8%, than the diameter of the bore hole, and/or a reinforcement and/or anchor bolt is provided so that the flank angle of the reinforcement and/or anchor bolt is calculated according to the formula ((compressive strength of the rock—145)/−1.5)±10° when the compressive strength of the bedrock is between 10 and 100 mPa, and the flank angle is 30°±10° when the compressive strength of the bedrock is more than 100 mPa.
[0022] In another embodiment, a positive connection is created, especially by means of the thread, between the reinforcement and/or anchor bolt and the bedrock, and preferably the amount of the positive connection is at least 50%, 70%, 80% or 90% of the connection of the reinforcement and/or anchor bolt to the bedrock. Hence, the forces to be absorbed by the reinforcement and/or anchor bolt are transferred essentially positively into the bedrock and not by adhesion, by adhesive force or non-positively.
[0023] In particular, the bore hole is drilled with a varying diameter so that an inner section of the bore hole has a diameter that is smaller, preferably by less than 2%, 5%, 10% or 20%, than the diameter in an outer bore hole section.
[0024] In another embodiment, after the reinforcement and/or anchor bolt has been screwed completely into the bore hole, its bolt shaft that is provided with the thread is situated essentially in the inner bore hole section and its bolt shaft without the thread is situated in the outer bore hole section.
[0025] In another variant, after the reinforcement and/or anchor bolt has been screwed completely into the bore hole, the ratio of the anchoring depth of the reinforcement and/or anchor bolt to the diameter of the bore hole is between 20 and 150, preferably between 30 and 120, especially between 40 and 100.
[0026] The invention also relates to the use of a reinforcement and/or anchor bolt in mining and/or tunnel construction for reinforcing bedrock and/or for anchoring, whereby a reinforcement and/or anchor bolt described in this patent application is used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Below, embodiments of the invention will be described in greater depth with reference to the accompanying drawings. The following is shown:
[0028] FIG. 1 a side view of a reinforcement and/or anchor bolt with a partial lengthwise section of a bore hole in bedrock,
[0029] FIG. 2 a lengthwise section of the reinforcement and/or anchor bolt in the bore hole in a first embodiment,
[0030] FIG. 3 a lengthwise section of the reinforcement and/or anchor bolt in the bore hole in a second embodiment,
[0031] FIG. 4 a lengthwise section of the reinforcement and/or anchor bolt in the bore hole in a third embodiment, and
[0032] FIG. 5 a perspective view of a drill rod.
DETAILED DESCRIPTION
[0033] FIG. 1 shows a reinforcement and/or anchor bolt 1 for use in mining and/or tunnel construction. When used as a reinforcement bolt, bolt 1 serves essentially for reinforcing and stabilizing the bedrock 7 , and thus less for absorbing forces that are applied to the reinforcement bolt 1 on the air-side bolt head 2 and that are especially directed towards a longitudinal axis of the reinforcement bolt 1 . When used as an anchor bolt, bolt 1 serves less for reinforcing and stabilizing the bedrock 7 , but essentially for absorbing forces on the air-side bolt head 2 of the anchor bolt 1 . The reinforcement and/or anchor bolt 1 shown in FIG. 1 can be used as a reinforcement bolt 1 and also as an anchor bolt 1 in mining or tunnel construction.
[0034] The reinforcement and/or anchor bolt 1 ( FIGS. 1 through 4 ) has the air-side bolt head 2 , a bolt end 3 that is arranged in a bore hole 6 ( FIGS. 2 through 4 ), and a thread 5 on a bolt shaft 4 . The bolt shaft 4 has a section that is configured without the thread 5 in the area of the bolt head 2 as a bolt shaft 18 without the thread 5 , and it has a section on the bolt end 3 that is configured as a bolt shaft 19 with a thread 5 . Here, the bolt end 3 is partially configured as a conical tip 9 ( FIG. 1 ). The bolt shaft 4 of the reinforcement and/or anchor bolt 1 has a core diameter D i on the bolt shaft 18 without the thread 5 as well as on the bolt shaft 19 with the thread 5 , and it has an outer diameter D a on the thread 5 and a length A. Furthermore, the thread 5 has a pitch P that corresponds to the distance between two windings of the thread 5 . The thread 5 also has a flank angle α. FIG. 1 also shows the bore hole 6 in the bedrock 7 . The bore hole 6 here has a diameter of D b .
[0035] FIG. 2 shows a first embodiment of an arrangement of the reinforcement and/or anchor bolt 1 in a bore hole 6 that has been drilled in the bedrock 7 . The reinforcement and/or anchor bolt 1 is configured in the area of the bolt head 2 on the bolt shaft 18 in such a way that said bolt shaft does not have a thread 5 , and in another section of the bolt shaft 4 on the bolt end 3 , it has a thread 5 , or else a thread 5 is formed on the bolt shaft 19 . Here, the outer diameter D a of the reinforcement and/or anchor bolt 1 is 20% to 30% larger than the diameter D b of the bore hole 6 . After the bore hole 6 has been drilled, for example, with a drill rod 12 , whereby the bore hole 6 has a constant diameter D b , the reinforcement and/or anchor bolt 1 is screwed into the bore hole 6 in that a torque is applied to the bolt head 2 . Due to the larger outer diameter D a of the reinforcement and/or anchor bolt 1 relative to the diameter D b of the bore hole 6 , the thread 5 cuts its way into the bedrock 7 and a positive connection is created between the thread 5 and the bedrock 7 . In FIG. 2 , the reinforcement and/or anchor bolt 1 is screwed completely into the bore hole 6 and can rest with or without pre-tensioning on a head plate 8 . Here, a force is exerted by the bolt head 2 onto the head plate 8 , preferably with pre-tensioning. FIG. 2 also shows an anchoring depth L of the reinforcement and/or anchor bolt 1 and the length B of the bore hole 6 . The reinforcement and/or anchor bolt 1 in FIG. 2 has a bolt end 3 that is completely configured as a conical tip 9 . The bolt end 3 or the conical tip 9 can also be detachably connected to the rest of the bolt shaft 4 , for example, by means of a screwed connection or a bayonet connection. Through the use of different bolt ends 3 , the reinforcement and/or anchor bolt 1 can be adapted to different types of bedrock 7 . Moreover, the core diameter D i of the bolt shaft 4 is approximately 8% smaller than the diameter D b of the bore hole 6 . As a result, in an advantageous manner, no friction occurs between the bolt shaft 4 and the bedrock 7 when the reinforcement and/or anchor bolt 1 is screwed into the bore hole 6 , so that consequently, the torque that has to be applied to the bolt head 2 to screw in the reinforcement and/or anchor bolt 1 can be reduced.
[0036] When the reinforcement and/or anchor bolt 1 is used in bedrock 7 having a high compressive strength, e.g. solid rock, the bolt shaft 4 is generally configured with a solid profile, whereas, when the reinforcement and/or anchor bolt 1 is used in bedrock 7 having a low compressive strength, e.g. gravel, the bolt shaft 4 is generally configured with a hollow profile. When the reinforcement and/or anchor bolt 1 is used in a bedrock or substrate having a low compressive strength, a hollow profile is already sufficient to absorb the forces that act radially on the bolt shaft 4 . This can save material during the production of the reinforcement and/or anchor bolt 1 . The thread 5 for the reinforcement and/or anchor bolt 1 , especially when the bolt shaft 4 is configured as a hollow profile, can be created, for example, in that a profile wire is wound onto the bolt shaft 4 and laminated into it.
[0037] FIG. 3 shows a second embodiment of the arrangement of the reinforcement and/or anchor bolt 1 in the bedrock 7 . The diameter of the bore hole 6 drilled into the bedrock 7 is larger on an outer bore hole section 11 than on an inner bore hole section 10 . The bolt shaft 19 with the thread 5 is essentially arranged on the inner bore hole section 10 , for instance, with a deviation of less than 40%, 30%, 20%, 10% or 5%. Here, the diameter D b of the bore hole 6 on the inner bore hole section 10 is about 4% to 8% smaller than the outer diameter D a of the reinforcement and/or anchor bolt, so that consequently, a positive connection is created between the thread 5 and the bedrock 7 on the inner bore hole section 10 . The diameter D b on the outer bore hole section 11 is larger here than the outer diameter D a of the reinforcement and/or anchor bolt. As a result, the reinforcement and/or anchor bolt can initially be inserted with a small amount of force into the anchoring area, namely, into the inner bore hole section 10 . Furthermore, this means that a lower and more constant screwing torque has to be applied onto the bolt head 2 , and a better and constant support is possible due to the smaller diameter D b on the inner bore hole section 10 . For the rest, the second embodiment shown in FIG. 3 corresponds to the first embodiment shown in FIG. 2 .
[0038] FIG. 4 shows a third embodiment of an arrangement of the reinforcement and/or anchor bolt 1 in a bore hole 6 that has been drilled in the bedrock 7 . Like in the first embodiment, the bore hole 6 has a constant diameter D b . In contrast to the first embodiment, however, the core diameter D i of the reinforcement and/or anchor bolt 1 is smaller on the bolt shaft 18 without the thread 5 , for example, 2% to 8% smaller than the core diameter D i on the bolt shaft 19 with the thread 5 . The outer diameter D a of the reinforcement and/or anchor bolt 1 on the thread 5 is about 20% to 30% larger than the diameter D b of the bore hole 6 , so that in the third embodiment as well, the thread 5 cuts its way into the bedrock 7 when the reinforcement and/or anchor bolt 1 is screwed into the bore hole 6 , and moreover, as a result, a positive connection can be created between the thread 5 and the bedrock 7 . Due to the fact that the core diameter D i of the reinforcement and/or anchor bolt 1 on the bolt shaft 18 without the thread 5 is smaller than on the bolt shaft 19 with the thread 5 , the torque that is needed on the bolt head 2 can be reduced, since there is less friction between the bolt shaft 4 and the bedrock 7 .
[0039] FIG. 5 shows a perspective view of the drill rod 12 for drilling a bore hole 6 with a varying diameter D b as shown for the second embodiment in FIG. 3 . The drill rod 12 has a drilling crown 13 , a stabilizer 14 , a first boring bar 15 having a small diameter, a boring tool 16 and a second boring bar 17 having a large diameter. Here, for example, the drilling crown 13 , the stabilizer 14 and the first boring bar 15 have a diameter of 15 mm, the boring tool 16 has a diameter of 32 mm, and the second boring bar 17 has a diameter of 18 mm. The diameter of the boring tool 16 is thus larger than the diameter of the second boring bar 17 , and the diameter of the second boring bar 17 is larger than the diameter of the first boring bar 15 .
[0040] All in all, the reinforcement and/or anchor bolt 1 entails major advantages. The force that is to be exerted by the reinforcement and/or anchor bolt 1 into the bedrock 7 is applied by the thread 5 essentially positively into the bedrock 7 . The reinforcement and/or anchor bolt 1 is essentially connected with a positive fit or anchored to the bedrock 7 at its bolt shaft 19 with the thread 5 . Thus, it is possible to dispense with a complicated and disadvantageous anchoring of the reinforcement and/or anchor bolt by means of adhesion or by means of a non-positive connection (expansion). Hence, the reinforcement and/or anchor bolt 1 can be inserted into the bedrock 7 with little technical effort in that first a bore hole 6 is drilled, and subsequently the reinforcement and/or anchor bolt with the thread 5 is screwed into the bore hole 6 . | With a reinforcement and/or anchor bolt ( 1 ) that can be used in mining and/or tunnel construction and that is to be screwed into bedrock ( 7 ), and that includes a bolt head ( 2 ), a bolt end ( 3 ), a bolt shaft ( 4 ) and a thread ( 5 ) that is at least partially configured on the bolt shaft ( 4 ), the objective is to attach the reinforcement and/or anchor bolt ( 1 ) inexpensively and reliably to the bedrock ( 7 ) with little technical effort. A ratio of the length of the reinforcement and/or anchor bolt ( 1 ) to the outer diameter of the reinforcement and/or anchor bolt ( 1 ) is greater than 20. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an attachment for sinks. Specifically, this invention relates to an attachment for a sink that provides an apparatus for draining water flowing from a tap while maintaining a sealed sink.
[0003] 2. Background
[0004] Single basin sinks present several drawbacks with respect to washing articles in the sink. Once the sink drain is sealed, liquid flowing from a tap may not be drained. As the volume of liquid added to the sink increases the sink may begin to overflow. Therefore, during the article washing or rinsing process, the sink drain must be opened at regular intervals to reduce the volume of liquid in the sink. This process reduces the efficiency of washing or rinsing articles.
[0005] Several devices exist to avoid the problem described above. For example, an hourglass-shaped receptacle is described in U.S. Pat. No. 2,988,755. Other sink receptacles are described in U.S. Pat. Nos. 3,070,812, 3,289,218, 4,128,905, 5,435,022, 4,648,140 and 4,698,861. Each of these receptacles allow for draining of tap water while the sink is sealed, but each receptacle comprises a rigid immobile structure that occupies the center of the sink. Therefore, the location of these devices is not ideal, and the location may not be changed readily after the device is put into place without unsealing the sink.
[0006] A portable sink attachment is described in U.S. Pat. No. 4,370,762 titled “Portable Attachment for Sinks.” The device contains an upper wide mouth connected to an elbow that is relatively flat. The elbow is connected to a sealing means that plugs the sink. Unlike the previous devices, this device does not occupy the center of the sink. This device, however, is not attached to the sides of the sink.
[0007] Several means are known for attachment of devices to sinks. One such device is described in U.S. Pat. No. 4,531,246. The device has a cylindrical ring and removable means for attachment. The removable mounting means are positioned ninety degrees from each other and secure the device to the sink.
[0008] There exists a need in the art for a sink attachment that provides an apparatus for draining liquids while simultaneously sealing the sink. The device should require a minimum amount of sink space and should be securely, but removably, attached to the sink.
SUMMARY OF THE INVENTION
[0009] Now there is provided by the present invention a sink attachment that provides for draining of tap water while simultaneously sealing the sink. The device is mobile, flexible, removable and occupies limited space in the sink.
[0010] It is therefore, a principal object of the present invention to provide a sink attachment that fits into a sink and seals the drain of the sink effectively preventing any liquid in the sink from draining out. The use of this sink attachment allows the sink to be filled with a liquid, i.e. filled with soapy water to wash dishes, but provides an avenue for draining any liquid that flows from a tap, i.e. water that may be used to rinse the dishes.
[0011] In a first embodiment, the sink attachment comprises a basin, a drain tube, and a sealing member. The basin may be removably attached to the sink using an attaching member. The attaching member may be any device or material that provides for reversible attachment including two sided tape, Velcro, magnets, or suction cups. Preferably the attaching member is suction cups. The drain tube and the basin are in communication, and a liquid-tight seal is created when the drain tube is connected to an opening in the basin. This liquid-tight seal prevents water from leaking out of the sink attachment and into the sink. The liquid-tight seal also prevents water in the sink from leaking into the sink attachment to prevent draining of the water from the sink. The method of connecting the drain tube to the basin may be any method known to those skilled in the art. Preferably the drain tube is connected to the basin using one or more devices, such as fittings selected from the group consisting of compression fittings, PVC fittings, bulkhead fittings, flare fittings, and couplers. Optionally, the drain tube may be permanently fixed to the basin using adhesives or the like.
[0012] The drain tube is in communication with a sealing member. A liquid tight seal is also created between the drain tube and the sealing member. The drain tube is connected to the sealing member using one or more devices, such as the fittings and devices described hereinabove. The drain tube may also be attached to the sealing member using an adhesive.
[0013] The sealing member fits over the sink drain to retain water in the sink. The sealing member may be any apparatus that creates a liquid tight seal between the sealing member and the sink drain. More preferably the sealing member is any standard sink stopper or garbage disposal stopper. Most preferably the sealing member is a flat sink stopper or a garbage disposal stopper. Upon contacting the sink drain, the flat sink stopper and the garbage disposal stopper create a suction to prevent liquid from draining out of the sink.
[0014] The components of the sink attachment may be made from numerous materials. These materials include plastics, rubber, polymers, metals, Plexiglas®, glass, ABS, or combinations thereof. The metal material may be any metal material but is preferably a metal that is resistant to rusting and tarnishing, such as brass. Optionally, the metal may be galvanized or coated with a substance, such as Teflon, to prevent rusting and to increase the life of the sink attachment.
[0015] In a second embodiment, the opening in the basin comprises a screen. The screen prevents particulate matter from draining into the sink and potentially clogging the sink. Other aspects of the invention are disclosed below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features and advantages of the present invention will become more apparent in view of the following detailed description in conjunction with the accompanying drawings, of which:
[0017] [0017]FIG. 1 is a side view of the sink attachment in accordance with the present invention;
[0018] [0018]FIG. 2 is a top view of the sink attachment in accordance with the present invention;
[0019] [0019]FIG. 3 is a side view of the basin of the sink attachment in accordance with the present invention;
[0020] [0020]FIG. 4 is a top view of an embodiment of the basin of the sink attachment in accordance with the present invention;
[0021] [0021]FIG. 5 is a side view of the drain tube in accordance with the present invention;
[0022] [0022]FIG. 6 is a side view of an embodiment of a sealing member in accordance with the present invention;
[0023] [0023]FIG. 7 is a top view of an embodiment of a sealing member in accordance with the present invention;
[0024] [0024]FIG. 8 is a perspective view of additional embodiments of a sealing member; and
[0025] [0025]FIG. 9 is a perspective view of the sink attachment placed in a sink in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The preferred embodiment of the present invention will be described herein with reference to illustrative embodiments of a sink attachment which follows.
[0027] Referring to FIG. 1 and FIG. 2, there is shown the sink attachment of the present invention generally referred to as numeral 1 . The sink attachment comprises a basin 10 having at least one attaching member 15 . The basin portion may comprise any geometric shape but is preferably shaped to fit into a corner of a standard kitchen sink. As used herein, standard kitchen sink means any kitchen sink used in the United States or in foreign countries. Preferably standard kitchen sink means those kitchen sinks used in homes and businesses throughout the United States.
[0028] The basin is preferably attached to the sides of the sink to facilitate washing of dishes or articles that are in the sink. Attachment of the basin to the sides of the sink maximizes the amount of space available for soaking or washing dishes or articles. The attaching member may be any apparatus that attaches the basin to one or more sides of the sink. The attaching member is preferably at least one small magnets or at least one suction cup. More preferably, the attaching member comprises a total of two suction cups where one suction cup is positioned on one face of the basin and the other suction cup is positioned on an adjacent face of the basin. Most preferably, the attaching member comprises a total of four suctions cups where two suction cups are positioned on one face of the basin and the other two suction cups are positioned on an adjacent face of the basin (see 15 in FIG. 2). One skilled in the art would recognize that other attaching members may be used to secure the basin to the sides of the sink.
[0029] Referring to FIG. 1, the lower portion of the basin comprises an opening 20 . Attached to the opening 20 is a drain tube 40 . The drain tube 40 connects to a sealing member 60 for sealing the drain of a sink. Therefore, the liquid flows into the basin, through the drain tube, and into the sink drain that is sealed by the sealing member. The sealing member may be any device that fits over the drain of a sink and creates a liquid tight seal. Most preferably the sealing member is a flat sink stopper or a garbage disposal stopper. Both the flat sink stopper and the garbage disposal stopper create a suction that prevents liquid from leaking out of the sink. Additionally, the flat sink stopper or the garbage disposal stopper is easily removed when the sink needs draining.
[0030] Referring to FIG. 3 and FIG. 4, a first embodiment of a basin 10 is shown. The basin comprises an outer wall 12 and an inner wall 14 . The basin and the walls may be made of any material. Preferably the basin and the walls are composed of material selected from plastics, rubber, polymers, metals, Plexiglas®, glass, ABS, or combinations thereof. The basin may have any geometric shape or dimensions capable of fitting into a corner of a sink. In a preferred embodiment, the basin 10 comprises three faces A, B, and C which form a triangular shape comprising round corners (see FIG. 4). In preferred embodiments, face C is approximately 5-12 inches long and faces A and B are each approximately 3-9 inches long. In the most preferred embodiment, face C is 8 inches long from corner to corner and faces A and B are each 5 inches long from corner to corner. One skilled in the art would recognize that the length of the sides may be altered to fit into any sink including sinks used in the United States as well as sinks used in foreign countries. Attached to sides A and B are at least one attaching member 15 . More preferably attached to each side A and B is two attaching members. The attaching members located on sides A and B are in communication with the sides of the sink. Preferably the attaching members are suction cups. Side C faces outward towards the center of the sink. Since the sink attachment sits in the corner of the sink, the remaining portion of the sink is free for washing or rinsing articles.
[0031] The opening 20 of the basin comprises a fitting that extends below the basin for receiving a drain tube 40 . In preferred embodiments, the fitting is threaded and capable of receiving a nut. In other preferred embodiments, the fitting is a plastic or glass connector capable of receiving a drain tube and creating a liquid tight seal without using a nut. Examples of such embodiments are the glass and polypropylene connectors that are commercially available from Fisher Scientific (Pittsburgh, Pa.), which are used for connecting pieces of tubing such as Tygon® tubing. The fitting may be attached to the basin using an epoxy, an adhesive, welding, soldering, or other methods that create a liquid tight seal between the fitting and the basin. The fitting may optionally be manufactured as an integrated part of the basin.
[0032] Referring to FIG. 5, a drain tube 40 comprising an upper end 44 and a lower end 46 is shown. The upper end 44 of the drain tube 40 attaches to the fitting of the basin. A liquid-tight seal is created by inserting the upper end 44 of the drain tube 40 into the drain fitting of the sink. In this embodiment, the drain tube is held in place using a nut 42 . Optionally a washer may be inserted around the upper end 44 of the drain tube 40 , prior to tightening the nut 42 , to enhance the liquid-tight seal.
[0033] At the opposite end of the drain tube 40 , the lower end 46 is in communication with the sealing member 60 . Referring to FIG. 6 and FIG. 7, the lower end 46 couples to a fitting 62 of the sealing member 60 . Fitting 62 is preferably made of plastic, PVC, ABS, or other material that creates a liquid tight seal when the lower end 46 of the drain tube 40 is attached to the sealing member 60 . Fitting 62 may comprise any or all of the fittings discussed herein including straight fittings, elbow fittings, and the like. Fitting 62 may be attached using an epoxy, an adhesive, welding, soldering or other methods that create a liquid tight seal between the fitting and the sealing member. The fitting may optionally be manufactured as an integrated part of the sealing member.
[0034] Several embodiments of a sealing member are shown in FIG. 8. A first embodiment of a sealing member comprises a flat sink stopper 70 . A second embodiment of a sealing member comprises a standard garbage disposal stopper 75 . One skilled in the art would recognize that different shapes and sizes of sealing members exist that may be used to create a liquid-tight seal between the sink drain and the sink attachment. For example, the technology described herein may be adapted for use in a sink comprising an ovoid shaped drain by providing an ovoid shaped sealing member.
[0035] Referring to FIG. 9, to use the sink attachment for washing dishes, the sealing member is first put into place over the drain of the sink. The basin is then attached to the sink 100 using the attaching member of the basin. The sink may then be filled with water, detergent, or other liquids. During the course of washing dishes, tap water may be used to rinse the dishes by placing a dish over the sink attachment and running water onto the dish and into the basin of the sink attachment. The rinse water drains through the sink attachment thus preventing loss of suds in the sink.
[0036] One skilled in the art would recognize that the sink attachment described herein may be used in any situation where a liquid holding vessel, such as a sink, comprises a single basin, and where more than one liquid must be used to complete the desired process. For example, the chemical industry might use the sink attachment for washing or rinsing glassware. Glassware may be placed into the sink for washing or soaking. The sink may then be filled with a detergent or a chemical solution, such as a basic solution, for washing the glassware. If a base bath is used, each piece of glassware may be placed above the sink attachment and rinsed with a neutralizing solution, such as a mild acid. The use of this sink attachment would prevent neutralization of the basic solution in the sink.
[0037] The attachment may also be used by the automotive industry. Many avenues of the auto repair industry require that residual material be removed from auto parts before installation into an automobile. The parts are often soaked in a hydrocarbon solution such as kerosene. The sink attachment may be used to rinse the auto parts after soaking in the kerosene bath. Therefore, any particulate matter in the hydrocarbon bath would not contaminate the parts.
[0038] Although the invention has been shown and described with respect to exemplary embodiments thereof, various other changes, additions and omissions in the form and detail thereof may be made therein without departing from the spirit and scope of the invention. | A sink attachment having a basin, a drain tube, and a sealing member is disclosed. The sink attachment provides for simultaneously draining tap water or other liquids and sealing the sink. The attachment may be relocated without having to remove the sealing member from the sink drain. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. Ser. No. 09/997,021, filed Nov. 28, 2001, now U.S. Pat. No. 6,938,689, which is a continuation-in-part of U.S. Ser. No. 09/179,507, filed Oct. 27, 1998, now U.S. Pat. No. 6,283,227.
TECHNICAL FIELD
The invention relates generally to interactive and/or secure activation of tools, such as tools used in well, mining, and seismic applications.
BACKGROUND
Many different types of operations can be performed in a wellbore. Examples of such operations include firing guns to create perforations, setting packers, opening and closing valves, collecting measurements made by sensors, and so forth. In a typical well operation, a tool is run into a wellbore to a desired depth, with the tool being activated thereafter by some mechanism, e.g., hydraulic pressure activation, electrical activation, mechanical activation, and so forth.
In some cases, activation of downhole tools creates safety concerns. This is especially true for tools that include explosive devices, such as perforating tools. To avoid accidental detonation of explosive devices in such tools, the tools are typically transferred to the well site in an unarmed condition, with the arming performed at the well site. Also, there are safety precautions taken at the well site to ensure that the explosive devices are not detonated prematurely. Another safety concern that exists at a well site is the use of wireless, especially radio frequency (RF), devices, which may inadvertently activate certain types of explosive devices. As a result, such wireless devices are usually not allowed at a well site, thereby limiting communications options that are available to well operators. Yet another concern associated with using explosive devices at a well site is the presence of stray voltages that may inadvertently detonate the explosive devices.
A further safety concern with explosive tools is that they may fall into the wrong hands. Such explosive tools pose great danger to persons who do not know how to handle explosive tools, or who want to use the explosive tools to harm others.
In addition to well applications, other applications that involve the use of explosive tools include mining applications and seismic applications. Similar types of safety concerns exist with such other types of explosive tools. Thus, a need continues exist to enhance the safety associated with the use of explosive tools as well as with other types of tools. Also, a need continues to exist to enhance the flexibility of controlling the operation of such explosive tools.
SUMMARY OF THE INVENTION
In general, an improved method and apparatus is provided to enhance the safety and flexibility associated with use of a tool. For example, a method of activating a tool includes checking an authorization code of a user to verify that the user has access to activate the tool. In addition, data pertaining to an environment around the tool is received. Activation of the tool is enabled in response to the authorization code and the data indicating that the environment around the tool meets predetermined one or more criteria for activation of the tool.
Other or alternative features will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is block diagram of an example arrangement of control systems, sensors, and a downhole well tool.
FIG. 2 is a block diagram of a perforating tool, according to one embodiment, that can be used in the system of FIG. 1 .
FIGS. 3A-3B are a flow diagram of a process performed by a surface unit in accordance with an embodiment.
FIGS. 4 and 5 illustrate processes for secure and interactive activation of a perforating tool.
FIG. 6 is a block diagram of an example test arrangement including a tester box coupled to a tool under test, and a user interface device to control the tester box.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
As used here, the terms “up” and “down”; “upper” and “lower”; “upwardly” and downwardly”; “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
Referring to FIG. 1 , a system according to one embodiment includes a surface unit 100 that is coupled by cable 102 (e.g., a wireline) to a tool 104 . In the example shown in FIG. 1 , the tool 104 is a tool for use in a well. For example, the tool 104 can include a perforating tool or other tool containing explosive devices, such as pipe cutters and the like. In other embodiments, other types of tools can be used for performing other types of operations in a well. For example, such other types of tools include tools for setting packers, opening or closing valves, logging, taking measurements, core sampling, and so forth. In the embodiments described below, safety issues associated with well tools containing explosive devices are discussed. However, similar methods and apparatus can be applied to tools having explosive devices in other applications, e.g., mining, seismic acquisition, surface demolition, armaments, and so forth.
The tool 104 includes a safety sub 106 and a plurality of guns 108 . In one embodiment, the safety sub 106 differs from the gun 108 in that the safety sub 106 does not include explosive devices that are present in the guns 108 . The safety sub 106 serves one of several purposes, including providing a quick connection of the tool 104 to the cable 102 . Additionally, the safety sub 106 allows electronic arming of the perforating tool 104 downhole instead of at the surface. Because the safety sub 106 does not include explosive devices, it provides electrical isolation between the cable 102 and the guns 108 so that electrical activation of the guns 108 is disabled until the safety sub 106 has been activated to close an electrical connection.
In the example of FIG. 1 , the cable 102 is run through a winch assembly 110 , which is coupled to a depth sensor 112 . The depth sensor 112 monitors the rotation of the winch assembly 110 to determine the depth of the perforating tool 104 . The data relating to the depth of the tool 104 is communicated to the surface unit 100 .
In some systems, an internal (hardware or software) drive system can be used to simulate that the tool 104 has descended to a certain depth in the wellbore, even though the tool 104 is still at the earth surface. The depth sensor 112 can be used by the surface unit to verify that the tool 104 has indeed been lowered into the wellbore to a target depth. As a safety precaution, the ability to use the output of the internal hardware or drive system to enable activation of the tool 104 is prohibited.
The perforating tool 104 also includes a number of sensors, such as sensors 114 in the safety sub and sensors 116 in the guns 108 . Although FIG. 1 shows each gun 108 as containing sensors 116 , less than all of the guns can be selected to include sensors in other embodiments.
Data from the sensors 114 and 116 are communicated over the cable 102 to a logging module 120 in the surface unit 100 . The logging module 120 is capable of performing bi-directional communications with the sensors 114 and 116 over the cable 102 . For example, the logging module 120 is able to issue commands to the sensors 114 and 116 to take measurements, and the logging module 120 is then able to receive measurement data from the sensors 114 and 116 . Data collected by the logging module 120 is stored in a storage 122 in the surface unit 100 . Examples of the storage 122 include magnetic media (e.g., a hard disk drive), optical media (e.g., a compact disk or digital versatile disk), semiconductor memories, and so forth. The surface unit 100 also includes activation software 124 that is executable on a processor 126 . The activation software 124 is responsible for managing the activation of the perforating tool 104 in response to user commands. The user commands can be issued from a number of sources, such as directly through a user interface 128 at the surface unit 100 , from a remote site system 130 over a communications link 132 , or from a portable user interface device 134 over a communications link 136 .
In one embodiment, the communications links 132 and 136 include wireless links, in the form of radio frequency (RF) links, infrared (IR) links, and the like. Alternatively, the communications links 132 and 136 are wired links. The surface unit 100 includes a communications interface 138 for communicating with the user interface device 134 and the remote site system 130 over the respective links. The remote site system 130 also includes a communications interface 140 for communicating over the communications link 132 to the surface unit 100 . Also, the remote site system 130 includes a display 142 for presenting information (e.g., status information, logging information, etc.) associated with the surface unit 100 .
The user interface device 134 also includes a communications interface 144 for communicating over the communications link 136 with the surface unit 100 . Additionally, the user interface device 134 includes a display 146 to enable the user to view information associated with the surface unit 100 . An example of the user interface device 134 is a personal digital assistant (PDA), such as a PALM® device, a WINDOWS® CE device, or other like device. Alternatively, the user interface device 134 includes a laptop or notebook computer.
In accordance with an embodiment, a security feature of the surface unit 100 is a smart card interface 148 for interacting with a smart card of a user. The smart card interface 148 is capable of reading identification information of the user (e.g., a digital signature, a user code, an employee number, and so forth). The activation software 124 uses this identification information to determine if the user is authorized to access the surface unit 100 and to perform activation of the perforating tool 104 . The identification information is part of the “authorization code” provided by a user to gain access to the surface unit 100 .
A smart card is basically a card with an embedded processor and storage, with the storage containing various types of information associated with a user. Such information includes a digital signature, a user profile, and so forth.
In an alternative embodiment, instead of a smart card interface 148 , the surface unit 100 can include another type of security feature, such as providing a prompt in which a user has to enter his or her user name and password. In yet another embodiment, the security mechanism of the surface unit 100 includes a biometric device to scan a biometric feature (e.g., fingerprint) of the user. The user interface device 134 can similarly include a smart card reader or biometric input device.
Alternatively, the user enters information and commands using either the user interface device 134 or the remote site system 130 . The user interface device 134 may itself store an authorization code, such as in the form of a user code, digital signature, and the like, that is communicated to the surface unit 100 with any commands issued by the user interface device 134 . Only authorized user interface devices 134 are able to issue commands that are acted on by the surface unit 100 . Although not shown, the user interface device 134 can optionally include a smart card interface to interact with the smart card of the user.
In the example shown, the remote site system 130 also includes a smart card interface 150 . Thus, before a user is able to issue commands from the remote site system 130 to the surface unit 100 to perform various actions, the user must be in possession of a smart card that enables access to the various features provided by the surface unit 100 .
In this way, the surface unit 100 cannot be accessed by unauthorized users. Therefore, safety problems associated with the unauthorized use of the perforating tool 104 is avoided.
Another safety feature offered by the perforating tool 104 is that each of the guns 108 is associated with a unique code or identifier. This code or identifier must be issued by the surface unit 100 with an activate command for the gun 108 to be activated. If the code or identifier is not provided, then the gun 108 cannot be fired. Thus, if the perforating tool 104 is stolen or is lost, unauthorized users will not be able to activate the guns 108 since they do not know what the codes or identifiers are. The safety sub 106 is also associated with a unique code or identifier that must be received by the safety sub 106 for the safety sub 106 to be activated to electrically arm the perforating tool 104 .
Another feature allowed by using unique codes or identifiers for the guns 108 is that the guns can be traced (to enable the tracking of lost or misplaced guns). Also, the unique codes or identifiers enable inventory control, allowing a well operator to know the equipment available for well operations.
Yet another safety feature associated with the guns 108 according to one embodiment is that they use exploding foil initiators (EFIs), which are safe in an environment in which wireless signals, such as RF signals, are present. As a result, this feature of the guns 108 enables the use of RF communications between the surface unit 100 and the remote site system 130 and with the user interface device 134 . However, in other embodiments, conventional detonators can be used in the perforating tool 104 , with precautions taken to avoid use of RF signals. The EFI detonator is one example of an electro-explosive device (EED) detonator, with other examples including an exploding bridge wire (EBW) detonator, semiconductor bridge detonator, hot-wire detonator, and so forth.
Another feature offered by the surface unit 100 according to some embodiments is the ability to perform “interactive” activation of the perforating tool 104 . The “interactive” activation feature refers to the ability to communicate with the sensors 114 and/or 116 in the perforating tool 104 before, during, and after activation of the perforating tool 104 . For example, the sensors 114 and/or 116 are able to take pressure measurements (to determine if an under balance or over balance condition exists prior to perforating), take temperature measurements (to verify explosive temperature ratings are not exceeded), and take fluid density measurements (to differentiate between liquid and gas in the wellbore). Also, the surface unit 100 is able to interact with the depth sensor 112 to determine the depth of the perforating tool 104 . This is to ensure that the perforating tool 104 is not activated prior to it being at a safe depth in the wellbore. As an added safety precaution, a user will be prevented from artificially setting the depth of the perforating tool below a predetermined depth for test purposes. In some systems, such a depth can be set by software or hardware to simulate the tool being in the wellbore. However, due to safety concerns, artificially setting the depth to a value where a gun is allowed to be activated is prohibited.
The sensors 114 and/or 116 may also include voltage meters to measure the voltage of the cable 102 at the upper head of the perforating tool 104 , the voltages at the detonating devices in the respective guns 108 , the amount of current present in the cable 102 , the impedance of the cable 102 and other electrical characteristics. The sensors may also include accelerometers for detecting tool movement as well as shot indication. Shot indication can be determined from waveforms provided by accelerometers over the cable 102 to the surface unit 100 . Alternatively, the waveform of the discharge voltage on the cable 102 can be monitored to determine if a shot has occurred.
The sensors 114 and/or 116 may also include moisture detectors to detect if excessive moisture exists in each of the guns 108 . Excessive moisture can indicate that the gun may be flooded and thus may not fire properly or at all.
The sensors may also include a position or orientation sensor to detect the position or orientation of a gun in well, to provide an indication of well deviation, and to detect correct positioning (e.g., low side of casing) before firing the gun. Also, the sensors may include a strain-gauge bridge sensor to detect external strain on the perforating tool 104 that may be due to pulling or other type of strain on the housing or cable head of a gun that is stuck in the well. Other types of sensors include acoustic sensors (e.g., a microphone), and other types of pressure gauges.
Other types of example sensors include equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, scale detectors, viscosity sensors, density sensors, bubble point sensors, composition sensors, infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, casing collar locators, and so forth.
One of the aspects of the sensors 116 is that they are destroyed with firing of the guns 108 . However, the sensors 114 in the safety sub 106 may be able to survive detonation of the guns 108 . Thus, these sensors 114 can be used to monitor well conditions (e.g., measure pressure, temperature, and so forth) before, during, and after a perforating operation.
In addition to the sensors that are present in the perforating tool 104 , other sensors 152 can also be located at the earth surface. The sensors 152 are able to detect shock or vibrations created in the earth due to activation of the perforating tool 104 . For example, the sensors 152 may include geophones. The sensors 152 are coupled by a communications link 154 , which may be a wireless link or a wired link, to the surface unit 100 . Data from the sensors 152 to the surface unit 100 provide an indication of whether the perforating tool 104 has been activated.
The safety sub 106 and guns 108 of the perforating tool 104 are shown in greater detail in FIG. 2 . In the example shown in FIG. 2 , the safety sub 106 includes a control unit 14 A, and the guns 108 include control units 14 B, 14 C. Although only two guns 108 are shown in the example FIG. 2 , other embodiments may include additional guns 108 . Each control unit 14 is coupled to switches 16 and 18 (illustrated at 16 A- 16 C and 18 A- 18 C). The switches 18 A- 18 C are cable switches that are controllable by the control units 14 A- 14 C, respectively, between on and off positions to enable or disable current flow through portions of the cable 102 . When the switch 18 is off, then the portion of the cable 102 below the switch 18 is isolated from the portion of the cable 102 above the switch 18 . The switches 16 A- 16 C are detonating switches.
In the safety sub 106 , the detonating switch 16 A is not connected to a detonating device. However, in the guns 108 , the detonating switches 16 B, 16 C are connected to detonating devices 22 B, 22 C, respectively. If activated to an on position, a detonating switch 16 allows electrical current to flow to a coupled detonating device 22 to activate the detonating device. The detonating device 22 B, 22 C includes an EFI detonator or other detonators. The detonating devices 22 B, 22 C are ballistically coupled to explosives, such as shaped charges or other explosives, to perform perforating.
As noted above, the safety sub 106 provides a convenient mechanism for connecting the perforating tool 104 to the cable 102 . This is because the safety sub 106 does not include a detonating device 22 or any other explosive, and thus does not pose a safety hazard. The switch 18 A of the safety sub 106 is initially in the open position, so that all guns of the perforating tool 104 are electrically isolated from the cable 102 by the safety sub 106 . Because of this feature, electrically arming of the perforating tool 104 does not occur until the perforating tool 104 is positioned downhole and the switch 18 A is closed.
Another feature allowed by the safety sub 106 is that the guns 108 can be pre-armed (by connecting each detonating device 22 in the gun 108 ) during transport or other handling of the perforating tool 104 . Thus, even though the perforating tool 104 is transported ballistically armed, the open switch 18 A of the safety sub 106 electrically isolates the guns 108 from any activation signal during transport or other handling.
FIGS. 3A-3B are a flow diagram of a tool activation process, which is performed by the activation software 124 according to one embodiment. Before access is provided for activating the perforating tool 104 , the activation software 124 checks (at 202 ) if an authorization code has been received. The authorization code includes a digital signature, a user code, a user name and password, or some other code. The authorization code can be stored on a smart card and communicated to the surface unit 100 through the smart card interface 148 . Alternatively, the authorization code can be manually entered by the user through a user interface.
If an authorization code has been received and verified, the activation software 124 determines (at 204 ) the level of access provided to the user. Users are assigned a hierarchy of usage levels, with some users provided with a higher level of access while others are provided with a lower level of access. For example, a user with a higher level of access is authorized to activate the perforating tool to fire guns. A user with a lower access level may be able only to send inquiries to the perforating tool to determine the configuration of the perforating tool, and possibly, to perform a test of the perforating tool (without activating the detonating devices 22 in the perforating tool 104 ).
The activation software 24 also checks (at 206 ) for a depth of the perforating tool 104 in the well. Activation of the perforating tool 104 is prohibited unless the perforating tool 104 is at the correct depth. While the perforating tool 104 is not at a correct depth, as determined (at 208 ), further actions are prevented. However, once the perforating tool 104 is at the correct depth, the activation software 124 performs (at 210 ) various interrogations of control units 14 in the perforating tool 100 . Interrogations may include determining the positions of switches 16 and 18 in the perforating tool 104 , the status of the control unit 14 , the configuration and arrangement of the perforating tool 104 (e.g., number of guns, expected identifications or codes of each control unit, etc.), and so forth.
Once the status information has been received from the perforating tool 104 , the activation software 124 compares (at 212 ) the information against an expected configuration of the perforating tool 104 . Based on the interrogations and the comparison performed at 210 and 212 , the activation software 124 determines (at 214 ) if the perforating tool 104 is functioning properly or is in the proper configuration. If not, then the activation process ends with the tool 104 remaining deactivated. However, if the tool is determined to be functioning properly and in the expected configuration, the activation software 124 waits (at 216 ) for receipt of an arm command from the user. The arm command can be provided by the user through the user interface 128 of the surface unit 100 , through the user interface device 134 , or through the remote site system 130 .
Upon receipt of the arm command, the activation software 124 checks (at 218 ) the depth of the perforating tool 104 again. This is to ensure that the perforating tool 104 has not been raised from its initial depth.
Next, the activation software 124 checks (at 220 ) for various downhole environment conditions, including pressure, temperature, the presence of gas or liquid, the deviation of the wellbore, and so forth.
If the proper condition is not present, as determined at 224 , the activation software 124 communicates (at 226 ) an indication to the user, such as through the user interface 128 of the surface unit 100 , the display 146 of the user interface device 134 , or the display 142 of the remote site system 130 . Arming is prohibited.
However, if the condition of the well and the position of the perforating tool 104 is proper, the activation software 124 issues an arm command (at 228 ) to the perforating tool 100 . The arm command is received by the safety sub 106 , which closes the cable switch 18 A in response to the arm command. Optionally, the cable switches 18 B, 18 C can also be actuated closed at this time.
The activation software 124 waits (at 230 ) for receipt of an activate command from the user. Upon receipt of the activate command, the activation software 124 re-checks (at 232 ) the environment conditions and the depth of the penetrating tool. The activation software 124 also checks (at 234 ) the gun position and orientation. It may be desirable to shoot the gun at a predetermined angle with respect to the vertical. Also, the shaped charges of the perforating tool 104 may be oriented to shoot in a particular direction, so the orientation has to be verified.
If the environment condition and gun position is proper, as determined at 236 , the activation software 124 sends (at 238 ) the activate command to the perforating tool 104 . The activate command may be encrypted by the activation software 124 for communication over the cable 102 . The control units 14 in the perforating tool 104 are able to decrypt the encrypted activate command. In one embodiment, the activate command is provided with the proper identifier code of each control unit 14 . Each control unit 14 checks this code to ensure that the proper code has been issued before activating the appropriate switches 16 and 18 to fire the guns 108 in the perforating tool 104 .
In one sequence, the guns 108 of the perforating tool 104 are fired sequentially by a series of activate commands. In another sequence, the activate command is provided simultaneously to all guns 108 , with each gun 108 preprogrammed with a delay that specifies the delay time period between the receipt of the activate command and the firing of the gun 108 . The delays in plural guns 108 may be different.
During and after activation of the perforating tool 104 , measurement data is collected (at 240 ) from the various sensors 114 , 116 , and 152 . The collected measurement data is then communicated (at 242 ) to the user.
FIG. 4 illustrates a flow diagram of a process of performing secure activation of an explosive tool, such as the perforating tool 104 , according to one embodiment. A central management site (not shown) provides (at 302 ) a profile of a user that includes his or her associated identifier, authorization code, personal identification number (PIN) code, digital signature, and access level. This profile is loaded as a certificate (at 304 ) into the surface unit 100 , where it is stored in the storage 122 . During use, a user inserts (at 306 ) his or her smart card into the smart card interface 148 of the surface unit 100 . The surface unit 100 may prompt for a PIN code through the user interface 128 , which is then entered by the user. The surface unit 100 checks (at 308 ) to ensure that a user is authorized to use a system based on the stored certificate and notifies the user of access grant.
Next, the user requests (at 310 ) arming of the perforating tool 104 , which is received by the surface unit 100 . In response, as discussed above, the surface unit 100 checks (at 312 ) the depth of the perforating tool 104 and the data from other sensors from the perforating tool 104 to determine if the perforating tool 104 is safe to arm.
The user then issues a fire command (at 314 ), which is received by the surface unit 100 . The surface unit 100 then checks (at 316 ) that the perforating tool 104 is safe to activate, and if so, sends an encrypted activate command to the perforating tool 104 .
The control unit 14 A in the safety sub 106 stores a private key at manufacture. This private key is used by the control unit 14 A in the safety sub 106 to decrypt the activate command (at 318 ). The decrypted activate command is then forwarded to the guns 108 to fire the guns.
FIG. 5 illustrates a flow diagram of a process of remotely activating the perforating tool 104 . In the context of FIG. 1 , the remote activation is performed by a user at the remote site system 130 . In the example of FIG. 5 , two users are involved in remotely activating the perforating tool 104 , with user 1 at the well site and user 2 at the remote site system 130 . As before, a central management system authorizes user names and their associated information and access levels (at 302 ) and communicates certificates containing the profiles (at 404 ) to the surface unit 100 and to the remote site system 130 for storage.
At the surface unit 100 , user 1 inserts (at 406 ) his or her smart card into the surface unit 100 , along with the user's PIN code, to request remote arming and activation of the perforating tool 104 . This indication is communicated (at 408 ) from the surface unit 100 to the remote site system 130 over the communications link 132 . User 1 also verifies (at 407 ) that all is safe and ready to fire at the surface unit 100 .
User 2 inserts his or her smart card into the smart card interface 150 of the remote site system 130 to gain access to the remote site system 130 . Once authorized, user 2 requests (at 410 ) arming of the perforating tool 104 . The surface unit 100 checks (at 412 ) that user 2 is authorized by accessing the certificate stored in the surface unit 100 . This check can alternatively be performed by the remote site system 130 .
The surface unit 100 then checks (at 414 ) the depth of the perforating tool 104 along with data from other sensors of the perforating tool 104 to ensure that the perforating tool 104 is safe to arm. Once the verification has been performed and communicated back to the remote site system 130 , user 2 issues an activate command (at 416 ) at the remote site system 130 . The surface unit 100 checks (at 418 ) to ensure that the perforating tool 104 is safe to activate, and then sends an encrypted activate command. The encrypted activate command is received by the safety sub 106 , with the encrypted activate command decrypted (at 420 ) by the control unit 14 A in the safety sub 106 .
According to some embodiments of the invention, another feature is the ability to test the perforating tool 104 to ensure the perforating tool 104 is functioning properly. The test can be performed at the well site or at an assembly shop that is remote from the well site. To do so, as shown in FIG. 6 , a tester box 500 is coupled to the perforating tool 104 over a communications link 502 through a communications interface 504 . If the test is performed at the well site, the tester box 500 can be implemented in the surface unit 100 . At the assembly shop or at some other location, the tester box 500 is a stand-alone unit. The tester box 500 includes a communications port 503 that is capable of performing wireless communications with communications port 144 in the user interface device 134 . The communications can be in the form of IR communications, RF communications, or other forms of wireless communications. The communications between the user interface device 134 and the tester box 500 can also be over a wired link.
In one embodiment, various graphical user interface (GUI) elements (e.g., windows, screens, icons, menus, etc.) are provided in the display 146 of the user interface device 134 . The GUI elements include control elements such as menu items or icons that are selectable by a user to perform various acts. The GUI elements also include display boxes or fields in which information pertaining to the perforating tool 104 is displayed to the user.
In response to user selection of various GUI elements, the user interface device 134 sends commands to the tester box 500 to cause a certain task to be performed by control logic in the tester box 500 . Among the actions taken by the tester box 500 is the transmission of signals over the cable 502 to test the components of the perforating tool 104 . Feedback regarding the test is communicated back to the tester box 500 , which in turn communicates data over the wireless medium to the user interface device 134 , where the information is presented in the display 146 . As an added safety feature, the tester box 500 can also include a smart card reader or biometric input device to verify user authorization.
A more detailed description of the tester box 500 and components in the perforating tool 104 to enable this testing feature is discussed in greater detail in U.S. Ser. No. 09/997,021, entitled “Communicating with a Tool,” filed Nov. 28, 2001, which is hereby incorporated by reference.
The various systems and devices discussed herein each includes various software routines or modules. Such software routines or modules are executable on corresponding control units or processors. Each control unit or processor includes a microprocessor, a microcontroller, a processor card (including one or more microprocessors or microcontrollers), or other control or computing devices. As used here, a “controller” refers to a hardware component, software component, or a combination of the two. Although used in the singular sense, a “controller” can also refer to plural hardware components, plural software components, or a combination thereof.
The storage devices referred to in this discussion include one or more machine-readable storage media for storing data and instructions. The storage media include different forms of memory including semiconductor memory devices such as dynamic or static random access memories (DRAMs or SRAMs), erasable and programmable read-only memories (EPROMs), electrically erasable and programmable read-only memories (EEPROMs) and flash memories; magnetic disks such as fixed, floppy and removable disks; other magnetic media including tape; and optical media such as compact disks (CDs) or digital video disks (DVDs). Instructions that make up the various software routines or modules in the various devices or systems are stored in respective storage devices. The instructions when executed by a respective control unit or processor cause the corresponding node or system to perform programmed acts.
The instructions of the software routines or modules are loaded or transported to each device or system in one of many different ways. For example, code segments including instructions stored on floppy disks, CD or DVD media, a hard disk, or transported through a network interface card, modem, or other interface device are loaded into the device or system and executed as corresponding software routines or modules. In the loading or transport process, data signals that are embodied in carrier waves (transmitted over telephone lines, network lines, wireless links, cables, and the like) communicate the code segments, including instructions, to the device or system. Such carrier waves are in the form of electrical, optical, acoustical, electromagnetic, or other types of signals.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention. | A tool activation system and method includes receiving an authorization code of a user to verify access rights of a user to activate the tool. In one example, the authorization code is receive from a smart card. The environment around the tool, which can be in a wellbore, for example, is checked. In response to the authorization code and the checking of the environment, activation of the tool is enabled. |
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FIELD OF THE INVENTION
This invention relates generally to tile and masonry installation; and specifically to a method and framework for installing tiles.
BACKGROUND OF THE INVENTION
The building industry has long used various types of tiles in construction projects. Tiles come in many forms and are manufactured from various types of materials, in a wide variety of colors and surface textures. For example, ceramic tile is often used in bathroom applications. Marble tile is often used for flooring and other decorative applications.
Better techniques for installation of tiles have evolved over time. In fact, many patents that describe installation techniques have been granted. Most of these evolutions in tile installation techniques have been developed in response to the inadequacy of former installation methods. One common problem with installation of any tile is the fact that individual tiles need to be aligned relative one to another. In response to this problem, prior art methods for installation of tile include methods where spacers are introducing between individual tiles in order to ensure uniform tile installation. In fact, all of the known art addresses this major problem. Various techniques for the installation of tile spacers have been devised including the use of a pre-fabricated lattice that can be placed on an installation surface. Once the pre-fabricated lattice is installed, individual tiles may be secured into the lattice resulting in a clean, uniform installation. Of course, all of these prior art methods require the use of a mortar in order to secure an individual tile to the installation surface. Additional mortar (i.e. “grout”) is then used to fill the interspatial gap in between individual tiles.
These prior art methods fail to address some other major problems associated with the installation of tile in typical construction applications. One such problem is the need to easily replace an individual tile if it where to be inadvertently damaged. Yet another problem is that all known tile installation techniques apply an individual tile to a installation surface that is, in many cases, a cold concrete slab. Hence, a tile floor constructed according to conventional wisdom results in a cold, heat-sunk surface.
SUMMARY OF THE INVENTION
The present invention comprises a method for installing tiles that results in much warmer floor when compared to tile floors constructed according to prior art techniques. According to one example method, a support is provided substantially around the outer perimeter of a tile. This support is typically provided within the footprint of the tile. According to this method, a border is also provided around the tile. This border eliminates the need for tile grout. According to the method, the support holds the tile up off of an installation surface (e.g. a concrete slab). Because the tile is supported off from the installation surface, it is easily replaced in the event of damage. Also, heat is retained by the tile because it does not come in contact with the installation surface. This results in a “warmer” tile floor.
According to one variation of the present method, a support may be provided for a tile by placing a first railing that has a first end. A second railing may be attached orthogonally to the first railing. The position of the second railing is adjusted along the length of the first railing so as to accommodate a tile of a particular dimension. According to yet another alternative method, a third railing is also orthogonally attached to the first railing. The position of the third railing relative to the second railing is then adjusted to accommodate a tile of a particular dimension. According to yet another variation of the present method, the second railing may be attached to the first railing by mating a slide bushing on the second railing with a linear trackway on the first railing.
In one variation of the present method, support proximate to the outer perimeter of the tile is provided by a ledge along the first railing. According to yet another variation of the present method, a border may be provided by providing a raised surface along the first railing that is an opposition to a support ledge. According to yet another variation of the present method, drainage is provided across the border and the support. Yet another variation of this method, airflow is provided across the border and the support.
The present invention further comprises a an alternative method for installing tiles the comprises the provision of a plurality of railings each having end connectors and the provision of a plurality of railing ties each of which has at least two railing connectors. The railings, according to this alternative method, a been attached to the railing ties in order to form a receptacle. Tiles may then be installed in the receptacle.
The present invention further comprises a tile installation fixture. According to one embodiment of the invention, a tile installation fixture comprises a linear support having top and bottom surfaces and a border also having top and bottom surfaces. The border is a collinear with the linear support. According to one alternative example embodiment of the invention, the tile installation picture further comprises a linear attachment trackway disposed in a collinear manner to the linear support. According to one illustrative embodiment of invention, the linear attachment trackway is formed by a notch that is set collinearly in the top surface of the linear support. According to yet another alternative embodiment of the invention, the tile installation picture further comprises the orifice that leads for the top surface to the bottom surface of the linear support. This orifice may serve as a drainage for any moisture that may collect at the surface of the linear support or in any notch that may form a linear trackway is said linear support.
According to one alternative embodiment of the invention, the tile installation fixture further comprises a slide bushing data substantially perpendicular to the linear support. Generally, this slide bushing is disposed at one end of the tile installation fixture in may be embodied as a finger set orthogonal to the linear support and oriented downward from the top surface of the border. According to yet another alternative embodiment of the invention, the tile installation fixture further comprises an airflow pathway that is notch into the bottom surfaces of the linear support and the border. This pathway is set orthogonal to the linear support.
The present invention further comprises a tile installation railing tie. Such tile installation railing tie comprises at least two railing connectors and a border disposed between said two railing connectors. Generally, railing ties may be used to hold railings together to form a receptacle capable of receiving a tile.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects are better understood from the following detailed description of one embodiment of the invention with reference to the drawings, in which:
FIG. 1 is a flow diagrams that depicts one example method for installing tiles according to the present invention;
FIG. 2 is a flow diagram that depicts one alternative example method for providing a support proximate to the outer perimeter of a tile;
FIG. 3 is a flow diagram that depicts one alternative method for installing tiles;
FIG. 4 is a pictorial diagram that illustrates the installation of tiles in a lattice of tile receptacles according to the present invention;
FIG. 5 is a pictorial diagram that illustrates the installation of a tile into a receptacle according to method of the present invention;
FIGS. 6 through 9 are pictorial diagrams that illustrate one example embodiment of an attachment means for orthogonally attaching one railing to another according to the present invention;
FIG. 10 is a pictorial diagram that depicts a rail tie that can be used to tie rails together according to the method of the present invention; and
FIG. 11 is a pictorial diagram of a tile installation fixture comprising drainage and airflow paths according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a flow diagrams that depicts one example method for installing tiles according to the present invention. According to this example method, tiles may be installed in a lattice of receptacles wherein each receptacle is formed by providing a support proximate to the outer perimeter of the tile (step 5 ). Each of said tiles typically have a top and bottom surface and an outer perimeter. According to one example embodiment, the support is provided within the footprint of the tile. According to this method, a border is provided around the tile (step 10 ). This border may be of any width and typically eliminates the need for tile grout. The support generally provides an offset for an installed tile and prevents the bottom surface of the tile from contacting a substrate (e.g. a concrete slab). Hence, the support is generally disposed in between the bottom surface of the tile and an installation substrate. Since the tile is not adhered to the installation substrate, it may be easily removed in the event that an individual tile is damaged through either ordinary or extraordinary use. According to one alternative method, adhesive may be introduced between the top surface of the support and the bottom of the tile placed thereon. This precludes inadvertent movement of the tile or accidental discharge from the receptacle.
According to one variation of this method, airflow is provided between receptacles by providing an airflow pathway across the support and the border (step 15 ). According to yet another variation of this method, a drainage path is provided through the support (step 20 ). This drainage path allows moisture that may accumulate at the top surface of the support to drain downward.
FIG. 2 is a flow diagram that depicts one alternative example method for providing a support proximate to the outer perimeter of a tile. According to this alternative method, a support is provided by placing a first rail (step 25 ) onto an installation substrate. A second rail is orthogonally attached to the first rail (step 30 ). The position of the second rail along the first rail is then adjusted. This may be accomplished in order to accommodate a tile of a particular dimension. According to one alternative variation of this illustrative method, a third rail is orthogonally attached to the first rail (step 40 ). The position of the third rail along the first rail is then adjusted to accommodate a tile of a particular dimension (step 45 ).
According to one variation of this illustrative method, attachment of the second railing to the first railing may be a cottage by mating a slide bushing on the second railing with a linear trackway on the first railing. According to yet another variation of this illustrative method, a support proximate to be outer brother of the tile may be provided by means of a ledge running along the first rail. According to yet another variation of this method, a border may be provided by means of a raised surface that also runs along the railing alongside the ledge comprising the support.
FIG. 3 is a flow diagram that depicts one alternative method for installing tiles. According to this example method, a lattice of tile receptacles is established by providing a plurality of railings (step 50 ) and a plurality of railing ties (step 55 ). The railings are then attached to the railing ties to form a lattice (step 60 ). Individual tiles may then be installed into resulting lattice of tile receptacles.
FIG. 4 is a pictorial diagram that illustrates the installation of tiles in a lattice of tile receptacles according to the present invention. Railings 70 , which are also known as tile installation fixtures, are attached to other railings to form receptacles capable of receiving a tile 75 . According to this exemplary embodiment, the railings form a herringbone pattern where one railing 80 is orthogonally attached approximately mid-span to an adjoining railing 70 .
FIG. 5 is a pictorial diagram that illustrates the installation of a tile into a receptacle according to method of the present invention. According to this example embodiment, a tile 75 is installed into a receptacle 90 . The receptacle 90 is generally formed by railings 70 substantially about the outer perimeter of the tile 75 . Note that the railings typically comprise a tile support 95 and a border 100 .
FIGS. 6 through 9 are pictorial diagrams that illustrate one exemplary embodiment of an attachment means for orthogonally attaching one railing to another according to the present invention. According to one exemplary embodiment of the present invention, a first tile installation fixture 125 comprises a tile support 95 and a border 100 . Generally, both the tile support 95 and the border 100 have top and bottom surfaces. According to this exemplary embodiment, the tile installation fixture 125 may be installed on a substrate 101 wherein the bottom surface of both the tile support 95 and the border 100 contact the substrate 101 .
The tile support 95 is set colinear with the border 100 . The top surface of the tile support 95 is at lower elevation relative to the top surface of the border 100 . The difference in the elevation between the top surface of the border 100 and the linear support 95 is typically set to the thickness of a particular tile. Hence, once a tile is positioned on the tile support 95 , the top surface of the tile will finish substantially flush with the top surface of the border 100 .
First tile installation fixture 125 is typically placed onto the substrate 101 and a second tile installation fixture 130 is then attached orthogonally to the first fixture 125 . According to one exemplary embodiment of the present invention, the orthogonal attachment is accomplished by means of a linear attachment trackway. Hence, according to this exemplary embodiment of the present invention, the first fixture 125 comprises a linear attachment trackway 105 . According to one alternative exemplary embodiment, the linear attachment trackway 105 comprises a notch colinearly disposed into the top surface of the tile support 95 .
According to this exemplary embodiment, the second rail 130 comprises a slide bushing 117 ( FIG. 8 ) oriented substantially perpendicular to the tile support 95 . The slide bushing 117 ( FIG. 8 ), according to one alternative embodiment of the invention, comprises a finger that protrudes downward from the top surface of the border of second rail 130 . As depicted in the figure, the bottom surface of the border is itself partially notched at the end of the tile installation fixture in order to form the finger 110 . According to yet another exemplary embodiment, the slide bushing further comprises a carrier slot 115 that is also formed by a deeper notch into the bottom surface of the border. This carrier slot 115 is disposed in between the finger 110 and the main body of the border of second rail 130 . It is important to note that the finger and the carrier slot are typically sized according to a corresponding linear trackway 105 , which, according to one embodiment, comprises a notch in the tile support 95 .
In application, the finger 110 and the carrier slot 115 that form the slide bushing 117 disposed at the end of second railing 130 interlock 111 (as shown in FIG. 9 ) with the linear trackway 105 of first railing 125 . Those skilled in the art will recognize that any suitable linear trackway and slide bushing structure may be utilized in order to orthogonally attach the first railing 125 to the second railing 130 and that the scope of the present invention is not intended to be limited to any particular exemplary embodiment herein described. Once the attachment is made, the position 131 ( FIG. 6 ) of the second railing 130 along the first railing 125 can be adjusted to accommodate the dimension of a particular type of tile.
FIG. 10 is a pictorial diagram that depicts a rail tie that can be used to tie rails together according to the method of the present invention. According to one alternative embodiment of the invention, a tile installation rail tie comprises at least two railing connectors 150 and a border 130 . Individual railings can be attached to the rail tie using the slide bushing 117 ( FIG. 8 ) comprising one end of the railing. Hence, according to this embodiment, the railing connectors mimic a linear trackway 135 normally found as a colinear feature of a railing, i.e. tile installation fixture of the present invention.
FIG. 11 is a pictorial diagram of a tile installation fixture comprising drainage and airflow paths according to the present invention. According to one illustrative embodiment, a railing 185 comprises an airflow path 190 . This may comprise a slot cut into the lower surface of the railing 185 orthogonal to the linear support comprising the railing. According to one alternative embodiment of a tile installation railing, a drainage orifice 195 is included in the invention. Such an orifice provides for the drainage of moisture from the support surface of the railing. In one exemplary embodiment, the drainage orifice 195 is disposed in a linear attachment trackway 105 embodied as a notch in a linear support surface. Hence, moisture accumulations in said trackway are drained downward towards the base (i.e. lower surface) of the railing and onto substrate 180 ( FIG. 11 ).
In all of the embodiments henceforth described, tile installation fixtures (i.e. railings) may be fabricated from any suitable material. For example wood or plastic may be used to fabricate the tile installation fixtures. Selection of proper material relies on the ability of the material to hold a form while supporting normal tile floor loading. This typically requires that the material exhibit a high strength when subject to compression loading.
ALTERNATIVE EMBODIMENTS
While this invention has been described in terms of several preferred embodiments, it is contemplated that alternatives, modifications, permutations, and equivalents thereof will become apparent to those skilled in the art upon a reading of the specification and study of the drawings. It is therefore intended that the true spirit and scope of the present invention include all such alternatives, modifications, permutations, and equivalents. | A lattice of support surfaces are used to support substantially the perimeter of a construction tile. The support surface is made integral with a decorative border. Linear railways attach orthogonally to other railways to form the lattice. Tiles are set into the lattice providing a warmer installation relative to installation over concrete tile foundation. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of co-pending U.S. patent application Ser. No. 11/328,554, filed Jan. 10, 2006, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to slide and hinge suspension systems for supporting cabinet doors. More particularly, the present invention relates to a hinge bracket for use in converting common pocket door slide systems from achieving an inset or a partial overlay configuration when the door is in a closed position to achieving a full overlay configuration when the door is in a closed position.
[0004] 2. Description of the Related Art
[0005] It has become more common for cabinets to be used as entertainment centers to house televisions or other audio and/or visual equipment. The design of such cabinets has evolved into a fairly common style of product. Entertainment centers often comprise an upright cabinet that may be camouflaged by style and finish to appear as though it were one of the existing pieces of furniture in a room.
[0006] This type of cabinet typically has a pair of large doors that enclose a front opening in an upper portion of the cabinet. These doors may be opened to reveal a television set, stereo or other entertainment system that has been conveniently hidden from view until it is desired to be used. Many times, these cabinets are found in hotel rooms where they combine a series of drawers within a lower portion of the same cabinet, providing storage as well as the provisions for the entertainment center.
[0007] Because it has been found to be desirable to keep the components of the entertainment center out of sight when not in use, the doors that are found on such cabinets provide an important function of concealment. As the design of this type of cabinetry evolved, it was not satisfactory to have the doors merely hinged onto the sides of the cabinet walls because they could rotate back into a semi-closed or fully closed position but would potentially obscure the entertainment center or present an obstacle in proximity of the cabinet.
[0008] As a result, suspension systems for hanging the doors on such cabinets were developed to allow the doors to be hinged to an open position, and thereafter, to traverse rearward into the interior of the cabinet, into a so-called “pocket” space in parallel alignment with the cabinet side walls. The door suspension systems have typically been based upon the usage of drawer slide technology, notably precision drawer slide technology using telescoping slide members and ball or roller bearings, such as is found in office furniture applications and the like, although other more simplistic drawer slides may be used. In the case of such door applications, however, it is necessary to use a specialized slide adapted in a way that allows the door to be mounted to a portion of a sliding element, while at the same time allowing it to hinge when it reaches the fully opened position. In this manner, the functionality of the suspension system provides both a hinged opening and closing relationship relative to the door and the hinge, as well as a translational action between a forward position at a ninety degree angle to the front of the cabinet, and a rearward position within the cabinet body.
[0009] Given their movement and storage position within the cabinet, doors of this type have become known as “pocket doors”. In turn, the slide suspension systems that support each pocket door in these applications have become known as “pocket door slides”.
[0010] A number of pocket door slide systems have been developed in the prior art, with particular structures designed to keep the doors from sagging, racking or otherwise becoming misaligned when in position to be moved rearward into the cabinet or forward out from the cabinet. For instance, there are systems that use a rigid follower strip, anti-racking plate or bar, made for instance of wood, metal or other suitable materials or combinations thereof, and connected to the upper and lower pocket door slides and their hinge mounting assemblies, such as are shown in U.S. Pat. No. 5,108,165, to positively maintain the alignment of such components. Alternatively, there are pocket door slide systems that use a cable system to keep the door aligned by connecting the slide assemblies and their hinges, such as disclosed in U.S. Pat. Nos. 4,974,912 and 5,395,165. Further alternative alignment components for pocket door slide systems are disclosed in U.S. Patent Application Publication US 2004/0046488. These systems utilize rack and pinion components that offer a pair of racks and pinion gears for each slide, which are connected via an axle. While such systems may be constructed in many forms and may be used with a pair of hinges on a standard door, such rack and pinion systems may be constructed to be particularly well suited for maintaining alignment of very large pocket doors that require more than two hinges.
[0011] In all of these or other prior art pocket door slide systems, the slides are typically mounted to the inner surface of the outer side walls of the cabinet. In turn, hinges commonly known as a “Euro-hinge”, manufactured for instance by Arutro Salice S.p.A., typically have either a 35 mm or 40 mm hinge mounting cup, and are mounted to the slides to achieve full inset doors, i.e., doors that when hinged to the closed position are recessed so as to have their front surface be substantially flush with, or in the same plane as, the front edges of the cabinet side walls. These hinges have numerous advantages, including their three-way adjustability and the ability to remove the hinged door easily from the cabinet.
[0012] With full inset doors, a gap exists between the outer edge of each door and the respective adjacent cabinet side wall when the door is in the closed position. In applications where the piece of furniture has a cabinet above drawers and the drawers also are of the inset style, this is acceptable. However, a popular style is full overlay, where the doors and drawers fully overlay the cabinet sides which are typically ¾″ thick. It is desirable to match the pocket doors to the full overlay drawers, but to date, the systems capable of achieving a full overlay for pocket doors when in a closed door position require specialized slide components, or specific components necessary to modify the cabinet, which are unique to a full overlay application, as opposed to using commonly stocked components and cabinet structures from an inset system.
[0013] An example of a system having specialized slide components is disclosed in U.S. Patent Application Publication US 2004/0239216. However, such systems are more complicated and expensive. The need to stock specialized slides, which are a fairly costly part of a pocket door slide system, just for use in full overlay pocket door applications, is not desirable.
[0014] Similarly, an example of a cabinet requiring specialized components to modify the cabinet to achieve a full overlay system is disclosed in U.S. Pat. No. 5,108,165. This cabinet system requires specialized columnar frame members to be mounted to an inner cabinet wall to space the entire slide and hinge system from the inner wall, as well as a specific anti-rack plate to achieve the full overlay result. Once again, the specialized nature of the components and mounting is not desirable.
[0015] Alternatively, some systems have attempted to use hinges mounted on a thinly milled wood follower strip to achieve partial pocket door overlay. However, due to the limitations of the wood strength and the need to fasten the hinge bases to the follower strips at the thinned sections, only modest improvement in door overlay has been achieved using these designs. As a result, these modified systems are not capable of achieving a full overlay position, and thus do not cover the entire front edge of the adjacent side wall.
[0016] Therefore, it would be advantageous to be able to convert conventional pocket door slide system hardware, that utilizes relatively standard drawer slides and common Euro-hinge style components regularly stocked by cabinet manufacturers and designed to achieve an inset or partial overlay position, to a system that can alternatively achieve a full overlay position for pocket doors when in the closed position. It also would be advantageous to be able to achieve the full overlay position regardless of which pocket door slide system is used to maintain the door alignment, whether it be of the type which uses an anti-racking bar, cable system, rack and pinion, or other approach to coordinating the movement of the drawer slides.
[0017] It further would be advantageous to be able to utilize a single bracket for all hinge mounting positions, whether on the left or right side of the cabinet and whether it be for use with an upper or lower slide.
[0018] It also would be advantageous to be able to achieve such conversion of hardware, whether the particular application has one or two hinges associated with each slide unit.
[0019] In the full overlay position, each door is positioned to fully cover the front edge of the respective adjacent cabinet side wall. To the knowledge of the inventors, prior to the development of the present invention, the common slides and Euro-hinge style hinges used for inset or partial overlay pocket doors were not able to be conveniently adapted to achieve a full overlay position for pocket doors when hinged to the closed position.
SUMMARY OF THE INVENTION
[0020] The purpose and advantages of the invention will be set forth in or otherwise apparent from the description and drawings that follow, as well as will be learned by practice of the invention.
[0021] The present invention is generally embodied in a hinge bracket attachable to a pocket door slide system wherein the pocket door slide system comprises components capable of achieving a full inset or partial overlay pocket door position without the hinge bracket, and wherein use of the hinge bracket enables the pocket door slide system to achieve a substantially full overlay pocket door position.
[0022] In another aspect of the invention, the hinge bracket has a first planar portion and at least one second planar portion with the first and second planar portions positioned in two spaced apart and substantially parallel planes.
[0023] In a related further aspect of the invention, the hinge bracket has at least one offset portion connecting the first planar portion to a second planar portion.
[0024] In another aspect of the invention, the hinge bracket has a first planar portion located in a first plane and a pair of second planar portions located in a second plane spaced apart from and substantially parallel to the first plane.
[0025] In a related further aspect of the invention, the hinge bracket has a pair of offset portions, wherein each offset portion connects the first planar portion to a second planar portion.
[0026] In yet another aspect of the invention, a pocket door slide system is adapted to mount a door to a cabinet having a side wall wherein when the door is in a closed position an outer edge of the door is substantially in the same plane as an outer surface of the side wall, the pocket door slide system having at least two pocket door slides, each pocket door slide having a slidable member, and a hinge bracket being connectable to the slidable member by at least one fastener at a first location on the hinge bracket and having at least one pair of holes spaced 32 mm apart and being connectable to a respective at least one hinge at a second location on the hinge bracket, wherein the hinge is further adapted to be connected to a door.
[0027] In a related further aspect of the invention, the first location is located on a first planar portion of the hinge bracket and the respective second location is located on a respective second planar portion of the hinge bracket, wherein the first planar portion is in a first plane and the respective second planar portion is in a second plane spaced from and substantially parallel to the first plane.
[0028] In a further related aspect of the invention, the hinge bracket comprises at least two second locations, with each second location being located on a respective second planar portion.
[0029] Thus, the present invention presents an alternative to prior art specialized drawer slide and cabinet components needed to achieve a full overlay position for pocket doors. The present invention also simplifies the structure needed to achieve full overlay pocket doors by using simple hinge brackets to convert conventional pocket door slide system components that were designed for inset or partial overlay doors. With present known Euro-hinge geometry, substantially full overlay may be achieved on cabinets having a side wall thickness of up to approximately ¾″. It will be appreciated that changes in hinge geometry may yield increased or decreased side wall overlay capabilities.
[0030] It is to be understood that both the foregoing general description and the following detailed description are exemplary and provided for purposes of explanation only, and are not restrictive of the invention, as claimed. Further features and objects of the present invention will become more fully apparent in the following description of the preferred embodiments and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In describing the preferred embodiments, reference is made to the accompanying drawing figures wherein like parts have like reference numerals, and wherein:
[0032] FIG. 1 is a front perspective view of a prior art, conventional pocket door slide system for an inset door configuration, as it would be configured with a follower strip alignment system and with the slide mounted to the inner surface of an outer wall of a cabinet.
[0033] FIG. 2 is a front perspective view of a first embodiment in accordance with the invention where a hinge bracket is used with the hardware of each conventional pocket door slide system of FIG. 1 to convert to a full overlay system, wherein the system is shown in relation to a cabinet and the slide is mounted to the outer surface of an inner cabinet wall.
[0034] FIG. 3 is a more isolated front perspective view of the converted pocket door slide system of FIG. 2 with the slide mounted to the outer surface of an inner cabinet wall.
[0035] FIG. 4 is a front perspective view of a second embodiment in accordance with the invention where a hinge bracket is used with the hardware of each conventional pocket door slide system that is configured with a cable alignment system to convert to a full overlay system, and wherein the slide is mounted to the outer surface of an inner cabinet wall.
[0036] FIG. 5 is a front perspective view of a third embodiment in accordance with the invention where a hinge bracket capable of accepting a plurality of hinges is used with the hardware of each conventional pocket door slide system that is configured with a rack and pinion alignment system to convert to a full overlay system, and wherein the slide is mounted to the outer surface of an inner cabinet wall.
[0037] FIG. 6 is a front perspective view of a further embodiment of a hinge bracket in accordance with the invention where the hinge bracket is adapted for use with the hardware of conventional pocket door slide systems and is adapted for mounting a first planar portion to the hinge mounting holes on a slide and a second planar portion is adapted to accept two hinges in a conversion to a full overlay system that uses two hinges per slide.
[0038] FIG. 7 is a front perspective view of yet another embodiment of a hinge bracket in accordance with the invention where the hinge bracket is adapted for use with the hardware of conventional pocket door slide systems and is adapted for mounting a first planar portion to the hinge mounting holes on a slide and a pair of second planar portions are each adapted to accept a hinge in a conversion to a full overlay system that uses two hinges per slide.
[0039] FIGS. 8A-8D are top cross-sectioned views of an embodiment in accordance with the invention showing a pocket door in a series of positions from being moved toward its fully forward position, parallel to the cabinet outer side wall, to hinging to a closed position where it is in a full overlay position relative to the cabinet outer side wall.
[0040] It should be understood that the drawings are not necessarily to scale and provide various views of assemblies that are within the spirit and scope of the invention which may be used in various configurations of pocket door slide systems. While some mechanical details of such systems, including other plan and section views of the particular components, have been omitted, such details are considered well within the comprehension of those skilled in the art in light of the present disclosure. It also should be understood that the present invention is not limited to the preferred embodiments illustrated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] Referring generally to FIG. 2-8D , it will be appreciated that the present invention generally may be embodied within numerous configurations within pocket door slide systems for pocket doors.
[0042] In accordance with FIG. 1 , a prior art conventional pocket door slide system 10 for an inset door configuration is shown. Pocket door slide system 10 includes a pair of complimentary upper and lower slide and hinge systems, one of which will be described in detail for clarity and ease of viewing. However, it will be appreciated by one of skill in the art that the two are complimentary and are essentially configured as a mirror image of each other.
[0043] Thus, pocket door slide system 10 includes slides 12 mounted, such as by conventional screw type fasteners (not shown) to the inner surface I of a right hand outer side wall SW of a cabinet. Slides 12 are shown as having an outer track 14 and an inner slide member 16 which may include, for instance, ball bearing retainers 18 that permit inner slide member 16 to translate forward and rearward with respect to outer track 14 . Pocket door slide system 10 further includes a backing plate 20 mounted to inner slide member 16 , such as by welding at two or more spot welds, or by other suitable fastening means for connection or manufacture of an integral piece.
[0044] To provide the hinge motion necessary to move a door from an open position, parallel to side wall SW, to a closed position, inset and perpendicular to SW, hinges 30 are provided. In this prior art embodiment, system 10 is equipped with Euro-hinge style hinges 30 which are well known in the art. Hinges 30 include a base 32 mounted to backing plate 20 , such as by conventional screw type fasteners 34 , a body 36 connected to base 32 , hinge arms 38 extending from body 36 and connected to a door mounting cup 40 . Door mounting cup 40 is configured to be mounted by conventional means to a recess in a door (not shown) which is conventional in the art. Also of note, the holes through hinge base 32 for mounting to a backing plate typically have a standard spacing of 32 mm apart.
[0045] In order to maintain proper door alignment, system 10 also includes a follower strip 42 or anti-racking plate mounted to backing plates 20 of the upper and lower slide and hinge systems. Follower strip 42 is shown as being made of a solid material, such as wood, for ease of mounting to backing plate 20 with conventional fasteners, such as screws or the like (not shown). Follower strip 42 , which it will be appreciated may be in many different forms, serves to keep inner slide members 16 moving in unison so as to prevent racking of the pocket door.
[0046] This prior art, conventional pocket door slide system 10 , as described, uses conventional slide and hinge components designed to achieve an inset door position when the pocket door is in a fully closed position. As such, when in the closed position, the outer or front surface of the pocket door will be relatively flush with or in the same plane as the front edge of side wall SW. However, as previously mentioned, the door will not match the styling of the full overlay drawers.
[0047] Now turning to FIGS. 2 and 3 , a cabinet C is shown in FIG. 2 having a full overlay pocket door slide system 110 consistent with the present invention. Cabinet C comprises at least a top panel T, a bottom panel B, left and right outer side walls SW, left and right inner walls IW, and left and right pocket doors L and R, respectively. Left and right inner walls IW may be fastened in place within cabinet C in a conventional manner, such as by using L-shaped brackets and conventional screw type fasteners, or by other suitable means. It will be appreciated that each door has a respective system 110 , although the right inner wall effectively hides the right hand system from view. Cabinet C may take many forms, need not be part of an entertainment center, and it will be understood that it generally is representative of the upper portion of an entertainment center having pocket doors.
[0048] As seen in FIGS. 2 and 3 , pocket door slide system 110 also is constructed with upper and lower slides with hinges, one of which will be described in detail for clarity and ease of viewing. Again however, it will be appreciated by one of skill in the art that the two are complimentary and are essentially configured as a mirror image of each other to achieve a pocket door slide system 110 .
[0049] With respect to left door L, system 110 is mounted to the outer surface 0 of left inner wall IW of cabinet C. More particularly, each of the slides 12 of suspension system 110 is mounted, such as by conventional screw type fasteners (not shown) to the outer surface 0 of left hand inner wall IW of cabinet C. Slides 12 may be constructed as described in relation to the prior art conventional slides in FIG. 1 , having an outer track 14 , an inner slide member 16 , and ball bearing retainers 18 . Similarly, suspension system 110 further includes a backing plate 20 mounted to inner slide member 16 , as described in relation to FIG. 1 .
[0050] Each of the slide and hinge systems of pocket door slide system 110 also includes a hinge bracket 60 mounted to backing plate 20 by conventional fasteners. Hinge bracket 60 has first and second planar portions 62 and 64 , and an offset portion 66 connected to and between planar portions 62 and 64 so as to locate planar portions 62 and 64 in spaced apart substantially parallel respective planes. The offset preferably being in the range of 0.59 to 1.13 inches to accommodate common component thicknesses and hinge heights. First planar portion 62 preferably has a pair of mounting holes 68 by which hinge bracket 60 may be mounted to backing plate 20 by conventional fasteners. Mounting holes 68 are preferably in the same configuration as would be the mounting holes of a conventional hinge base 32 , such as with a 32 mm spacing, so that new fastening holes need not be made in backing plate 20 to accommodate the mounting of hinge bracket 60 .
[0051] Pocket door slide system 110 uses the same conventional Euro-hinge style hinges 30 as used in prior art system 10 . However, hinge 30 is mounted to the inner surface of second planar portion 64 , which preferably has a pair of mounting holes 70 to mount hinge 30 by conventional fasteners. To readily accept mounting of hinge base 32 , holes 70 are preferably of the same configuration as the original mounting holes in backing plate 20 , such as 32 mm apart. In addition, respective mounting holes 68 and 70 are preferably aligned, so as to maintain the same fore and aft location of left door L with respect to the slide member, as best seen with respect to backing plate 20 . If respective mounting holes 68 and 70 are aligned and centered with respect to bracket 60 , then bracket 60 will be universally adapted for left and right doors and for both top and bottom slide assemblies. It will be appreciated that if the respective mounting holes 68 and 70 are aligned but not centered with respect to bracket 60 , each upper and lower bracket 60 would be a mirror image of one another, and therefore, it may be preferable to have a tab or other locating feature to assure proper orientation of bracket 60 to prevent improper assembly.
[0052] In this configuration, left door L is then mounted to door mounting cup 40 of hinge 30 in a conventional manner. Pocket door slide system 110 also is able to use the same door alignment hardware as in the prior art system, which includes follower strip 42 mounted to backing plates 20 of the upper and lower slide and hinge systems.
[0053] Thus, it will be appreciated that by using hinge bracket 60 , the mounting of conventional slide and hinge components that are designed for inset pocket door slide systems may be reconfigured to achieve the desired full overlay pocket door slide systems.
[0054] Turning to FIG. 4 , a further embodiment in accordance with the invention is shown. FIG. 4 illustrates that hinge brackets 60 may be used with pocket door slide systems that have alternative door alignment means. For instance, the pocket door slide system 210 of FIG. 4 represents a system that uses conventional prior art slide and hinge components of the type having a cable system 80 to synchronize the upper and lower slide and hinge systems to maintain proper door alignment.
[0055] Accordingly, pocket door slide system 210 also is constructed with upper and lower slide and hinge systems, similar to those in FIGS. 2 and 3 , and would be mounted to outer surface 0 of left inner wall IW of cabinet C. However, pocket door slide system 210 has alternative backing plates 82 , pulleys 84 , cables 86 , forward cable end mountings 88 and rearward cable end mountings (not shown), as substituted for backing plates 20 and follower strip 42 . Thus, by using hinge brackets 60 , pocket door slide system 210 may be converted from the conventional configuration, in which it would be designed to be mounted to the inner surface of an outer side wall and to achieve an inset or partial overlay pocket door position, to a new configuration in which it is mounted to an outer surface of an inner wall and can achieve a full overlay pocket door slide system.
[0056] A further alternative embodiment is shown in FIG. 5 , for use in slide and hinge suspension systems designed to support very large cabinet doors. In FIG. 5 , pocket door slide system 310 is configured to allow a cabinet door to be mounted by four hinges, and incorporates a prior art rack and pinion door alignment system 90 , disclosed in U.S. Patent Application Publication US 2004/0046488, to accommodate the increased mass of a larger door, while still using conventional slide and hinge components.
[0057] As with the other embodiments, pocket door slide system 310 is constructed with upper and lower slide and hinge systems, one of which will be described in detail for clarity and ease of viewing. Once again, it will be appreciated by one of skill in the art that the two are complimentary and are essentially configured as a mirror image of each other.
[0058] Pocket door slide system 310 is shown for use with a left cabinet door. More particularly, each of the slides 12 of system 310 is mounted to the outer surface 0 of a left hand inner wall IW of a cabinet, by similar fastening means to that used with the other embodiments. Slides 12 again may be constructed as described in relation to the prior art conventional slides in FIG. 1 , having an outer track 14 , an inner slide member 16 , and ball bearing retainers 18 .
[0059] In this embodiment, pocket door slide system 310 further includes alternative backing plate 92 mounted to inner slide member 16 , and having an axle or synchronization shaft 94 mounted thereto by means of pillow block type shaft housings 96 . Pinion gears 98 are mounted on axle 94 and engage teeth of rack member 100 which is mounted in cooperation with slide 12 to the outer surface 0 of the left hand inner wall IW. This system also uses an alternative hinge bracket 360 in accordance with the invention to accommodate the mounting of two hinges 30 for each respective slide 12 .
[0060] As shown in FIG. 5 , hinge bracket 360 has a first planar portion 362 and a pair of second planar portions 364 , with a pair of respective offset portions 366 connecting first planar portion 362 to the respective pair of second planar portions 364 , and thereby locating first planar portion 362 and second planar portions 364 in spaced apart substantially parallel respective planes. As in the prior embodiment the offset preferably is in the range of 0.59 to 1.13 inches. First planar portion 362 preferably has two pair of mounting holes 368 by which hinge bracket 360 may be mounted to backing plate 92 by conventional fasteners. Mounting holes 368 are preferably in the same configuration as would be the mounting holes for a pair of conventional hinge bases 32 , such as the previously noted 32 mm common spacing, and so that new fastening holes need not be made in backing plate 92 to accommodate the mounting of hinge bracket 360 .
[0061] Pocket door slide system 310 uses the same conventional Euro-hinge style hinges 30 as in the prior art system 10 . However, a hinge 30 is mounted to the inner surface of each of the pair of second planar portions 364 , and each preferably has a pair of mounting holes 370 spaced apart in a manner consistent with a hinge base 32 to mount a hinge 30 by conventional fasteners, such as with the previously noted 32 mm common spacing. Similarly to the other embodiments, respective mounting holes 368 and 370 are preferably aligned on bracket 360 , so as to maintain the same fore and aft location of left door L with respect to the slide member, as best seen with respect to the front edge of backing plate 92 . In this configuration, left door L is then mounted to door mounting cup 40 of each hinge 30 in a conventional manner. Pocket door slide system 310 thus uses alternative hinge brackets 360 to convert hardware designed as an inset pocket door slide system for a large door to a full overlay pocket door slide system.
[0062] Turning to FIGS. 6 and 7 , two examples of further alternative embodiments of hinge brackets in accordance with the invention are shown. These examples represent further hinge brackets of the invention adapted to convert common pocket door slide hardware from a design for use with one hinge per slide and to achieve an inset door to a design for use with two hinges per slide and to achieve a full overlay door. In FIG. 6 , a hinge bracket 460 is somewhat like the bracket 60 of FIGS. 2-4 , but bracket 460 is adapted to have a first planar portion 462 mounted at a pair of holes 468 to the mounting holes on a slide that would have been used to accommodate a single hinge for an inset door, and has a second planar portion 464 with two pair of hinge mounting holes 470 to accept two hinges of a conventional pocket door slide system. First planar portion 462 and second planar portion 464 are connected by offset portion 466 so as to locate planar portions 462 , 464 in spaced apart substantially parallel respective planes.
[0063] The embodiment of hinge bracket 560 shown in FIG. 7 is somewhat like the bracket 360 of FIG. 5 , but bracket 560 is adapted to have a first planar portion 562 mounted at a pair of holes 568 to the mounting holes on a slide that would have been used to accommodate a single hinge for an inset door, and has a pair of second planar portions 564 , each having a pair of hinge mounting holes 570 to collectively accept two hinges of a conventional pocket door slide system. A pair of respective offset portions 566 connect first planar portion 562 to the respective pair of second planar portions 564 in spaced apart substantially parallel respective planes.
[0064] The embodiments shown in FIGS. 2-7 demonstrate that the present invention may be used in various configurations to achieve a full overlay closed door position. It will be appreciated that the movement of the door relative to the cabinet will be quite similar in each of these embodiments, and such movement is illustrated generally in FIGS. 8A-8D .
[0065] For instance, in FIG. 8A , left door L is shown from a top view with respect to inner wall IW and outer side wall SW. In this view, left door L is in a first position where the door is being moved toward its fully forward position, parallel to the cabinet outer side wall SW. In FIG. 8B , left door L is shown in a second position where the door has been moved to its fully forward position and is being hinged toward a closed position. In FIG. 8C , left door L is shown in a third position where the door is being hinged still closer toward a closed position. In FIG. 8D , left door L is shown in a fourth position where door L has been hinged to a fully closed position, and is located in a full overlay position relative to cabinet outer side wall SW.
[0066] It will be appreciated that the pocket door slide systems and hinge brackets disclosed in accordance with the present invention may be provided in various configurations, having any of a number of components used for the slides and to maintain door alignment, and regardless of whether the system has two or more slides and one or more hinges per slide. Also, any variety of suitable materials of construction, configurations, shapes and sizes for the components and methods of connecting the components may be utilized to meet the particular needs and requirements of an end user. It will be apparent to those skilled in the art that various modifications can be made in the design and construction of such components without departing from the scope or spirit of the present invention, and that the claims are not limited to the preferred embodiments illustrated. | A hinge bracket attachable to a pocket door slide system wherein the pocket door slide system comprises components capable of achieving a full inset or partial overlay pocket door position without the hinge bracket, and wherein use of the hinge bracket enables the pocket door slide system to achieve a substantially full overlay pocket door position. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to a hinge for wings or doors.
The use of a hinge made in accordance with the present invention is particularly advantageous for constraining the door of an electrical appliance to the respective supporting frame.
In the following description and by way of example only, without limiting the scope of the invention, the present invention is described with reference to an oven.
In known types of ovens hinges usually comprise two separate elements, kinematically connected to one another and both having a box-shaped structure. More precisely, one of the two box-shaped structures is fixed to the oven supporting frame, at one side of the oven mouth, whilst the other is fixed to one edge of the door, which is that way is rendered movable with a tilting action relative to the above-mentioned frame.
Between the two box-shaped structures a lever, usually a rocker lever, is operatively inserted, pivoting on one of the two box-shaped structures, usually on the one fixed to the door, and having a first arm rigidly constrained to the other of the two box-shaped structures. The second arm of the lever, coplanar with the first, is operated on by elastic elements which influence the movement of the door, for both opening and closing. Said elastic elements are housed in the box-shaped structure to which the lever is hinged and, more precisely, operate between that box-shaped structure and a rod positioned inside it. The free end of the rod, that is to say the end not interacting with the elastic elements, pivots at the above-mentioned second arm of the lever.
During door rotation starting from the closed position, the elastic elements oppose, during a first step, the detachment of the door from the oven supporting frame and, in a second step, subsequent rotation of the door and its consequent lowering to an end of stroke position in which the oven mouth is completely open. In this second opening step, the door, under the combined action of its own weight which promotes its descent and of the elastic elements which apply a braking action, performs a gradual rotation.
During door rotation starting from its open end of stroke position, the action of the elastic elements is first balanced by the weight of the door, initially guaranteeing gradual closing rotation; however, then, in the absence of a braking action by the user, the elastic elements push the door towards the oven frame with such a force that it often closes in a rather sudden and noisy way.
SUMMARY OF THE INVENTION
The present invention has for an aim to provide a hinge for wings or doors which is free of the above-mentioned disadvantage.
Accordingly, the present invention provides a hinge for wings or doors comprising the features described in any of the claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is now described, by way of example and without limiting the scope of application, with reference to the accompanying drawings, in which:
FIGS. 1 a and 1 b are respectively a front view and longitudinal section of a hinge made in accordance with the present invention, in its closed position and associated with an oven, the latter only partly, schematically illustrated;
FIG. 2 is an exploded view of the hinge of FIG. 1 a;
FIGS. 3 a , 3 b and 3 c are respectively a front view, a longitudinal section and a perspective view with some parts cut away for clarity, of the hinge of FIG. 1 a in an intermediate position; and
FIGS. 4 a and 4 b are respectively a front view and a longitudinal section of the hinge of FIG. 1 a in its open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 a and 1 b , the numeral 1 denotes as a whole an oven comprising a frame 2 to which a door 3 is connected by two hinges 4 , only one of which is illustrated.
Each of the two hinges 4 comprises a first element 5 , fixed to the oven 1 frame 2 at a respective side of the oven mouth, and a second element 6 , fixed to a respective edge of the door 3 . In particular, the shape of the first element 5 and the second element 6 is substantially box-shaped and extended and they are kinematically connected to one another by a connecting lever 7 which is also part of the hinge 4 . The lever 7 is a rocker lever, pivoting on the second element 6 by means of a pin 8 and has a first arm 9 a rigidly constrained to the first element 5 to render the door 3 movable with a tilting action relative to the frame 2 between a closed position and an open position.
The central longitudinal axes of the lever 7 and of the second element 6 , labeled A and B respectively, lie in a plane at a right angle to the central longitudinal axis of the pin 8 , labeled C, which is the axis of rotation of the door 3 relative to the frame 2 , and they are at a right angle to one another in the above-mentioned closed position ( FIGS. 1 a and 1 b ) and substantially aligned in the above-mentioned open position ( FIGS. 4 a and 4 b ).
As illustrated in FIG. 1 b , the second element 6 has a transversal separator 10 , in an intermediate position between the two longitudinal ends of the second element 6 , specifically between the end hinged to the lever 7 , labeled 11 , and an end opposite to the latter, labeled 12 .
Between the separator 10 and the end 12 there is a pre-compressed helical spring 13 , held in contact with the separator 10 by the head 14 of a rod 15 positioned coaxially inside the spring 13 .
The rod 15 exits the spring 13 longitudinally with one end 16 , which passes through an opening made in the separator 10 and points towards the above-mentioned end 11 . In this way, the opening made in the separator 10 acts as a guide for the rod 15 , constraining it to a longitudinal linear motion.
The end 16 of the rod 15 is hinged, by a pin 17 , to the first longitudinal end 18 of a fork 19 , whose second longitudinal end 20 is hinged to the lever 7 by a pin 21 positioned near the above-mentioned pin 8 . The pin 17 is slidably constrained to two guide and end of stroke slots 22 , made in the sides of the second element 6 and extending in a prevalent direction of extension parallel with the direction B.
The position of the pin 21 , which is closer to the axis B than the pin 8 , and the pre-compression of the spring 13 , guarantee an elastic action which tends to continuously push and hold the door 3 in its closed position.
Only when the closed position is almost reached, from and towards the closed position, overlapping with the above-mentioned elastic action of the spring 13 there is the action of another pre-compressed helical spring 23 , designed to operate in conjunction with a cam 24 made on a second arm 9 b of the rocker lever 7 , through a rod 25 acting on a cam follower 26 , to give the door 3 a spring-to closing movement and to define a door stable semi-open position. Specifically, the follower 26 is supported by a pin 27 slidably constrained to two guide and end of stroke slots 28 , made in the sides of the second element 6 and extending in a prevalent direction of extension parallel with the direction B. The follower 26 is pushed towards the cam 24 by a race made on one end of the rod 25 , and the latter is pushed by the spring 23 which is stopped in contact with a transversal separator 29 in the second element 6 . The separator 29 is in an intermediate position between the separator 10 and the end 11 of the second element 6 and has an opening which acts as a guide for the rod 25 , so as to constrain the rod to a longitudinal linear motion.
The spring 23 is smaller than the spring 13 , since, while the function of the spring 13 is mainly to balance the weight of the door 3 , the function of the spring 23 is, as indicated, to give the door 3 a spring-to closing movement and to define a door stable semi-open position.
The two springs 13 and 23 , the relative rods 15 and 25 , the fork 19 and the cam follower 26 as a whole form elastic means 30 , inserted between the second element 6 and the lever 7 to apply on the lever 7 a two-step elastic action, specifically, during a first step, when the closed position is almost reached, from and towards the closed position, in which the action of the two springs 13 and 23 overlaps, and in a second step, between the above-mentioned door 3 stable semi-open position and the fully open position, in which the elastic action on the lever 7 is only applied by the spring 13 .
Each of the two hinges 4 also comprises damping means 31 , contained in the second element 6 and designed to apply a damping action on the lever 7 at the end of the closing stroke, that is to say, during the reciprocal motion of the first element 5 and the second element 6 , when the door 3 closed position is almost reached.
The damping means 31 comprise a gas or fluid cylinder 32 , having an outer body 33 mounted in the second element 6 , near the longitudinal end 12 of the latter, and a rod 34 which can move with linear motion relative to the outer body 33 .
The outer body 33 is housed in a fixed position in a support 35 which is constrained to the above-mentioned end 12 by a cylindrical hinge 36 .
The rod 34 consists of a first portion 37 acting directly on the cylinder 32 piston and of a second portion 38 forming an extension, having a first longitudinal end 39 connected to the first portion 37 and a second longitudinal end 40 which is free, designed to act on the lever 7 during the reciprocal motion of the first element 5 and the second element 6 and when the closed position is almost reached.
For this purpose, the lever 7 has two thrust projections 41 , extending in such a way that they are aligned with one another longitudinally from two opposite faces of the lever 7 , and the end 40 has a fork-shaped free end portion, designed to make contact with the projections 41 , simultaneously, when the door 3 has almost reached its closed position, and to remain in contact until the closed position is reached. As illustrated in FIG. 2 , the projections 41 are formed by the two longitudinal ends of a cylindrical element 42 , inserted in a through-hole 43 in the lever 7 and rigidly constrained to the lever.
The following is a brief description of the operation of one of the two hinges 4 starting at the door 3 closed position, illustrated in FIGS. 1 a and 1 b.
The torque applied to the door 3 when it is opened by the user and, beyond a predetermined rotation, by the weight of the door 3 , conflicts with the torque generated by the elastic means 30 , which therefore render the movement of the door 3 towards the fully open position gradual and subject to a braking action. During the initial opening step, the action applied on the lever 7 by the damping means 31 , which continues for as long as there is contact between the end 40 and the projections 41 , is negligible compared with the torque applied by the user.
Starting from the door 3 fully open position, a rotation of the door towards the closed position is promoted by the action of the elastic means 30 and is initially hindered by the weight of the door 3 . When the door 3 reaches an intermediate closing position, in which contact is made between the end 40 and the projections 41 ( FIGS. 3 a , 3 b and 3 c ), following cylinder 32 compression, the damping means 31 apply a damping action conflicting with the closing action applied by the elastic means 30 , and therefore render the door 3 movement towards the fully closed position gradual and subject to a braking action.
It is therefore evident that, even in the absence of a braking action by the user, the door 3 , pushed towards the oven 1 frame 2 by the elastic means 30 , reaches the frame in a gentle, silent way thanks to the end of stroke damping provided by the damping means 31 .
It should also be emphasized that the damping means 31 are housed in the hinge 4 , in a position hidden from view and protected from impacts or dirt, with obvious advantages in terms of appearance and reliable operation.
According to an alternative embodiment, not illustrated, the first element 5 is fixed to one edge of the door 3 and the second element 6 is fixed to the oven 1 frame 2 at one side of the mouth of the oven.
It is also evident that, in addition to the specific example of use described above, a hinge of the type disclosed may advantageously be used to constrain a generic wing to a respective frame. | A hinge for wings or doors, in particular of electrical appliances, having a first element, a second element and a rocker lever for connecting the first and second elements; the lever pivots on the second element and has a first arm integral with the first element to render the first and second elements movable relative to one another with a tilting action between a closed position and an open position; the second element consisting of a substantially box-shaped body containing both elastic parts, inserted between the second element and a second arm of the lever to apply an elastic action on the lever, and a damping device, for applying a damping action on the lever during the reciprocal motion of the first and second elements, when the closed position is almost reached. |
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BACKGROUND OF THE INVENTION
The present invention relates to a safety device for a fluid production well, of the type comprising:
a valve housing intended to be fixed tightly inside a fluid flow conduit, the housing delimiting a fluid flow passage and comprising:
a valve used to seal the passage, and which can move between an open position of the passage and a closed position of the passage; means for permanently biasing the valve towards its closed position; and means for connecting the housing to a coupling member for a working wire line intended to move and anchor the housing in the conduit;
means for holding the valve in the open position against the permanent biasing means, said holding means comprising at least one movement element for the valve, which can move in the valve housing between a rest position and an active valve biasing position, and an element for permanently returning the movement element to its rest position; and means for hydraulically actuating the holding means, which can be controlled by a control signal to actuate the holding means upon receipt of a valve open control signal by the actuating means, and to deactivate the holding means in the absence of said signal.
Such a device is used to secure a well for the production of oil or another fluid (notably gas, vapour or water), in particular when said well is eruptive and can be sealed rapidly in case of failure of the surface installation, said failure producing the disconnection of the open control signal.
A device of the above-mentioned type is known from U.S. Pat. No. 4,002,202, said device being lowered in a production casing of an oil well by means of a working wire line. Said device comprises a valve housing, a rod for holding the valve in the open position and electromagnetic coils for actuating the support rod. The coils are fixed to the outside of the casing at a determined point thereon on, and are connected electrically to the surface by electric cables.
When an electric control signal is received by the electromagnetic coils, the valve is held in the open position by the support rod, against a return spring.
In the absence of a control signal, the return spring is deployed to move the rod, which allows rapid sealing of the valve.
A safety device of the same type is also known, driven by a hydraulic control line extending outside the casing from the surface.
Such devices are not entirely satisfactory. The safety device must be positioned at a determined point of the well, opposite the actuating coils, and the coils must be connected to the surface by electric power supply lines, or must be positioned opposite the inlet of the hydraulic conduit.
SUMMARY OF THE INVENTION
An object of the invention is therefore to provide an autonomous safety device, comprising a safety valve that can be installed and anchored at any point of the well whatever the finished architecture thereof, and that can be controlled from the surface.
Accordingly, the invention relates to a device of the above-mentioned type, characterised in that the holding means and actuating means are connected to the housing in such a way that they can be moved simultaneously under the control of the working wire line.
The device according to the invention may comprise one or more of the following characteristics, taken in isolation or in a technically feasible combination:
actuating means comprising a hydraulic cylinder and a hydraulic unit for controlling the cylinder; the hydraulic unit projects at least in part in relation to the housing, outside the flow passage, the flow passage being clear between the connection means and the valve; the hydraulic unit can be removed from the valve housing, said valve housing comprising means for receiving the unit; the cylinder comprises a chamber for pressurising control fluid, said chamber receiving a portion of the movement element of the valve; and a tank for reserving and discharging control fluid,
and the hydraulic control unit comprises a pump for feeding the control fluid into the pressurising chamber, a pressurising conduit connecting the pressurising chamber to the discharge tank, a first discharge conduit connected to the pressurising conduit provided with a discharge valve that is open in the absence of the control signal and closed in the presence of said signal;
the return element loads a piston for pressurising the tank; the actuating means comprise a rapid discharge conduit, connected to the pressurising conduit, the rapid discharge conduit being provided with a sealing element that can be released when the discharge valve is open; the maximum cross-section of the first discharge conduit and of the upstream portion of the pressurising conduit situated upstream of the releasable sealing element is less than the minimum cross-section of the rapid discharge conduit and of the downstream portion of the pressurising conduit situated downstream of the releasable sealing element; the actuating means comprise a control fluid accumulator connected to the pressurising chamber; the actuating means comprise a zero-leakage non-return valve, interposed between the pump and the pressurising chamber; the hydraulic unit comprises means for controlling the cylinder, said control means comprising a receiver, a control unit suitable for driving the cylinder to actuate the holding means upon receipt of a valve open control signal by the receiver and to deactivate said holding means in the absence of said signal; the control unit is suitable for driving the cylinder to actuate, at least temporarily, the holding means in the absence of a valve open signal, after reception of a silence signal by the receiver; and the device comprises releasable means for anchoring the housing in the conduit, carried by the housing.
The invention also relates to a safety installation for a fluid production well comprising a fluid flow conduit, said installation comprising:
a device as defined above; and means for deploying said device in the conduit comprising a working wire line connected releasably to the connection means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood on reading the description that follows, given solely by way of an example and with reference to the accompanying drawings, in which:
FIG. 1A is a cross-sectional view along a vertical mid-plane of an oil well equipped with a safety device according to the invention, during operation of the well;
FIG. 1B is a similar view to FIG. 1A , when the device is installed in the well;
FIG. 2 is a side view of the safety device illustrated in FIG. 1A and in FIG. 1B ;
FIG. 3 is a cross-sectional view along a vertical mid-plane of a detail of the device in FIG. 2 ;
FIG. 3A is a view of a detail marked IIIA in FIG. 3 ;
FIG. 4 is a lateral cross-sectional view along the plane IV-IV of FIG. 3 ;
FIG. 5 is a diagrammatic view of the hydraulic actuating means of the device in FIG. 2 ; and
FIG. 6 is a similar view to FIG. 3 in which the valve of the safety device is sealed.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the remaining text, the term “proximal” means relatively closer to the ground surface, whereas the term “distal” means relatively closer to the bottom of a well made in the ground.
The autonomous safety device 10 according to the invention, illustrated in FIGS. 1 to 6 , is intended to be lowered into an oil well 12 using wire deployment means 14 . The device 10 is placed at a chosen point in the well 12 , for example situated at a depth of between 10 m and 1000 m, to replace a faulty safety valve, or to add an intermediate safety valve.
As illustrated in FIGS. 1A and 1B , the well 12 comprises a first conduit 16 known as the “casing” made in the sub-soil 18 and a second conduit or pipe 20 known as the “production casing” secured substantially in the centre of the first conduit 16 .
The well 12 further comprises a wellhead 22 at the surface to seal selectively the first conduit 16 and the second conduit 20 .
The second conduit 20 is not as long as the first conduit 16 . It opens at a point 23 into the first conduit 16 situated in a distal portion of the well 12 . Annular packing elements 24 are arranged between the first conduit 16 and the second conduit 20 in the vicinity of the point 23 .
These elements 24 seal tightly the annular space 25 defined between the conduits 16 and 20 .
The second conduit 20 defines internally a plurality of circular engagement grooves or annular engagement recesses 26 A, 26 B, designated by the term “landing nipple”. Said recesses 26 A, 26 B are situated at points spaced longitudinally along the conduit 20 .
In a variant, the second conduit 20 is not provided with recesses 26 A, 26 B, and the device 10 is anchored directly against a smooth wall of the conduit 20 .
As illustrated in FIG. 1B , for the installation of the device 10 in the well 12 , the deployment means 14 of the device 10 comprise a working wire line 30 , a surface hoist 32 enabling the line 30 to be deployed or retracted in the well 12 , and pulleys 34 for orienting the line 30 mounted on the wellhead 22 .
The line 30 is formed for example by a smooth single strand wire of the “piano wire” type, commonly referred to by the term “slickline”, with or without electrical insulation on its outer surface. The line 30 comprises, at its distal end, an installation gear 31 for the device 10 .
In a variant, the line 30 is a mechanically reinforced electric cable, commonly referred to by the term “electric line”, or a hollow spiral cable, commonly referred to by the term “coiled tubing”.
The hoist 32 and the pulleys 34 allow the working line 30 to be deployed successively in the second conduit 20 , then in the first conduit 16 via the wellhead 22 .
As illustrated in FIG. 1A , when operating the well 12 , the deployment means 14 have been withdrawn and the well 12 comprises means 35 for emitting a signal for controlling the safety device 10 . In the example illustrated, the control signal is an electromagnetic signal and the means 35 are arranged at the surface. In a variant, said signal is an acoustic signal.
As illustrated in FIG. 2 , the safety device 10 comprises a safety valve housing 40 , means 42 for holding the safety valve in an open position, and a hydraulic cylinder 44 for actuating the holding means 42 . The device 10 also comprises a hydraulic unit 46 fixed removably at a distal end of the housing 40 , the unit 46 comprising means 48 for controlling the cylinder 44 , and batteries 49 for supplying electrical power to the unit 46 .
As illustrated in FIG. 3 , the valve housing 40 comprises a tubular body 50 with a longitudinal axis X-X′ delimiting internally a longitudinal through-flow passage 52 for circulating an oil fluid, means 54 for connecting to the installation gear 31 , mounted at a proximal end of the body 50 , and means 56 for anchoring the device 10 in the second conduit 20 .
The housing 40 further comprises, in the vicinity of its distal end, a valve 58 for sealing the passage 52 .
When moving from a proximal end, to the right in FIG. 3 , to a distal end, to the left in FIG. 3 , the body 50 comprises a proximal tubular portion 60 , a portion 62 for guiding and holding the valve, and a distal portion 64 for connecting to the hydraulic unit 46 .
As illustrated in FIG. 3A , the mid-portion 62 defines a proximal sheath 66 mounted in the tubular portion 60 and delimiting an annular transverse surface 68 directed towards the body 60 .
The mid-portion 62 also delimits a distal annular shoulder 70 directed towards the distal portion 64 and a cylindrical guide surface 72 extending between the proximal surface 68 and the distal shoulder 70 .
The cylindrical surface 72 delimits, between the distal shoulder 70 and the proximal surface 68 , an annular recess which receives a proximal sealing gasket 73 .
By moving distally along the axis X-X′ in FIG. 3 , the distal tubular portion 64 delimits a lateral valve retraction opening 74 , which opens into the passage 52 , an annular shoulder 76 oriented towards the distal end of the body 40 , and a lateral passage 78 (i.e., a receiving portion) for assembling the hydraulic unit opening into the flow passage 52 . The portion 64 has at its distal end a distal opening which opens into the flow passage 52 .
The connection means 54 comprise a head 80 for receiving the installation gear 31 delimiting an internal recess 82 . The head 80 is screwed to the proximal end of the tubular portion 60 .
The recess 82 opens distally into the passage 52 and proximally through a proximal opening 84 . A fluid may thus penetrate into the passage 52 of the housing 40 when the installation gear 31 is arranged at a distance from the housing 82 .
The anchoring means 56 comprise lateral locking mandrels or “dogs” referred to by the term “lock mandrel”. The dogs 86 project radially outside of the head 80 and have a form complementary to that of the engagement recesses 26 A, 26 B arranged in the second conduit 20 .
The anchoring means 56 also comprise compressible annular packing (not illustrated) intended to form a seal between the wall of the conduit 20 and the head 80 .
The sealing valve 58 comprises an annular seat 88 mounted integrally with the body 50 in the passage 52 , and a shutter 90 that can move between an open position of the passage 52 and a sealed position of the passage 52 . The valve 58 also comprises a spring 92 for returning the shutter 90 to its sealed position.
The valve seat 88 is fixed in the passage 52 and forms a mechanical connection between the mid-portion 62 and the distal tubular portion 64 . As illustrated in FIG. 3A , a proximal annular surface 93 of the seat extends opposite the distal surface 70 of the mid-portion 62 . A distal conical annular surface 94 of the seat 88 is flush with the wall of the distal portion 64 in the region of the lateral reception opening 74 .
The shutter 90 can rotate about a horizontal axis perpendicular to the axis X-X′ situated in the vicinity of the distal surface 94 of the seat 88 .
In the open position of the shutter 90 , said shutter 90 extends substantially in the extension of the tubular portion 64 to seal the lateral opening 74 and free the passage 52 .
In the sealed position, illustrated in FIG. 6 , the shutter 90 extends in a plane that is substantially perpendicular to the longitudinal axis X-X′ of the valve housing 40 . It rests on the distal conical annular surface 94 to seal the passage 52 .
The spring 92 permanently biases the shutter 90 towards its sealed position.
The means 42 for holding the valve in its open position comprise a cylindrical sleeve 98 mounted movably in translation along the axis X-X′ in the passage 52 , between a proximal rest position and a distal open position of the valve 58 . The means 42 further comprise, mounted on the sleeve 98 , a distal pressurisation piston 100 , a proximal end stop 102 for guiding the sleeve, and a spiral spring 104 for returning the sleeve to its proximal position.
The sleeve 98 extends longitudinally in the body 40 opposite the proximal tubular portion 60 , the mid-portion 62 and, in its proximal position, the distal portion 64 . As illustrated in FIG. 4 , it comprises an outer surface 106 of transverse cross-section substantially complementary to the guide surface 72 of the mid-portion 62 in such a way that the mid-portion 62 guides the sleeve 98 when it moves between its proximal position and its distal position.
As illustrated in FIG. 3A , the surface 106 delimits with the seat 88 , an annular space 107 . It comprises an annular rib 107 B which delimits a distal recess oriented towards the seat 88 . The recess receives a sealing gasket 108 which distally seals the annular space 107 . The space 107 is sealed proximally by the proximal gasket 73 .
The distal annular piston 100 is mounted slidingly on the sleeve 98 between the outer surface 106 and the proximal tubular portion 60 . It delimits a distal annular surface 110 which extends opposite the proximal surface 68 . It further delimits a proximal annular surface 112 on which a distal end of the spring 104 rests.
The proximal annular end stop 102 is mounted integrally with the proximal end of the sleeve 98 . It extends between the sleeve 98 and the tubular portion 60 . The end stop 102 slides in the tubular portion 60 and delimits a distal annular surface 114 on which the proximal end of the spring 104 rests. The end stop 102 comprises a wiper gasket 115 arranged resting on the tubular portion 60 .
In the proximal position of the sleeve 98 , illustrated in FIG. 6 , the gasket 108 extends in the vicinity of the proximal surface 93 of the seat 88 . In addition, the end stop 102 is situated in the vicinity of the receiving head 80 . The distance separating the piston 100 and the end stop 102 is then at the maximum. The spring 104 is pre-stressed in such a way that it exerts a minimal return force on the piston 100 and on the end stop 102 . In this position, the annular rib 107 B of the sleeve 98 rests against the shoulder 70 .
In this position, the distal edge of the sleeve 98 is arranged opposite the seat 88 , proximally in relation to the shutter 90 .
In the distal position of the sleeve 98 , illustrated in FIG. 3 , the distance between the piston 100 and the end stop 102 is minimal and the compression of the spring 104 is at the maximum in such a way that it exerts maximum return force on the piston 100 and on the end stop 102 .
In this position, a distal portion of the sleeve 98 extends opposite the lateral opening 74 . The distal edge of the sleeve 98 rests on the end stop shoulder 76 of the distal portion 64 . The sleeve 98 covers the shutter 90 . In addition, the gasket 108 is at a distance distally from the proximal surface 93 of the valve seat 88 .
As illustrated in FIGS. 3 to 6 , the hydraulic cylinder 44 comprises a pressurising chamber 120 and a reserve and discharge tank 122 which are connected hydraulically to the unit 46 by the respective connection conduits 124 A, 124 B. The tank 122 and the chamber 120 contain a hydraulic fluid for controlling the cylinder 44 .
The chamber 120 comprises an intermediate space 121 of constant volume and the annular space 107 of variable volume.
The intermediate space 121 extends between the body 50 and the sleeve 98 . It is delimited proximally by the distal shoulder 70 of the mid-portion 62 , by the proximal surface 93 of the seat 88 , and by the outer surface 106 of the sleeve. The space 121 is connected to the annular space 107 .
In the proximal position of the sleeve 98 , the distance between the proximal gasket 73 and the distal gasket 108 is minimal and the volume of the chamber 120 is minimal. In the distal position of the sleeve 98 , this distance is at the maximum and the volume of the chamber 120 is at the maximum.
The tank 122 extends between the body 50 and the sleeve 98 proximally in relation to the chamber 120 . It is delimited by the proximal tubular portion 60 , by the proximal surface 68 of the mid-portion 62 , by the surface 106 , and by the distal surface 110 of the piston 100 .
The volume of the tank 122 depends on the longitudinal position of the piston 100 along the sleeve 98 and along the body 50 .
As illustrated in FIG. 2 , the conduits 124 A, 124 B extend outside the body 50 along said body. They open out distally in the region of the lateral passage 78 for assembling the unit 46 . In addition, the distal connection conduit 124 A opens proximally in the intermediate space 121 of the chamber 120 via the mid-portion 62 .
The proximal connection conduit 124 B opens proximally in the tank 122 through the mid-portion 62 .
As illustrated in FIG. 5 , the unit 46 comprises a tubular housing 125 receiving a hydraulic electric pump 126 and a conduit 128 for selectively pressurising the chamber 120 , connecting the electric pump 126 to the distal connection conduit 124 A.
The tubular housing 125 projects distally outside the body 50 along the axis X-X′. The proximal end thereof is introduced into the distal opening of the distal portion 64 and received in the assembly passage 78 in order to be fixed to the distal portion 64 of the body 50 .
The electric pump 126 connects the proximal connection conduit 124 B to an inlet of the conduit 128 so as to connect the tank 122 to the conduit 128 .
The pressurising conduit 128 comprises, from upstream to downstream, from the electric pump 126 to the chamber 120 , a zero-leak non-return valve 130 and an upstream portion 128 A on which are fastened a safety conduit 132 and a first discharge conduit 134 received in the housing 125 . The conduit 128 also comprises a downstream portion 128 B on which are connected a rapid discharge conduit 136 and an accumulator 138 , received in the tubular housing 125 .
The safety conduit 132 is connected on the upstream portion of the pressurising conduit 128 at the outlet of the valve 130 . It opens at the inlet of the proximal connection conduit 124 B. The safety conduit 132 is provided, from upstream to downstream, with a pressure switch 140 and a pressure relief valve 142 .
The first discharge conduit 134 is fastened on the upstream portion 128 A of the conduit 128 downstream of the conduit 132 . The conduit 134 is provided with a controlled safety solenoid valve 144 , which is normally open, and which opens into the proximal connection conduit 124 B.
The solenoid valve 144 is connected electrically to the control means 48 .
The rapid discharge conduit 136 is connected on the pressurising conduit 128 by means of a bypass valve 146 , delimiting the upstream portion 128 A and the downstream portion 128 B on the conduit 128 .
The valve 146 comprises a primary inlet 148 and a primary outlet 150 opening respectively into the upstream portion 128 A of the pressurising conduit 128 towards the electric pump 126 , and into the downstream portion 128 B of the conduit 128 towards the chamber 120 . The valve 146 also comprises a secondary outlet 152 connected to the rapid discharge conduit 136 .
When the pressure that prevails in the region of the primary inlet 148 is greater than or substantially equal to the pressure that prevails in the region of the primary outlet 150 , the secondary outlet 152 is sealed in such a way that the primary inlet 148 is connected hydraulically to the primary outlet 150 .
On the other hand, when the pressure that prevails in the region of the primary inlet 148 is less than the pressure that prevails in the region of the primary outlet 150 , the primary inlet 148 is sealed and the primary outlet 150 is connected hydraulically to the secondary outlet 152 and thus to the tank 122 by means of the conduit 124 B.
The minimum flow cross-section through the downstream portion 128 B, the secondary outlet 152 and through the rapid discharge conduit 136 is very much greater than the maximum flow cross-section through the upstream portion 128 A, the solenoid valve 144 and through the first discharge conduit 134 , for example at least twice as great.
As illustrated in FIG. 2 , the control means 48 are received in the tubular housing 125 . They comprise a receiver 154 and a unit 156 for controlling the cylinder 44 . The receiver 154 is able to receive a valve open control signal emitted from the surface and to transmit an order to the control unit 156 to hold the shutter 90 in its open position, for as long as the control signal is received by the receiver 154 .
The receiver 154 is also able to receive a temporary silence signal for the well 12 and to transmit an order to the control unit 156 , to hold the shutter 90 temporarily in its open position even in the absence of a valve open signal.
The control unit 156 is connected electrically to the solenoid valve 144 , to the electric pump 126 , and to the pressure switch 140 for controlling the cylinder 44 .
The operation of the autonomous safety device 10 according to the invention to replace a defective valve in the well 12 will now be described.
Initially, a valve housing 40 is selected of suitable dimensions for insertion into the second conduit 20 .
A hydraulic unit 46 common to valve housings 40 of different diameters is fixed in the lateral passage 78 and is connected hydraulically to the distal ends of the conduits 124 A and 124 B.
The autonomous device 10 according to the invention is thus formed.
Then, with reference to FIG. 1B , the deployment means 14 are arranged on the wellhead 22 . The installation gear 31 is mounted on the receiving head 80 at the proximal end of the valve housing 40 .
The valve housing 40 , the holding means 42 , the hydraulic actuating cylinder 44 and the hydraulic unit 46 connected to the housing 40 , forming the device 10 , are then introduced into the second conduit 20 and are thus lowered simultaneously under the control of the working wire line 30 .
When the device 10 reaches the desired position in the second conduit 20 , for example when the anchoring means 56 are arranged opposite an engagement recess 26 B, the working wire line 30 is halted.
The anchoring means 56 are then actuated by the operator to lock the housing 40 in position in the conduit 20 .
Accordingly, the engagement dogs 86 are inserted in the recesses 26 B and a sealed connection is formed between the housing 40 and the second conduit 20 . Then, the installation gear 31 is released from the connection means 54 , to free the opening 84 at the inlet of the passage 52 . The deployment means 14 are then withdrawn ( FIG. 1A ).
The shutter 90 is maintained in the position in which it seals the passage 52 , the sleeve 98 being in its proximal position.
The safety device 10 then tightly seals the second conduit 20 .
When the well operator wishes to open the second conduit 20 , he actuates the emission means 35 at the surface to emit a valve open control signal.
When the receiver 154 receives the valve open control signal, it transmits an actuation order to the control unit 156 . The unit 156 then actuates the electric pump 126 and the solenoid valve 144 to introduce a portion of the liquid contained in the tank 122 into the chamber 120 . The volume of the tank 122 reduces, which causes the distal movement of the piston 100 .
In this regard, the priming of the electric pump 126 is assisted by the presence of the pre-stressed return spring 104 which rests on the piston 100 when the sleeve 98 is in its proximal position, to compress slightly the fluid contained in the tank 122 .
Once the electric pump 126 is primed and the solenoid valve 144 is closed, the pressure in the chamber 120 increases and is applied in the annular space 107 , between the proximal gasket 73 and the distal gasket 108 , which causes the sleeve 98 to move towards its distal position, against the return spring 104 which is compressed between the piston 100 and the end stop 102 .
During this movement, the distal edge of the sleeve 98 pushes the shutter 90 , and moves it from the sealed position to its open position, against the biasing spring 92 .
When the sleeve 98 has reached the position in which it comes to a stop against the end-stop shoulder 76 , the shutter 90 is secured against the distal portion 64 and seals the lateral opening 74 , as illustrated in FIG. 3 .
Moreover, the pressure in the chamber 120 increases to a threshold value which is detected by the pressure switch 140 and transmitted to the unit 156 . When the control unit 156 determines that the pressure in the chamber 120 is greater than the threshold value, it disconnects the electric pump 126 .
The solenoid valve 144 is kept sealed for as long as the receiver 154 receives a valve open control signal.
If the pressure in the chamber 120 falls below a re-start value for the electric pump 126 , the control unit 156 actuates the electric pump 126 once again to raise the pressure in the chamber 120 to the threshold value.
However, the presence of a zero-leak non-return valve 130 reduces the operating time of the electric pump 126 and increases the autonomy of the device 10 .
The accumulator 138 allows pressure variations in the chamber 120 , due in particular to temperature variations in the housing 40 , to be compensated.
In the event of an incident at the surface, the valve open control signal emitted by the emission means 35 is disconnected.
Once the receiver 154 no longer receives said signal, the control unit 156 determines whether a temporary silence signal has been emitted before disconnecting the valve open control signal. In the absence of such a silence signal, the control unit 156 deactivates the solenoid valve 144 and then resumes its normally open position.
With reference to FIG. 5 , the fluid contained in the upstream portion 128 A of the conduit 128 , upstream of the primary inlet 148 of the rapid discharge valve 146 is then reintroduced into the tank 122 via the first discharge conduit 134 and the proximal connection conduit 124 B.
The pressure that prevails in the region of the primary inlet 148 thus reduces to a value below that which prevails at the primary outlet 150 .
As a follow-up, the secondary outlet 152 of the rapid discharge valve 146 opens, and the primary inlet 148 closes. The fluid contained in the pressurising chamber 120 is therefore discharged very rapidly into the tank 122 via the downstream portion 128 B of the conduit 128 , the primary outlet 150 , the secondary outlet 152 , the rapid discharge conduit 136 and the proximal connection conduit 124 B.
As the pressure in the chamber 120 falls rapidly, the return spring 104 moves the sleeve 98 towards its proximal position very rapidly. It will be noted that only one spring 104 is necessary to pressurise the tank 122 when the pump 104 is deactivated, and to allow the sleeve 98 to return towards its proximal position in the event of an incident at the surface. The length of the housing 40 is thus reduced. In addition, since the volume of the tank 122 increases after the rapid discharge valve 146 opens, the difference in length of the spring 104 resting proximally on the piston 100 between the proximal position and the distal position of the sleeve 98 is less than the travel of the sleeve 98 between said positions.
The biasing spring 92 then returns the shutter 90 to its sealed position across the passage 52 , as illustrated in FIG. 6 . The well 12 is thus made safe.
However, if the operator has issued a previously programmed silence signal, before the disconnection of the valve open signal, the control unit 156 maintains the solenoid valve 144 sealed and the chamber 120 under pressure for a determined period of time, despite the absence of a control signal. The shutter 90 therefore remains in the open position.
This operating method maintains production of the well 12 , even if an intervention requiring the absence of any control signal must be carried out on another nearby well.
If a control signal is once more emitted, the control unit 156 is reinitialised, such that the disconnection of the control signal causes the shutter 90 to close once more.
With the aid of the invention that has just been described, it is possible to have an autonomous safety device 10 that is easily installed and anchored in a well 12 by a working wire line 30 . Said device comprises a valve housing 40 , means 42 for holding the valve in an open position, and hydraulic actuating means 44 , 46 holding means 42 , connected to the housing 40 , for the simultaneous movement thereof in the well 12 .
Such a device 10 can be used at any point in the well 12 , without the need to introduce hydraulic or electric control lines, either to replace an existing defective valve in the well 12 , or to install a new valve in the well 12 without having to raise the production casing.
The arrangement of the hydraulic unit 46 in the valve housing frees the fluid flow passage 52 inside the valve housing and opens a passage 52 of sufficient diameter for the production of hydrocarbons or the passage of tools as far as the shutter 90 .
The structure of the hydraulic unit 46 is suitable for connection thereof to valve housings 40 of different diameters. In addition, the structure thereof consumes little energy, for autonomous operation of the device 10 over a long period of between six months and two years without the need to raise the device 10 to the surface. | The invention relates to a safety device for an oil well and to the associated safety installation. The inventive device comprises a valve housing ( 40 ) which defines a fluid flow passage ( 52 ). The aforementioned housing ( 40 ) comprises a valve ( 48 ) which is used to seal the passage and which can move between an open position and a closed position and means for permanently biasing the valve towards the closed position thereof. The housing ( 40 ) also comprises releasable means ( 54 ) for connecting same to a working line with tubing that is intended to move the housing ( 40 ) in the conduit. In addition, the device comprises retractable means ( 42 ) for supporting the valve ( 58 ) in the open position and hydraulic means ( 44, 46 ) for actuating the support means ( 42 ) in order to activate same upon reception of a valve open control signal. The aforementioned support means ( 42 ) and actuation means ( 44, 46 ) are solidly connected to the housing ( 40 ) such that they can be moved simultaneously under the control of the line. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is related to U.S. Provisional Application No. 62/193,103, entitled “Grapple Attachment for Tractor” invented by Marcus Jay Ferguson, filed on Jun. 16, 2015, now abandoned.
FIELD OF USE
[0002] The present invention relates to a grapple assembly, and in particular, a grapple assembly that is compatible with a quick-hitch mounting system to operate front-mounted implements on a tractor.
BACKGROUND OF THE INVENTION
[0003] John Deere quick hitches are designed to interface with a snow/dirt blade (plow), a snow blower, a rotary sweeper, and a plow shovel.
[0004] There are many various attachments available to the owner of small yard tractor, with a grapple assembly seemingly lacking. While there are many grapple attachments available for larger tractors and skid steer vehicles, there are not any specifically made for the smaller John Deere® tractors typically found in use by private individuals.
U.S. Pat. No. 8,109,709 (Gaetze) discloses a removable grapple apparatus for a loader bucket is disclosed, and comprises a grapple assembly comprising at least one grapple arm having an inboard end and an outboard end, and a grapple fork mounted on the grapple arm toward the outboard end thereof. The apparatus includes a mounting assembly configured to removably mount the grapple assembly to the bucket when the mounting assembly is mounted on the bucket. The grapple assembly is pivotally mounted on the mounting assembly to permit pivot movement of the grapple assembly with respect to the mounting assembly. The apparatus includes a grapple movement assembly configured to pivotally move the grapple assembly with respect to the mounting assembly U.S. Pat. No. 7,934,758 (Stamey, et al.) discloses a connecting and adapting system for interconnecting a pair of jaws of a grapple assembly and for adapting the grapple assembly for connecting to a plurality of linkages. The system includes bearings, where the bearings have a flange, an elongated section, and a bore. The flange of the bearings abuts a portion of one of the jaws, the elongated section of the bearings interconnects the jaws, and the bore of the bearing receives a pin to provide a connecting location. A portion of the bearing, being positioned opposite the flange, receives a collar that abuts a portion of one of the jaws. This prior art discloses only reinforced certain parts of the magazine, such as the feed lips or the lockup points. Also, some of this prior art relies on heavy polymers in the areas of the most stress. U.S. Pat. No. 6,601,891 (Gregory, Jr.) discloses a grapple attachment is presented for use with motorized vehicles. The grapple attachment is comprised of upper and lower jaws having a plurality of elongated, substantially angular tines that are adapted for dislodging, lifting and carrying whole concrete slabs, vertically disposed posts, horizontally disposed logs, rocks and other awkward debris. The tines are further adapted for use in scarifying and ripping ground surfaces. The upper and lower jaws are pivotally connected to each other at the rearward ends thereof, thus forming the body of the grapple. A single actuator moves the grapple jaws between open and closed positions. The grapple is pivotally connected to the front-end loader using a universal hitch that is adapted for use on a plurality of motorized vehicles, including front-end loaders, skid loaders, tractors, backhoes, excavators and end loaders.
[0008] What is needed is a grapple assembly that utilizes the John Deere quick-hitch and hydraulic cylinder, which can then be raised and move a heavy object as needed. John Deere® is a registered trademark of the Deere & Company of Moline Ill.
[0009] What is needed is a grapple assembly which is compatible with a quick hitch system, such as the John Deere quick hitch system, that is essentially toolless and easily attached with a minimum of effort. This system is a universal mounting system which enables the use of any attachment made by John Deere or other third party manufacturers.
[0010] What is needed is a grapple assembly compatible with small tractors that utilize the John Deere front mounted quick-hitch as a means to powerfully grasp and lift logs, rocks, boulders, brush, branches, limbs and many other objects, that can be used for lifting, and transporting and depositing objects to a new location with virtually no physical effort by the operator.
SUMMARY OF THE INVENTION
[0011] The grapple assembly of the present invention addresses the aforementioned needs.
[0012] The grapple assembly of the present invention is a small grapple which is designed to be used with the John Deere® quick hitch system found on many small tractors used by homeowners and small contractors. The system enables the attachment of different implements ranging from blades for snow removal to material handling devices such as forks or drum carriers.
[0013] The grapple assembly of the present invention is designed for front mounting and attachment to a quick hitch of a tractor or tractor-like vehicle.
[0014] The grapple assembly comprises an upper and lower jaw, which oppose each other, and a cylinder mount.
[0015] The grapple assembly mounts to the universal quick hitch and provides a cylinder mount to allow for the angling cylinder, hereafter referred to as the grapple hydraulic cylinder, to rotate the grapples upper jaw relative to the lower jaw.
[0016] The upper jaw is rotated using the existing hydraulics and repositioned cylinder, to engage the lower jaw, the upper jaw is attached to the lower jaw by one or more pins, the one or more pins enabling the upper jaw to rotate relative to the lower jaw. The one or more rods engage into a pair of slots located on each side of the quick hitch of the vehicle.
[0017] A cylinder mount is secured onto the quick hitch. The cylinder mount engages with a grapple hydraulic cylinder. The grapple hydraulic cylinder has two ends. The second end of the grapple hydraulic cylinder is secured to the upper jaw.
[0018] The upper jaw opens relative to the lower jaw via the grapple hydraulic cylinder to allow the grapple to be moved onto an object. The upper jaw then closes relative to the lower jaw via the grapple hydraulic cylinder to tightly grasp the object. The object can then be relocated using the vehicle.
[0019] John Deere has manufacturing garden tractors and sub-compact utility tractors since the mid 1980's which utilize the quick hitch mounting system. The quick hitch mounting system is a system for mounting various implements—all of which are made by John Deere as well as other third-party manufacturers. These implements include a snow blower, rotary broom (sweeper), blade (plow), and plow shovel (a device that attaches to the blade to enable the blade to be used as a bucket for scooping, moving and lifting various loose materials, such as mulch, dirt, snow, etc.).
[0020] As used herein the term “quick hitch” refers to quick hitches that are designed to interface with a snow/dirt blade (plow), a snow blower, a rotary broom (sweeper), and a plow shovel and utilize a linear actuator, such as a hydraulic cylinder to actuate these implements. Such power sources are readily available in the industry such as those produced by John Deere. The grapple assembly of the present invention is compatible with John Deere® quick hitches: BM1821, BM17347, BM19782, BM20921, BM18122, BM18644, BLV10159, BM26047, BM24898 and with minor modification is compatible with other manufacture of quick hitches.
[0021] For a complete understanding of the grapple assembly of the present invention, reference is made to the accompanying drawings and description in which the presently preferred embodiments of the invention are shown by way of example. As the invention may be embodied in many forms without departing from spirit of essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1 and 2 depict an assembly view of the preferred embodiment of a grapple assembly of the present invention attached to the quick hitch, the grapple assembly having the grapple jaws open.
[0023] FIGS. 3 and 4 depict an assembly view of the preferred embodiment of the grapple assembly of FIGS. 1 and 2 attached to the quick hitch, the grapple assembly having the grapple jaws closed.
[0024] FIG. 5 depicts an isometric view of the grapple assembly of FIGS. 3 and 4 , the grapple hydraulic cylinder being shown in phantom, absent the quick hitch, the grapple assembly having the grapple jaws closed.
[0025] FIG. 6 depicts a side view of the grapple assembly of FIGS. 1 and 2 , the grapple hydraulic cylinder being shown in phantom, absent the quick hitch, the grapple assembly having the grapple jaws open.
[0026] FIG. 7 depicts a side view of the grapple assembly of FIG. 5 , the grapple hydraulic cylinder being shown in phantom, the grapple assembly having the grapple jaws closed.
[0027] FIG. 8 depicts an isometric view of the upper jaw of FIG. 5 of the grapple assembly of the present invention.
[0028] FIG. 9 depicts an isometric view of the lower jaw of FIG. 5 of the grapple assembly of the present invention.
[0029] FIG. 10 depicts an isometric view of the hydraulic cylinder mount of FIG. 5 of the grapple assembly of the present invention.
[0030] FIG. 11 depicts an assembly view of the grapple assembly of FIG. 2 , the grapple assembly having the grapple jaws closed.
[0031] FIG. 12 depicts an assembly view of the grapple assembly of FIG. 1 , the grapple assembly having the grapple jaws open.
[0032] FIG. 13 depicts a side of the grapple assembly of FIG. 11 , the grapple assembly having the grapple jaws closed.
[0033] FIG. 14 depicts a side of the grapple assembly of FIG. 12 , the grapple assembly having the grapple jaws open.
[0034] FIG. 15 depicts a side of the grapple assembly of FIG. 2 attached to the quick hitch, the grapple assembly having the grapple jaws closed.
[0035] FIG. 16 depicts a side of the grapple assembly of FIG. 1 attached to the quick hitch, the grapple assembly having the grapple jaws open.
[0036] FIGS. 17A, 17B, and 17C depict a side view of the present invention connected to the quick hitch being used to grab an object.
[0037] FIGS. 18 and 19 depict two different assembly views of a simplified quick hitch which is attached to the grapple assembly of the present invention of FIGS. 1, 2, 3, and 4 .
[0038] FIG. 20 depicts an assembly view of the grapple assembly of FIG. 1 , the grapple assembly having the grapple jaws open.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to the drawings, FIGS. 1, 2, 3, and 4 depict various isometric views of the grapple assembly [ 1 ] of the present invention as depicted attached to a John Deere quick hitch [ 7 ], with the jaws either open or closed. The grapple assembly of the present invent includes an upper jaw [ 2 ], a lower jaw [ 3 ] and lower hydraulic cylinder mount [ 5 ]. The upper jaw [ 2 ] and the lower jaw [ 3 ] each include side plates made from laser cut steel. The upper jaw [ 2 ], comprises two upper side plates [ 15 ] which are attached to the upper front cross brace [ 17 ], and upper rear cross brace [ 12 ]. At the ends of the side plates [ 15 ] are upper jaw support brackets [ 24 ] which are welded into place to add more rigidity to the gripping surface of the upper jaw [ 2 ]. Instead of the support brackets [ 24 ], a straight tube can be used. Attached to the middle of the upper front and rear cross brace [ 17 and 18 ] is the center cross brace for the upper jaw [ 19 ] which also part of the hydraulic cylinder [ 4 ] mount attached. Welded onto the rear cross brace for the upper jaw [ 18 ] next to the center cross brace for the upper jaw [ 19 ] is the other half of the upper hydraulic cylinder [ 4 ] mount [ 6 ].
[0040] The hydraulic cylinder [ 4 ] which opens and closes the upper jaw [ 2 ] is attached at this point via two pins [ 14 ] and secured with cotter pins [ 8 ]. The lower hydraulic cylinder mount [ 5 ] is attached to the John Deere quick hitch mount and the lower part of the hydraulic cylinder [ 4 ] is attached. The hydraulic cylinder [ 4 ] is the lower cylinder of the quick hitch [ 7 ] which is normally used to move various implements from side to side, but in this application, is relocated so as to be used to open and close the upper jaw of the grapple assembly. Not all quick hitches come with the extra hydraulic cylinder to move the implements from side to side. This option is normally standard when using the snow blower attachment and the cylinder can be purchased separately if needed.
[0041] The grapple cylinder lower mount [ 5 ] is used to alter the angle of grapple hydraulic cylinder [ 4 A] of the grapple assembly [ 1 ] of the present invention and is secured to the quick hitch [ 7 ]. This enables the upper jaw of the grapple assembly to open and close to grasp various objects (logs, rocks, brush, etc.). The quick hitch [ 7 ] can then be raised and the object moved to a new location. The proprietary concepts of this design include the concept of relocating an existing grapple hydraulic cylinder [ 4 A] to provide the opening and closing function of the opposing grapple jaws [ 2 and 3 ].
[0042] This grapple hydraulic cylinder [ 4 A] is relocated and becomes the method for opening and closing the upper opposing jaw [ 2 ] of the grapple assembly [ 1 ].
[0043] Once installed on the quick-hitch [ 7 ], these opposing jaws [ 2 and 3 ] can be raised and lowered by the up/down cylinder on the quick-hitch [ 7 ] and opened and closed by the relocated grapple hydraulic cylinder [ 4 A]. This device can then be used to powerfully grasp and lift logs, rocks, boulders, brush, branches, limbs and many other objects.
[0044] Once lifted, they can be transported and deposited in a new location. The grapple assembly [ 1 ] of the present invention can be used for transporting, lifting and holding logs and limbs for cutting.
[0045] A grapple cylinder lower mount [ 5 ] bolts to the quick-hitch [ 7 ] to hold the relocated grapple hydraulic cylinder [ 4 A]. This grapple cylinder lower mount [ 5 ] comprises a bottom plate and 2 tabs welded together with opposing holes that enable the end of the grapple hydraulic cylinder [ 4 A] to attach with a pin. This grapple cylinder lower mount [ 5 ] attaches to the quick hitch [ 7 ] with either a carriage bolt and pin or even 2 pins. This hardware is provided with the grapple assembly [ 1 ] of the present invention. Since the quick hitch [ 7 ] has the ability to angle for the blade and the sweeper, it has a locking feature designed in (by John Deere) to enable a pin to be inserted that will lock the front section of the quick hitch [ 7 ] from rotating. Since the grapple assembly [ 1 ] does not rotate side to side (which is also not desired), this grapple cylinder lower mount [ 5 ] attaches to the quick hitch [ 7 ] using the anti-rotation hole so that the pin or carriage bolt will both secure the bracket to the hitch as well as lock the front section from rotating (killed 2 birds with 1 stone kind of thing). The John Deere hydraulic cylinders used by the quick hitch have 4 inches of total travel. They are 8″ when closed and 12″ when open. One primary challenge in designing the grapple assembly [ 1 ] of the present invention is to arrange the pivot points in such a way as to enable the necessary rotation of the upper opposing jaw [ 2 ] in order to be able to open far enough to grab large objects as well as to close completely shut for small objects.
[0046] The cylinder mounting points (on both ends) and the pivot points on the upper jaw have been creatively positioned to accomplish this challenging design criteria.
[0047] It was also necessary in redesigning the configuration so that the relocated grapple hydraulic cylinder [ 4 A] is not pinched or crushed when the quick-hitch [ 7 ] is raised by the hitch hydraulic cylinder [ 4 B].
[0048] The grapple hydraulic cylinder [ 4 A] is relocated to the location shown and attaches to the grapple cylinder lower mount [ 5 ] that bolts to the quick hitch [ 7 ]. The grapple hydraulic cylinder [ 4 A] also attaches to the upper jaw [ 2 ] for opening and closing.
[0049] The grapple cylinder lower mount [ 5 ] mounts to the quick hitch [ 7 ] using an existing hole in the quick hitch [ 7 ]. This hole is normally used to put an anti-rotation pin (or bolt) into when the angling cylinder is not used (using a snow blower). The bolt will come with my grapple assembly and serves a dual purpose to attach the bracket and provide anti rotation to the quick hitch much like the snow blower. The angling function is not needed or desired when using the grapple assembly [ 1 ] of the present invention.
[0050] The grapple hydraulic cylinder [ 4 A] that is relocated to operate the upper opposing jaw has 4 inches of total travel (pivot to pivot). It is 12 inches when extended and 8 inches when contracted. The pivot points of the grapple assembly [ 1 ] have been designed such that the upper opposing jaw [ 2 ] is in a closed position when the grapple hydraulic cylinder [ 4 A] is completely extended and will rotate 90 degrees open as the grapple hydraulic cylinder [ 4 A] contracts to 8 inches.
[0051] The lower hydraulic cylinder mount [ 5 ] is attached to the quick hitch [ 7 ] via two holes [ 20 ] located on the quick hitch [ 7 ]—depicted in FIG. 10 —the front most being the hole used to locate an anti-rotation pin when using a snow-blower and other similar attachments which do not use the hydraulic cylinder [ 4 ] used to move implements side to side. The bolt used to secure the lower hydraulic cylinder mount [ 5 ] replaces the anti-rotation pin which is normally used to lock the quick hitch [ 7 ] place.
[0052] To attach the grapple assembly [ 1 ] of the present invention to the quick hitch [ 7 ], the grapple assembly [ 1 ] is aligned with the quick hitch [ 7 ] and the quick hitch [ 7 ] is lowered and the tractor driven forward until the upper mounting slot [ 11 ] on the quick hitch [ 7 ] is aligned with the steel rod [ 21 ] which spans the width of the upper part of the lower jaw [ 3 ] of the grapple assembly [ 1 ]. Alternatively, in another preferred embodiment a rod [ 21 ] preferably made of steel or the like disposed on the grapple assembly [ 1 ] slides into a slot [ 11 ] disposed on the quick hitch [ 7 ] (on each side). The quick hitch [ 7 ] is then raised and the lower part of the grapple jaw [ 2 ] is attached to the lower part of the quick hitch [ 7 ] via a retractable pin [ 10 ] located on each side of the quick hitch [ 7 ]. Once this is done, the hydraulic cylinder [ 4 ] is then attached to the upper and lower mounts [ 5 and 6 ].
[0053] The lower hydraulic cylinder mount [ 5 ] is secured to the quick hitch using an existing hole in the quick hitch [ 7 ]. This hole is normally used to insert an anti-rotation pin or bolt into when the angling cylinder is not used e.g.—using snow blower. The bolt will come with the grapple assembly [ 1 ] pf the present invention and serves a dual purpose to attach the lower hydraulic cylinder mount [ 5 ] and provide anti-rotation to the quick hitch [ 7 ] (like the snow blower), the angling function is not needed or desired when using the grapple assembly [ 1 ] of the present invention.
[0054] FIG. 5 is an assembly depiction of the grapple assembly [ 1 ] of the present invention, and lower hydraulic cylinder mount [ 6 ] of the present invention not mounted on the John Deere quick hitch [ 7 ]. FIGS. 6, and 7 are side views of the grapple assembly [ 1 ] and lower hydraulic cylinder mount [ 6 ] of the present invention with the FIG. 6 depicting the grapple assembly [ 1 ] with the upper jaw [ 2 ] in the open position, while FIG. 7 is a depiction of the grapple assembly [ 1 ] with the upper jaw [ 2 ] in the closed position.
[0055] FIGS. 8 and 9 depict an assembly view of the upper and lower jaws [ 2 , 3 ] respectively while FIG. 10 is the lower hydraulic cylinder mount [ 5 ]. FIGS. 11 and 12 , show the assembled grapple [ 1 ]. In this view, it is possible to see how the upper jaw [ 2 ] is attached to the lower jaw [ 2 ] via two pins [ 14 ]. These pins [ 14 ] are held in place via a cotter pin [ 8 ]. This makes assembly and disassembly for maintenance very easy, as well as tool free, without comprising durability and strength.
[0056] FIGS. 13, and 14 depict a side view of the assembled grapple assembly [ 1 ] and attached cylinder [ 4 ]. In FIG. 13 , the upper jaw [ 2 ] is closed, and FIG. 14 , the upper jaw [ 2 ] is open. The cylinder [ 4 ] is attached to the upper jaw [ 2 ] and the lower mount [ 6 ]. During operation, the cylinder stays in the same position with only the piston moving and the upper jaw [ 2 ] opening, or closing.
[0057] FIG. 15 depicts a side of the grapple assembly of FIG. 2 attached to the quick hitch, the grapple assembly [ 1 ] having the grapple jaws [ 2 and 3 ] closed. And, FIG. 16 depicts a side of the grapple assembly of FIG. 1 attached to the quick hitch, the grapple assembly [ 1 ] having the grapple jaws [ 2 and 3 ] open. “DETAIL A” is an exploded view from FIG. 15 and depicts a rod [ 21 ] in the grapple assembly [ 1 ] of the present invention meshing into an upper mounting slot [ 11 ] in the quick hitch [ 7 ].
[0058] FIGS. 17A, 17B, and 17C depict the side view of the grapple assembly [ 1 ] of the present invention as it appears while grabbing and object [ 25 ]. To grab an object [ 25 ] ( FIG. 17A ) relative to the ground [ 26 ] the user moves the grapple assembly [ 1 ] down ( FIG. 17B ) and opens the upper jaw [ 2 ], then drives the tractor forward until the object is positioned far enough onto the lower jaw [ 3 ]. The upper jaw [ 2 ] is then closed and the grapple assembly [ 1 ] then raised ( FIG. 17C ) the object [ 25 ] relative to the ground [ 26 ].
[0059] FIGS. 18 and 19 depict two different assembly views of a simplified quick hitch [ 7 ] which is attached to the grapple assembly [ 1 ] of the present invention of FIGS. 1, 2, 3, and 4 .
[0060] FIG. 20 depicts an assembly view of the grapple assembly of FIG. 1 , the grapple assembly having the grapple jaws open. “DETAIL B” is an exploded view from FIG. 20 and depicts the pin detail pivotally connecting the upper jaw [ 2 ] to lower jaw 3 .
[0061] One of the challenges of the present invention was being able to get the hydraulic cylinder [ 4 ] to not be crushed or have any binding during use due to the mounting location being on top of the quick hitch base. Not only was this overcome, but the original hydraulic cylinder [ 4 ] has a movement range of only 4 ″ and the pivot points of the grapple upper jaw [ 2 ] had to be set to work within the limited range, while having a full range of operation.
[0062] The grapple assembly [ 1 ] of the present invention can be used for a variety of uses ranging from clearing debris, moving falling trees, pieces of concrete, etc. The advantage to using the present invention is its use of the John Deere® quick hitch system. This eliminates the need for separate mount, while enabling the user to also use all of the other implements which are also made by third party manufacturers. By using the existing hydraulic cylinders of the quick hitch [ 7 ] many people who already own a quick hitch [ 7 ] already have half the components necessary, thus saving money while also reducing the amount of parts necessary to use the grapple assembly [ 1 ] of the present invention. The grapple assembly [ 1 ] of the present invention can also hold objects, such as tree limbs securely, for cutting into smaller sections. It also greatly reduces the amount physical work necessary to move various objects and transport them.
[0063] Throughout this application, various Patents and Applications are referenced by number and inventor. The disclosures of these documents in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains.
[0064] It is evident that many alternatives, modifications, and variations of the grapple assembly [ 1 ] of the present invention will be apparent to those skilled in the art in light of the disclosure herein. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.
PARTS LIST
[0000]
1 . Grapple Assembly
2 . Upper Jaw
3 . Lower Jaw
4 A. Grapple Hydraulic Cylinder
4 B. Hitch Hydraulic Cylinder
5 . Grapple Cylinder Lower Mount
6 . Grapple Cylinder Upper Mount
7 . Quick Hitch
8 . Cotter Pin
9 . Hinge
10 . Retractable Pin
11 . Upper Mounting Slot
12 . Upper Cross Brace
13 . Front Cross Brace, Lower Jaw
14 . Pin
15 . Upper Side Plates
16 . Lower Side Plates
17 . Front Cross Brace, Upper Jaw
19 . Center Cross Brace with Hydraulic Cylinder Attachment, Upper Jaw
20 . Fastener Hole
21 . Rod
22 . Gripping Tooth
23 . Rear Cross Brace, Lower Jaw
24 . Upper Jaw Reinforcement
25 . Object
26 . Ground | A grapple assembly for a small tractor, which uses the John Deere front mounted quick hitch system in which the existing angular position cylinder of the quick hitch is repositioned so as to open and close the upper jaw of said grapple. The grapple assembly is compatible with small tractors that utilize the John Deere front mounted quick-hitch as a means to powerfully grasp and lift logs, rocks, boulders, brush, branches, limbs and many other objects, and transport and deposit these objects to a new location with virtually no tools and no physical effort by the operator. The grapple assembly is used for transporting, lifting and holding logs and limbs for cutting. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to provisional application 61/739561, filed Dec. 19, 2012.
FIELD OF THE DISCLOSURE
The present disclosure relates in general to electrical submersible well pump assemblies, and in particular o a well pump assembly having segments that are coupled to each other by a connector that allows pivoting between adjacent segments.
BACKGROUND
In oil wells and other similar applications in which the production of fluids is desired, a variety of fluid lifting systems have been used to pump the fluids to surface holding and processing facilities. It is common to employ various types of downhole pumping systems to pump the subterranean formation fluids to surface collection equipment for transport to processing locations. One such conventional pumping system is a submersible pumping assembly which is supported and immersed in the fluids in the wellbore. The submersible pumping assembly includes a pump and a motor to drive the pump to pressurize and pass the fluid through production tubing to a surface location. A typical electrical submersible pump assembly (“ESP”) includes a submersible pump, an electric motor and a seal section interdisposed between the pump and the motor. Sometimes the ESP assembly can include a separator to isolate fluids of different phases from one another. Depending on the particular application, the pump is usually a centrifugal pump or a progressing cavity pump.
Not all wells from which fluid is pumped with an ESP assembly are vertical. Some wells are deviated, i.e. not vertical, and some have are highly deviated and include horizontal portions. Because the upper portions of substantially all wells are vertical, wells having a horizontal portion bend when transitioning from vertical to horizontal. The bend in the well can introduce difficulties when deploying the ESP assembly, as the segments of the ESP assemblies form an elongate rigid member; which must flex to the same radius as the bend when being inserted downhole.
SUMMARY
The electrical submersible pump assembly disclosed herein has segments attached end to end and including a motor, a pump, and a seal section between the pump and the motor. Each of the segments has a housing and a rotatable shaft. At least one pivotal housing connector is attached between the housings of adjacent segments, allowing pivoting of the housings relative to each other. At least one pivotal shaft connector is attached between the shafts of adjacent segments. The shaft connector allows pivoting of the shafts of adjacent segments.
Preferably, the pivotal shaft connector is a universal joint mounted within the pivotal housing connector. The pivotal housing connector prevents axial rotation of one of the housings relative to the other of the housings. In the embodiment shown, the pivotal housing connector has two flanges facing in opposite directions. The flanges are bolted or secured by threads to the housings.
The pivotal housing connector may comprises a ball and socket arrangement. A key and slot located between the socket and the ball element prevent axial rotation of one of the housings relative to the other of the housings.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the features and benefits of the present disclosure having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a side partial sectional view of an example of an electrical submersible pumping (ESP) system disposed in a deviated wellbore in accordance with the present disclosure.
FIG. 2 is a side sectional view of an example of a connector for pivotingly connecting adjacent segments of the ESP system of FIG. 1 and in accordance with the present disclosure.
While the subject device and method will be described in connection with the preferred embodiments but not limited thereto. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the present disclosure as defined by the appended claims.
DETAILED DESCRIPTION
The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.
FIG. 1 is a side partial sectional view of an example of an electrical submersible pump assembly 10 deployed within a wellbore 12 that has a vertical portion 14 A and a deviated portion 14 B, both normally being cased. Deviated portion 14 B may be horizontal. The embodiment of the pump assembly 10 illustrated includes a motor 16 on its lower end whose upper end is coupled with a seal section 18 . Seal section 18 has means, such as a bladder, for reducing a pressure differential between lubricant in the motor and hydrostatic well fluid pressure. An optional separator 20 is shown attached on an upper end of seal section 18 and distal from motor 16 . A pump 22 is shown mounted onto an end of separator 20 distal from seal section 18 . Production tubing 24 is shown connected to an end of pump 22 opposite separator 20 and extending upward through the wellbore 12 . An upper end of the production tubing 24 terminates within a wellhead assembly 26 shown mounted on surface above an opening to the wellbore 12 . An inlet 27 is shown formed through a side wall of separator 20 which allows for fluid within wellbore 12 to enter the pump assembly 10 . Inside the separator 20 , different phases within the fluid (not shown) are isolated from one another. Liquid extracted from the wellbore fluid is directed to the pump 22 , where it is pressurized and delivered, to production tubing 24 for delivery to the wellhead assembly 26 . The vapor fraction of the wellbore fluid can be directed up the wellbore 12 to the wellhead assembly 26 , and outside of the pump assembly 10 . Embodiments of a pump assembly 10 not having a separator 20 exist, in these embodiments inlet 27 may be provided on the pump 22 .
The segments of the pump assembly 10 , e.g., motor 16 , seal section 18 , separator 20 , and pump 22 , are connected to one another by connectors 28 shown set between each adjacent segment. Each connector 28 is pivotable, so that the segments that it joins can pivot relative to each other When passing through the transition between well vertical portion 14 A and horizontal portion 14 B. That is, each segment can pivot into an orientation with its axis oblique to an axis of an adjacent segment. Thus when the pump assembly 10 encounters a curved transition in the wellbore 12 , the pivoting connectors 28 introduces pliability to the pump assembly 10 so it can flex to a curved shape of the wellbore 12 and be inserted past the bend in the wellbore 12 .
Alternately, some of the connectors between segments could be rigid, non pivoting types, and others could be pivotal connectors 28 . As an example, some of the segments of pump assembly 10 are much longer than others, such as a length of motor 16 versus seal section 18 . An operator may choose to employ a rigid connection between motor 16 and seal section 18 , as an example. Also, motor 16 could be tandem motors coupled together and pump 22 could comprise, tandem pumps 22 . The tandem components could be coupled together by conventional rigid connectors or by pivotal connectors 28 .
Referring now to FIG. 2 , an example of a connector 28 is shown in a side sectional view. FIG. 2 illustrates the connector 28 connecting between seal section 18 and motor 16 , but the description applies to the other modules of pump assembly 28 , as well. Further, even though connector 28 is shown connecting motor 16 with seal section 18 , a conventional non pivotal connector could be employed between motor 16 and seal section 18 , and pivotal connector 28 employed elsewhere in pump assembly 10 .
Connector 28 includes a housing connector or socket assembly 30 having a passage or bore 32 extending along an axis A x of the socket assembly 30 . A curved cavity 34 , which may be spherical, is formed within the socket assembly 30 and circumscribes a mid-portion of bore 32 ; socket cavity 34 movably receives therein a male portion 36 of socket assembly 30 . The male portion 36 of socket assembly 30 has a curved member shown to be spherically-shaped ball 38 shown set within cavity 34 .
Socket assembly 30 has an annular collar 33 with an external flange 35 on an end opposite cavity 34 . External flange 35 threadingly secures to a housing 39 of seal section 18 , such as by bolts 37 . Alternately, flange 35 could be rigidly connected in other manners, such as by external threads on flange 35 that engage internal threads in seal section housing 39 .
Male portion 36 has an annular collar 40 extending downward from ball 38 to outside of the socket assembly 30 . Collar 40 has a flange 41 that threadingly couples to a housing 43 of motor 16 , such as by bolts 45 . Alternately, the outer diameter of flange 41 could have external threads that engage internal threads in housing 43 . Connector 28 could be inverted with flange connecting to seal section 18 and flange 35 rigidly connecting to motor 16 .
The socket assembly 30 is shown having a male end 42 that threadingly couples to a female end 44 , where female end 44 circumscribes a portion of the ball 38 adjacent collar 40 , and also circumscribes a portion of collar 40 . Male end 42 circumscribes a portion of ball 38 distal from collar 40 . Included with male end 42 is an annular external pin portion 46 that extends axially towards the collar 40 and has threads provided along at least some of its outer surface. Pin portion 46 inserts into a box 48 that is coaxially formed within female end 44 and configured to receive pin portion 46 therein. Threads provided along an inner surface of box 48 mate with threads on the outer portion of pin 46 to form a threaded connection that extends coaxially around axis A x . In one example of assembly of the connector 28 , while male and female ends 42 , 44 are initially disconnected from one another, ball portion 36 inserts into spherical cavity 34 and is oriented so that collar 40 projects through an opening formed in the side of female end 44 formed by bore 32 . With ball 38 positioned inside cavity 34 , the pin 46 on male end 42 can be inserted within box 48 on female end 44 , and a threaded connection formed to couple together male and female ends 42 , 44 .
A slot 50 and key 52 are located between ball 38 and spherical cavity 34 to restrict pivotal movement of ball 38 in cavity 34 to a single plane. FIG. 2 shows key 52 mounted to a circumferential portion of cavity 34 and slot 50 on ball 38 , but that arrangement could be reversed. Slot 50 is elongated more than a height of key 52 to enable ball 38 to pivot at oblique angle relative to axis Ax. Slot 50 and key 52 prevent rotation of ball 38 in socket 34 about axis Ax, thus connectors 28 prevent axial rotation of the housings of the various segments of ESP 10 relative to each other. Arrangements other than slot 50 and key 52 are feasible to prevent rotation of ball 38 in cavity 34 about axis Ax are feasible.
Still referring to FIG. 2 , a passage or bore 54 is shown formed axially through the ball portion 36 and generally coaxial with axis A x . Bore 54 is in fluid communication with passage 32 , and both are in fluid communication with interior portions of seal section 18 and motor 16 . Preferably bores 32 and 54 are sealed from exterior well fluid, and this may be done with seals 53 that seal between socket cavity 34 and ball 38 . In this example, one seal 53 is mounted to male end 42 within cavity 34 and another to female end 44 within cavity 34 , but other arrangements are feasible.
A pivotal shaft connector or coupling assembly 56 , shown set within bore 54 , rotationally couples motor shaft 58 to seal section shaft 60 . Shaft coupling assembly 56 transmits torque between shafts 58 , 60 and allows shafts 58 , 50 to tilt oblique to axis Ax. Shaft coupling assembly 56 is preferably a universal joint. In the example of FIG. 2 , shaft coupling assembly 56 has a first coupling member 62 and a second coupling member 66 . First coupling member 62 is shown in cross section, and second coupling member 66 is shown in a side view. Each coupling member 62 , 66 has an internal splined receptacle 63 . Each shaft 58 , 60 has a splined end 64 that inserts into and meshes with one of the splined receptacles 63 .
Each shaft coupling member 62 , 66 has circumferentially spaced apart lugs 70 on the end opposite its splined receptacle 63 . Lugs 70 extend axially and are spaced apart 180 degrees. Pins 72 extend between lugs 70 and a central gimbal 74 , which may be a cylindrical disk. Lugs 70 and pins 72 on one of the coupling members 62 , 66 are spaced 90 degrees from those on the other coupling member 62 , 66 . Coupling members 62 , 66 allow tilting of shafts 58 , 60 relative to each other, but still transmit rotation. Shaft coupling assembly 56 is centrally located within ball bore 54 and sealed from well fluids by seals 53 . Other types of shaft coupling assemblies 56 rather than the universal joint shown are feasible.
During operation, the operator secures the various segments, such as motor 16 , seal section 18 , pump 20 , and optionally gas separator 22 with connectors, at least one of which will be a pivotal connector 28 . While lowering the pump assembly 10 in cased well 12 , the segments can pivot relative to each other when reaching the transition between the vertical portion 14 A and the inclined portion 14 B of well 12 . While pivoting, ball 38 will pivot relative to cavity 34 oblique to axis Ax, rotating about a center point of ball 38 along the portion of axis Ax within ball bore 54 . Similarly, shaft coupling 62 will pivot relative to shaft coupling 66 about a center point of gimbal 74 perpendicular to the portion of axis Ax passing through shaft coupling 56 . The center or pivot points of socket assembly 30 and shaft connector 56 may coincide with each other.
When reaching the desired depth, typically pump assembly 10 will be within a straight portion of the inclined section 14 B of well 12 . Motor 16 , seal section 18 , separator 20 and pump 22 will again be co-axial with each other. The operator supplies electrical power to motor 16 , which causes shaft 58 to rotate. Shaft coupling 56 transmits the rotation to seal section shaft 60 . The various couplings between the shafts of the segments of pump assembly 10 cause pump 22 to operate and pump fluid from the well. Housings 39 and 43 of seal section 18 and motor 16 do not rotate about their axes. Slot and key 50 , 52 prevent housings 39 and 43 front axial rotation relative to each other. Pump assembly 10 can also be operated with segments within a curved transition of well 12 . Shaft coupling 56 will transmit rotation of shaft 58 to shaft 60 even when the axis of shaft 58 is inclined relative to the axis of shaft 60 .
It is understood that variations may be made in the above without departing from the scope of the disclosure. While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this disclosure. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | An electrical submersible pumping system (ESP) for pumping fluids from a wellbore is made of segments, which include a motor, a seal section, a pump, and a shaft assembly connected to an output of the motor drives the pump. The motor, seal section, and pump are elongate members and coupled end to end to one another by housing connectors and shaft connectors. At least one of the housing connectors and shaft connectors have portions that are pivotable with other portions, so that adjacent segments of the ESP system can pivot with respect to one another. The housing connector can be a ball and socket assembly, where the ball fits within a spherically shaped chamber in the socket assembly. Opposing ends of the housing connector can mount to respective segments by threads or bolt flanges. The pivotal shaft connector may be a universal joint. |
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BACKGROUND OF THE INVENTION
This invention relates to the field of latches usable with sliding and swinging doors, gates, and the like and is particularly adapted to retaining the corners of machine shed doors and fence gates.
While the invention disclosed herein is adaptable to a variety of sliding and swinging doors or gates, it is particularly adaptable to the retention and latching of the large sliding doors commonly found on farm machine sheds. Such machine sheds normally have either one or two large sliding doors to permit tractors, implements, and the like to be moved into and out of the machine shed and such doors are normally slidably mounted and suspended from an overhead track. Because of the substantial size of such doors, they are particularly susceptible to dislodgment by wind and, even in moderate winds, have a tendency to swing and flap. If such flapping is not arrested, its frequency and magnitude can increase until the door is dislodged from the overhead track or even blown off the machine shed.
A partial solution to the wind dislodgment problem has been the driving of one or more heavy stakes or pipes into the earth adjacent the door to resist flapping movement. While this step is partially successful, the pipe is often in the way, is hazardous to those walking near the door and generally must be placed so near the door that it also provides interference with door movement when ice and snow accumulate in winter months. For these reasons, an improved apparatus for containment of machine shed doors is needed so as to retain the door closely against the machine shed in both open and closed positions of the door, to be resistant to ice, snow and extremes of weather and to be nonhazardous to those using the doors. The present invention solves these problems.
SUMMARY OF THE INVENTION
The invention utilizes a mounting bracket which is attached to a door frame or fence frame adjacent the door or gate to be restrained by the latch apparatus. The bracket has a pair of spaced-apart, converging guideways into which a tongue member of a keeper is removably inserted. Fixed to and extending outwardly from the tongue is a rigid, L-shaped strap which fits about the corner of the door and closely retains the door between the strap and the mounting bracket.
Because wind forces applied to machine shed doors can sometimes be intense, it is necessary to provide a latch apparatus which is resistant to such forces and which will resist dislodgment of the tongue from the guideways even under high wind conditions. This result is obtained by use of a special guideway and tongue construction. The guideways are provided with spacer plates fixed to the mounting bracket and having a thickness greater than the tongue. A guide plate is rigidly fixed to each spacer and the plates overlie the spacers to define a pair of tracks into which the tongue is inserted. Because the tongue is of less thickness than the spacers, the tongue has a tendency to cam and lock within the tracks when the door is urged outwardly against the strap as would be the result in response to wind applied to the door.
The lateral, track engaging sides of the tongue are provided with camming edges which, during camming, interlock with a roughened spacer support surface along each spacer to thereby further resist extraction of the tongue from the guideways.
Another problem to be overcome by a latch apparatus usable with machine shed doors is that such latches are commonly exposed to ice and snow, and it is desirable that the tongue not be frozen in place in the guideways or be unremovable by an operator. This problem is solved by providing the lateral track engaging sides of the tongue with fulcrums which bear against the spacer support surface when the tongue is inserted in the guidemeans, permitting an operator to sharply jerk the outwardly extending strap and cause sharp pivoting movement of the tongue about the fulcrum to thereby break loose and dislodge any ice or snow accumulation between tongue and guidemeans.
The latch apparatus has a tongue which is generally flat and hexagonal with the lateral track-engaging sides having upper and lower converging and generally equal length sections so that the tongue may be inserted within the guidemeans with either the upper sections or lower sections entering the guideways first. This results in the tongue being reversible to permit the L-shaped strap to extend laterally leftward or rightward from the mounting bracket and to thus retain the door in open or closed position.
While the invention is particularly well-adapted to the containment of machine shed doors, it should be understood that it is equally adaptable to a wide range of sliding or swinging doors and is particularly useful for the containment of sliding or swinging gates of fences where substantial forces can be expected to be applied to the gate by livestock.
The advantages and novel features which characterize the invention are set out with particularity in the claims attached hereto and forming a part of this description. For a full understanding of the invention and the objects and advantages obtained through its use, reference should be made to the drawing which forms a further part hereof and to the accompanying description in which is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view showing an enlarged embodiment of the latch apparatus in operation and attached to the side of a machine shed and retaining a sliding door of the shed.
FIG. 2 is an exploded perspective view of the embodiment of the latch apparatus shown in FIG. 1.
FIG. 3 is a front elevation view of the mounting bracket used with the embodiment of the latch apparatus shown in FIG. 2.
FIG. 4 is a top elevation view of the mounting bracket shown in FIG. 3.
FIG. 5 is a cross sectional, front elevation view of a keeper embodying the invention and taken in the direction of arrows 5--5 of FIG. 2.
FIG. 6 is a front elevation view partially in phantom of the keeper in rest position and in pivoted dislodging position within the mounting bracket showing the pivoting action of the tongue by which ice and snow may be shattered and dislodged from the mounting bracket.
FIG. 7 is a top elevation view of the lock apparatus showing the camming action between keeper and mounting bracket with the keeper in camming position.
FIG. 8 is a cross sectional front elevation view of the latch apparatus of FIG. 7 taken in the direction of arrows 8--8 and showing in enlarged form the interlocking action of the tongue's camming edges with the roughened spacer surfaces.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, the latch apparatus 10 includes a mounting bracket 12 attachable to a door frame or wall 52 of a machine shed 15 and a keeper 14 which is slidably, removably insertable in the bracket 12, as shown in FIG. 1.
The keeper 14 has a tongue 16 made of a rigid material such as steel sheet and preferably being flat and hexagonal in shape. The tongue 16 has an outer face 18 and a substantially parallel reverse face 20.
Generally parallel tongue top 22 and bottom 24 are interconnected by spaced-apart, symmetrical, lateral, track-engaging sides 26 and 28. Lateral side 26 includes upper and lower sections 26a and 26b, respectively, and lateral side 28 includes substantially identical upper and lower sections 28a and 28b, respectively.
The intersection of upper and lower sections 26a and 26b defines a reasonably sharp camming edge 26c, which is oriented transversely to the plane of the flat tongue 16 and will be described further hereafter. Similarly, the intersection between upper and lower sections 28a and 28b defines a camming edge 28c.
The tongue 16, which is preferably shaped as a regular hexagon with upper and lower sections 26a, 26b, 28a and 28b being of equal length also has the described upper and lower sections protruding laterally outwardly to define two opposed corners of the hexagonal plate, resulting in the formation of fulcrums 26d and 28d which permit pivoting of the tongue 16 about the camming edges 26c and 28d against the guidemeans as will be described further hereafter.
Fixed to the tongue 16 in any way known to the art, and extending transversely forwardly, outwardly from the outer face 18 is an integral rigid door-engaging strap 30 which is preferably formed of rigid material such as steel. The strap 30 has a first generally straight segment 32 which preferably extends outwardly from and perpendicular to the outer face 18. Extending transversely from the first segment 32 is a second segment 34 which is preferably oriented perpendicular to segment 32 and extends laterally, horizontally from the first segment of the tongue and is preferably parallel to the outer face 18. The segments 32 and 34 define a door corner retaining means which closely confronts and encompasses a corner 34 of a door 36 to be retained by the latch 10, and the first and second segments cooperate with the mounting bracket 12 to retain the door therebetween.
While the invention is described as being primarily used for retaining of a machine shed door, it should be understood that it may just as readily be used on other doors, gates or other sliding or swinging closures, and the term door, as used throughout this disclosure should be construed to include other closures including, but not limited to, fence gates and doors in general.
Located at the free end of the strap 30 and extending from the second segment 34 is a third segment 42 which is angled forwardly, transversely outwardly from the second segment 34 at an angle of approximately 30 degrees, although this angle may be increased or decreased somewhat while still being effective. The third segment has a door deflecting surface 44 positioned to receive and guide an approaching sliding door 40 as it nears the latch apparatus 10 so as to direct the door within the second segment 34 and against the first segment 32 where it can be retained between the strap 30 and the mounting bracket 12. As best shown in FIG. 1, a sliding door moving toward the latch apparatus 10 in direction 68 will strike door deflecting surface 44 (FIG. 7) and be guided along the second segment 34 of the strap 30.
The mounting bracket 12 has a generally elongated, rectangular, rigid mounting plate 46 preferably formed of sheet steel and suitable for attachment to the door frame or wall 52 adjacent doorway or fence, the mounting plate 46 being provided with transverse screw receiving apertures 48 extending between outer surface 53 and reverse surface 54, through which screws 50 extend into the door frame or wall 52.
The mounting bracket 12 includes first and second spaced-apart, converging guideways 56 and 58, respectively, each of which is rigidly fixed to the outer surface 53 of the mounting plate in any way known to the art, welding being preferred. The guideway 56 includes a spacer 56a which is rigidly, flushly fixed to the mounting bracket 12 by welding, the spacer being generally flat and extending outwardly from the face 53 a distance exceeding the thickness of the tongue 16. The guidemeans 56 further includes a guide plate 56b which is fixed to the spacer 56a by any means known to the art, such as welding, and overlies the spacer to cooperate with the spacer 56a and the outer face 53 of the mounting bracket to define a track 56c along which the tongue 16 is slidably receivable and in which the tongue can be retained when in rest position 60. Similarly, the second guideway 58 includes a substantially identical spacer 58a having a thickness exceeding the thickness of the tongue 16 and having fixed to the spacer a guide plate 58b which overlies the spacer 58a so as to define a track 58c along which the tongue is slidably receivable.
Each of the spacers 56a and 58a have a spacer support surface 56d and 58d, respectively, against which the lateral sides 26 and 28 of the tongue 16 will bear when the tongue is in rest position 60.
Each of the spacer support surfaces 56d and 58d has a rough texture, as best shown in FIG. 8, so as to confront and interlock with the camming edges 26c and 28c when the tongue 16 moves into camming position 78 in the guideways, as will be more fully described hereafter. Normally, the roughened texture of the spacer support surface 56d and 58d will result from cutting of the sheet material.
Accordingly, the spaced-apart converging guideways 56 and 58, which are oriented relative to one another to form a V-like configuration, provide a tongue retaining means by which the tongue 16 may be supported in a rest position 60 within the tracks 56c and 58c.
In operation, the mounting bracket 12 is attached to the door frame or wall 52 adjacent a door 40. Ordinarily, with the sliding doors associated with machine sheds, the door 40 is slidably movable between a closed position 62, wherein the door fully covers the doorway, and an open position 64, wherein the door is clear of the doorway and spaced several inches away from the doorway, as best shown in FIG. 1. Preferably, the mounting bracket 12 is positioned on the wall or doorway such that it occupies the location between the open and closed positions of the door 40 so that the latch apparatus may be used to retain the door 40 in either open or closed position. The mounting bracket 12 is secured to the wall 52 in the desired position by screws 50 inserted through screw apertures 48 in the bracket 12.
In describing the operation of the latch apparatus 10, it will be presumed that the door 40 is slidably mounted and is initially in the closed position 62. The operator first slidably inserts the tongue 16 of the keeper 14 into the tracks 56c and 58c of the guideways 56 and 58, respectively, with the L-shaped strap 30 being oriented in position 66 to extend toward the door 40, as shown in FIG. 1. The door 40 is slidably moved toward the first segment 32 of the strap 30 in direction 68 until the leading edge 70 of the door 40 contacts the door guiding surface 44 of segment 32. As the door 40 moves toward the segment 32, the leading edge 70 is directed by the surface 44 inwardly toward and along the second segment 34 until the edge 70 contacts the first segment 32. At this stage, the corner 38 of the door 40 is closely confronting and encompassed by the segments 32 and 34 of the strap 30. In this door position 62, the door 40, when subjected to wind forces in the direction 72 (FIG. 7), cannot escape the strap 30 and hence is retained in the upright position 62 without swinging or flapping movement.
When a force 72 acts on the door 40, (FIG. 7) the door corner 38 exerts an outward force 74 on the strap 30, causing the tongue 16 to swing from a rest position 60 within the tracks 56c and 58c to a cammed position 78 wherein the plane of the tongue outer face 18 becomes transverse to the outer face 53 of the mounting bracket with the tongue 16 camming between the spacers 56a and 58a, one of the guide plates, namely 58b and the outer face 53 of the mounting bracket. This camming movement causes the tongue 16 to lock within the guideways 56 and 58 and to thus resist extraction caused by wind or other force 74 applied to the door 40. The described camming is also important in retaining the tongue 16 in the tracks when the latch apparatus is used on gates of fences in which livestock is contained. Not infrequently, livestock will roughly, sharply collide with the fence gate and, without the camming action of the tongue, the applied forces could be adequate to extract the tongue from the mounting bracket.
As the tongue 16 cams in the guideways, the camming edges 26c and 28c tend to tightly engage the roughened surfaces 80 of the spacer support surfaces 56d and 58d as shown in FIG. 8, causing the camming edges 26c and 28c to interlock with the roughened surfaces 80 to further resist extraction of the tongue from the guideways.
During winter weather, snow and ice tend to accumulate in the tracks 56c and 58c and, were it not for the shape of the tongue 16, could cause the tongue 16 to become rigidly jammed or frozen in the tracks and difficult to use. This problem has been anticipated and solved by causing the upper and lower sections of the lateral sides 26 and 28 of the tongue 16 to be angled laterally outwardly toward the spacer support surfaces 56d and 58d so that none of the upper and lower sections 26a, 26b, 28a, 28b, are parallel to the spacer support surfaces when the tongue is in rest position 60, resulting in the tongue 18, when in rest position 60, (FIG. 6) having its fulcrums 26d and 28d contacting the spacer support surfaces at camming edges 26c and 28c, respectively. As best shown in FIG. 6, when the camming edges contact the spacer support surfaces, there remains a gap 82 between the lower sections 26b and 28b and the adjacent spacer support surface 56d and 58d, respectively. To remove ice accumulation in the gaps 82, an operator grasps the outwardly extending strap 30 and sharply twists and jerks the strap so as to generate a force couple comprised of forces F 1 and F 2 , causing the tongue 16 to pivot on the camming edge 28c and swing to an ice dislodging position 84. When the force F 1 and F 2 are applied by the operator, the ice accumulation in gap 82 is sharply compressed and fractured and the tongue 16 immediately freed from the guidemeans 56 and 58.
When it is desired to move the door 40 to an open position 64, the operator lifts the keeper 14 from the guidemeans 56 and 58 and then slides the door 40 to the open position 64. To retain the door in the open position 64, the operator rotates the keeper 14 through a 180 degree arc about the first segment 32 of the keeper, resulting in the strap 30 now being in position 86 (FIGS. 1 and 2) so as to confront and closely retain the door in open position 64. It should be understood that the upper sections 26a and 28a of the track engaging sides 26 and 28 are now positioned downwardly within the guidemeans 56 and 58 but that since the lengths of the upper sections 26a and 28a and their angular orientation are identical to the lower sections 26b and 28b, the function and operation of the keeper is identical to that described earlier and accordingly, the tongue is reversible to have the strap 30 extending leftward in position 86 or rightward in position 66 from the mounting bracket 12.
While the operation has been described in detail, when a sliding door is used with the latch apparatus 10, it should be understood that the sliding door may be replaced by a swinging door or gate and that such swinging door can be as readily retained by the apparatus, which functions substantially identically whether the door is swingably mounted or slidably mounted. While it has been indicated that the invention is particularly well adapted to machine shed doors and farm fences and gates, it should be understood that the invention may be used with other gate or door structures and all such uses as would be apparent to one skilled in the art are within the purview of the invention.
While the preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | A latch apparatus for doors and gates usable with swinging or sliding doors has a mounting bracket which is fixed to a door frame adjacent the door with a pair of converging guideways for retention of a keeper having a slidable tongue which may be removably inserted into the guideways. Extending outwardly from the tongue is a rigid L-shaped strap which fits about and retains a corner of a door to restrain swinging or sliding of the door relative to the strap. The tongue lockably cams within the guideways when force is applied against the strap so as to force the door. Additionally, the lateral sides of the tongue are provided with camming edges which engage a roughened surface within the guideways to further lock the tongue within the guideways. Each lateral side of the tongue has a fulcrum which bears against the guideways to permit the tongue to be sharply pivoted about the fulcrum by an operator so as to shatter and dislodge ice and accumulations in the guideways which would otherwise interfere with operation of the latch. |
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BACKGROUND and FIELD OF THE INVENTION
This invention relates to an improved system to indicate the vertical distance between points, and more particularly to a system that displays the vertical distance between points by means of sensing the pressure difference atop a fluid column through circuitry employing an electronic pressure sensor or sensors.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a closed top fluid filled column is set with one end in a fixed position while the other movable end, which is terminated with a membrane that exerts no force on the enclosed fluid except for that from atmospheric pressure, is placed upon any points within the range of the system or placed a fixed vertical distance from any points. Sensing the pressure difference at the fixed position end of fluid column gives a measure that is proportional to the vertical difference between points being measured. Using an electronic pressure sensor to measure pressure then enables the pressure differential to be converted to a readable display indicating the vertical distance between points, one point being a reference.
In an alternative application of the same invention, the system configuration is similar but, two fluid columns are used with the movable ends of the fluid columns being in line with, on opposite sides of, and positioned as equal distance from a movable point that is a fixed vertical distance from any point of interest, within the range of the system. In this application, the pressures at the top or closed end of the fluid columns are averaged and the resultant is again proportional to the vertical distance between points within the range of the system. One point is a reference and the relative vertical distance of other points is measured compared to it.
The specific objective of the invention is to advance the previous state of art to:
1) allow application on an excavator
2) improve accuracy
3) improve convenience of use
4) improve durability
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects and advantages of the invention will become more apparent by reference to the following detailed description of an embodiment when considered in conjunction with the accompanying drawings, which are schematic diagrams and illustrations of a Vertical Measurement System incorporating the principles of the invention.
FIG. 1 is a basic schematic diagram of the Vertical Measurement System.
FIG. 2 is an alternative embodiment of the Vertical Measurement System also depicting a portion of an excavator or backhoe.
FIG. 3 is a schematic diagram of the electronic circuitry that converts the output voltage of the electronic pressure sensor(s) to a digital signal that drives the display module. FIG. 4 is a side view of a backhoe or excavator stick and bucket with the applicant's Vertical Measurement System embodied in FIG. 2 attached.
FIG. 5 is a side view diagram of a backhoe with the applicant's Vertical Measurement System embodied in FIG. 2 attached.
FIG. 6 is a side view of a backhoe or excavator stick and bucket with the applicant's Vertical Measurement System embodied in FIG. 1 attached.
FIG. 7 is a side view diagram of an excavator with the applicant's Vertical Measurement System embodied in FIG. 1 attached.
DETAILED DESCRIPTION
Referring to drawing FIG. #1, a Vertical Measurement System includes a direct current voltage source which may be conveniently provided by a conventional battery 10 or a regulated power supply each having positive and negative terminals. The negative terminal of the battery 10 is connected directly to ground. Further, the illustrated Measurement System includes an electronic Pressure Sensor 12 having three terminals, low voltage which is connected to system ground, high voltage which is connected to the positive terminal of the battery, and an output voltage terminal which is connected to electronic circuitry 14, detailed in drawing FIG. #3, that converts the pressure sensor output voltage to indicate a vertical measurement on the incorporated display. The electronic circuitry 14 also is connected to the battery 10 terminals. Also, the illustrated Measurement System includes a flexible, fluid 20 filled, columnar hose 16 having a metal protective wrap, also having a cross sectional area that does not significantly change when flexed or when subjected to an internal vacuum. One end of this hose is connected to the electronic pressure sensor port and the other end 18 terminated with a membrane 22 that contains the fluid 20 but exerts no force on the enclosed fluid except for atmospheric pressure. This membrane is protected by a cover 42 which is ported 46 to the atmosphere. The configuration of the cover is not critical and is best determined by the specific application.
The Vertical Measurement System generates a desired display which represents the vertical distance between any points within range of the system by having the movable end of the fluid column 18 placed upon a reference point or a fixed distance above it, then placed upon other points or a fixed distance above them. The electronic circuitry 14 converts the electronic pressure sensor output to a readable display which represents the vertical distance between any point and the reference point. The display is continuously updated with information from the electronic pressure sensor through the electronic circuitry. This is possible because it is not necessary to include a fluid value which must be opened to obtain data. The protective fluid valve used in prior art, can be eliminated because there is very little fluid movement in the system due to the relatively small fluid cavity of the electronic pressure sensor and the constant cross sectional area of the protective wire wrapped hose used to contain the fluid column. This embodiment of the Vertical Measurement System as applied to a backhoe or excavator is illustrated in FIGS. #6 and #7.
In an alternative embodiment of the invention illustrated in drawing FIGS. #2, #4 and #5, the Vertical Measurement System is applied to a backhoe 50 or excavator. In such an application the battery 10 is the conventional battery on the backhoe or excavator. Other components of the system are as previously described and shown in drawing #1 but it may be desirable to add a second electronic pressure sensor 24, hose 26, fluid 28, and membrane 30. When utilizing two electronic pressure sensors, it is also necessary to include an averaging network shown in drawing #2 by resistors of equal value 32 and 34 but not limited to such an averaging network. In this embodiment of the invention, the movable ends of the fluid columns 18 and 36 are in line with the center of the pin 38 that connects the bucket to the end of the backhoe or excavator stick 40. The ends of the fluid columns 18 and 36 are equidistant from the pin and protected by covers 42 and 48 which are ported 46 and 48 to the atmosphere. This arrangement gives a particular advantage in this preferred embodiment of the invention in that the center of the pin 38 is a fixed distance from points of interest that are to be measured. Pin 38 also requires free access during the course of operation by the backhoe or excavator operator. The design configuration illustrated in drawing FIGS. #2, #4 and #5, yields a system equivalent of having the movable end of a fluid column at the center of the pin without hampering free access to that pin.
Applied to a backhoe or excavator, the applicant's Vertical Measurement System satisfies the previously stated objectives in a unique manner.
1) The system can be utilized on a excavator illustrated in FIG. 7 by fixing the top of the fluid column(s) at a point directly above the excavator crawler swing pivot 54. As the excavator body 52 rotates over the stationary crawler frame 56, only points directly above the swing pivot 54 are a constant vertical distance from a reference point on the ground if the crawler frame is not level. Since in most instances the crawler frame is not level, the top of the flexible fluid filled column(s) must be mounted along a line passing through the excavator crawler swing pivot 54. Since this area is not readily seen by the excavator operator, a remote pressure sensing device 12 must be used atop the fluid filled column(s), remote from the system display 14. This prevents a mechanical dial indicator from being used on a excavator but the applicant's Vertical Measurement System easily addresses the condition by utilizing an electronic pressure sensor(s)12 and remote system display 14 shown in FIGS. #1 and #7. These same comments apply to the embodiment of the Vertical Measurement System shown in FIG. #2 as applied to an excavator.
2) The applicant's Vertical Measurement System improves accuracy over previous state of art by selecting a fluid to fill the flexible column that has characteristics which compliment the selected electronic pressure sensor. The low end operating range of the Vertical Measurement System (maximum depth of the movable end of the fluid filled column(s) below the fixed position closed top end) is equal to the vertical column of fluid supported by the minimum operating pressure of the selected electronic pressure sensor. The high end operating range of the Vertical Measurement System (maximum height of the movable end of the flexible column(s) above the fixed position end of the column(s)) is equal to the height of a vertical column of fluid supported by the maximum operating pressure of the electronic pressure sensor. Accuracy is improved by selecting a fluid that is dense, so as to accentuate pressure differences atop the column(s) while meeting the other necessary characteristics of the fluid (inertness, fluidity, low freezing point). Additionally a compatible electronic pressure sensor must be selected that has an operating range which yields a total system range of approximately 24 feet. Most backhoes and excavators have an excavation depth of 24 feet or less which dictates a total system range requirement of approximately 24 feet.
Absolute accuracy of the electronic pressure sensor is proportional to its full scale reading. Therefore accuracy is improved by selecting an electronic pressure sensor with an operating range as small as possible yet one that can satisfy the total system range requirement. The specific gravity of the selected fluid coupled with the operating range of the selected electronic pressure sensor therefor have a significant effect upon accuracy. Accuracy is also improved by incorporating a ratiometric design on the input to the analog to digital converter ADC1225CCJ in FIG. #3, also by using 9 bits of conversion with the analog to digital conversion of the output voltage of the electronic pressure sensor(s).
3) The system improves convenience of use in several ways:
a) The system display 14 is remote from the electronic pressure sensor(s) 12 and 24, allowing both to be located at optimum positions, the electronic pressure sensor(s) directly above the excavator crawler swing pivot 54 and the system display in easy and close visual contact with with the backhoe or excavator operator.
b) The display is alpha numeric, indicating distance in English (feet and inches) or Metric scales. The English scale is easy to comprehend since it displays feet and inches as opposed to tenths of feet.
c) Once a single calibration point is made to any reference point, such as a grade stake, the applicant's Vertical Measurement System offers the user a continuous display of the vertical position of the movable end of the flexible fluid filled column(s). As applied to a backhoe or excavator, the operator of that equipment initially calibrates the system by placing the bucket on any known reference point and adjusts R1 of FIG. 3 which is a panel mounted potentiometer to cause the display to indicate the known elevation. Note that "0 feet and 0 inches" can also be used as the reference elevation. After this initial adjustment, the display continuously indicates the vertical position of the bucket as long as the bucket angularity relative to vertical is maintained. If the backhoe or excavator is repositioned for further excavation, the initial calibration procedure is repeated but any reference point where the elevation is known can be used, including an excavated area that was previously measured with the system.
d) The applicant's system does not require a protective fluid valve because the electronic pressure sensor has a small fluid cavity compared to typical mechanical pressure gauges and because a protective wire wrapped hose is utilized to contain the fluid column, this hose having a relatively constant cross sectional area when flexed or when subjected to an internal vacuum. Unlike previous state of art designs, no valve must be opened or closed to obtain a reading. This improves convenience of use as well as accuracy by not introducing a variable that could effect fluid pressure.
4) The system inherently has improved durability over previous state of art electronic designs because the electronic pressure sensor(s) and the electronic circuitry associated with it is located in or on the body of the excavator 52 or backhoe 50, away from the rugged environment of the bucket or stick. The durability of the membrane is also improved in that essentially no fluid is displaced from the electronic pressure sensor to the membrane or vice versa. The membrane therefore has little flexing during operation.
When an embodiment of the invention is applied to a backhoe or excavator, the invention furnishes the operator of such equipment the vertical distance of the bucket above or below an established reference point. In a Vertical Measurement System constructed in accordance with this preferred embodiment of the invention illustrated in drawing FIG. #2, the following circuit components were found to yield satisfactory results:
Battery 10: 14 volts from the backhoe standard battery regulated to 5.1 volts with a National Semiconductor LM123AK voltage regulator plus filter capacitors
Pressure Sensor 12 and 24: Fuji part number EP3445 with back side silicon sensing
Electronic Circuitry 14: Intel TP87C51FA microcontroller, a Saronix 1.8432 MHz crystal oscillator, a National Semiconductor ADC1225CCJ A/D Converter, a National Semiconductor LM358A Operational Amplifier used to establish a reference voltage, a Futaba M20SDOICA Display Module, and various resistors, capacitors and switches shown in FIG. #3
Hose 16 and 26: a vinyl inner sheave with a 1/4 inch inside diameter, protected by a wire wrap layer
Fluid 20 and 28: Prestone Ethylene glycol based antifreeze coolant
Membrane 22 and 30: Davol finger cot
Resistor 32 and 34: 27000 ohm+1% 1/4 watt
Using these selected components the following total system range and accuracy can be predicted:
System range=W/D×(Rmax-Rmin)/100 ]
where: W=the vertical column height of water supported by 1 atmosphere (100 KPa)
D=specific gravity of the fluid in the system
Rmax=the maximum operating pressure point of the selected electronic pressure sensor (KPa)
Rmin=the minimum operating pressure point of the selected electronic pressure sensor (KPa)
System range=[34 ft./1.11×(100-20)/100]
System range=24 feet, 6 inches
Accuracy=[Lerror×System range]
where: Lerror=the linearity error of the electronic pressure sensor
Accuracy=24 ft. 6 in.×0.5% maximum error
Accuracy=1.5 inches maximum error
Note: Accuracy calculations are at a constant temperature.
Other factors that could negatively affect accuracy are minimized and are not significant in the applicant's Vertical Measurement System. Factors such as:
Voltage sensitivity is minimized by use of a ratiometric design as shown in FIG. 3.
Analog to digital conversion error is minimized by using 9 bits of conversion as shown in FIG. 3.
Hysteresis is minimized by eliminating trapped air in the fluid filled column. Response time is also improved by eliminating all air from the fluid filled column.
It will now be readily appreciated that the invention provides a Vertical Measurement System which is particularly, though not exclusively, applicable to backhoes or excavators. However, it is to be understood that the preferred embodiment of the invention disclosed herein is shown for illustrative purposes only and that various modifications and alterations may be made thereto without departing from the spirit and scope of the invention. | The pressure atop a fluid filled flexible column, with the top end in a fixed position, is electronically measured and the result is utilized to indicate the vertical distance between points of interest. Associated electronics plus a suitable display, indicates the vertical distance between the points. As the lower end of the flexible fluid column is moved, the display continuously indicates the vertical distance relative to a reference point. The points of interest (one being a reference point) are measured by placing the opposite end of the flexible column on those points. As applied to a backhoe or excavator, the fluid filled flexible column is adhered to the boom and stick (major moving members of the equipment) and thereby furnishes the equipment operator the vertical position of the bucket (cutting edge of the equipment) compared to an established reference. The system continuously displays the relative vertical position of the bucket without the operator having to actuate any switch or valve. The display furnishes direct information to the operator, no manual calculations are required. |
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This is a division, of prior application Ser. No. 09/161,840, filed Sep. 28, 1998 which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates generally to movable barrier operators for operating movable barriers or doors. More particularly, it relates to garage door operators having improved safety and energy efficiency features.
Garage door operators have become more sophisticated over the years providing users with increased convenience and security. However, users continue to desire further improvements and new features such as increased energy efficiency, ease of installation, automatic configuration, and aesthetic features, such as quiet, smooth operation.
In some markets energy costs are significant. Thus energy efficiency options such as lower horsepower motors and user control over the worklight functions are important to garage door operator owners. For example, most garage door operators have a worklight which turns on when the operator is commanded to move the door and shuts off a fixed period of time after the door stops. In the United States, an illumination period of 4½ minutes is considered adequate. In markets outside the United States, 4½ minutes is considered too long. Some garage door operators have special safety features, for example, which enable the worklight whenever the obstacle detection beam is broken by an intruder passing through an open garage door. Some users may wish to disable the worklight in this situation. There is a need for a garage door operator which can be automatically configured for predefined energy saving features, such as worklight shut-off time.
Some movable barrier operators include a flasher module which causes a small light to flash or blink whenever the barrier is commanded to move. The flasher module provides some warning when the barrier is moving. There is a need for an improved flasher unit which provides even greater warning to the user when the barrier is commanded to move.
Another feature desired in many markets is a smooth, quiet motor and transmission. Most garage door operators have AC motors because they are less expensive than DC motors. However, AC motors are generally noisier than DC motors.
Most garage door operators employ only one or two speeds of travel. Single speed operation, i.e., the motor immediately ramps up to full operating speed, can create a jarring start to the door. Then during closing, when the door approaches the floor at full operating speed, whether a DC or AC motor is used, the door closes abruptly with a high amount of tension on it from the inertia of the system. This jarring is hard on the transmission and the door and is annoying to the user.
If two operating speeds are used, the motor would be started at a slow speed, usually 20 percent of full operating speed, then after a fixed period of time, the motor speed would increase to full operating speed. Similarly, when the door reaches a fixed point above/below the close/open limit, the operator would decrease the motor speed to 20 percent of the maximum operating speed. While this two speed operation may eliminate some of the hard starts and stops, the speed changes can be noisy and do not occur smoothly, causing stress on the transmission. There is a need for a garage door operator which opens the door smoothly and quietly, with no abruptly apparent sign of speed change during operation.
Garage doors come in many types and sizes and thus different travel speeds are required for them. For example, a one-piece door will be movable through a shorter total travel distance and needs to travel slower for safety reasons than a segmented door with a longer total travel distance. To accommodate the two door types, many garage door operators include two sprockets for driving the transmission. At installation, the installer must determine what type of door is to be driven, then select the appropriate sprocket to attach to the transmission. This takes additional time and if the installer is the user, may require several attempts before matching the correct sprocket for the door. There is a need for a garage door operator which automatically configures travel speed depending on size and weight of the door.
National safety standards dictate that a garage door operator perform a safety reversal (auto-reverse) when an object is detected only one inch above the DOWN limit or floor. To satisfy these safety requirements, most garage door operators include an obstacle detection system, located near the bottom of the door travel. This prevents the door from closing on objects or persons that may be in the door path. Such obstacle detection systems often include an infrared source and detector located on opposite sides of the door frame. The obstacle detector sends a signal when the infrared beam between the source and detector is broken, indicating an obstacle is detected. In response to the obstacle signal, the operator causes an automatic safety reversal. The door stops and begins traveling up, away from the obstacle.
There are two different “forces” used in the operation of the garage door operator. The first “force” is usually preset or setable at two force levels: the UP force level setting used to determine the speed at which the door travels in the UP direction and the DOWN force level setting used to determine the speed at which the door travels in the DOWN direction. The second “force” is the force level determined by the decrease in motor speed due to an external force applied to the door, i.e., from an obstacle or the floor. This external force level is also preset or setable and is any set-point type force against which the feedback force signal is compared. When the system determines the set point force has been met, an auto-reverse or stop is commanded.
To overcome differences in door installations, i.e. stickiness and resistance to movement and other varying frictional-type forces, some garage door operators permit the maximum force (the second force) used to drive the speed of travel to be varied manually. This, however, affects the system's auto-reverse operation based on force. The auto-reverse system based on force initiates an auto-reverse if the force on the door exceeds the maximum force setting (the second force) by some predetermined amount. If the user increases the force setting to drive the door through a “sticky” section of travel, the user may inadvertently affect the force to a much greater value than is safe for the unit to operate during normal use. For example, if the DOWN force setting is set so high that it is only a small incremental value less than the force setting which initiates an auto-reverse due to force, this causes the door to engage objects at a higher speed before reaching the auto-reverse force setting. While the obstacle detection system will cause the door to auto-reverse, the speed and force at which the door hits the obstacle may cause harm to the obstacle and/or the door.
Barrier movement operators should perform a safety reversal off an obstruction which is only marginally higher than the floor, yet still close the door safely against the floor. In operator systems where the door moves at a high speed, the relatively large momentum of the moving parts, including the door, accomplishes complete closure. In systems with a soft closure, where the door speed decreases from full maximum to a small percentage of full maximum when closing, there may be insufficient momentum in the door or system to accomplish a full closure. For example, even if the door is positioned at the floor, there is sometimes sufficient play in the trolley of the operator to allow the door to move if the user were to try to open it. In particular, in systems employing a DC motor, when the DC motor is shut off, it becomes a dynamic brake. If the door isn't quite at the floor when the DOWN travel limit is reached and the DC motor is shut off, the door and associated moving parts may not have sufficient momentum to overcome the braking force of the DC motor. There is a need for a garage door operator which closes the door completely, eliminating play in the door after closure.
Many garage door operator installations are made to existing garage doors. The amount of force needed to drive the door varies depending on type of door and the quality of the door frame and installation. As a result, some doors are “stickier” than others, requiring greater force to move them through the entire length of travel. If the door is started and stopped using the full operating speed, stickiness is not usually a problem. However, if the garage door operator is capable of operation at two speeds, stickiness becomes a larger problem at the lower speed. In some installations, a force sufficient to run at 20 percent of normal speed is too small to start some doors moving. There is a need for a garage door operator which automatically controls force output and thus start and stop speeds.
SUMMARY OF THE INVENTION
A movable barrier operator having an electric motor for driving a garage door, a gate or other barrier is operated from a source of AC current. The movable barrier operator includes circuitry for automatically detecting the incoming AC line voltage and frequency of the alternating current. By automatically detecting the incoming AC line voltage and determining the frequency, the operator can automatically configure itself to certain user preferences. This occurs without either the user or the installer having to adjust or program the operator. The movable barrier operator includes a worklight for illuminating its immediate surroundings such as the interior of a garage. The barrier operator senses the power line frequency (typically 50 Hz or 60 Hz) to automatically set an appropriate shut-off time for a worklight. Because the power line frequency in Europe is 50 Hz and in the U.S. is 60 Hz, sensing the power line frequency enables the operator to configure itself for either a European or a U.S. market with no user or installer modifications. For U.S. users, the worklight shut-off time is set to preferably 4½ minutes; for European users, the worklight shut-off time is set to preferably 2½ minutes. Thus, a single barrier movement operator can be sold in two different markets with automatic setup, saving installation time.
The movable barrier operator of the present invention automatically detects if an optional flasher module is present. If the module is present, when the door is commanded to move, the operator causes the flasher module to operate. With the flasher module present, the operator also delays operation of the motor for a brief period, say one or two seconds. This delay period with the flasher module blinking before door movement provides an added safety feature to users which warns them of impending door travel (e.g. if activated by an unseen transmitter).
The movable barrier operator of the present invention drives the barrier, which may be a door or a gate, at a variable speed. After motor start, the electric motor reaches a preferred initial speed of 20 percent of the full operating speed. The motor speed then increases slowly in a linearly continuous fashion from 20 percent to 100 percent of full operating speed. This provides a smooth, soft start without jarring the transmission or the door or gate. The motor moves the barrier at maximum speed for the largest portion of its travel, after which the operator slowly decreases speed from 100 percent to 20 percent as the barrier approaches the limit of travel, providing a soft, smooth and quiet stop. A slow, smooth start and stop provides a safer barrier movement operator for the user because there is less momentum to apply an impulse force in the event of an obstruction. In a fast system, relatively high momentum of the door changes to zero at the obstruction before the system can actually detect the obstruction. This leads to the application of a high impulse force. With the system of the invention, a slower stop speed means the system has less momentum to overcome, and therefore a softer, more forgiving force reversal. A slow, smooth start and stop also provide a more aesthetically pleasing effect to the user, and when coupled with a quieter DC motor, a barrier movement operator which operates very quietly.
The operator includes two relays and a pair of field effect transistors (FETs') for controlling the motor. The relays are used to control direction of travel. The FET's, with phase controlled pulse width modulation, control start up and speed. Speed is responsive to the duration of the pulses applied to the FETs. A longer pulse causes the FETs to be on longer causing the barrier speed to increase. Shorter pulses result in a slower speed. This provides a very fine ramp control and more gentle starts and stops.
The movable barrier operator provides for the automatic measurement and calculation of the total distance the door is to travel. The total door travel distance is the distance between the UP and the DOWN limits (which depend on the type of doors. The automatic measurement of door travel distance is a measure of the length of the door. Since shorter doors must travel at slower speeds than normal doors (for safety reasons), this enables the operator to automatically adjust the motor speed so the speed of door travel is the same regardless of door size. The total door travel distance in turn determines the maximum speed at which the operator will travel. By determining the total distance traveled, travel speeds can be automatically changed without having to modify the hardware.
The movable barrier operator provides full door or gate closure, i.e. a firm closure of the door to the floor so that the door is not movable in place after it stops. The operator includes a digital controller or processor, specifically a microcontroller which has an internal microprocessor, an internal RAM and an internal ROM and an external EEPROM. The microcontroller executes instructions stored in its internal ROM and provides motor direction control signals to the relays and speed control signals to the FETs. The operator is first operated in a learn mode to store a DOWN limit position for the door. The DOWN limit position of the door is used as an approximation of the location of the floor (or as a minimum reversal point, below which no auto-reverse will occur). When the door reaches the DOWN limit position, the microcontroller causes the electric motor to drive the door past the DOWN limit a small distance, say for one or two inches. This causes the door to close solidly on the floor.
The operator embodying the present invention provides variable door or gate output speed, i.e., the user can vary the minimum speed at which the motor starts and stops the door. This enables the user to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces. The minimum barrier speeds in the UP and DOWN directions are determined by the user-configured force settings, which are adjusted using UP and DOWN force potentiometers. The force potentiometers set the lengths of the pulses to the FETs, which translate to variable speeds. The user gains a greater force output and a higher minimum starting speed to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces speed, without affecting the maximum speed of travel for the door. The user can configure the door to start at a speed greater than a default value, say 20 percent. This greater start up and slow down speed is transferred to the linearly variable speed function in that instead of traveling at 20 percent speed, increasing to 100 percent speed, then decreasing to 20 percent speed, the door may, for instance, travel at 40 percent speed to 100 percent speed and back down to 40 percent speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a garage having mounted within it a garage door operator embodying the present invention;
FIG. 2 is an exploded perspective view of a head unit of the garage door operator shown in FIG. 1;
FIG. 3 is an exploded perspective view of a portion of a transmission unit of the garage door operator shown in FIG. 1;
FIG. 4 is a block diagram of a controller and motor mounted within the head unit of the garage door operator shown in FIG. 1;
FIGS. 5A-5D are a schematic diagram of the controller shown in block format in FIG. 4;
FIGS. 6A-6B are a flow chart of an overall routine that executes in a microprocessor of the controller shown in FIGS. 5A-5D;
FIGS. 7A-7H are a flow chart of the main routine executed in the microprocessor;
FIG. 8 is a flow chart of a set variable light shut-off timer routine executed by the microprocessor;
FIGS. 9A-9C are a flow chart of a hardware timer interrupt routine executed in the microprocessor;
FIGS. 10A-10C are a flow chart of a 1 millisecond timer routine executed in the microprocessor;
FIGS. 11A-11C are a flow chart of a 125 millisecond timer routine executed in the microprocessor;
FIGS. 12A-12E are a flow chart of a 4 millisecond timer routine executed in the microprocessor;
FIGS. 13A-13B are a flow chart of an RPM interrupt routine executed in the microprocessor;
FIG. 14 is a flow chart of a motor state machine routine executed in the microprocessor;
FIG. 15 is a flow chart of a stop in midtravel routine executed in the microprocessor;
FIG. 16 is a flow chart of a DOWN position routine executed in the microprocessor;
FIGS. 17A-17C are a flow chart of an UP direction routine executed in the microprocessor;
FIG. 18 is a flow chart of an auto-reverse routine executed in the microprocessor;
FIG. 19 is a flow chart of an UP position routine executed in the microprocessor;
FIGS. 20A-20D are a flow chart of the DOWN direction routine executed in the microprocessor;
FIG. 21 is an exploded perspective view of a pass point detector and motor of the operator shown in FIG. 2;
FIG. 22A is a plan view of the pass point detector shown in FIG. 21; and
FIG. 22B is a partial plan view of the pass point detector shown in FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and especially to FIG. 1, a movable barrier or garage door operator system is generally shown therein and referred to by numeral 8 . The system 8 includes a movable barrier operator or garage door operator 10 having a head unit 12 mounted within a garage 14 . More specifically, the head unit 12 is mounted to a ceiling 15 of the garage 14 . The operator 10 includes a transmission 18 extending from the head unit 12 with a releasable trolley 20 attached. The releasable trolley 20 releasably connects an arm 22 extending to a single panel garage door 24 positioned for movement along a pair of door rails 26 and 28 .
The system 8 includes a hand-held RF transmitter unit 30 adapted to send signals to an antenna 32 (see FIG. 4) positioned on the head unit 12 and coupled to a receiver within the head unit 12 as will appear hereinafter. A switch module 39 is mounted on the head unit 12 . Switch module 39 includes switches for each of the commands available from a remote transmitter or from an optional wall-mounted switch (not shown). Switch module 39 enables an installer to conveniently request the various learn modes during installation of the head unit 12 . The switch module 39 includes a learn switch, a light switch, a lock switch and a command switch, which are described below. Switch module 39 may also include terminals for wiring a pedestrian door state sensor comprising a pair of contacts 13 and 15 for a pedestrian door 11 , as well as wiring for an optional wall switch (not shown).
The garage door 24 includes the pedestrian door 11 . Contact 13 is mounted to door 24 for contact with contact 15 mounted to pedestrian door 11 . Both contacts 13 and 15 are connected via a wire 17 to head unit 12 . As will be described further below, when the pedestrian door 11 is closed, electrical contact is made between the contacts 13 and 15 closing a pedestrian door circuit in the receiver in head unit 12 and signalling that the pedestriam door state is closed. This circuit must be closed before the receiver will permit other portions of the operator to move the door 24 . If circuit is open, indicating that the pedestrian door state is open, the system will not permit door 24 to move.
The head unit 12 includes a housing comprising four sections: a bottom section 102 , a front section 106 , a back section 108 and a top section 110 , which are held together by screws 112 as shown in FIG. 2 . Cover 104 fits into front section 106 and provides a cover for a worklight. External AC power is supplied to the operator 10 through a power cord 122 . The AC power is applied to a step-down transformer 120 . An electric motor 118 is selectively energized by rectified AC power and drives a sprocket 125 in sprocket assembly 124 . The sprocket 125 drives chain 144 (see FIG. 3 ). A printed circuit board 114 includes a controller 200 and other electronics for operating the head unit 12 . A cable 116 provides input and output connections on signal paths between the printed circuit board 114 and switch module 39 . The transmission 18 , as shown in FIG. 3, includes a rail 142 which holds chain 144 within a rail and chain housing 140 and holds the chain in tension to transfer mechanical energy from the motor to the door.
A block diagram of the controller and motor connections is shown in FIG. 4 . Controller 200 includes an RF receiver 80 , a microprocessor 300 and an EEPROM 302 . RF receiver 80 of controller 200 receives a command to move the door and actuate the motor either from remote transmitter 30 , which transmits an RF signal which is received by antenna 32 , or from a user command switch 250 . User command switch 250 can be a switch on switch panel 39 , mounted on the head unit, or a switch from an optional wall switch. Upon receipt of a door movement command signal from either antenna 32 or user switch 250 , the controller 200 sends a power enable signal via line 240 to AC hot connection 206 which provides AC line current to transformer 212 and power to work light 210 . Rectified AC is provided from rectifier 214 via line 236 to relays 232 and 234 . Depending on the commanded direction of travel, controller 200 provides a signal to either relay 232 or relay 234 . Relays 232 and 234 are used to control the direction of rotation of motor 118 by controlling the direction of current flow through the windings. One relay is used for clockwise rotation; the other is used for counterclockwise rotation.
Upon receipt of the door movement command signal, controller 200 sends a signal via line 230 to power-control FET 252 . Motor speed is determined by the duration or length of the pulses in the signal to a gate electrode of FET 252 . The shorter the pulses, the slower the speed. This completes the circuit between relay 232 and FET 252 providing power to motor 118 via line 254 . If the door had been commanded to move in the opposite direction, relay, 234 would have been enabled, completing the circuit with FET 252 and providing power to motor 118 via line 238 .
With power provided, the motor 118 drives the output shaft 216 which provides drive power to transmission sprocket 125 . Gear reduction housing 260 includes an internal pass point system which sends a pass point signal via line 220 to controller 200 whenever the pass point is reached. The pass point signal is provided to controller 200 via current limiting resistor 226 to protect controller 200 from electrostatic discharge (ESD). An RPM interrupt signal is provided via line 224 , via current limiting resistor 228 , to controller 200 . Lead 222 provides a plus five volts supply for the Hall effect sensors in the RPM module. Commanded force is input by two force potentiometers 202 , 204 . Force potentiometer 202 is used to set the commanded force for UP travel; force potentiometer 204 is used to set the commanded force for DOWN travel. Force potentiometers 202 and 204 provide commanded inputs to controller 200 which are used to adjust the length of-the pulsed signal provided to FET 252 .
The pass point for this system is provided internally in the motor 118 . Referring to FIG. 21, the pass point module 40 is attached to gear reduction housing 260 of motor 118 . Pass point module 40 includes upper plate 42 which covers the three internal gears and switch within lower housing 50 . Lower housing 50 includes recess 62 having two pins 61 which position switch assembly 52 in recess 62 . Housing 50 also includes three cutouts which are sized to support and provide for rotation of the three geared elements. Outer gear 44 fits rotatably within cutout 64 . Outer gear includes a smooth outer surface for rotating within housing 50 and inner gear teeth for rotating middle gear 46 . Middle gear 46 fits rotatably within inner cutout 66 . Middle gear 46 includes a smooth outer surface and a raised portion with gear teeth for being driven by the gear teeth of outer ring gear 44 . Inner gear 48 fits within middle gear 46 and is driven by an extension of shaft 216 (FIG. 4 ). Rotation of the motor 118 causes shaft 216 to rotate and drive inner gear 48 .
Outer gear 44 includes a notch 74 in the outer periphery. Middle gear includes a notch 76 in the outer periphery. Referring to FIG. 22A, rotation of inner gear 48 rotates middle gear 46 in the same direction. Rotation of middle gear 46 rotates outer gear 44 in the same direction. Gears 46 and 44 are sized such that pass point indications comprising switch release cutouts 74 and 76 line up only once during the entire travel distance of the door. As seen in FIG. 22A, when switch release cutouts 74 and 76 line up, switch 72 is open generating a pass point presence signal. The location where switch release cutouts 74 and 76 line up is the pass point. At all other times, at least one of the two gears holds switch 72 closed generating a signal indicating that the pass point has not been reached.
The receiver portion 80 of controller 200 is shown in FIG. 5 A. RF signals may be received by the controller 200 at the antenna 32 and fed to the receiver 80 . The receiver 80 includes variable inductor L 1 and a pair of capacitors C 2 and C 3 that provide impedance matching between the antenna 32 and other portions of the receiver. An NPN transistor Q 4 is connected in common-base configuration as a buffer amplifier. Bias to the buffer amplifier transistor Q 4 is provided by resistors R 2 , R 3 . The buffered PR output signal is supplied to a second NPN transistor Q 5 . The radio frequency signal is coupled to a bandpass amplifier 280 to an average detector 282 which feeds a comparator 284 . Referring to FIGS. 5C and 5B, the analog output signal A, B is applied to noise reduction capacitors C 19 , C 20 and C 21 then provided to pins P 32 and P 33 of the microcontroller 300 . Microcontroller 300 mans be a Z86733 microprocessor.
As can be seen in FIG. 5D, an external transformer 212 receives AC power from a source such as a utility and steps down the AC voltage to the power supply 90 circuit of controller 200 . Transformer 212 provides AC current to full-wave bridge circuit 214 , which produces a 28 volt full wave rectified signal across capacitor C 35 . The AC power may have a frequency of 50 Hz or 60 Hz. An external transformer is especially important when motor 118 is a DC motor. The 28 volt rectified signal is used to drive a wall control switch, an obstacle detector circuit, a door-in-door switch and to power FETs Q 11 and Q 12 (FIG. 5C) used to start the motor. Zener diode D 18 protects against overvoltage due to the pulsed current, in particular, from the FETs rapidly switching off inductive load of the motor. The potential of the full-wave rectified signal is further reduced to provide 5 volts at capacitor C 38 , which is used to power the microprocessor 300 , the receiver circuit 80 and other logic functions.
The 28 volt rectified power supply signal indicated by reference numeral T in FIG. 5C is voltage divided down by resistors R 61 and R 62 , then applied to an input pin P 24 of microprocessor 300 (FIG. 5 B). This signal is used to provide the phase of the power line current to microprocessor 300 . Microprocessor 300 constantly checks for the phase of the line voltage in order to determine if the frequency of the line voltage is 50 Hz or 60 Hz. This information is used to establish the worklight time-out period and to select the look-up table stored in the ROM in the microcontroller for converting pulse width to door speed.
When the door is commanded to move, either through a signal from a remote transmitter received through antenna 32 and processed by receiver 80 , or through an optional wall switch, the microprocessor 300 commands the work light to turn on. Microprocessor 300 (FIG. 5B) sends a worklight enable signal from pin P 07 . In FIG. 5C, the worklight enable signal is applied to the base of transistor Q 3 , which drives relay K 3 . AC power from a signal U provides power for operating the worklight 210 .
Microprocessor 300 reads from and writes data to an EEPROM 302 via its pins P 25 , P 26 and P 27 . EEPROM 302 may be a 93C46. Microprocessor 300 provides a light enable signal at pin P 21 which is used to enable a learn mode indicator yellow LED D 15 . LED D 15 is enabled or lit when the receiver is in the learn mode. Pin P 26 provides double duty. When the user selects switch S 1 , a learn enable signal is provided to both microprocessor 300 and EEPROM 302 . Switch S 1 is mounted on the head unit 12 and is part of switch module 39 , which is used by the installer to operate the system.
An optional flasher module provides an additional level of safety for users and is controlled by microprocessor 300 at pin P 22 . The optional flasher module is connected between terminals 308 and 310 . In the optional flasher module, after receipt of a door command, the microprocessor 300 sends a signal from P 22 which causes the flasher light to blink for 2 seconds. The door does not move during that 2 second period, giving the user notice that the door has been commanded to move and will start to move in 2 seconds. After expiration of the 2 second period, the door moves and the flasher light module blinks during the entire period of door movement. If the operator does not have a flasher module installed in the head unit, when the door is commanded to move, there is no time delay before the door begins to move.
Microprocessor 300 provides the signals which start motor 118 , control its direction of rotation (and thus the direction of movement of the door) and the speed of rotation (speed of door travel). FETs Q 11 and Q 12 are used to start motor 118 . Microprocessor 300 applies a pulsed output signal to the gates of FETs Q 11 and Q 12 . The lengths of the pulses determine the time the FETs conduct and thus the around of time current is applied to start and run the motor 118 . The longer the pulse, the longer current is applied, the greater the speed of rotation the motor 118 will develop. Diode D 11 is coupled between the 28 volt power supply and is used to clean up flyback voltage to the input bridge D 4 when theFETs are conducting. Similarly, Zener diode D 19 (see FIG. 5D) is used to protect against overvoltage when the FETs are conducting.
Control of the direction of rotation of motor 118 (and thus direction of travel of the door) is accomplished with two relays, K 1 and K 2 (FIG. 5 C). Relay K 1 supplies current to cause the motor to rotate clockwise in an opening direction (door moves UP); relay K 2 supplies current to cause the motor to rotate counterclockwise in a closing direction (door moves DOWN). When the door is commanded to move UP, the microprocessor 300 sends an enable signal from pin P 05 to the base of transistor Q 1 , which drives relay K 1 . When the door is commanded to move DOWN, the microprocessor 300 sends an enable signal from pin P 06 to the base of transistor Q 2 , which drives relay K 2 .
Door-in-door contacts 13 and 15 are connected to terminals 304 and 306 . Terminals 304 and 306 are connected to relays K 1 and K 2 . If the signal between contacts 13 and 15 is broken, the signal across terminals 304 and 306 is open, preventing relays K 1 and K 2 from energizing. The motor 118 will not rotate and the door 24 will not move until the user closes pedestrian door 1 l, making contact between contacts 13 and 15 .
In FIG. 5B, the pass point signal 220 from the pass point module 40 (see FIG. 21) of motor 118 is applied to pin P 23 of microprocessor 300 . The RPM signal 224 from the RPM sensor module in motor 118 is applied to pin P 31 of microprocessor 300 . Application of the pass point signal and the RPM signal is described with reference to the flow charts.
An optional wall control, which duplicates the switches on remote transmitter 30 , may be connected to controller 200 at terminals 312 and 314 . When the user presses the door command switch 39 , a dead short is made to ground, which the microprocessor 300 detects by the failure to detect voltage. Capacitor C 22 is provided for RF noise reduction. The dead short to ground is sensed at pins P 02 and P 03 , for redundancy.
Switches S 1 and S 2 are part of switch module 39 mounted on head unit 12 and used by the installer for operating the system. As stated above, S 1 is the learn switch. S 2 is the door command switch. When S 2 is pressed, microprocessor 300 detects the dead short at pins P 02 and P 03 .
Input from an obstacle detector (not shown) is provided at terminal 316 . This signal is voltage divided down and provided to microprocessor 300 at pins P 20 and P 30 , for redundancy. Except when the door is moving and less than an inch above the floor, when the obstacle detector senses an object in the doorway, the microprocessor executes the auto-reverse routine causing the door to stop and/or reverse depending on the state of the door movement.
Force and speed of door travel are determined by two potentiometers. Potentiometer R 33 adjusts the force and speed of UP travel; potentiometer R 34 adjusts the force and speed of DOWN travel. Potentiometers R 33 and R 34 ,act as analog voltage dividers. The analog signal from R 33 , R 34 is further divided down by voltage divider R 35 /R 37 , R 36 /R 38 before it is applied to the input of comparators 320 and 322 . Reference pulses from pins P 34 and P 35 of microprocessor 300 are compared with the force input from potentiometers R 33 and R 34 in comparators 320 and 322 . The output of comparators 320 and 322 is applied to pins P 01 and P 00 .
To perform the A/D conversion, the microprocessor 300 samples the output of the comparators 320 and 322 at pins P 00 and P 01 to determine which voltage is higher: the voltage from the potentiometer R 33 or R 34 (IN) or the voltage from the reference pin P 34 or P 35 (REF). If the potentiometer voltage is higher than the reference, then the microprocessor outputs a pulse. If not, the output voltage is held low. The RC filter (R 39 , C 29 /R 40 , C 30 ) converts the pulses into a DC voltage equivalent to the duty cycle of the pulses. By outputting the pulses in the manner described above, the microprocessor creates a voltage at REF which dithers around the voltage at IN. The microprocessor then calculates the duty cycle of the pulse output which directly correlates to the voltage seen at IN.
When power is applied to the head unit 12 including controller 200 , microprocessor 300 executes a series of routines. With power applied, microprocessor 300 executes the main routines shown in FIGS. 6A and 6B. The main loop 400 includes three basic functions, which are looped continuously until power is removed. In block 402 the microprocessor 300 handles all non-radio EEPROM communications and disables radio access to the EEPROM 302 when communicating. This ensures that during normal operation, i.e., when the garage door operator is not being programmed, the remote transmitter does not have access to the EEPROM, where transmitter codes are stored. Radio transmissions are processed upon receipt of a radio interrupt (see below).
In block 404 , microprocessor 300 maintains all low priority tasks, such as calculating new force levels and minimum speed. Preferably, a set of redundant RAM registers is provided. In the event of an unforeseen event (e.g., an ESD event) which corrupts regular RAM, the main RAM registers and the redundant RAM registers will not match. Thus, when the values in RAM do not match, the routine knows the regular RAM has been corrupted. (See block 504 below.) In block 406 , microprocessor 300 tests redundant RAM registers. Several interrupt routines can take priority over blocks 402 , 404 and 406 .
The infrared obstacle detector generates an asynchronous IR interrupt signal which is a series of pulses. The absence of the obstacle detector pulses indicates an obstruction in the beam. After processing the IR interrupt, microprocessor 300 sets the status of the obstacle detector as unobstructed at block 416 .
Receipt of a transmission from remote transmitter 30 generates an asynchronous radio interrupt at block 410 . At block 418 , if in the door command mode, microprocessor 300 parses incoming radio signals and sets a flag if the signal matches a stored code. If in the learn mode, microprocessor 300 stores the new transmitter codes in the EEPROM.
An asynchronous interrupt is generated if a remote communications unit is connected to an optional RS-232 communications port located on the head unit. Upon receipt of the hardware interrupt, microprocessor 300 executes a serial data communications routine for transferring and storing data from the remote hardware.
Hardware timer 0 interrupt is shown in block 422 . In block 424 , microprocessor 300 reads the incoming AC line signal from pin P 24 and handles the motor phase control output. The incoming line signal is used to determine if the line voltage is 50 Hz for the foreign market or 60 Hz for the domestic market. With each interrupt, microprocessor 300 , at block 426 , task switches among three tasks. In block 428 , microprocessor 300 updates software timers. In block 430 , microprocessor 300 debounces wall control switch signals. In block 432 , microprocessor 300 controls the motor state, including motor direction relay outputs and motor safety systems.
When the motor 118 is running, it generates an asynchronous RPM interrupt at block 434 . When microprocessor 300 receives the asynchronous RPM interrupt at pin P 31 , it calculates the motor RPM period at block 436 , then updates the position of the door at block 438 .
Further details of main loop 400 are shown in FIGS. 7A through 7H. The first step executed in main loop 400 is block 450 , where the microprocessor checks to see if the pass point has been passed since the last update. If it has, the routine branches to block 452 , where the microprocessor 300 updates the position of the door relative to the pass point in EEPROM 302 or non-volatile memory. The routine then continues at block 454 . An optional safety feature of the garage door operator system enables the worklight, when the door is open and stopped and the infrared beam in the obstacle detector is broken.
At block 454 , the microprocessor checks if the enable/disable of the worklight for this feature has been changed. Some users want the added safety feature; others prefer to save the electricity used. If new input has been provided, the routine branches to block 456 and sets the status of the obstacle detector-controlled worklight in non-volatile memory in accordance with the new input. Then the routine continues to block 458 where the routine checks to determine if the worklight has been turned on without the timer. A separate switch is provided on both the remote transmitter 30 and the head unit at module 39 to enable the user to switch on the worklight without operating the door command switch. If no, the routine skips to block 470 .
If yes, the routine checks at block 460 to see if the one-shot flag has been set for an obstacle detector beam break. If no, the routine skips to block 470 . If yes, the routine checks if the obstacle detector controlled worklight is enabled at block 462 . If not, the routine skips to block 470 . If it is, the routine checks if the door is stopped in the fully open position at block 464 . If no, the routine skips to block 470 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8) to enable the appropriate turn off time (4.5 minutes for 60 Hz systems or 2.5 minutes for 50 Hz systems). At block 468 , the routine turns on the worklight.
At block 470 , the microprocessor 300 clears the one-shot flag for the infrared beam break. This resets the obstacle detector, so that a later beam break can generate an interrupt. At block 472 , if the user has installed a temporary password usable for a fixed period of time, the microprocessor 300 updates the non-volatile timer for the radio temporary password. At block 474 , the microprocessor 300 refreshes the RAM registers for radio mode from non-volatile memory (EEPROM 302 ). At block 476 , the microprocessor 300 refreshes I/O port directions, i.e., whether each of the ports is to be input or output. At block 478 , the microprocessor 300 updates the status of the radio lockout flag, if necessary. The radio lockout flag prevents the microprocessor from responding to a signal from a remote transmitter. A radio interrupt (described below) will disable the radio lockout flag and enable the remote transmitter to communicate with the receiver.
At block 480 , the microprocessor 300 checks if the door is about to travel. If not, the routine skips to block 502 . If the door is about to travel, the microprocessor 300 checks if the limits are being trained at block 482 . If they are, the routine skips to block 490 . If not, the routine asks at block 484 if travel is UP or DOWN. If DOWN, the routine refreshes the DOWN limit from non-volatile memory (EEPROM 302 ) at block 486 . If UP, the routine refreshes the UP limit from non-volatile memory (EEPROM 302 ) at block 488 . The routine updates the current operating state and position relative to the pass point in non-volatile memory at block 490 . This is a redundant read for stability of the system.
At block 492 , the routine checks for completion of a limit training cycle. If training is complete, the routine branches to block 494 where the new limit settings and position relative to the pass point are written to non-volatile memory.
The routine then updates the counter for the number of operating cycles at block 496 . This information can be downloaded at a later time and used to determine when certain parts need to be replaced. At block 498 the routine checks if the number of cycles is a multiple of 256. Limiting the storage of this information to multiples of 256 limits the number of times the system has to write to that register. If yes it updates the history of force settings at block 500 . If not, the routine continues to block 502 .
At block 502 the routine updates the learn switch debouncer. At block 504 the routine performs a continuity check by comparing the backup (redundant) RAM registers with the main registers. If they do not match, the routine branches to block 506 . If the registers do not match, the RAM memory has been corrupted and the system is not safe to operate, so a reset is commanded. At this point, the system powers up as if power had been removed and reapplied and the first step is a self test of the system (all installation settings are unchanged).
If the answer to block 504 is yes, the routine continues to block 508 where the routine services any incoming serial messages from the optional wall control (serial messages might be user input start or stop commands). The routine then loads the UP force timing from the ROM look-up table, using the user setting as an index at block 510 . Force potentiometers R 33 and P 34 are set by the user. The analog values set by the user are converted to digital values. The digital values are used as an index to the look-up table stored in memory. The value indexed from the look-up table is then used as the minimum motor speed measurement. When the motor runs, the routine compares the selected value from the look-up table with the digital timing from the RPM routine to ensure the force is acceptable.
Instead of calculating the force each time the force potentiometers are set, a look-up table is provided for each potentiometer. The range of values based on the range of user inputs is stored in ROM and used to save microprocessor processing time. The system includes two force limits: one for the UP force and one for the DOWN force. Two force limits provide a safer system. A heavy door may require more UP force to lift, but need a lower DOWN force setting (and therefore a slower closing speed) to provide a soft closure. A light door will need less UP force to open the door and possibly a greater DOWN force to provide a full closure.
Next the force timing is divided by power level of the motor for the door to scale the maximum force timeout at block 512 . This step scales the force reversal point based on the maximum force for the door. The maximum force for the door is determined based on the size of the door, i.e. the distance the door travels. Single piece doors travel a greater distance than segmented doors. Short doors require less force to move than normal doors. The maximum force for a short door is scaled down to 60 percent of the maximum force available for a normal door. So, at block 512 , if the force setting is set by the user, for example at 40 percent, and the door is a normal door (i.e., a segmented door or multi-paneled door), the force is scaled to 40 percent of 100 percent. If the door is a short door (i.e., a single panel door), the force is scaled to 40 percent of 60 percent, or 24 percent.
At block 514 , the routine loads the DOWN force timing from the ROM look-up table, using the user setting as an index. At block 516 , the routine divides the force timing by the power level of the motor for the door to scale the force to the speed.
At block 518 the routine checks if the door is traveling DOWN. If yes, the routine disables use of the MinSpeed Register at block 524 and loads the MinSpeed Register with the DOWN force setting, i.e., the value read from the DOWN force potentiometer at block 526 . If not, the routine disables use of the MinSpeed Register at block 520 ant loads the MinSpeed Register with the UP force setting from the force potentiometer at block 522 .
The routine continues at block 528 where the routine subtracts 24 from the MinSpeed value. The MinSpeed value ranges from 0 to 63. The system uses 64 levels of force. If the result is negative at block 530 , the routine clears the MinSpeed Register at block 532 to effectively truncate the lower 38 percent of the force settings. If no, the routine divides the minimum speed by 4 to scale 8 speeds to 32 force settings at block 534 . At block 536 , the routine adds 4 into the minimum speed to correct the offset, and clips the result to a maximum of 12. At block 538 the routine enables use of the MinSpeed Register.
At block 540 the routine checks if the period of the rectified AC line signal (input to microprocessor 300 at pin P 24 ) is less than 9 milliseconds (indicating the line frequency is 60 Hz). If it is, the routine skips to block 548 . If not, the routine checks if the light shut-off timer is active at block 542 . If not, the routine skips to block 548 . If yes, the routine checks if the light time value is greater than 2.5 minutes at block 544 . If no, the routine skips to block 548 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8 ), to correct the light timing setting, at block 546 .
At block 548 the routine checks if the radio signal has been clear for 100 milliseconds or more. If not, the routine skips to block 552 . If yes, the routine clears the radio at block 550 . At block 552 , the routine resets the watchdog timer. At block 554 , the routine loops to the beginning of the main loop.
The SetVarLight subroutine, FIG. 8, is called whenever the door is commanded to move and the worklight is to be turned on. When the SetVarLight subroutine, block 558 is called, the subroutine checks if the period of the rectified power line signal (pin P 24 of microprocessor 300 ) is greater than or equal to 9 milliseconds. If yes, the line frequency is 50 Hz, and the timer is set to 2.5 minutes at block 564 . If no, the line frequency is 60 Hz and the timer is set to 4.5 minutes at block 562 . After setting, the subroutine returns to the call point at block 566 .
The hardware timer interrupt subroutine operated by microprocessor 300 , shown at block 422 , runs every 0.256 milliseconds. Referring to FIGS. 9A-9C, when the subroutine is first called, it sets the radio interrupt status as indicated by the software flags at block 580 . At block 582 , the subroutine updates the software timer extension. The next series of steps monitor the AC power line frequency (pin P 24 of microprocessor 300 ). At step 584 , the subroutine checks if the rectified power line input is high (checks for a leading edge). If yes, the subroutine skips to block 594 , where it increments the power line high time counter, then continues to block 596 . If no, the subroutine checks if the high time counter is below 2 milliseconds at block 586 . If yes, the subroutine skips to block 594 . If no, the subroutine sets the measured power line time in RAM at block 588 .
The subroutine then resets the power line high time counter at block 590 and resets the phase timer register in block 592 .
At block 596 , the subroutine checks if the motor power level is set at 100 percent. If yes, the subroutine turns on the motor phase control output at block 606 . If no, the subroutine checks if the motor power level is set at 0 percent at block 598 . If yes, the subroutine turns off the motor phase control output at block 604 . If no, the phase timer register is decremented at block 600 and the result is checked for sign at block 602 . If positive the subroutine branches to block 606 ; if negative the subroutine branches to block 604 .
The subroutine continues at block 608 where the incoming RPM signal (at pin P 31 of microprocessor 300 ) is digitally filtered. Then the time prescaling task switcher (which loops through 8 tasks identified at blocks 620 , 630 , 640 , 650 ) is incremented at block 610 . The task switcher varies from 0 to 7. At block 612 , the subroutine branches to the proper task depending on the value of the task switcher.
If the task switcher is at value 2 (this occurs every 4 milliseconds), the execute motor state machine subroutine is called at block 620 . If the task is value 0 or 4 (this occurs every 2 milliseconds), the wall control switches are debounced at block 630 . If the task value is 6 this occurs every 4 milliseconds), the execute 4 ms timer subroutine is called at block 640 . If the task is value 1, 3, 5 or 7, the 1 millisecond timer subroutine is called at block 650 . Upon completion of the called subroutine, the 0.256 millisecond timer subroutine returns at block 614 .
Details of the 1 ms timer subroutine (block 650 ) are shown in FIGS. 10A-10C. When this subroutine is called, the first step is to update the A/D converters on the UP and DOWN force setting potentiometers (P 34 and P 35 of microprocessor 300 ) at block 652 . At block 654 , the subroutine checks if the A/D conversion (comparison at comparators 320 and 322 ) is complete. If yes, the measured potentiometer values are stored at block 656 . Then the stored values (which vary from 0 to 127) are divided by 2 to obtain the 64 level force setting at block 658 . If no, the subroutine decrements the infrared obstacle detector timeout timer at block 660 . In block 662 , the subroutine checks if the timer has reached zero. If no, the subroutine skips to block 672 . If yes, the subroutine resets the infrared obstacle detector timeout timer at block 664 . The flag setting for the obstacle detector signal is checked at block 666 . If no, the one-shot break flag is set at block 668 . If yes, the flag is set indicating the obstacle detector signal is absent at block 670 .
At block 672 , the subroutine increments the radio time out register. Then the infrared obstacle detector reversal timer is decremented at block 674 . The pass point input is debounced at block 676 . The 125 millisecond prescaler is incremented at block 678 . Then the prescaler is checked to see if it has reached 63 milliseconds at block 680 . If yes, the fault blinking LED is updated at block 682 . If no, the prescaler is checked if it has reached 125 ms at block 684 . If yes, the 125 ms timer subroutine is executed at block 686 . If no, the routine returns at block 688 .
Turning to FIGS. 11A-C, the 125 millisecond timer subroutine (block 690 ) is used to manage the power level of the motor 118 . At block 692 , the subroutine updates the RS-232 mode timer and exits the RS-232 mode timer if necessary. The same pair of wires is used for both wall control switches and RS-232 communication. If RS-232 communication is received while in the wall control mode, the RS-232 mode is entered. If four seconds passes since the last RS-232 word was received, then the RS-232 timer times out and reverts to the wall control mode. At block 694 the subroutine checks if the motor is set to be stopped. If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent. If no, the subroutine checks if the pre-travel safety light is flashing at block 696 (if the optional flasher module has been installed, a light will flash for 2 seconds before the motor is permitted to travel and then flash at a predetermined interval during motor travel). If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent.
If no, the subroutine checks if the microprocessor 300 is in the last phase of a limit training mode at block 698 . If yes, the subroutine skips to block 710 . If no, the subroutine sets the motor ramp-up complete flag in step 702 and checks if the microprocessor 300 is in another part of the limit training mode at block 700 . If no, the subroutine skips to block 710 . If yes, the subroutine checks if the minimum speed (as determined by the force settings) is greater than 40 percent at block 704 . If no, the power level is set to 40 percent at block 708 . If yes, the power level is set equal to the minimum speed stored in MinSpeed Register at block 706 .
At block 710 the subroutine checks if the flag is set to slow down. If yes, the subroutine checks if the motor is running above or below minimum speed at block 714 . If above minimum speed, the power level of the motor is decremented one step increment (one step increment is preferably 5% of maximum motor speed) at block 722 . If below the minimum speed, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) to minimum speed at block 720 .
If the flag is not set to slow down at block 710 , the subroutine checks if the motor is running at maximum allowable speed at block 712 . If no, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) at block 720 . If yes, the flag is set for motor ramp-up speed complete.
The subroutine continues at block 724 where it checks if the period of the rectified AC power line (pin P 24 of microprocessor 300 ) is greater than or equal to 9 ms. If no, the subroutine fetches the motor's phase control information (indexed from the power level) from the 60 Hz look-up table stored in ROM at block 728 . If yes, the subroutine fetches the motor's phase control information (indexed from the power level) from the 50 Hz look-up table stored in ROM at block 726 .
The subroutine tests for a user enable/disable of the infrared obstacle detector-controlled worklight feature at block 730 . Then the user radio learning timers, ZZWIN (at the wall keypad if installed) and AUXLEARNSW (radio on air and worklight command) are updated at block 732 . The software watchdog timer is updated at block 734 and the fault blinking LED is updated at block 736 . The subroutine returns at block 738 .
The 4 millisecond timer subroutine is used to check on various systems which do not require updating as often as more critical systems. Referring to FIGS. 12A and 12B, the subroutine is called at block 640 . At block 750 , the RPM safety timers are updated. These timers are used to determine if the door has engaged the floor. The RPM safety timer is a one second delay before the operator begins to look for a falling door, i.e., one second after stopping. There are two different forces used in the garage door operator. The first type force are the forces determined by the UP and DOWN force potentiometers. These force levels determine the speed at which the door travels in the UP and DOWN directions. The second type of force is determined by the decrease in motor speed due to an external force being applied to the door (an obstacle or the floor). This programmed or pre-selected external force is the maximum force that the system will accept before an auto-reverse or stop is commanded.
At block 752 the 0.5 second RPM timer is checked to see if it has expired. If yes, the 0.5 second timer is reset at block 754 . At block 756 safety checks are performed on the RPM seen during the last 0.5 seconds to prevent the door from falling. The 0.5 second timer is chosen so the maximum force achieved at the trolley will reach 50 kilograms in 0.5 seconds if the motor is operating at 100 percent of power.
At block 758 , the subroutine updates the 1 second timer for the optional light flasher module. In this embodiment, the preferred flash period is 1 second. At block 760 the radio dead time and dropout timers are updated. At block 762 the learn switch is debounced. At block 764 the status of the worklight is updated in accordance with the various light timers. At block 766 the optional wall control blink timer is updated. The optional wall control includes a light which blinks when the door is being commanded to auto-reverse in response to an infrared obstacle detector signal break. At block 768 the subroutine returns.
Further details of the asynchronous RPM signal interrupt, block 434 , are shown in FIGS. 13A and 13B. This signal, which is provided to microprocessor 300 at pin P 31 , is used to control the motor speed and the position detector. Door position is determined by a value relative to the pass point. The pass point is set at 0. Positions above the pass point are negative; positions below the pass point are positive. When the door travels to the UP limit, the position detector (or counter) determines the position based on the number of RPM pulses to the UP limit number. When the door travels DOWN to the DOWN limit, the position detector counts the number of RPM pulses to the DOWN limit number. The UP and DOWN limit numbers are stored in a register.
At block 782 the RPM interrupt subroutine calculates the period of the incoming RPM signal. If the door is traveling UP, the subroutine calculates the difference between two successive pulses. If the door is traveling DOWN, the subroutine calculates the difference between two successive pulses. At block 784 , the subroutine divides the period by 8 to fit into a binary word. At block 786 the subroutine checks if the motor speed is ramping up. This is the max force mode. RPM timeout will vary from 10 to 500 milliseconds. Note that these times are recommended for a DC motor. If an AC motor is used, the maximum time would be scaled down to typically 24 milliseconds. A 24 millisecond period is slower than the breakdown RPM of the motor and therefore beyond the maximum possible force of most preferred motors. If yes, the RPM timeout is set at 500 milliseconds (0.5 seconds) at block 790 . If no, the subroutine sets the RPM timeout as the rounded-up value of the force setting in block 788 .
At block 792 the subroutine checks for the direction of travel. This is found in the state machine register. If the door is traveling DOWN, the position counter is incremented at block 796 and the pass point debouncer is sampled at block 800 . At block 804 , the subroutine checks for the falling edge of the pass point signal. If the falling edge is present, the subroutine returns at block 814 . If there is a pass point falling edge, the subroutine checks for the lowest pass point (in cases where more than one pass point is used). If this is not the lowest pass point, the subroutine returns at block 814 . If it is the only pass point or the lowest pass point, the position counter is zeroed at block 812 and the subroutine returns at block 814 .
If the door is traveling UP, the subroutine decrements the position counter at block 794 and samples the pass point debouncer at block 798 . Then it checks for the rising edge of the pass point signal at block 802 . If there is no pass point signal rising edge, the subroutine returns at block 814 . If there is, it checks for the lowest pass point at block 806 . If no the subroutine returns at block 814 . If yes, the subroutine zeroes the position counter at block 810 and returns at block 814 .
The motor state machine subroutine, block 620 , is shown in FIG. 14 . It keeps track of the state of the motor. At block 820 , the subroutine updates the false obstacle detector signal output, which is used in systems that do not require an infrared obstacle detector. At block 822 , the subroutine checks if the software watchdog timer has reached too high a value. If yes, a system reset is commanded at block 824 . If no, at block 826 , it checks the state of the motor stored in the motor state register located in EEPROM 302 and executes the appropriate subroutine.
If the door is traveling UP, the UP direction subroutine at block 832 is executed. If the door is traveling DOWN, the DOWN direction subroutine is executed at block 828 . If the door is stopped in the middle of the travel path, the stop in midtravel subroutine is executed at block 838 . If the door is fully closed, the DOWN position subroutine is executed at block 830 . If the door is fully open, the UP position subroutine is executed at block 834 . If the door is reversing, the auto-reverse subroutine as executed at block 836 .
When the door is stopped in midtravel, the subroutine at block 838 is called, as shown in FIG. 15 . In block 840 the subroutine updates the relay safety system (ensuring that relays K 1 and K 2 are open). The subroutine checks in block 842 for a received wall command or radio command. If there is no received command, the subroutine updates the worklight status and returns at block 850 . If yes, the motor power is set to 20 percent at block 844 and the motor state is set to traveling DOWN at block 846 . The worklight status is updated and the subroutine returns at block 850 . If the door is stopped in midtravel and a door command is received, the door is set to close. The next time the system calls the motor state machine subroutine, the motor state machine will call the DOWN direction subroutine. The door must close to the DOWN limit before it can be opened to the full UP limit.
If the state machine indicates the door is in the DOWN position (i.e. the DOWN limit position), the DOWN position subroutine, block 830 , at FIG. 16 is called. When the door is in the DOWN position, the subroutine checks if a wall control or radio command has been received at block 852 . If no, the subroutine updates the light and returns at block 858 . If yes, the motor power is set to 20 percent at block 854 and the motor state register is set to show the state is traveling UP at block 856 . The subroutine then updates the light and returns at block 858 .
The UP direction subroutine, block 832 , is shown in FIGS. 17A-17C. At block 860 the subroutine waits until the main loop refreshes the UP limit from EEPROM 302 . Then it checks if 40 milliseconds have passed since closing of the light relay K 3 at block 862 . If not, the subroutine returns at block 864 . If yes, the subroutine checks for flashing the warning light prior to travel at block 866 (only if the optional flasher module is installed). If the light is flashing, the status of the blinking light is updated and the subroutine returns at block 868 . If not, or the flashing is terminated, the motor UP relay is turned on at block 870 . Then the subroutine waits until 1 second has passed after the motor was turned on at block 872 . If no, the subroutine skips to block 888 . If yes, the subroutine checks for the RPM signal timeout at block 874 . If no, the subroutine checks if the motor speed is ramping up at block 876 by checking the value of the RAMPFLAG register in RAM (i.e., UP, DOWN, FULLSPEED, STOP). If yes, the subroutine skips to block 888 . If no, the subroutine checks if the measured RPM is longer than the allowable RPM period at block 878 . If no, the subroutine continues at block 888 .
If the RPM signal has timed out at block 874 or the measured time period is longer than allowable at block 878 , the subroutine branches to block 880 . At block 880 , the reason is set as force obstruction. At block 882 , if the training limits are being set, the training status is updated. At block 884 the motor power is set to zero and the state is set as stopped in midtravel. At block 886 the subroutine returns.
At block 888 the subroutine checks if the door's exact position is known. If it is not, the door's distance from the UP limit is updated in block 890 by subtracting the UP limit stored in RAM from the position of the door also stored in RAM. Then the subroutine checks at block 892 if the door is beyond its UP limit. If yes, the subroutine sets the reason as reaching the limit in block 894 . Then the subroutine checks if the limits are being trained. If yes, the limit training machine is updated at block 898 . If no, the motor's power is set as zero and the motor state is set at the UP position in block 900 . Then the subroutine returns at block 902 .
If the door is not beyond its UP limit, the subroutine checks if the door is being manually positioned in the training cycle at block 904 . If not, the door position within the slowdown distance of the limit is checked at block 906 . If yes, the motor slow down flag is set at block 910 . If the door is being positioned manually at block 904 or the door is not within the slow down distance, the subroutine skips to block 912 . At block 912 the subroutine checks if a wall control or radio command has been received. If yes, the motor power is set at zero and the state is set at stopped in midtravel at block 916 . If no, the system checks if the motor has been running for over 27 seconds at block 914 . If no, the subroutine returns at block 918 . If yes, the motor power is set at zero and the motor state is set at stopped in midtravel at block 916 . Then the subroutine returns at block 918 .
Referring to FIG. 18, the auto-reverse subroutine block 836 is described. (Force reversal is stopping the motor for 0.5 seconds, then traveling UP.) At block 920 the subroutine updates the 0.5 second reversal timer (the force reversal timer described above). Then the subroutine checks at block 922 for expiration of the force-reversal timer. If yes, the motor power is set to 20 percent at block 914 and the motor state is set to traveling UP at block 926 and the subroutine returns at block 932 . If the timer has not expired, the subroutine checks for receipt of a wall command or radio command at block 928 . If yes, the motor power is set to zero and the state is set at stopped in midtravel at block 930 , then the subroutine returns at block 932 . If no, the subroutine returns at block 932 .
The UP position routine, block 834 , is shown in FIG. 19 . Door travel limits training is started with the door in the UP position. At block 934 , the subroutine updates the relay safety system. Then the subroutine checks for receipt of a wall command or radio command at block 936 indicating an intervening user command. If yes, the motor power is set to 20 percent at block 938 and the state is set at traveling DOWN in block 940 . Then the light is updated and the subroutine returns at block 950 . If no wall command has been received, the subroutine checks for training the limits at block 942 . If no, the light is updated and the subroutine returns at block 950 . If yes, the limit training state machine is updated at block 944 . Then the subroutine checks if it is time to travel DOWN at block 946 . If no, the subroutine updates the light and returns at block 950 . If it is time to travel DOWN, the state is set at traveling DOWN at block 948 and the system returns at block 950 .
The DOWN direction subroutine, block 828 , is shown in FIGS. 20A-20D. At block 952 , the subroutine waits until the main loop routine refreshes the DOWN limit from EEPROM 302 . For safety purposes, only the main loop or the remote transmitter (radio) can access data stored in or written to the EEPROM 302 . Because EEPROM communication is handled within software, it is necessary to ensure that two software routines do not try to communicate with the EEPROM at the same time (and have a data collision). Therefore, EEPROM communication is allowed only in the Main Loop and in the Radio routine, with the Main loop having a busy flag to prevent the radio from communicating with the EEPROM at the same time. At block 954 , the subroutine checks if 40 milliseconds has passed since closing of the light relay K 3 . If no, the subroutine returns at block 956 . If yes, the subroutine checks if the warning light is flashing (for 2 seconds if the optional flasher module is installed) prior to travel at block 958 . If yes, the subroutine updates the status of the flashing light and returns at block 960 . If no, or the flashing is completed, the subroutine turns on the DOWN motor relay K 2 at block 962 . At block 964 the subroutine checks if one second has passed since the motor was first turned on. The system ignores the force on the motor for the first one second. This allows the motor time to overcome the inertia of the door (and exceed the programmed force settings) without having to adjust the programmed force settings for ramp up, normal travel and slow down. Force is effectively set to maximum during ramp up to overcome sticky doors.
If the one second time has not passed, the subroutine skips to block 984 . If the one second time limit has passed, the subroutine checks for the RPM signal time out at block 966 . If no, the subroutine checks if the motor speed is currently being ramped up at block 968 (this is a maximum force condition). If yes, the routine skips to block 984 . If no, the subroutine checks if the measured RPM period is longer than the allowable RPM period. If no, the subroutine continues at block 984 .
If either the RPM signal has timed-out (block 966 ) or the RPM period is longer than allowable (block 970 ), this is an indication of an obstruction or the door has reached the DOWN limit position, and the subroutine skips to block 972 . At block 972 , the subroutine checks if the door is positioned beyond the DOWN limit setting. If it is, the subroutine skips to block 990 where it checks if the motor has been powered for at least one second. This one second power period after the DOWN limit has been reached provides for the door to close fully against the floor. This is especially important when DC motors are used. The one second period overcomes the internal braking effect of the DC motor on shut-off. Auto-reverse is disabled after the position detector reaches the DOWN limit. If the door is not positioned beyond the DOWN limit setting, the subroutine sets the reason as force obstruction at block 974 , updates the training status if the operator is training limits at block 976 , and sets the motor power at 0 at block 978 . The motor state is set as auto-reverse at block 980 , and the subroutine returns at block 982 .
If the subroutine determines that the door position is beyond the DOWN limit setting and if the motor has been running for one second, at block 990 , the subroutine sets the reason as reaching the limit at block 994 . The subroutine then checks if the limits are being trained at block 998 . If yes, the limit training machine is updated at block 1002 . If no, the motor's power is set to zero and the motor state is set at the DOWN position in block 1006 . In block 1008 the subroutine returns.
If the motor has not been running for at least one second at block 990 , the subroutine sets the reason as early limit at block 1026 . Then the subroutine sets the motor power at zero and the motor state as auto-reverse at block 1028 and returns at block 1030 .
Returning to block 984 , the subroutine checks if the door's position is currently unknown. If yes, the subroutine skips to block 1004 . If no, the subroutine updates the door's distance from the DOWN limit using internal RAM in microprocessor 300 in block 986 . Then the subroutine checks at block 988 if the door is three inches beyond the DOWN limit. If yes, the subroutine skips to block 990 . If no, the subroutine checks if the door is being positioned manually in the training cycle at block 992 . If yes, the subroutine skips to block 1004 . If no, the subroutine checks if the door is within the slow DOWN distance of the limit at block 996 . If no, the subroutine skips to block 1004 . If yes, the subroutine sets the motor slow down flag at block 1000 .
At block 1004 , the subroutine checks if a wall control command or radio command has been received. If yes, the subroutine sets the motor power at zero and the state as auto-reverse at block 1012 . If no, the subroutine checks if the motor has been running for over 27 seconds at block 1010 . If yes, the subroutine sets the motor power at zero and the state at auto-reverse at block 1012 . If no, the subroutine checks if the obstacle detector signal has been missing for 12 milliseconds or more at block 1014 indicating the presence of the obstacle or the failure of the detector. If no, the subroutine returns at block 1018 . If yes, the subroutine checks if the wall control or radio signal is being held to override the infrared obstacle detector at block 1016 . If yes, the subroutine returns at block 1018 . If no, the subroutine sets the reason as infrared obstacle detector obstruction at block 1020 . The subroutine then sets the motor power at zero and the state as auto-reverse at block 1022 and returns at block 1024 . (The auto-reverse routine stops the motor for 0.5 seconds then causes the door to travel up.)
The appendix attached hereto includes a source listing of a series of routines used to operate a movable barrier operator in accordance with the present invention.
While there has been illustrated and described a particular embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which followed in the true spirit and scope of the present invention. | A movable barrier operator having improved safety and energy efficiency features automatically detects line voltage frequency and uses that information to set a worklight shut-off time. The operator automatically detects the type of door (single panel or segmented) and uses that information to set a maximum speed of door travel. The operator moves the door with a linearly variable speed from start of travel to stop for smooth and quiet performance. The operator provides for full door closure by driving the door into the floor when the DOWN limit is reached and no auto-reverse condition has been detected. The operator provides for user selection of a minimum stop speed for easy starting and stopping of sticky or binding doors. |
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BACKGROUND OF THE INVENTION
The invention generally relates to rotary drilling heads for the oil industry and more particularly to a rotary drilling head that includes a diamond enhanced bearing assembly which can be retrieved through the rotary table of the drill rig and which increases rotational drilling speeds and lengthens service intervals.
Referring initially to FIG. 1, there is shown a conventional rig 10 for rotating a drill bit 12 on the end of a drill string 14 for drilling a well bore 16 . The drilling rig 10 includes a rotary table 18 located on the floor 20 of rig 10 for transmitting torque to the drill string 14 . The drill string 14 extends through a blowout preventer (“BOP”) stack located beneath the rig floor 20 and includes a kelly 22 at its upper end and a plurality of drill pipes 24 including a plurality of drill collars 26 connected at it lower end to the drill bit 12 . The drill string 14 transmits rotational and axial movements to the drill bit 12 for drilling the well bore 16 .
Referring now additionally to FIGS. 2 and 3, there is shown a typical kelly 22 having threaded rotary shouldered connections 28 at its top and bottom and a center section 30 with a polygonal outer cross section. The rotary table 18 includes a clearance hole, typically 17.5″ or 22.5″ in diameter, for housing a drive bushing that corresponds to the polygonal geometry 30 of kelly 22 for applying torque to kelly 22 . Kelly 22 in turn transmits torque to the drill string 14 and bit 12 at the bottom of well bore 16 .
Drilling fluids, often referred to as drilling mud, are pumped downward through the flowbore of the drill string 14 under high pressure, through drill bit 12 and then returns upwardly via the annulus 44 formed between well bore 16 and drill string 14 to remove the cuttings to the surface. The returning mixture of drilling fluids and cuttings is diverted beneath the rig floor 20 to a mud reservoir by means of a device commonly referred to in the industry as a rotary drilling head assembly 46 .
A rotary drilling head assembly 46 is typically mounted below the floor 20 of the drilling rig 10 on the top of the BOP stack to redirect the drilling fluid returning from the well bore 16 and to allow rotation and deployment of the drill string 14 through the rotary table 18 . During normal drilling operations, the blowout preventers are maintained in the “open” position, leaving only the rotary drilling head to divert the returning pressurized drilling fluids away from the rig 10 .
FIG. 2 illustrates a typical prior art rotary drilling head assembly 46 having an outer stationary housing or bowl 48 and an inner drive ring 50 with a bearing assembly 52 disposed in between allowing drive ring 50 to rotate within bowl 48 . Outer bowl 48 includes a flange 54 for mounting the assembly 46 to the BOP stack and a flow diverter port or outlet 56 having a flange 58 for the attachment of a pipe extending to the mud reservoir. Assembly 46 further includes an inner stripper assembly 60 slidably received within drive ring 50 and connected to the upper end of drive ring 50 by a retaining clamp 62 allowing stripper assembly 60 to rotate with inner drive ring 50 . Stripper assembly 60 includes an outer housing 66 bonded by a rubber insert 68 to inner drive bushing 32 . The lower end of outer housing 66 is bolted to a flange 64 which is bonded onto stripper rubber 42 . A primary non-rotary seal 70 and a secondary non-rotary seal 72 serve to statically seal the outside of stripper assembly 60 from bearing assembly 52 and rig floor 20 . Bearing assembly 52 includes an upper set of roller bearings 74 and a lower set of roller bearings 76 . Upper and lower roller bearings 74 , 76 , respectively, are separated axially by a bearing spacer 78 . An external pressurized oil system lubricates the bearings 74 , 76 through hydraulic quick connects 80 , and is maintained by rotary lubrication bearing seal members 82 above and below the bearing assembly 52 . Bearing seal members 82 are stationary even while there is full 360° rotation of stripper assembly 60 and drive ring 50 within outer bowl 48 . Since the clamp assembly clamps the rotating side of the bearing assembly, the clamp assembly must also rotate.
The rotary drilling head assembly 46 counteracts forces due to the upward pressure from the returning drilling fluids, the radial wobble of the drill string 14 , and the downward engagement forces of drill string 14 . The bearing assembly 52 of a conventional drilling head assembly 46 includes tapered roller bearings to enable rotation of the drive ring 50 with respect to the outer bowl 48 and to overcome these various forces. Previous designs utilize two horizontally opposed tapered roller bearings 74 , 76 spaced apart axially to handle the loads encountered during drilling operations, as shown in FIG. 2 . Because the design of tapered roller bearings allows them to counteract loads in both the thrust and radial directions, the lower set of bearings 76 encounters the upward annular fluid forces and radial wobble forces simultaneously, while the upper set of bearings 74 encounters the downward drill string and radial wobble forces. This arrangement allows radial and axial forces to be countered regardless of the direction that they may be acting upon rotary drilling head 46 .
During operation, individual sections of drill pipe 24 are connected to the upper end of drill string 14 with their upper end attached to the lower end of kelly 22 . The new section of drill pipe 24 is then lowered through the stripper assembly 60 . As the rotary table 18 rotates, rotary table 18 rotates kelly 22 and thus kelly bushing 34 disposed within drive bushing 32 and around kelly 22 . As shown in FIG. 3, drive bushing 34 includes an inside cutout geometry 36 , an outside geometry 38 , and a split cut 40 . Inside geometry 36 corresponds to polygonal section 30 of kelly 22 , and outside geometry 38 corresponds to a drive bushing seat 32 of a stripper assembly 60 hereinafter described. Split cut 40 facilitates the assembly and disassembly of drive bushing 34 about kelly 22 . Drive bushing 34 is slidably engaged both about polygonal section 30 of kelly 22 and within the corresponding geometry of drive bushing seat 32 . Kelly bushing 34 thereby allows kelly 22 to pass through the rotary drilling head 46 while also transmitting torque from the rotary table 18 to the drill string 14 and stripper assembly 60 of the drilling head 46 simultaneously.
Stripper rubber 42 seals with drill string 14 as the drill string 14 moves axially through stripper assembly 60 . Kelly 22 , drill pipes 24 , and threaded pipe connections 28 therebetween may be of many different sizes and shapes and yet must pass through stripper rubber 42 . Therefore, the stripper rubber 42 of rotary drilling head assembly 46 must be flexible to sealingly engage and accommodate the various sizes of the components of drill string 14 . Rubber stripper 42 also diverts the drilling mud through side port outlet 56 of drilling head 46 in maintaining the sealing engagement with drill string 14 .
From time to time the stripper assembly 60 must be removed to replace the stripper rubber 42 . This requires disconnecting the retaining clamp 62 to release outer housing 66 of stripper assembly 60 . When the outer housing 66 is larger than the opening through the rotary table 18 , the stripper assembly 60 must be removed from beneath the rig floor 20 which is expensive.
Further, when service intervals dictate, the bearing assembly 52 must be replaced. This requires that the drilling head assembly 46 be dismantled and the bearing assembly 52 lifted out of outer bowl 48 . This is done by removing bearing retaining screws 84 that secure bearing assembly 52 to outer barrel 48 . Once removed, bearing assembly 52 can be inspected, replaced or repaired if no longer functioning properly. To prevent disrupting operations with time consuming disassembly procedures, the clearance diameters of rotary table 18 and any other equipment between it and rotary drilling head 46 must be larger than the maximum diameter of bearing assembly 52 . If smaller rig floor equipment is used, then rotary drilling head assembly 46 must be removed from beneath the rig floor 20 for disassembly.
One major limitation of prior art rotary drilling head designs is that the roller bearing assemblies require a large radial clearance. Thus, prior art drilling head designs either require a large hole in the rotary table 18 or must be removed from beneath the rig floor 20 for dismantling. It is desirable to produce a rotary drilling head assembly 46 that has a small radial clearance that will allow the stripper assembly 60 and bearing assembly 52 to be removed through the opening in the rotary table 18 .
During drilling operations, the seals that maintain the lubrication oil on the drilling head bearing packages may fail prematurely. In the event that a lubrication seal is lost, the roller bearings are destroyed and must be immediately replaced. When seal failure occurs, the entire drilling operation must be stopped so that the rotary head bearing assembly 52 can be replaced. To replace the roller bearings, the whole rotating bead must be removed from the well casing. To prevent costly outages and repair regimens, a more durable bearing design that can function following a lubrication seal loss is desirable to minimize down time.
Diamond bearings are disclosed in U.S. Pat. No. 4,410,054 for use in downhole mud motors. The present invention overcomes the deficiencies of the prior art.
SUMMARY OF THE INVENTION
The rotary drilling head assembly of the present invention includes a housing having a bore for receiving a drive member. The drive member has an outer diameter of less than 17{fraction (1/2+L )} inches so as to pass through the 17{fraction (1/2+L )} inch opening in a rotary table. A bearing assembly is disposed between the housing and drive member allowing the drive member to rotate within the housing and includes an outer stationary portion and an inner rotating portion maintained in place by upper and lower threaded retaining rings. Retaining clamps attach the outer stationary portion to the housing and the rotating portion to the drive member. Rotary seal assemblies isolate the bearing assembly and its lubrication system from the drilling fluid to prevent premature wear and failure of the bearing.
The bearing assembly includes a plurality of opposing disc-like members that have flat bearing surfaces meeting on a substantially planar surface of contact. The disc-like members are preferably made of a polycrystalline diamond material. The highly wear resistant polycrystalline diamond bearing resists drill string and axial loads.
The bearing assembly includes at least two long-lasting diamond bearings to carry axial thrust loads. Each bearing includes annular bearing plates each supporting a plurality of friction bearing members having bearing faces of highly wear resistant polycrystalline diamond to carry the thrust load.
The diamond enhanced bearing of the present invention is more compact than equivalent roller bearing assemblies of the prior art rotary head assemblies. By reducing the space required in the radial dimension, the diamond enhanced rotary drive assembly fits through the opening in, a 17.5″ rotary table which was not possible with the over 20″ diameter roller bearing design of the prior art. Some current roller bearings are small enough to be retrieved through a 17.5″ rotary table but their load carrying capacity is limited by their diminished radial envelope.
Additionally, the diamond enhanced bearing package of the improved rotary drilling head assembly is designed to be symmetrical. In the event that one side of the bearing wears faster than the other, the bearing may be removed and reversed to allow the drilling head to continue in service. Rotary seals are positioned below and above the diamond enhanced bearings of the present invention encapsulating a lubricant fluid that provides lubrication to the bearing members. The use of diamond bearings, however, makes it possible for the bearings to be safely cooled and lubricated by the drilling fluid in the event of a lubrication seal failure.
By incorporating the inherent fail-safe properties of diamond enhanced bearings into the rotary drilling head assembly of the present invention, considerable advances in drilling head life can be achieved. By utilizing a more durable rotary drilling head with a higher maximum rotational speed, production costs can be reduced by both reducing the number of expensive bearing replacement operations and being able to drill at a faster rate than before.
Other objects and advantages of the present invention will become apparent from the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of a preferred embodiment of the invention, reference will now be made to the accompanying drawings wherein:
FIG. 1 is a schematic of a conventional drilling system for a well;
FIG. 2 is a sectional view of a prior art rotary drilling head assembly with roller cone bearings;
FIG. 3 top view of a kelly bushing for use with the prior art drilling head assembly of FIG. 2;
FIG. 4 is a sectional view of a rotary drilling head assembly constructed in accordance with a preferred embodiment of the present invention;
FIG. 5 is a top view of a diamond bearing showing an overlap geometry in accordance with the preferred embodiment of the present invention;
FIG. 6 is an enlarged cross sectional view of one side of the rotary drilling head assembly of FIG. 4;
FIG. 7 is an enlarged cross-sectional view of the bearing assembly of the preferred embodiment of the present invention shown in FIG. 4; and
FIG. 8 is an enlarged cross-sectional view of an alternative embodiment of the bearing assembly shown in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to now FIGS. 4-8, the rotary drilling head assembly 100 of the preferred embodiment includes an outer stationary housing or bowl 102 and an inner drive ring 104 with a bearing assembly 106 disposed between the drive ring 104 and bowl 102 . Assembly 100 further includes a stripper assembly 110 slidably received within drive ring 104 and mounted to the top of drive ring 104 by fastener members such as bolts 108 . Stripper assembly 110 includes a drive bushing 112 having a stripper rubber 114 bonded at 116 to its lower end. Seals 118 are provided to seal between drive bushing 112 and drive ring 104 .
Outer bowl 102 includes an inlet mounting flange 122 for connection to the BOP stack and an outlet port 124 with a flange 126 for connection to a pipe extending to the mud reservoir. A bushing sleeve 128 is disposed within the upper cylindrical bore 130 in bowl 102 . The outer diameter of bushing sleeve 128 is less than the diameter of the opening in the rotary table and typically is 17.5 inches or less so as to allow sleeve 128 to pass through the opening in the rotary table.
Drive ring 104 and bushing sleeve 128 form an envelope for housing bearing assembly 106 . A retaining ring 132 is threaded onto the lower end of drive ring 104 to position and retain the bearing assembly 106 within the drive ring 104 . Bushing sleeve 128 rests on an upwardly facing shoulder 136 on bowl 102 extending inwardly into bore 130 and also includes a inwardly extending flange 138 forming an upwardly facing shoulder 140 . Sleeve 128 is maintained in position by a stationary retaining clamp assembly 142 which engages an outwardly extending flange 144 on the upper end of bowl 102 and bears against the upper terminal end of sleeve 128 forcing sleeve 128 against upwardly facing shoulder 136 .
Bushing sleeve 128 also includes upper and lower hydraulic ports 146 , 148 , respectively, communicating with hydraulic ports 150 , 152 , respectively, for providing lubricating and cooling fluids to bearing assembly 106 . Seals 154 are provided to seal around ports 146 , 148 . Upper and lower seal assemblies 156 , 158 are disposed above and below bearing assembly 106 . Each seal assembly 156 , 158 includes a seal housing 160 having a passageway 162 communicating with either hydraulic port 146 or 148 and the inner surface of seal housing 160 between a pair of seal grooves housing seal members 164 , 166 . A check valve 95 is disposed in passageway 162 . Upper and lower bushings 168 , 170 are disposed between seal assemblies 156 , 158 and drive ring 104 with a seal member 101 sealing therebetween.
Referring particularly to FIG. 7, bearing assembly 106 includes a housing 172 having a plurality of upwardly facing apertures 174 and a plurality of downwardly facing apertures 176 for housing disc-shaped bearing members 178 such as members 180 , 182 , respectively. Housing 172 also includes a inwardly facing being race 184 for housing a plurality of radial load carrying roller bearings 186 , such as needle bearings, equally spaced about the outer diameter of bearing race 184 with their axis extending parallel to the central axis 188 of rotary drilling head assembly 100 . Assembly 106 also includes an outer spacer bushing 190 which bears against roller bearings 186 . Bearing assembly 106 further includes an upper bearing ring 192 and a lower bearing ring 194 , each having a plurality of apertures 196 , 198 , respectively, for also housing disc-shaped bearing members 178 such as members 200 , 202 , respectively.
As shown on the left hand side of FIG. 4 and in closer detail in FIG. 8, roller bearings 186 may be replaced by a journal bearing with hard surface facing 204 on the outer radial surface of housing 172 . Hardened surface 204 bears against the inner diameter of bushing 190 . Hardened surface 204 can also be manufactured of diamond material. Alternatively, instead of disposing the radial bearings 186 between the upper and lower assemblies 206 , 208 , radial bearings may be disposed outboard of the upper and lower assemblies 206 , 208 with radial bearings above the upper bearing assembly 206 and radial bearings below the lower bearing assembly 208 to increase stability and eliminate any pivoting about radial bearings 186 .
Bearing members 178 are generally in the shape of cylindrical studs that are secured in their respective mounting apertures by conventional methods and are able to withstand large compressive loads and vibrations. The material of the bearing members 178 is a hard material such as tungsten carbide and is capable of bonding well with the polycrystalline diamond compound that is secured thereon. The diamond substrate is applied to the exposed circular faces and about the periphery of the cylindrical bearing members 178 for the purpose of reducing frictional wear on the members, is extremely wear and heat resistant once applied, and offers performance that well exceeds that of roller bearings. The diamond coated surfaces of each bearing member 178 in their respective mounting ring collectively act as a single hardened bearing surface. The bearing members are preferably cylindrical studs having flat faces with initially flat disc-shaped diamond wafers supported thereon. There is preferably one more of the diamond bearing wafers on one of the annular bearing plates than on the other and it is preferred to have all diamond wafers be of the same size and diameter. Wafers currently manufactured by Megadiamond Industries that are 13 mm in size are acceptable for this application.
The diamond bearing of the present invention utilizes a thrust surface that is only ½″ wide radially. Roller bearings of the same load capacity would require 1{fraction (1/2+L )}″ to 2″ of radial width. Diamond bearings may save as much as 1″ of radial space (at least 2″ on the diameter) over the roller bearings of the prior art. To accomplish this space savings with roller bearings, the size of the roller bearings may have to be reduced which would reduce their load carrying capacity. Even though smaller, the diamond bearings exceed the load carrying capacity of the roller bearings by 5 to 10 times.
Diamond bearings are able to run at higher temperatures than other types of bearings under similar loads. The diamond wafers of the present invention do not begin to deteriorate until they reach 1300° F. The diamond bearings allow the rotary drilling head assembly to operate at speeds much higher than previously allowable with roller bearings. Whereas diamond drilling head assemblies utilizing diamond bearings can operate at speeds up to 200 RPM and up to 600 RPM in special situations, current rotary drilling head assemblies typically allow the drill string to only rotate at 100 RPM or less. Since the bearing seal components only operate effectively below 400° F., a chiller system may be required to keep the lubrication system cool.
Upon assembly, upper bearing ring 192 with apertures 196 housing members 200 is disposed opposite upwardly facing apertures 174 with members 180 on housing 172 to form an upper diamond bearing assembly 206 . Similarly, lower bearing ring 194 with apertures 198 housing members 202 is disposed opposite downwardly facing apertures 176 with members 182 on housing 172 to form a lower diamond bearing assembly 208 . Housing 172 thus provides two arrangements of bearing members 178 that face in opposite directions from each other in the axial direction. This arrangement allows housing 172 to act both as bottom ring for bearing members 180 for upper bearing assembly 206 and as top ring for bearing members 182 for lower bearing assembly 208 .
Referring particularly to FIG. 5, upper and lower bearing assemblies 206 , 208 thus form upper and lower polycrystalline diamond enhanced thrust bearing surfaces. Each of the two complimentary surfaces are horizontally opposed and include rings of disc-shaped bearing members 178 that are equally spaced into a circular pattern within their mounting plates. To ensure simplicity of design, all bearing members 178 are of a standard size and diameter. Since the bearing members 178 are all of the same diameter, the number of bearing members 178 in each of the two bearing rings within a bearing assembly, 206 or 208 , differs in number by one. This difference is necessary to ensure that at any position that the bearing assembly may encounter, no more that one pair of bearing members 178 may line up perfectly with one another such that all other engaging bearing members 178 overlap. Alternatively, bearing members 178 may have different diameters for each bearing ring and yet still accomplish the same result.
In the assembly of the bearing assembly 106 in the envelope formed by drive ring 104 and bushing sleeve 128 , an upper retainer ring 214 is threaded onto the upper end of bushing sleeve 128 thereby compressing upper and lower seal assemblies 156 , 158 and upper and lower bearing rings 192 , 194 with bushing 190 therebetween against shoulder 140 . Likewise lower retainer ring, 132 is threaded onto the lower end of drive ring 104 compressing the bushings 168 , 170 , housing 172 , and spacer rings 210 , 212 together against a downwardly facing shoulder 216 on drive ring 104 .
Housing 172 is thus attached to drive ring 104 and thereby rotates with drive ring 104 . The upper and lower bearing rings 192 , 194 are attached to the outer geometry of bearing assembly 106 and thus to outer bowl 102 . Thus, the bearing rings 192 , 194 are stationary and do not rotate.
In operation, as drill string 218 is rotated by the rotary table 18 (shown in FIG. 1 ), drive ring 104 rotates within outer bowl 102 . As the drill string 218 passes downwardly through the stripper assembly 110 , downward drill string forces 220 are placed on bearing assembly 106 . This causes the bearing members 182 , 202 to engage to absorb these downward axial forces on the drilling head assembly 100 . The downhole pressure on the returning drilling fluids also places upward annular forces 222 on bearing assembly 106 . This causes the bearing members 180 , 200 to engage to absorb these upward axial forces on the drilling head assembly 100 . Only one bearing assembly 206 , 208 engages at any one time. When upper bearing assembly 206 engages, lower bearing assembly 208 separates and disengages and when lower bearing assembly 208 engages, upper bearing assembly 206 separates and disengages. The radial forces on the drilling head assembly 100 caused by the rotation of the drill string 218 are absorbed by the roller bearings 186 . Bearing housing 172 and diamond bearing members 180 , 182 also rotate within their respective diamond enhanced bearing assemblies 206 , 208 , serving to counteract axial forces 220 , 222 experienced by rotary drilling head assembly 100 .
The preferred embodiment of the present invention incorporates a bearing assembly with two bearing systems that each contain sets of horizontally opposed bearing members that meet with each other in a planar geometric fashion. Such an embodiment is highly effective in countering axial thrust loads but does not offer any resistance to radial drill string loads. Since loads in the radial direction are much lower than those in the axial direction, the secondary radial bearing system incorporated into the present invention is in the form of roller bearings 186 .
An external pressurized cooling and oiling system 225 communicates through hydraulic quick connects 224 in fluid communication with seal members 164 , 166 above and below bearing assembly 106 to cool and lubricate the bearings. System 225 may include an oil chiller. Seal members 164 , 166 are constructed to remain in place while allowing full 360° rotation of the mating drive ring 104 with maintenance of seal integrity.
Because forces from the annular return of drilling fluids can be greater than downward drill string forces 220 by 10 times or more, upper bearing assembly 206 wears at a faster rate than lower system 208 . To compensate for any uneven wear between bearing assemblies 208 , 206 , bearing assembly 106 is constructed symmetrically so that it may be removed from rotary head assembly 100 , reversed, and reinstalled so that the lesser worn bearing system opposes smaller downward drill string loads 220 . By utilizing the less worn bearing system of the assembly in place of the heavily worn bearing system, use of drilling head assembly 100 can be continued on a temporary basis until a replacement bearing assembly 106 can be located and installed.
Alternatively, a cost saving embodiment for the bearing assembly design includes; a diamond bearing assembly to offset the larger annular return forces and a roller bearing assembly to offset the smaller drill string forces. Such an alternative reduces cost but would not be reversible. Where vertical height restrictions are critical, a still further alternative utilizes only one bearing assembly which offsets both upward and downward forces. Such an alternative reduces the vertical height of the drilling head assembly but requires that the stripper assembly 110 float up and down.
When it is time for bearing replacement, stationary retaining clamp 142 is removed and drive ring 104 and bearing assembly 106 are removed through the opening in rotary table 18 . The current art design presented is capable being retrieved through a 17.5″ clearance rotary table. The prior art presented requires a 22.5″ rotary table clearance.
In the alternative to the preferred embodiment, the diamond bearing members 178 of each opposing bearing ring meet each other at a contact surface with a conical profile. Two horizontally opposed conical diamond bearing systems would suffice to oppose both radial and thrust forces encountered in drill string operations. However, to do so, each of the wafers would have to have a concave surface which is properly oriented. The concave surfaces could be created by arranging the initially flat diamond bearing members in a conical arrangement and rotating them under load until they are “broken in” and obtain the conical profiles.
Although the invention is described with particular reference to a rotary drilling head assembly used in well drilling operations, it will be recognized that certain features thereof may be used or adopted for use in other applications. Inventions relating to oilfield well drilling have applications in other industries that also require earth drilling including, but not limited to, the drilling of water wells, underground electrical conduits, fluid pipelines, or geo-thermal energy systems. While the preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. For example, the relative dimensions of various parts, the materials from which the components are made and other parameters can be varied.
The embodiments described herein are exemplary only, and are not limiting. Many variations and modifications of the invention and the principles disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. | The rotary drilling head assembly of the present invention includes a housing having a bore for receiving a drive member. The drive member has an outer diameter of less than 17 ½ inches to pass through a 17½ inch opening in a rotary table. A bearing assembly is disposed between the housing and drive member allowing the drive member to rotate within the housing and includes an outer stationary portion and an inner rotating portion. Retaining clamps attach the outer stationary portion to the housing and the rotating portion to the drive member. Rotary seal assemblies isolate the bearing assembly and its lubrication system from the drilling fluid and prevent premature wear and failure of the bearing. The bearing assembly includes a plurality of opposing disc-like members that have flat bearing surfaces meeting on a substantially planar surface of contact. The disc-like members are preferably made of a polycrystalline diamond material. |
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CROSS-REFERENCE TO RELATED APPLICATION
The application claims the benefit of the earlier filing date of U.S. Provisional Patent Application No. 61/729,564, filed Nov. 24, 2012 and incorporated herein by reference.
BACKGROUND OF THE INVENTION
A difficult obstacle associated with the exploration and production of oil and gas is management of significant ocean currents. These currents can produce vortex-induced vibration (VIV) and/or large deflections of tubulars associated with drilling and production. VIV can cause substantial fatigue damage to the tubular or cause suspension of drilling due to increased deflections. Both helical strakes and fairings can provide sufficient VIV suppression, but can be slow and unsafe to install.
Most helical strakes consist of one or more fins that are attached to a shell, often with the fins molded into the shell. However, the elimination of the shell can reduce cost substantially.
One method for eliminating the shell of a helical strake section is to wind the fins around the pipe directly without a shell present. However, it is difficult to align the pitch of each of the fins quickly and/or precisely without using measuring tools which can substantially slow down the installation.
SUMMARY OF THE INVENTION
The present invention is directed to an installation assembly, such as a machine, and methods of, installing helical strake fins around a pipe directly without a shell present. The machine is configured to allow for quick and precise installation of the fins. In one embodiment, installation assembly may include an outer ring member dimensioned to encircle an underlying tubular and an inner ring member positioned concentrically inward from the outer ring member. The inner ring member is configured to rotate with respect to at least one of the outer ring member or the tubular as the outer ring member moves axially along the tubular. The apparatus may further include a fin guide configured to receive a fin and helically position the fin along the tubular as the inner ring member rotates.
Another embodiment of the invention the installation assembly may include a support member configured to wrap a VIV suppression fin helically around a tubular. The support member may be dimensioned to retain the VIV suppression fin along an inner surface. The support member may also be modifiable between a first open configuration and a second closed configuration. In the closed configuration, the VIV suppression fin is in a helical shape such that when the support member is wrapped around a tubular, the fin is helically positioned around the tubular. The support member may further include an attachment opening formed through a portion of the support member aligned with the VIV suppression fin. The opening may be used to receive a fastener to facilitate attachment of the VIV suppression fin helically around the tubular once the support member is removed.
Another embodiment of the invention may include a method of installing a vortex-induced vibration (VIV) suppression fin about a tubular which includes removably attaching a VIV suppression fin to an installation member. The installation member may be positioned along a tubular and moved about the tubular to helically position the fin around the tubular. Once the fin is helically positioned about the tubular, the installation member may be removed.
The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all apparatuses that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments disclosed herein are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and they mean at least one.
FIG. 1A is a top view of one embodiment of a reeled installation system turning ring.
FIG. 1B is side view of the reeled installation system of FIG. 1A with a turning ring.
FIG. 1C is side view of the reeled installation system of FIG. 1B with wheels to turn the rail system.
FIG. 1D is a side view of one embodiment of a band holding solid material fins in place.
FIG. 1E is a side view of one embodiment of a band holding two-piece fins in place.
FIG. 1F is a side view of one embodiment of a band holding two-piece fins in place.
FIG. 2A shows a plan view of one embodiment of a flexible installation sheet for positioning fins around a tubular.
FIG. 2B shows a plan view of one embodiment of a flexible installation sheet for positioning fins around a tubular.
FIG. 2C shows a front plan view of one embodiment of a flexible installation sheet for positioning fins around a tubular.
FIG. 2D shows a back plan view of the flexible installation sheet of FIG. 2C .
FIG. 2E is a side view of one embodiment of an installation sheet in place around a tubular.
FIG. 3A shows a side view of one embodiment of a rigid installation shell in place around a tubular.
FIG. 3B shows the installation shell of FIG. 3A along line A-A′.
FIG. 4A is a side view of one embodiment of a geared installation ring.
FIG. 4B is an end view of the geared installation ring of FIG. 4A .
FIG. 4C is a side view of one embodiment of a geared installation ring that is perpendicular to the view of FIG. 4A .
FIG. 5A is a side view of one embodiment of a sleeved installation ring.
FIG. 5B is a cross section view of the sleeved installation ring of FIG. 5A along line B-B′.
FIG. 5C is a cross section view of the sleeved installation ring of FIG. 5A along line C-C′.
FIG. 5D is a cross section view of the sleeved installation ring of FIG. 5A along line D-D′.
DETAILED DESCRIPTION OF THE INVENTION
In this section we shall explain several preferred embodiments with reference to the appended drawings. Whenever the shapes, relative positions and other aspects of the parts described in the embodiments are not clearly defined, the scope of the embodiment is not limited only to the parts shown, which are meant merely for the purpose of illustration. Also, while numerous details are set forth, it is understood that some embodiments may be practiced without these details. In other instances, well-known structures and techniques have not been shown in detail so as not to obscure the understanding of this description.
Referring now to the invention in more detail, FIG. 1A illustrates a top view of a reeled installation system turning ring. The turning ring 103 is made up of three sections 103 A, 103 B, and 103 C that are contained in ring housing 102 which is also made up of three sections 102 A, 102 B, and 102 C. Each of ring sections 103 A- 103 C and housing sections 102 A- 102 C may be separable to facilitate positioning of the assembly around tubular 100 , or integrally formed as one continuous unit. Connectors 155 A, 155 B, and 155 C join ring 103 with ring 101 , which surrounds tubular 100 . Ring 101 helps to stabilize ring 103 around tubular 100 at a fixed distance. Reels 104 A, 104 B, and 104 C contain fin rolls 105 A, 105 B, and 105 C, respectively. Reels 104 A- 104 C may be fixedly attached to turning ring 103 by any suitable mechanism (e.g., bolt, screw, bracket, molding, adhesive or the like) such that reels 104 A- 104 C rotate along with turning ring 103 . Guides 107 A, 107 B, and 107 C assist in laying out fins 106 A, 106 B, and 106 C, respectively.
Again referring to FIG. 1A , when ring 103 is rotated (as illustrated by arrow 180 ), reels 104 A- 104 C and ring housing 102 are also rotated. As reels 104 A- 104 C rotate, fins 106 A- 106 C, which are wound around reels 104 A- 104 C, are unwound and laid out onto the underlying tubular 100 . By rotating ring 103 and laying out fins 106 A- 106 C as tubular 100 is lowered (into the page), fins 106 A- 106 C produce a helical pattern on tubular 100 . This helical pattern can be controlled by varying the rate of rotation of ring 103 relative to the lowering of tubular 100 . Ring 103 may be rotated manually, such as by a technician on deck, or automatically, such as by a motor assembly connected to ring 103 . Once fins 106 A- 106 C are helically arranged along tubular 100 , the reeled installation system can be removed leaving fins 106 A- 106 C helically installed along tubular 100 .
Any number of ring sections 103 A- 103 C, housing sections 102 A- 102 C, connectors 155 A- 155 C, reels 104 A- 104 C, fin rolls 105 A- 105 C, fins 106 A- 106 C, and guides 107 A- 107 C may be used depending upon the design. Fins 106 A- 106 C may be made of material fabricated solely to act as a VIV suppression device or may be made of other auxiliary lines that assist with, or perform, other functions, or any combination thereof.
Still referring to FIG. 1A , tubular 100 may range between 2 inches and 60 inches in diameter. Fins 106 A- 106 C will typically have a thickness within a range from 5 percent to 30 percent of the diameter of tubular 100 . Reels 104 A-C may be dimensioned to contain between 6 ft. and 1000 ft. of fins 106 A- 106 C on fin rolls 105 A- 105 C.
Still referring to FIG. 1A , ring 103 , housing 102 , connectors 155 A- 155 C, and reels 104 A- 104 C may be made of any suitable material including, but not limited to, metal, plastic, fiberglass, wood, and composites. However, the material must be strong enough so that ring 103 may turn freely. Fin rolls 105 A- 105 C and fins 106 A- 106 C may also be made of any suitable material but typically will be made of a more flexible material such as an elastomer, plastic, or composite.
Referring now to FIG. 1B , FIG. 1B is a side view of FIG. 1A but with only two fins 106 A- 106 B shown wrapped around tubular 100 , and thus only two reels 104 A- 104 B and two fin rolls 105 A- 105 B are needed. Housing 102 sits on legs 112 which sit on deck 111 .
Again referring to FIG. 1B , since housing 102 is essentially fixed to deck 111 through legs 112 , the rotation of reels 104 A- 104 B is dependent upon rotation of the ring (not visible but shown in FIG. 1A as ring 103 ) which is constrained by housing 102 . By lowering tubular 100 while the ring (and therefore housings 104 A- 104 B) is rotating, the fins 106 A- 106 B are wrapped in a helical fashion around tubular 100 .
Still referring to FIG. 1B , deck 111 is typically part of an offshore drilling or production platform, but can also represent other support structures. For example, fins 106 A- 106 B could be wrapped around a structure in air as tubular 100 is raised (instead of lowered) while the ring is rotating. In addition, banding of the fins 106 A- 106 B can occur at the same, or different, level or deck 111 .
Referring now to FIG. 1C , this figure is similar to FIG. 1B except that legs 112 have been replaced with casters 113 .
Again referring to FIG. 1C , since casters 113 are able to roll along deck 111 , housing 102 may be rotated around tubular 100 and thus a rotatable ring, such as ring 103 of FIG. 1A , is not required. This simplifies the system but requires a deck 111 that can accommodate the rolling action of the casters 113 and also requires careful rotation of housing 102 about tubular 100 to keep them concentric.
Referring to FIG. 1D , FIG. 1D shows how a typical end termination can be made for fins 106 A- 106 B in order to secure them to tubular 100 . Representatively, in one embodiment, band 121 is put under tension so that it produces compression forces on fins 106 A-B and tubular 100 . Band 121 may be made of any suitable material including, but not limited to metal, plastic, synthetic, composite, rubber or other elastomer, or combinations of these materials. Alternatively, a collar or other clamp may be used in place of band 121 . Typically, band 121 may be under tension, but the only requirement is that band 121 produce a compressive force on fins 106 A-B and tubular 100 .
Referring to FIG. 1E , FIG. 1E is similar to FIG. 1D except that two part fins are presented along with additional end termination hardware. Representatively, in this embodiment, fins 106 A- 106 B include core portions 181 A and 181 B and sleeves 131 A and 131 B. Sleeves 131 A- 131 B are wrapped around core portions 181 A- 181 B, respectively. Core portions 181 A- 181 B are elongated structures which extend around tubular 100 while sleeves 131 A- 131 B are short tubular segments which wrap around core portions 181 A- 181 B, respectively. End terminations 136 A and 136 B may be used to assist with keeping core portions 181 A and 181 B in place as well with keeping sleeves 131 A- 131 B from sliding past band 121 .
Again referring to FIG. 1E , by placing sleeves 131 A- 131 B around core portions 181 A- 181 B, a relatively large fin which extends out from tubular 100 may be produced. Sleeves 131 A- 131 B may be hollow, and typically there will be a significant annulus between sleeves 131 A- 131 B and core portions 181 A- 181 B. Sleeves 131 A- 131 B and core portions 181 A- 181 B may be of any suitable cross sectional shape, including round, polygonal, elliptical, and partial common shapes (such as a semi-circle). End terminations 136 A- 136 B may consist of any useful device that can be clamped onto, or attached to, core portions 181 A- 181 B such as thimbles, clamps (including hose clamps), hooks, and fasteners. End terminations may also be partially or fully comprised of part of core portions 181 A- 181 B such as by tying a knot along the length.
Still referring to FIG. 1E , sleeves 131 A- 131 B and core portions 181 A- 181 B may be of any suitable size. Typically core portions 181 A- 181 B will range from about 1 percent to 10 percent of the diameter of tubular 100 while sleeves 131 A- 131 B will range from 5 percent to 30 percent of the diameter of tubular 100 .
Still referring to FIG. 1E , end terminations 136 A- 136 B, sleeves 131 A- 131 B and core portions 181 A- 181 B may be made of any suitable material including, but not limited to metal, plastic, synthetic, composite, rubber or other elastomer, or combinations of these materials.
Referring to FIG. 1F , this figure is similar to FIG. 1E except that fins 106 A and 106 B are aligned with one another by aligning their end terminations 136 A- 136 B using bands 121 A- 121 B. In one embodiment, end terminations 136 A and 136 B may be lined up by placing them under appropriate positions of their adjacent bands 121 A- 121 B and/or by connecting end terminations 136 A- 136 B to each other or to bands 121 A- 121 B. FIG. 1F further illustrates that in some embodiments, a stopper member 141 may be positioned around core portion 181 A (or 181 B) to help hold sleeves 131 A (or sleeves 131 B) at a desired position along core portion 181 A. Stopper member 141 may be, for example, a clamp, clip, ring, or any other structure capable of preventing movement of sleeves 131 A along core portion 181 A.
Referring now to FIG. 2A , FIG. 2A shows a wrap 201 with adjacent fins 206 A- 206 C. Openings 252 are present in wrap 201 . In this embodiment, fins 206 A- 206 C may be temporarily, or permanently, attached to wrap 201 so that, when wrap 201 is placed around a tubular, fins 206 A- 206 C are helically wrapped around the tubular. Openings 252 are present to assist with attaching fins 206 A- 206 C to the tubular. Wrap 201 may consist of more than one layer to provide proper stiffness and shape for a given application.
Still referring to FIG. 2A , fins 206 A- 206 C may be of any size, similar to the fins discussed above. Wrap 201 may be of any suitable shape (e.g., square, rectangular, circular, triangular, elliptical, etc.) and often will have an odd or non-geometric shape so that it can accommodate the fins and encircle the tubular with minimal overlap. Openings 252 may be of any size and shape so as to fulfill their function of assisting with fin attachment.
Still referring to FIG. 2A , fins 206 A- 206 C and wrap 201 may be of any suitable material including, but not limited to metal, plastic, fabric, synthetic, composite, rubber or other elastomer, or combinations of these materials. For example, fins 206 A- 206 C might consist of a rope such as polyester or nylon rope.
Referring now to FIG. 2B , FIG. 2B is similar to FIG. 2A except that fin openings 251 A- 251 C have been formed in wrap 201 . Fasteners 255 attach fins 206 A- 206 C to wrap 201 and openings 252 , such as those discussed in reference to FIG. 2A , are present to assist with attaching fins 206 A- 206 C to the tubular.
Again referring to FIG. 2B , fin openings 251 A- 251 C may be of any size or shape but are typically at least a little wider than fins 206 A- 206 C. Fin openings 251 A- 251 C may extend entirely through wrap 201 or may be receptacles or channels formed in wrap 201 which do not extend entirely through wrap 201 . Fin openings 251 A- 251 C may be of any suitable orientation but will typically be at an angle relative to the sides of wrap 201 . Fins 206 A- 206 C will typically align with fin openings 251 A- 251 C but may be at an angle relative to fin openings 251 A- 251 C. Fins 206 A- 206 C may, or may not, extend past wrap 201 as shown in FIG. 2B . The advantage of extending fins 206 A- 206 C past wrap 201 is that the ends of fins 206 A- 206 C may be banded or clamped against the tubular without removing all of, or part of, wrap 201 . However wrap 201 may completely cover fins 206 A- 206 C and additional openings 252 may be used to assist in attaching fins 206 A- 206 C to the tubular.
Fasteners 255 may further be provided to assist with attaching fins 206 A- 206 B to wrap 201 . Fasteners 255 may be a tape (shown in FIG. 2B ), screws, bolts, clamps, or any suitable fastening material. Fasteners 255 may be permanently attached to wrap 201 and/or fins 206 A-C, or fasteners 255 may be temporarily attached to wrap 201 and/or fins 206 A-C.
Still referring to FIG. 2B , each of the wrap 201 , fins 206 A- 206 C and fasteners 255 may be made of any suitable material. It is further contemplated that in some embodiments, a collar may be substituted for any of the previously discussed bands to facilitate with attachment and/or alignment of fins 106 A- 106 C and/or fins 206 A- 206 C along the associated tubular.
Referring now to FIG. 2C and FIG. 2D , FIG. 2C and FIG. 2D are similar to FIG. 2B except that straps 261 are included to facilitate positioning of wrap 201 about the tubular. FIG. 2C illustrates a front side view similar to FIG. 2B . Fin openings 251 A- 251 C are shown formed through wrap 201 and aligned with fins 206 A- 206 C. Openings 252 assist with attaching fins 206 A- 206 C to the underlying tubular (not shown). Fasteners 255 (shown as tape segments in FIG. 2C ) attach fins 206 A- 206 C to wrap 201 .
Again referring to FIG. 2C and FIG. 2D , when wrap 201 is closed around a tubular, fins 206 A- 206 C will be wrapped helically around the tubular. Straps 261 assist in pulling the wrap tight against itself. Straps 261 may be used to temporarily hold wrap 201 closed or may be used to pull on wrap 201 while fins 206 A- 206 C are secured around the tubular. Straps 261 may consist of any suitable mechanism or material. For example, straps 261 may consist of Velcro strips, hooks, buckles, belts, or latches. Once wrap 201 is closed around a tubular, fins 206 A- 206 C are clamped to the tubular using bands, collars, or any suitable attachment device. Openings 252 may be used to assist with clamping fins 206 A- 206 C to the tubular, for example by inserting a band over fins 206 A- 204 C but under the wrap and around the tubular. Once fins 206 A- 206 C are secure, then wrap 201 may be removed by opening straps 261 and removing wrap 201 . Fasteners 255 may be removed from wrap 201 or reused to for the next set of fins. Openings 251 A- 251 C may be used for attachment of fins 206 A- 206 C to wrap 201 or openings 251 A- 251 C may be used for simply marking the underlying tubular so that fins 206 A- 206 C may be attached with, or without, wrap 201 . Once fins 206 A- 206 C are placed around the tubular, a coating (such as a field joint coating) or other bonding material may be used to keep fins 206 A- 206 C in place on the tubular.
Still referring to FIG. 2C and FIG. 2D , straps 261 may be of any size, shape, or material suitable for attaching wrap 201 to a tubular and may be optional.
Referring now to FIG. 2E , FIG. 2E shows a wrap 201 similar to the wrap in FIG. 2C placed around tubular 200 with a pull ring 280 and twist handles 281 present. Pull ring 280 and twist handles 281 are attached to, or part of, wrap 201 . Fins 206 A- 206 B (fin 206 C is not shown) are clamped against tubular 200 by bands 221 A- 221 C while wrap 201 is temporarily secured around tubular 200 using straps 261 along seam 275 . Openings 252 are used to assist in getting band 221 C into position. Opening 270 is an extra opening shown here that provides room for connecting the two ends of band 221 C. Note that any fin openings are not shown in FIG. 2D but, as noted above in the discussion of FIG. 2B , underlying fin receptacles may be present in wrap 201 .
Again referring to FIG. 2E , in this embodiment, wrap 201 is placed around tubular 200 and secured with straps 261 . Band 221 A is then placed around fins 206 A- 206 B to hold them in place (the band 221 A may be attached to wrap 201 before installation of wrap 201 or after installation of wrap 201 ; a collar or other clamping device may be substituted for band 206 A). While pulling up on ring 280 and using twist handles 281 to keep the fins 206 A- 206 B in the proper helical position, bands 221 C and 221 B are secured around fins 206 A- 206 B. Once fins 206 A- 206 B are secured to tubular 200 by bands 221 A- 221 C, wrap 201 may be removed, fitted with three more fins, and the installation process may be repeated.
Still referring to FIG. 2E , opening 270 may be of any suitable size and shape and will typically be sufficiently large to accommodate any installation tools for band 221 C. As noted previously, bands 221 A- 221 C may be replaced by collars or other clamping devices in which case opening 270 would be sized to install those devices and accommodate their installation tools. Pull ring 280 and twist handles 281 may be made in any suitable size, shape, or material and may be fastened to wrap 201 or may be integral to wrap 201 . Pull ring 280 , twist handles 281 , and opening 270 are optional but may be used if they are useful for installation of fins 206 A- 206 C around tubular 200 .
Referring now to FIG. 3A , FIG. 3A illustrates a shell 301 similar to wrap 201 of FIG. 2A-2E except that shell 301 is a more rigid, less flexible shell-type structure having a first section 301 A and a second section 301 B. Shell 301 may, however, have a similar size and shape to that of wrap 201 . Fins 306 A- 306 C may be attached to shell 301 with underlying structures or with openings and fasteners (not shown here but identical to those of FIG. 2B and FIG. 2C ). Latches 363 are used to close shell 301 along seam 375 while bands 321 A- 321 C are used to clamp fins 306 A- 306 C to tubular 300 . Optional end terminations 336 A- 336 B are used to assist with keeping fins 306 A- 306 C from sliding past the adjacent bands. In this aspect, terminations 336 A- 336 B may be any type of structure capable of modifying (e.g., enlarging) the ends of fins 306 A- 306 C so that they do not slide under bands 321 A- 321 B. Openings 352 and 370 assist with attachment of band 321 C.
Again referring to FIG. 3A , when shell 301 is closed around tubular 300 as shown, fins 306 A- 306 C are held against tubular 300 . Bands 321 A- 321 C are then tightened around fins 306 A- 306 C and, in the case of band 321 C, utilizing openings 352 and 370 . Once bands 321 A- 321 C are in place, shell 301 may be removed. Shell 301 may be removed above the ocean surface or it may be removed below the ocean surface. For example, shell 301 may be used to assist with installing fins 306 A- 306 C via s-lay and removed underwater by a diver or by a remote operated vehicle or by other similar methods.
Still referring to FIG. 3A , shell 301 may be any size and may be made of any material suitable for facilitating attachment of fins 306 A- 306 C to tubular 300 . Representative materials may include, but are not limited to, plastic, metal, fiberglass, composite, wood, synthetics, and ceramics.
Referring now to FIG. 3B , FIG. 3B is a cross section along line A-A′ of FIG. 3A looking downward. Only a representative slice is shown and the bands are omitted. Only a slice of the fins 306 A- 306 C and fin housings 391 A- 391 C are shown for ease of understanding. Shell 301 has optional shell liner 390 attached to it. Fin housings 391 A- 391 C are attached to shell liner 390 and keep fins 306 A- 306 C aligned. In one embodiment, shell 301 and shell liner 390 are formed in sections that can be opened and closed around tubular 300 . Hinge 367 and latch 363 may be attached to opposing ends of the shell sections 301 A- 301 B and/or liner sections to allow for shell 301 and shell liner 390 to be opened up and placed around tubular 300 .
Again referring to FIG. 3B , shell liner 390 helps to decrease the inside diameter of shell 301 and/or to provide a surface to which to attach fin housings 391 A- 391 C. When shell 301 and shell liner 390 are placed around tubular 300 , fins 306 A- 306 C are pressed against tubular 300 . The latch 363 may be used to keep the shell 301 and shell liner 390 pressed against the tubular 300 . Next, fins 306 A- 306 C may be clamped (e.g., by using the bands shown in FIG. 3A ) against tubular 300 after which the shell 301 and shell liner 390 may be removed. Note that, while FIG. 3B shows shell 301 and shell liner 390 to be hinged, it is possible to simply make these parts in two halves and press them against tubular 300 by other means.
Still referring to FIG. 3B , shell liner 390 , fin housings 391 A- 391 C, latch 363 , and hinge 367 may be made of any shape or material suitable for facilitating attachment of fins 306 A- 306 B to tubular 300 , and each are optional with this design.
Referring now to FIG. 4A , FIG. 4A is a side view of an installation method that has fins 406 A- 406 B attached against tubular 400 using band 421 and other bands (not shown). Outer ring 457 is concentric with tubular 400 and inner (rotating) ring 458 , which is hidden in this view but can be seen in FIG. 4B . Worm gear 497 turns gear 498 which, in turn, rotates ring 458 . Handles 484 allow for ease of moving the rings axially along tubular 400 . End terminations 436 A- 436 B assist in keeping fins 406 A- 406 B from sliding under the bands.
Again referring now to FIG. 4A , when outer ring 457 is pushed axially (upwards in FIG. 4A ) by pushing on optional handles 484 , worm gear 497 turns and engages gear 498 which, in turn, rotates inner ring 458 . Fins 406 A and 406 B go through slots in ring 458 that wind fins 406 A- 406 B axially along tubular 400 as outer ring 457 traverses axially along tubular 400 . Outer ring 457 is donut shaped so that fins 406 A- 406 B can move freely around tubular 400 without engaging outer ring 457 .
Still referring to FIG. 4A , outer ring 457 , inner ring 458 , handles 484 , worm gear 497 , and gear 498 may be of any size suitable for positioning fins 406 A- 406 B around tubular 400 . Typically, worm gear 497 and gear 498 are sized to produce the required pitch for the helical winding of fins 406 A-B. Other gear types may also be used with the only limitation being that the gearing function must translate the axial movement of outer ring 457 to a combined axial and rotational movement of fins 406 A-B. Other ring arrangements may also be used to assist with providing structural support for this function.
Still referring to FIG. 4A , outer ring 457 , inner ring 458 , handles 484 , worm gear 497 , and gear 498 may be made of any material suitable for facilitating attachment of fins 406 A- 406 B about tubular 400 .
Referring to FIG. 4B , FIG. 4B shows an end view of FIG. 4A except that only a cross section of fins 406 A- 406 C and fin housings 491 A- 491 C are shown. The handles are also omitted for clarity. FIG. 4B shows outer ring 457 and inner ring 458 approximately concentric with tubular 400 . Outer ring 457 and inner ring 458 have hinge 467 and latch 463 to ease with placement around tubular 400 . Fin housings 491 A- 491 C can extend from an inner surface of inner ring 458 and toward tubular 400 . In this aspect, fin housings 491 A- 491 C can hold fins 406 A- 406 C in place against tubular 400 while they are being helically wound around tubular 400 . Representatively, as inner ring 458 rotates and travels along the tubular axis, fins 406 A- 406 C slide through housings 491 A- 491 C. Worm gear 497 rotates as the rings travel along the tubular axis and, in turn, turns gear 498 which, in turn, turns inner ring 458 through inner ring gear teeth 478 . Worm gear 497 is attached to ring 458 through struts 449 .
Again referring to FIG. 4B , fin housings 491 A- 491 C may be of any size and shape suitable for keeping fins 406 A- 406 B in place adjacent to tubular 400 and thus any suitable design will work. For example, housings 491 A- 491 C may be channels, recesses or other similar structure that retains fins 406 A- 406 C and open in a direction of tubular 400 so that fins 406 A- 406 C face tubular 400 and can slide through housings 491 A- 491 C as they are being helically wound around tubular 400 . Inner ring gear teeth 478 extend along an inner circumference of inner ring 458 , however, do not necessarily have to cover the entire circumference of inner ring 458 depending upon how much of the circumference is traversed as outer ring 457 travels down the pipe to install a given set of fins 406 A- 406 C. Worm gear 497 , gear 498 , inner ring gear teeth 478 , and inner ring 458 may be customized for a given application. Tubular diameter, fin size, desired fin pitch, etc. will determine the actual sizes and geometry of each of these parts.
Still referring to FIG. 4B , each part may be made of any material suitable for facilitating installation of fins 406 A- 406 C about tubular 400 . For this design, and for all of the other designs presented herein, it is to be understood that any number of fins and fin housings may be used. In some embodiments, fin housings 491 A- 491 C may be omitted and other methods may be used to keep fins 406 A- 406 C in place during installation, such as fastening or gluing fins 406 A- 406 C to ring 458 .
Referring now to FIG. 4C , this figure is similar to FIG. 4A except a different angle is shown and inner ring 458 has a slightly different design. In FIG. 4C , inner ring 458 extends through the opening of outer ring 457 which helps support outer ring 457 to keep it concentric with ring 457 . FIG. 4C also illustrates how handles 484 might connect to outer ring 457 . Band 421 keeps fins 406 A- 406 B in place at one end, and end connectors 436 A- 436 B help insure fins 406 A- 406 B do not slide out from under band 421 . In this aspect, end connectors 436 A- 436 B may be structures which are part of, or attached to, the end of fins 406 A- 406 B and of any size and shape suitable to prevent fins 406 A- 406 B from sliding out from under band 421 . Worm gear 499 , gear 498 , and inner ring 458 assist in turning inner ring 458 as outer ring 458 is pushed along tubular 400 .
Again referring to FIG. 4C , when inner ring 458 turns around tubular 400 , the portions on both sides of outer ring 457 turn together. Outer ring 457 does not turn. If outer ring 457 moves from right to left in FIG. 4C , worm gear 499 and gear 498 will stay on top of the pipe as shown, but inner ring 458 will rotate thereby wrapping fins 406 A- 406 B helically around tubular 400 . Inner ring 458 may be designed to produce a little tension in fins 406 A- 406 B to keep them tight against tubular 400 . This tension may be imposed by any one of several means, ranging from a geometric misalignment of the fin as it passes through inner ring 458 to one or more actual springs that keep fins 406 A- 406 C in tension.
Referring now to FIG. 5A , this figure shows a ring 555 that rotates through a sleeve 556 . Ring 555 has ring ridges 569 that rotate when they engage internal sleeve ridges 539 in sleeve 556 . Fins 506 A- 506 C extend through sleeve 556 and ring 555 and to an end that may have optional end terminations 536 A- 536 B, such as any of those previously discussed. Fins 506 A- 506 C are clamped to tubular 500 by bands 521 A- 521 C.
Again referring to FIG. 5A , as ring 555 travels from right to left through sleeve 556 , the internal sleeve ridges 539 and the ring ridges 569 on ring 555 cause it to rotate. As fins 506 A- 506 C pass through ring 555 , they are adjacent to tubular 500 and pass through helically due to the ring rotation. The bands 521 A- 521 C are used to keep the fins 506 A- 506 C in place against tubular 500 . Use of end terminations 536 A- 536 B may allow for greater tension to be put onto fins 506 A- 506 C which may allow for less dense use of bands 521 A- 521 C. Multiple sleeves 539 may be used to allow for faster installation of fins 506 A- 506 C. Sleeve 539 and ring 555 may be slid over the end of tubular 500 or made in one or more parts that are fastened together through hinges, fasteners, latches, or any suitable means.
Still referring to FIG. 5A , sleeve 556 , ring 555 , fins 506 A- 506 C, and bands 521 A- 521 C may be made in any size or shape suitable for installation of fins 506 A- 506 C about tubular 500 . Fins 521 A- 521 C may be flexible to allow for ease of installation. Internal sleeve ridges 539 and ring ridges 569 may be of any quantity, circumferential coverage, size, shape, and angle that is desired, and will typically be designed to produce the desired pitch (angle relative to the pipe longitudinal axis).
Still referring to FIG. 5A , all parts may be made of any material suitable for installing fins about a tubular, such as any of the previously discussed materials, and more than one material may be used for a given part.
Referring to FIG. 5B , this figure shows cross-section along line BB′ of FIG. 5A across the ring 555 . Ring 555 is shown centralized onto tubular 500 by fin housings 591 A- 591 C and fins 506 A- 506 C. Ring ridges 569 are shown along the exterior of ring 555 .
Again referring to FIG. 5B , fin housings 591 A- 591 C keep the fins from moving along the circumferential direction of tubular 500 and adjacent to tubular 500 . The fin housings 591 A- 591 C may be formed by any structure and geometry suitable for keeping the fins from moving along the circumferential direction of tubular 500 and adjacent to tubular 500 . For example, fin housings 591 A- 591 C may consist of channel, tape, fasteners, or any other suitable method of housing fins 506 A- 506 C. Fin housings 591 A- 591 C may be of any suitable size and material.
Referring to FIG. 5C , this figure shows cross section C-C′ of FIG. 5A across sleeve 539 near the ring end. Internal sleeve ridges 567 are attached or part of sleeve 556 and the sleeve is external to tubular 500 . Fins 506 A- 506 C are free to move inside of sleeve 556 and are each shown at only one possible location.
Again referring to FIG. 5C , since sleeve 539 is not free to rotate about tubular 500 , fins 506 A- 506 C will move around inside the annulus between sleeve 539 and tubular 500 as fins 506 A- 506 C are installed. Any number of internal sleeve ridges 567 may be used and they may be of any size or shape. Internal sleeve ridges 567 may, or may not, cover the entire circumference of the inside of sleeve 539 .
Still referring to FIG. 5C , internal sleeve ridges 567 may be made of any suitable material but will typically be sufficiently rigid and strong such that they stay in place with minimal deformation during installation of fins 506 A- 506 C.
Referring now to FIG. 5D , this figure shows a cross section along line D-D′ of FIG. 5A across sleeve 539 near the clamped end. At this end, internal sleeve ridges are not required (but may be present) and thus are not shown. Fins 506 A- 506 C are free to move around inside of the annulus between sleeve 539 and tubular 500 . However, sleeve supports 586 will restrict the movement of fins 506 A- 506 C to the area between adjacent sleeve supports. Sleeve supports 586 are used to keep sleeve 539 approximately concentric with tubular 500 with an annulus sufficient for installation of fins 506 A- 506 C.
The above embodiments may be mixed and matched to form an installation system or method. For example, the embodiments of FIG. 2A-D may be used in conjunction with the reeled installation system presented in FIG. 1A-F . The various features of each embodiment may be used in the other embodiments even if they are not specifically listed in the discussion of that invention.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. For several of the ideas presented herein, one or more of the parts may be optional. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. | An apparatus and method for helically installing a vortex-induced vibration (VIV) suppression fin about a tubular. The apparatus may include an outer ring member dimensioned to encircle an underlying tubular and an inner ring member positioned concentrically inward from the outer ring member. The inner ring member is configured to rotate with respect to at least one of the outer ring member or the tubular as the outer ring member moves along the tubular. The apparatus may further include a fin guide configured to receive a fin and helically position the fin along the tubular as the inner ring member rotates. A method of installing a vortex-induced vibration (VIV) suppression fin about a tubular may include removably attaching a VIV suppression fin to an installation member. The installation member may be positioned along a tubular and moved about the tubular to helically position the fin around the tubular. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to assemblable and disassemblable frame structures such as used for tents, awnings, canopies and the like, and more particularly relates to such structures which utilize conventional junction elements and compound tube beam and rafter components enabling relatively greater spans and relatively simpler construction than is possible with conventional single tube beam and rafter components.
2. Description of the Prior Art
Conventional tent, awning and canopy frame structures of a readily assemblable and disassemblable nature such as utilized in the rental trade are commonly made up of cylindrical tubing and various types of junction elements or connectors, or so-called slip fit or slip-on fittings, commonly termed corner, ridge intermediate, intermediate, three-way crown, four-way crown, six-way crown and eight-way crown fittings, fabricated of 1.66" OD aluminum or steel tubing. To assemble a given desired structure, it is conventional to use 2" OD cylindrical tubing with 1/8" inch wall thickness in appropriate lengths to make up the uprights (suitably in 7'8" lengths), eave beams (suitably in 9'4", 14'4" and 19'4" lengths) and hip rafters (suitably in 6'10", 10'6", 14'4", 21'10" and 29'4" lengths) and, where used, intermediate rafters (suitably 5', 10'6", 16'1" and 21'8" lengths) with the various rafters being interconnected by a crown fitting at the ridge or peak or peaks or by corner or intermediate fittings at the eave beams. Conventionally, also, the tubes and fittings are joined together in a telescoping manner with the tubes telescoped over associated arms of the fittings and the tubes and fittings are interlocked together by so-called locking quick pins. With such conventional single tube constructions, it is common to limit the span between uprights to ten feet, i.e. limit the length of the eave beams to 9'4" so that the structure had adequate strength to withstand unusual loads, windstorms or the like with an adequate safety margin. It is also known to use single tube eave beams of 14'4" length in certain light duty applications. However, when sturdy tent, awning or canopy structures are desired of relatively larger area coverage, the assemblage becomes quite complicated with need oftentimes for additional internally placed supporting components.
Crow U.S. Pat. No. 1,958,296 discloses tent frames providing an increased span between corner posts by use of arched braces, also called trusses, which in general are made up of laterly spaced top and bottom chords interconnected by spaced struts.
In general it is also known as in Dithridge U.S. Pat. No. 426,558 to construct "beams or sills for railway-cars" with tubular edges and with one or more connecting plates therebetween and with the one or more connecting plates arranged essentially coplanar with the axial centers of the tubular edges, but without any suggestion of utilization of any similar compound tubular configuration in readily assemblable and disassemblable structures such as the structures to which the present invention applies.
SUMMARY OF THE INVENTION
The principal feature and advantage of the present invention is the provision, in readily assembleable and disassemblable tent, awning and canopy structures, of double tubular rafters of unique cross section to double the span between upright posts and quadruple the area which the structure overlies, and to do so in a manner so that the double tube rafter components are usable with conventional interconnectors and are interchangeable with single cylindrical tubing components conventionally used, to the extent desired in any given structural configuration.
It is a further object and feature of the present invention to provide a double tube tent, awning or canopy frame beam and rafter configuration with a maximized strength-to-weight ratio and a like cross section end for end so as to be readily fabricated as by extrusion from high strength aluminum alloy or the like.
It is a further object and feature of the present invention to provide what has been heretofore a gap in the design of readilly assemblable and disassemblable tent frame structures, i.e. to provide what has been the missing structural component between typical small tent, awning or canopy frame components and the large building frame components using massive aluminum tubing of rectangular cross-section. Critical to the beam and rafter structure concept of the present invention is the feature of upward compatibility with all slip fit fittings for standard event tents. With the double tube beam and rafter constructions of the present invention it is possible to build a 40' frame tent structure using exactly the same fittings as are now used to build a 20' or a 30' frame. In addition, the assembly and disassembly times are markedly reduced, in some cases as much as 50%. With the double tube beam and rafter components provided by the present invention, it is possible to build a sturdy tent frame with 20', spacings between the legs or uprights. For example, one can build a 20' by 20' frame using only four corner fittings, four legs, four hip rafters, four eave beams, and one four-way crown fitting. Double tubing and conventional single tubing can be mixed and matched according to special event needs. For example, one can span one side of a 20' by 20' frame with only one twin tube beam, while using standard fittings and tubing on the other sides. When compared with standard 2" single tubing, the double tubing of the present invention provides up to six times the resistance to deflection.
These and other objects, features, advantages and applications of tent, awning and canopy structure and components thereof will be evident from the following description and accompanying illustrations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a conventional tent frame constructed of single 2" tubing and associated connectors to provide a 20' by 20' (20×20) structure;
FIG. 2 is an isometric view on an enlarged scale of a 20' by 20' (20×20) tent frame utilizing double tube beams and rafters according to the present invention and standard connectors;
FIG. 3 is an enlarged detail view of one of the corner connectors and associated beams and rafter of the tent structure shown in FIG. 2;
FIG. 4 is a further enlarged detail view of one of the double tube beams or rafter of the tent structure shown in FIGS. 2 and 3, showing a lateral cross section thereof;
FIG. 5 is a view similar to that of FIG. 4 showing the lateral cross section of a modified form of double tubing beam or rafter according to the present invention wherein the cylindrical portions thereof are spaced laterally a distance approximately equal to a diameter of the tubular portions;
FIG. 6 is an isometric view on a reduced scale, as compared with FIG. 2, of a more complex tent structure assembly according to the present invention utilizing the double tubes of the present invention for the rafters, eaves and uprights along with conventional connectors, the configuration of the structure providing a coverage of substantially 40' by 80' (40×80).
FIGS. 7A, 7B, 7C, 7D, 7E, 7F and 7G are diagrammatic showings of typical other structural arrangements of tent frames with double tube rafters according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring specifically to the drawings, FIG. 1 illustrates in somewhat schematic form a conventional assembly for a 20' by 20' tent frame (20×20), comprising single tube uprights or posts 10, single tube eave beams 12, four hip rafters 14, and four intermediate rafters 16. In conventional style, corner fittings 18 interconnect the corner uprights 10, the adjacent eave beams 12 and hip rafters 14, intermediate connectors 20 interconnect adjacent uprights 10, eave beams 12 and intermediate rafters 16, and the various hip and intermediate rafters 14, 16 are interconnected at the peak by an eight-way crown fitting 22. Such construction provides a substantially 10' span between uprights around the periphery of the structure. As is also conventional, the single tube uprights and rafters are commonly 2" OD aluminum tubing with a 1/8th inch wall thickness and the various slip fit or slip-on fittings have arms with a 1.66" OD and are fabricated of steel or aluminum alloy.
FIG. 2 illustrates on an enlarged scale a 20' by 20' (20×20) tent frame assembly according to the present invention. In this instance, corner fittings 18 are of the same conventional form as utilized in the structure of FIG. 1, as are the single tube uprights or posts 10. According to the invention, double tube eave beams 30 extend between adjacent corner fittings 18 over substantially a 20' span (with 19'4" eave beams) and the corner fittings 18 interconnect the corner uprights 10 and the eave beams 30 and associated hip rafters 32, also of double tube configuration, with the hip rafters 32 in turn being interconnected by being telescoped over four of the arms of an eight-way crown fitting 22, it being apparent with respect to this latter fitting that a four-way crown fitting would serve as well in that four of the arms of the eight-way crown fitting are not used in the assembly of FIG. 2.
FIG. 3 shows on a further enlarged scale one of the corner fittings 18 and portions of the associated double tube eave beams 30 and hip rafter 32 of the tent frame assembly shown in FIG. 2. In a manner conventional per se, the beams and rafter 30, 32 are assembled with one of the tubular portions at the respective ends 34, 36 thereof telescoped over respective arms 38, 40 of the fitting 18. In a manner also conventional per se, each of the arms 38, 40 and each of the beams and rafter 30, 32 is provided with a diametrically extending hole 31, 33, respectively, through which a conventional locking quick pin 42 is installed and is frictionally held in place by contact with the external surface of the beam or rafter. As will be understood, each beam and rafter 30, 32 is similarly interconnected with each corner fitting 18 in the tent frame assembly shown in FIG. 2, and a similar locked interconnection is provided between each of the hip rafters 32 and the associated arms of crown fitting 22 in the assembly of FIG. 2, although not there shown because of the smallness of this detail.
The detail showing in FIG. 3 also illustrates an optional aspect of the configuration of the eave beams 30, which are cut away at about a 45° angle in the end portion 44 thereof to accommodate closer assembly of the double tube form with respect to the associated hip rafter 32. Evident also in FIG. 3 is the arrangement of the downwardly depending arm 46 of the corner fitting 18 onto which the uprights or posts 10 are telescoped (as shown in FIG. 2).
In any tent frame structure such as shown in FIGS. 1 and 2, it is also conventional to stabilize the structure by cables or the like (not shown) extending outwardly from the corner fittings 18 to ground stakes or other anchors.
FIG. 4 shows further detail in lateral cross-section of the double tube beams and rafters 30, 32. In this form of double tube beam or rafter the strength-to-weight ratio is optimized with a cross-sectional configuration including two circular walls 50, 52 interjoined by two planar walls 54, 56 interconnecting the circular wall substantially at diametrically opposed circumferential locations in the circular walls. In this form of rafter wherein the circular walls are 2" in outside diameter (OD) and the wall thickness throughout is 1/8", the two circular walls are joined at the circumferential location 58 therebetween and the form overall can be simply categorized as being of 2" by 4" (2×4) size (actually 2"×37/8" by reason of the shared common circumferential wall portions).
FIG. 5 illustrates an alternative form of beam or rafter 60 wherein the configuration cross-sectionally comprises two circular walls 62, 64 interjoined by two planar walls 66, 68 with the innerfacing portions 70, 72 of the circular walls spaced apart a distance about equal to the diameter of the circular walls. This beam or rafter configuration, wherein the circular walls 62, 64 have an outside diameter of 2", and the wall thicknesses throughout are 1/8", can be categorized as being substantially 2" thick and 6" wide, i.e. 2×6 in form. This form is actually 2"×53/4" in an optimal design so that there is a clearance dimension of 13/4" along both the x-x axis and the y-y axis of the tubing. This configuration allows use of the 2×6 type tubing as uprights with corner fittings like that shown in FIG. 3 which are modified to have a double depending arm in place of the single depending arm 46 to fit within the double tubes of the 2×4 form (FIG. 4) and also the 2×6 form dimensioned as described.
FIG. 6 is a further illustration in isometric and somewhat schematic view of a more complex tent frame structure characteristic of the invention, utilizing double tube beams and rafters and, in this instance, double tube uprights or posts, the structure being designed to cover a ground or floor space approximately 40' by 80' (40×80). In this structure, conventional corner fittings 110 interjoin double tube corner posts 112, corner eave beams 114 and hip rafters 116. Intermediate six-way fittings 118 interjoin double tube posts 120, intermediate eave beams 122, center rafters 124 and diagonal 126. Like intermediate six-way fittings 128 (utilizing only four arms thereof) interjoin double tube posts 130, corner and intermediate eave beams 114, 122, and laterally intermediate rafters 132. Similarly, also, intermediate end end fittings 134 interjoin double tube posts 136, end eave beams 114 and longitudinal roof rafters 138. The various roof rafters 116, 126, 132, and 138 are joined along with double tube ridge beams 140 by eight-way crown fittings 142 and a center eight-way crown fitting 144, four arms of which are used, interconnects roof rafters 124 and ridge beams 140.
As an optional component, in some structures it may be considered desirable to increase the lateral support centrally of the frame, which can be done simply by cable interconnection between the center intermediate fittings 118, with such a cable connection being schematically indicated in FIG. 6 at 146. Comparable cable interconnections (not shown) may also interconnect intermediate fittings 128, if desired.
FIGS. 7A through 7G diagrammatically illustrate other typical tent frame structural arrangements possible with double tube rafters according to the present invention with 20' spans between uprights along the sides thereof.
FIG. 7A is a concept diagram of a 20×20 frame structure, which is the structure illustrated and discussed with respect to FIG. 2. FIG. 7B shows the rafter arrangement for a typical 20' by 40 ' (20×40) tent structure according to the present invention, the FIG. 7C shows a 20' by 60' (20×60) version thereof.
FIG. 7D, 7E and 7F respectively show diagrammatically the rafter plan for 40×40, 40×60 and 40×100 tent structures according the invention, all of which are similar in many respects to the 40×80 frame structure shown and discussed with respect to FIG. 6.
FIG. 7G is a further form of tent structure diagram according to the present invention, in this instance of hexagonal form with six sides (40x HEX) each approximately 20' in length with a single peak.
As an example of practice of the invention in the rental trade, it is common to color code various upright beams and rafters by color to denote application and length. Thus, an inventory of various styles, sizes and lengths can include, for both 2" single tubing and 2×4 double tubing, legs or uprights black in color and 7'8" in length, eave beams white in color and 9'4" in length, intermediate rafters green in color and 10'6" in length, hip rafters red in color and 14'4" in length, intermediate rafters brown in color and 16'1" in length (for 30' wide configurations), eave beams blue in color and 19'4" in length, hip rafters orange in color and either 21'81/2" in length in the 2×4 form or 21'10" in length for the 2" tubing form, and 2×6 double tube eave beams 29'4" in length and color coded yellow which are used for example to bridge over a substantially 30' span at the front of an open stage type tent frame.
As earlier indicated, the double tube forms of beams and rafters typifying and contemplated by the present invention are characterized by a substantially increased strength-to-weight ratio as compared with the conventional single tube rafter construction. This can be demonstrated by a comparison of the moment of inertia of the respective tubular configurations. Addressing first the conventional single tube rafter which had an outside diameter of 2" and a 1/8" wall thickness, and which is fabricated of a suitable aluminum alloy such as alloy 6005T5, and utilizing standard formulations such as found in, "Machinery's Handbook", 12 Ed., published by The Industrial Press, NY, N.Y. (1944), at pages 298, 346 and 347, the moment of inertia of a conventional single tube is 0.324 in 4 along both its X axis and Y axis, and the weight thereof is 0.884 pounds per foot. The 2×4 (actually 2" by 37/8") form of double tube as shown and discussed with respect to FIG. 4 has a moment of inertia of 1.92 in 4 along the X axis and 0.82 in 4 along the Y axis (with such axes being schematically shown in FIG. 4) and a weight per foot of 2.076 pounds. The 2×6 (actually 2" by 53/4") form of double tube as shown and discussed with respect to FIG. 5 demonstrates a moment of inertia of 7.1325 in 4 along the X axis and 1.31 in 4 along the Y axis (with such axes being shown schematically in FIG. 5) and a weight of 2.67 pounds per foot.
Correspondingly, consideration is to be accorded a form of double tube of the same alloy with two 2" OD cylinders of circular form in cross section and with 1/8" wall thicknesses, joined by a panel 1/4" thick in planar form along the Y axis and coplanar with the centers of the tubular components, which double tube form is essentially the same as that illustrated in FIG. 1 of Dithridge U.S. Pat. No. 426,558. Such component tube configuration demonstrates a moment of inertia of 6.708 in 4 along the X axis, a moment of inertia of 0.65 in 4 along the Y axis, and a weight of 2.37 pounds per foot.
From these comparative figures, it is to be observed that the 2×4 tubing is stronger along its X axis than is the single tube by a factor of 5.93:1 while being heavier by a factor of 2.35:1. Comparing the 2×6 double tube with the 2" single tube, the 2×6 tube is stronger by a factor of 22.01:1 while exhibiting an increased weight by a factor of 3.25:1 along its X axis and an increased strength by a factor of 2.53:1 along its Y axis. Comparing the 2×6 form with the form of double tube referred to in the Dithridge patent, the 2×6 form exhibits a strength factor of 1.06:1 along its X axis and a strength factor of 2.02:1 along its Y axis while being slightly heavier by a factor of 1.13:1. It is notable with respect to the strength factor along the Y axis that such strength factor is significant in relatively long span beam applications so that any tendency of the beam to buckle is minimized.
As will be evident, further forms of double tubes characteristic of the present invention with planar walls joining circular sides at substantially diametrically opposed circumferential locations on the circular walls can be fabricated to provide rafters for use in tent frame construction according to the invention, such as forms similar to that shown in FIG. 5 with a lesser or greater lateral spacing between the cylindrical portions such as 2×5 and 2×8 forms, for example. Other assembly configurations than those shown in FIGS. 6 and 7A-7G will also readily occur to those skilled in the art to which the invention is addressed. | Readily assemblable and disassemblable tent, awning and canopy frame structures incorporating conventional slip fit junction elements and beams and rafters of double tube form which enable greater spans between uprights and simplified structures for larger area tent or like frames, the configuration of the double tube beams and rafters being such that the double tube beam, rafter and upright components can be interchanged with single tube beams, rafters and uprights. The unique double tube forms are characterized by a cross-sectional configuration including two circular walls interjoined by two planar walls interconnected with the circular walls substantially at diametrically opposed circumferential locations in the circular walls and by increased strength-to-weight ratios. |
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FIELD OF THE INVENTION
The present invention relates to shower door assembly, and in particular, to adjustment assembly used therein which achieves fast assembling and adjustment.
BACKGROUND OF THE INVENTION
Doors used for shower enclosure are often mounted against wall surfaces and the doors thus mounted are kept as vertical as possible. However, the wall surfaces of buildings are often not exactly vertical, for example, titled toward outside/inside by an angle. Therefore, if mounted completely along the wall surface, the doors may not be smoothly opened or closed. In this regard, it is necessary to adjust the distances between the top/bottom end of a door and a wall surface so as to keep the door in a vertical position.
To achieve this adjustment, a door assembly usually comprises a stationary frame to be attached to a wall surface, and a movable frame connected with a door panel, such as a glass door panel. The stationary frame is firstly attached to the wall surface and then the movable frame is moved toward the stationary frame, during which the distances between the top and bottom ends of the movable frame, and the stationary frame are such adjusted that the movable frame is in a vertical position, and thus so is the door panel. The stationary and movable frames are finally connected to each other by drilling thereon and by using fasteners.
However, in one aspect, the drilling operation requires at least two people to cooperate and is very time-consuming. In another aspect, the drilling may inadvertently cause damages to the surfaces of the frames generally made of aluminum materials, which is undesirable to consumers.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a shower door assembly which comprises a stationary frame, a movable frame and at least one adjustment assembly disposed between the stationary frame and the movable frame, the at least one adjustment assembly comprising an adjustment device and a locking device, the adjustment device being detachably connected to the stationary frame and having an extension, the locking device being detachably connected to the movable frame and comprising
two opposite sides and a bottom side connecting said two opposite sides, the opposite sides and the bottom side defining a first cavity having a first depth and a second cavity having a second smaller depth, the first and second cavity jointly receiving the extension of the adjustment device;
a blocking element, a pressing element and an elastic element disposed between the blocking element and the pressing element being located in the first cavity, the elastic element being arc-shaped when unlocked, an interface between the first and the second cavity having at least a portion forming an inclined surface projecting to the blocking element; and
a driving device comprising a cam mechanism and a sliding element in the first cavity, the sliding element has one end in contact with the pressing element and the other end sliding along with the inclined surface when driven by the cam mechanism so as to push the pressing element toward the blocking element, and thus reduce the curvature of the arc-shaped elastic element until the elastic element is engaged with the adjustment device.
Preferably, the arc-shaped elastic element has an intrados facing towards the blocking element.
In one embodiment, the blocking element comprises a guiding rod. The pressing element and the arc-shaped each has a through hole, respectively, through which the guiding rod can pass so as to guide the movements of the pressing element and the elastic element within the first cavity.
In one embodiment, the pressing element has a guiding groove for receiving the one end of the sliding element. The guiding groove has a width large enough to maintain the one end within the guiding groove when the sliding element is sliding along the inclined surface.
In one embodiment, the locking device has a threaded hole penetrating through one of the two opposite sides such that when the locking device and the adjustment device are engaged, the engagement can be enhanced by screwing a screw into the threaded hole. Preferably, in this embodiment, a spacer element is disposed within the second cavity in a gap formed by the extension of the adjustment device. The spacer element is provided to prevent deformation of the elastic element already flattened, which may be caused by excessive force applied by the screwing as mentioned above.
In one embodiment, the pressing element has platforms at two sides, for in contact with the two opposite sides of the locking device, so as to prevent turnover of the pressing element during movement.
In one embodiment, the locking device has a receiving groove at one of the two opposite sides for receiving the cam mechanism.
In one embodiment, a surface of the extension of the adjustment device that is in contact with the arc-shaped elastic element is provided with teeth, such that the elastic element will be imbedded between two adjacent teeth when the elastic element is pressed, so as to enhance the engagement of the adjustment device and the locking device.
In one embodiment, the locking device is attached to the movable frame at at least two different linkage points, such that the locking device will not rotate about the movable frame.
In one embodiment, the arc-shaped elastic element is flattened when pressed, i.e., the curvature is zero.
In one embodiment, the stationary frame has two sidewalls, each received within respective slot provided with the locking device.
In one embodiment, the shower door assembly comprises two adjustment assemblies located at terminal ends of the stationary/movable frames, and the adjustment assemblies are disposed in opposite.
In one embodiment, the arc-shaped elastic element is constituted by a single metal sheet or a plurality of metal sheets that are disposed side by side. The single metal sheet, or the plurality of metal sheets as a whole, has a thickness between about 0.1 mm and no more than 0.2 mm, preferably 0.15 mm.
The shower door assembly provided by the present invention transfers the rotation of the cam mechanism to the translational movement of the pressing element by the inclined surface and the sliding element. The movement of the pressing element towards the blocking element makes the arc-shaped elastic element disposed there between flattened, such that the lateral width of the elastic element increases, causing engagement with the extension of the adjustment device. Therefore, the adjustment device is locked by the locking device and thus immovable, the relative position between the stationary frame and the movable frame is thus fixed. When the cam mechanism is counter-rotated, the arc-shaped elastic element will disengage with the adjustment device due to the restoring force of the elastic element and return to unlocked state. The adjustment device can achieve fast assembling and adjustment of the shower door and, in the meantime, is able to lock and release by minimum force.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 schematically and partially shows a locking device according to one embodiment of the invention.
FIG. 2 shows the locking device of FIG. 1 from another perspective of view, showing more elements.
FIG. 3 is an exemplary pressing element of the invention.
FIG. 4 is an exemplary sliding element of the invention.
FIG. 5 shows a sectional view of an exemplary locking device.
FIG. 6 shows an exemplary cam mechanism of the invention.
FIG. 7 shows an exemplary arc-shaped element of the invention.
FIG. 8 shows an exemplary adjustment device of the invention.
FIG. 9 is an exploded view showing a shower door assembly of the invention.
FIG. 10 shows an assembling state of the shower door assembly, wherein the door assembly is unlocked.
FIG. 11 shows another assembling state of the shower door assembly, wherein the door assembly is locked.
FIG. 12 is a sectional view of the state as shown in FIG. 10 .
FIG. 13 is a sectional view of the state as shown in FIG. 11 .
Elements that are irrelevant of the spirit of the invention is omitted from the drawings for clarity purpose.
DETAILED DESCRIPTION
The invention will now be described in more detail in reference to preferable examples in conjugation with the accompanied drawings.
FIG. 1 partially shows a locking device 300 according to one embodiment of the invention. The locking device 300 is substantially rectangular in shape. Two opposite sides 301 , 302 and a bottom side 303 jointly define an open internal space. The internal space comprises a first cavity 310 and a second cavity 320 . The second cavity 320 has a less depth than that of the first cavity 310 . An interface between the first and second cavities 310 , 320 has at least a part forming an inclined surface 330 projecting toward the first cavity 310 .
The locking device 300 is coupled to a movable frame 200 (see FIG. 9 ) at at least two linkage points 313 , 383 , such that the locking device 300 will not rotate around the movable frame 200 .
In FIG. 1 , a blocking element 311 is provided within the first cavity 310 at an end that is away from the bottom side 303 . In this example, the blocking element 311 has a guiding rod 312 for guiding the movements of other elements in the first cavity 31 .
FIG. 2 shows more elements of the locking device 300 . In the first cavity 310 is disposed a pressing element 315 , and an arc-shaped elastic element 314 between the pressing element 315 and the foresaid blocking element 311 . The arc-shaped elastic element 314 has an intrados facing toward the blocking element 311 . The pressing element 315 is able to be moved within the first cavity 310 in relation to the blocking element 311 so as to press or release from the elastic element 314 to change the curvature, and in turn the lateral width, of the elastic element 314 .
A sliding element 316 is further provided in the first cavity 310 and has one end in contact with the pressing element 315 , and the other end in contact with and sliding along the inclined surface 330 . Therefore, when actuated by the cam mechanism 317 , the sliding element 316 will slide along the inclined surface and push the pressing element to move toward the blocking element 311 . The locking device 300 has a groove 304 at its one side for receiving the cam mechanism 317 . FIG. 2 shows only a handle 371 of the cam mechanism 317 .
FIGS. 3 and 4 show an exemplary pressing element 315 and a sliding element 316 , respectively. The pressing element 315 comprises a sliding groove 353 for receiving the one end 361 of the sliding element 316 . The sliding groove 353 is wide enough such that the end 361 is always maintained therein during the slide of the sliding element 316 along the inclined surface 330 . The pressing element 315 has two platforms 352 at two sides for contacting the two opposite sides 301 , 302 of the locking device 300 , so as to prevent from overturn of the pressing element 315 during its movement. In this example, the pressing element 315 is provided with a through hole 354 , through which the guiding rod 312 of the blocking element 311 can pass, so as to guide the movement of the pressing element 315 .
The sliding element 316 comprises the one end 361 received within the sliding groove 353 , a contact surface 362 in contact with the cam mechanism 317 , and the other end 363 in contact with and sliding along the inclined surface 330 . When rotated, the cam mechanism 317 pushes, through the contact surface 362 , the sliding element 316 to rotate about the end 361 , and in the meantime, the other end 363 slides along the inclined surface 330 . Because the inclined surface 330 is projected toward the first cavity 310 , the sliding element 316 pushes the pressing element 315 to move toward the blocking element 311 .
FIG. 5 is a sectional view of the locking device, showing the relative positions of respective element in the first cavity 310 and the cooperation between them.
FIG. 6 shows an exemplary cam mechanism 317 which comprises a handle 371 and a cam portion 372 . The handle 371 is provided to facilitate rotation operation of the cam mechanism and the cam portion 372 is used for contact with the contact surface 362 of the sliding element 316 . The cam mechanism 317 may be attached to the side 301 by pins such that it may rotate about the side 301 , such that the cam portion 372 is in contact with the contact surface 362 to push the sliding element 316 to move.
FIG. 7 shows an exemplary elastic element 314 which has an intrados preferably facing toward the blocking element 311 . The elastic element 314 preferably has a through hole 341 through which the guiding rod 312 can pass to guide the movement of the elastic element 314 . When pressed by the pressing element 315 , the curvature of the elastic element 314 will decrease, so the lateral width increases. In one example, the curvature of the elastic element 314 is reduced to zero, i.e., the lateral width reaches maximum value and the elastic element 314 is flattened. The arc-shaped element can be a single metal sheet, or a plurality of metal sheets arranged side by side, so as to provide both suitable elastic force and strength. In the example, the elastic element has a thickness of about 0.15 mm. A thickness more than 0.2 mm may not provide sufficient elastic force and less than 0.1 mm may not provide sufficient strength.
FIG. 8 shows an exemplary adjustment device 400 comprising a securing portion 420 detachably connected to the stationary frame 100 , and an extension 410 . The inner surface of the extension is distributed with a plurality of teeth 411 . The teeth are provided to achieve more close and reliable engagement with the locking device 300 .
FIG. 9 schematically shows a shower door assembly of the present invention. The shower door assembly comprises a stationary frame 100 , a movable frame 200 , and two adjustment assemblies connected between the stationary frame 100 and the movable frame 200 , with each of the two adjustment assemblies being located at respective ends of the stationary frame/movable frame. Each adjustment assembly is consisted of the locking device 300 and the adjustment device 400 , the relative position and cooperation between them are shown in the figure. The movable frame 200 is coupled with a pivot door 250 which can be, for example, a glass door. The pivot door 250 may be connected to the movable frame 200 by suitable methods, for example by the locking device 300 . For example, a through hole can be provided on the locking device 300 , through which a pivot shaft of the pivot door can pass so as to be linked with the locking device 300 .
As shown in FIG. 9 , the stationary frame 100 have two sidewalls 101 , 102 which, when assembling, may be inserted into respective slot 381 , 382 (see FIG. 1 ) of the locking device 300 .
FIG. 10 shows the shower door assembly in a first state wherein the locking device and the adjustment device are combined, but the movable frame 200 and the stationary frame 100 are not locked. FIG. 12 shows a top view of the shower door assembly in this state. As shown, the cam mechanism 317 is in an open position and the sliding element 316 is not actuated. The elastic element 314 is thus in an uncompressed condition. The movable frame 200 and the stationary frame 100 can freely move with respect to each other.
FIG. 11 shows the shower door assembly in a second state wherein the locking and adjustment devices are locked together, so that the relative position between stationary frame 100 and the movable frame 200 can not be changed. FIG. 13 shows a top view of the shower door assembly in this state. As shown, the cam mechanism 317 is in a close position and received within the receiving groove 304 . The sliding element 316 is actuated to slide along the inclined surface 330 , so as to push the pressing element 315 to move towards the blocking element 311 . The elastic element 314 will then be pressed to gradually become flat. The lateral width of the elastic element 314 increases and eventually engages with the extension 410 of the adjustment device, such that the adjustment device is pressed against the two opposite sides of the locking device and therefore immovable in relation to the movable frame 200 . The stationary frame 100 is therefore immovable in relation to the movable frame 200 .
Optionally, in this example, the locking device 300 is provided with a threaded hole 305 penetrating through one side of the locking device. When the adjustment device 400 and the locking device 300 is locked, a screw 325 can be screwed into the threaded hole and abutted against the extension 410 so as to enhance the engagement between the flattened elastic element and the extension. On the other hand, in order not to cause unrecoverable deformation to the elastic element, it is preferably that, in the second cavity 320 , a spacer element 321 is provided in a space formed by the extension.
It should be understood that various example embodiments have been described with reference to the accompanying drawings in which only some example embodiments are shown. The present invention, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein. | A shower door assembly with at least one adjustment assembly has an adjustment device and a locking device. The locking device includes a blocking element, a pressing element and an elastic element between the blocking element and the pressing element. The elastic element is arc-shaped when unlocked. An inclined surface projects to the blocking element. The curvature of the elastic element is thus reduced until it engages with the adjustment device. A driving device includes a cam mechanism and a sliding element having one end in contact with the pressing element and the other end sliding along with the inclined surface when driven by the cam mechanism so as to push the pressing element toward the blocking element, and thus reduce the curvature of the arc-shaped elastic element until the elastic element is engaged with the adjustment device. |
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to environmental seal technology for spaced transparent armor and, more particularly, to environmental seal technology incorporated into a double-paned window having an inner desiccant seal combined with a structural spacer.
[0002] Spaced armor has been used for many years in opaque armor applications. The challenge for using it in transparent armor has been related to the environmental durability of the seal. The air between the glass laminate blocks must be kept clean and dry throughout the life of the armor.
[0003] In the insulated glass market, two or more panes of glass are used, with an air space defined between the panes. The primary purpose of the air space is for insulation. The primary purpose for the air space in transparent armor is for improved ballistic protection, although the air space also improves the product's insulation.
[0004] Several approaches have been used in the insulated glass industry to keep the air between the glass panes clean and dry. None of these approaches appears to use a seal having sufficient strength for environmental and mechanical durability in military applications. In the insulated glass industry, a seal of significant strength is not required. Thus, the primary seal is typically a low modulus elastomer. In a military vehicle application, the seal needs to be able to withstand substantial environmental and mechanical loading.
[0005] A few approaches that use an air gap have been tried in ballistic applications. Many of these approaches have been designed for use in the periscope market. An example is U.S. Pat. No. 4,149,778. This patent states that the void between the spaced blocks is preferably filled with an inert gas such as dry nitrogen or may have a vacuum formed therein. Having a vacuum or inert gas in the gap, however, has been found to be cumbersome and costly in larger military applications, such as double-paned windows for military vehicles.
[0006] Transparent armor for a passenger vehicle application is disclosed in U.S. Pat. No. 4,316,404. In this patent, a polycarbonate layer is bonded to a glass laminate using a double-sided tape, thus creating a thin air gap between the polycarbonate layer and the glass laminate. This approach, however, fails to use a seal having sufficient strength for environmental and mechanical durability in military applications, and does not address the issue of moisture within the air gap.
[0007] It should thus be appreciated that there is a need for environmental seal technology for spaced transparent armor that combines a strong, durable seal with a means for keeping the air between the glass laminate blocks clean and dry. The system should function without the need for inert gas or a vacuum in the gap between the glass laminate blocks. The present invention fulfills this need and provides further related advantages.
SUMMARY OF THE INVENTION
[0008] The present invention is embodied in a spaced transparent armor structure comprising a desiccant system and a structural spacer. The subject invention solves the problem of moisture between the window panes of the spaced transparent armor structure by keeping the internal gap dry using the desiccant system. The invention also incorporates a durable structural spacer that will not rupture under normal military vehicle loads and environmental conditions. The spacer is bonded to the window laminates using pressure-sensitive adhesives, thus allowing for easy manufacture.
[0009] In one embodiment, the spaced transparent armor structure comprises a first transparent laminate configured as a pane having a first face, a second face, and an edge; a second transparent laminate configured as a pane having a first face, a second face, and an edge; a structural spacer bonded to the second face of the first transparent laminate and to the first face of the second transparent laminate; and a desiccant. The first and second transparent laminates are spaced in a substantially parallel relationship so that an air gap is defined therebetween. The desiccant is positioned to absorb moisture trapped in the air gap.
[0010] In one embodiment, the desiccant is contained in an inner desiccant seal that circumscribes the air gap and that extends between the second face of the first transparent laminate and the first face of the second transparent laminate. The inner desiccant seal comprises a polymer binder. The desiccant is supported in the polymer binder. The polymer binder is selected from the group consisting of silicone foam, ethylene propylene (EPM), ethylene propylene diene (EPDM) rubber, styrene-butadiene rubber (SBR), nitrile, and polyurethanes. The inner desiccant seal comprises at least twenty percent desiccant.
[0011] In one embodiment, the structural spacer has an elastic modulus greater than 300 psi. The polymer binder has an elastic modulus greater than 200 psi and less than the elastic modulus of the structural spacer. The structural spacer circumscribes the inner desiccant seal and comprises a material selected from the group consisting of polyurethanes, polymethyl methacrylate, and metals.
[0012] In one embodiment, the desiccant is embedded in the structural spacer. In another embodiment, the structural spacer is configured as a hollow tube. The desiccant is embedded within the hollow of the tube.
[0013] In one embodiment, the spaced transparent armor structure further comprises a film adhesive. The structural spacer is bonded to the second face of the first transparent laminate and to the first face of the second transparent laminate by means of the film adhesive. The film adhesive is a pressure-sensitive tape adhesive, such as acrylic foam tape.
[0014] In one embodiment, the spaced transparent armor structure further comprises a gasket bonded to the edge of the first transparent laminate and to the edge of the second transparent laminate by means of a sealant. The sealant is selected from the group consisting of silyl modified polymer sealants, urethane sealants, polysulide sealants, silyl-terminated-polyether sealants, acrylic sealants, and silicone sealants. The gasket extends from the second face of the first transparent laminate to the second face of the second transparent laminate.
[0015] In one embodiment, the spaced transparent armor structure further comprises a urethane backfill that circumscribes the structural spacer and that extends between the second face of the first transparent laminate and the first face of the second transparent laminate. The urethane backfill additionally extends at least partially between the structural spacer and the second face of the first transparent laminate, and at least partially between the structural spacer and the first face of the second transparent laminate. The urethane backfill further extends around the edge of the first transparent laminate and the edge of the second transparent laminate.
[0016] In one embodiment, the spaced transparent armor structure further comprises a frame into which the first transparent laminate and the second transparent laminate are potted.
[0017] Other features and advantages of the invention should become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a cross-sectional view of a spaced transparent armor structure, in accordance with an embodiment of the present invention.
[0019] FIG. 2 is a partial cross-sectional view of a spaced transparent armor structure having a desiccant-filled structural spacer, in accordance with an embodiment of the present invention.
[0020] FIG. 3 is a partial cross-sectional view of a spaced transparent armor structure having a desiccant-filled structural spacer and a urethane backfill, in accordance with an embodiment of the present invention.
[0021] FIG. 4 is a partial cross-sectional view of a spaced transparent armor structure having a solid structural spacer and inner desiccant seal, in accordance with an embodiment of the present invention.
[0022] FIG. 5 is a partial cross-sectional view of a spaced transparent armor structure having a solid structural spacer, inner desiccant seal, and urethane backfill, in accordance with an embodiment of the present invention.
[0023] FIG. 6 is a partial cross-sectional view of a spaced transparent armor structure having a pair of transparent laminates, a structural spacer, and a urethane backfill that extends partially between the structural spacer and the transparent laminates, in accordance with an embodiment of the present invention.
[0024] FIG. 7 is a partial cross-sectional view of a spaced transparent armor structure having a pair of transparent laminates, a structural spacer, and a urethane backfill that extends around the edges of both transparent laminates as well as partially between the structural spacer and the transparent laminates, in accordance with an embodiment of the present invention.
[0025] FIG. 8 is a partial cross-sectional view of a spaced transparent armor structure having an elastomer gasket, in accordance with an embodiment of the present invention.
[0026] FIG. 9 is a partial cross-sectional view of a spaced transparent armor structure 180 having a pair of transparent laminates and a metal frame into which the transparent laminates are potted, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] With reference to FIG. 1 , there is shown a cross-sectional view of a spaced transparent armor structure 10 , in accordance with an embodiment of the present invention. The spaced transparent armor structure comprises a pair of transparent laminates 12 , each transparent laminate configured as a substantially rectangular pane having an outer face 14 , an inner face 16 , and an edge 18 . The transparent laminates may comprise glass and/or other transparent or translucent materials.
[0028] The inner faces 16 of the transparent laminates 12 are spaced in a substantially parallel relationship so that an air gap 20 is defined therebetween. The air gap is configured as a substantially rectangular space, the edges of which are bounded by an inner desiccant seal 22 that extends between the inner faces of the transparent laminates. Although FIG. 1 shows the spaced transparent armor structure 10 as having two transparent laminates, the present invention encompasses spaced transparent armor structures having more than two transparent laminates.
[0029] The inner desiccant seal 22 is a composition of a desiccant supported in a polymer binder. The desiccant absorbs moisture trapped between the inner faces 16 of the transparent laminates 12 . An advantage to this approach is that the spaced transparent armor structure 10 can be assembled without the need for an inert gas or vacuum, which gives this approach a cost advantage over other forms of fabrication.
[0030] The desiccant material can be embedded within one of a number of elastomers to create a seal. For example, Super Spacer® Triseal™ from Edgetech I.G. of Cambridge, Ohio, is a desiccant embedded in silicone foam. Other suitable elastomers include ethylene propylene (EPM), ethylene propylene diene (EPDM) rubber, styrene-butadiene rubber (SBR), nitrile, chloroprene, Epichlorohydrin, polyacrylic, fluorosilicone, perfluroelastomers, polyether block polyamides, chlorosulfonated polyethylene, ethylene-vinyl acetate, thermoplastic elastomers, thermoplastic vulcanizates, thermoplastic polyurethane (TPU), thermoplastic olefins, and polysulfide rubber. The desiccant could additionally or alternatively be embedded within one of a number of plastics, including polypropylene, polystyrene, acrylonitrile/butadiene/styrene (ABS), polyethylene terephthalate, polybutylene terephthalate, polyester alloys, nylons, poly(vinyl chloride), polyurethanes, polycarbonate, polyethylene, polymethyl methacrylate, polytetrafluoroethylene, polyetheretherketone, polyetherimide, and phenolics. In one embodiment, the desiccant is embedded within a polymer having an elastic modulus greater than 200 psi and less than the modulus of the structural spacer (described below).
[0031] Desiccants that may be used in the present invention include activated alumina, aerogel, benzophenone, bentonite clay, calcium chloride, calcium hydride, calcium sulfate, copper(II) sulfate, lithium chloride, lithium hydride, lithium bromide, magnesium, magnesium sulfate, magnesium perchlorate, sodium potassium alloy, phosphorus pentoxide, potassium carbonate, silica gel, sodium chlorate, sodium hydroxide, sodium sulfate, sodium benzophenone, and molecular sieves. In one embodiment, the inner desiccant seal 22 comprises twenty percent desiccant.
[0032] The spacing between the pair of transparent laminates 12 is maintained by a structural spacer 24 , which surrounds the inner desiccant seal 22 and extends between the inner faces 16 of the transparent laminates. The structural spacer may comprise hard elastomers, composites, plastics, metals, and/or metal alloys. Suitable hard elastomers include ethylene propylene monomer (EPM) rubber, ethylene propylene diene monomer (EPDM) rubber, styrene-butadiene (SBR), nitrile, chloroprene, Epichlorohydrin, polyacrylic, fluorosilicone, perfluroelastomers, polyether block polyamides, chlorosulfonated polyethylene, ethylene-vinyl acetate, thermoplastic elastomers, thermoplastic vulcanizates, thermoplastic polyurethane (TPU), thermoplastic olefins, and polysulfide rubber. Suitable plastics include polypropylene, polystyrene, acrylonitrile/butadiene/styrene (ABS), polyethylene terephthalate, polybutylene terephthalate, polyester alloys, nylons, poly(vinyl chloride), polyurethanes, polycarbonate, polyethylene, polymethyl methacrylate, polytetrafluoroethylene, polyetheretherketone, polyetherimide, and phenolics. Suitable metals and metal alloys include iron, aluminum, copper, stainless steel, nickel, magnesium, zinc, and titanium alloys. In one embodiment, the material comprising the structural spacer has an elastic modulus greater than 300 psi.
[0033] Composites, including fiber reinforced composites, would be suitable for lightweight structural spacers. Suitable fiber reinforced composites may comprise glass and/or carbon fibers, and matrices of epoxy, vinyl ester, polyester, phenolics, and/or polyimides. The structural spacer 24 also acts as a moisture barrier. Low permeability materials such as polyurethanes, polymethyl methacrylate, and metals are also suitable for the structural spacer.
[0034] In one embodiment, the structural spacer 24 is an extrusion of any of the previously stated materials. The extrusion may comprise polymer, composite, elastomer, plastic, and/or metallic extrusions. A desiccant may be embedded within the extrusion. The structural spacer may have a solid cross-section or a hollow cross-section (hollow tube).
[0035] The structural spacer 24 is bonded to the inner faces 16 of the transparent laminates 12 using a film adhesive, such as pressure-sensitive tape adhesive 26 . Bonding with a pressure-sensitive tape adhesive allows for a much quicker and cleaner application method than a paste adhesive, and the cleanliness of the pressure-sensitive tape adhesive eliminates a source of potential messes in the air gap 20 . A pressure-sensitive tape adhesive also has near immediate bond strength, thus allowing for a quicker and easier application method. Furthermore, a pressure-sensitive tape adhesive can act as an additional moisture barrier. Suitable pressure-sensitive tape adhesives include acrylic foam tapes, such as HyperJoint H8000 series (Nitto Denko Corporation of Osaka, Japan), HyperJoint H9000 series (Nitto Denko Corporation of Osaka, Japan) and Very High Bonding (VHB) tapes (3M Company of Maplewood, Minn.). Other suitable film adhesives include urethane, polyvinyl butyral (PVB), and epoxies. Although FIG. 1 shows the use of a pressure-sensitive tape adhesive, the present invention encompasses the use of other adhesives, including paste adhesives.
[0036] In one embodiment, a pressure-sensitive tape adhesive is not used, and the structural spacer 24 is instead bonded to the inner faces 16 of the transparent laminates 12 using a hot-melt adhesive. A hot-melt adhesive allows for good control of adhesive placement, without the need for cleanup. Suitable hot-melt adhesives include Jet-melt™ Adhesive by 3M Company of Maplewood, Minn.
[0037] To mount the transparent laminates 12 into a vehicle, the transparent laminates can be potted into a frame, or a gasket 28 can be bonded to the edges 18 of the transparent laminates and the structural spacer 24 using a sealant, such as pressure-sensitive tape adhesive 26 and/or urethane adhesive 30 . Either of these methods adds another sealant layer between the air gap 20 and the outside environment, and thus further improves the environmental and mechanical durability of the spaced transparent armor structure 10 . Suitable sealants include silyl modified polymer sealants, urethane sealants, polysulfide sealants, silyl-terminated-polyether sealants, acrylic sealants, and silicone sealants.
[0038] The gasket 28 is configured to extend around the edges 18 of both transparent laminates 12 , extending from the outer face 14 of one transparent laminate to the outer face of the other transparent laminate. In one embodiment, pressure-sensitive tape adhesive 26 is used to bond the gasket to the outer faces of the transparent laminates, while urethane adhesive 30 is used to bond the gasket to the edges 18 of the transparent laminates and the structural spacer 24 . The spaced transparent armor structure 10 may comprise a single gasket or a plurality of gaskets as needed to mount the transparent laminates into a vehicle.
[0039] In some embodiments, a desiccant is embedded within the structural spacer extrusion, so that a separate inner desiccant seal is unnecessary. With reference to FIG. 2 , there is shown a partial cross-sectional view of a spaced transparent armor structure 40 having a pair of transparent laminates 42 , an air gap 44 defined therebetween, and a desiccant-filled structural spacer 46 bonded to the transparent laminates using pressure-sensitive tape adhesive 48 , in accordance with an embodiment of the present invention. With reference to FIG. 3 , there is shown a partial cross-sectional view of a spaced transparent armor structure 60 having a pair of transparent laminates 62 , an air gap 64 defined therebetween, a desiccant-filled structural spacer 66 bonded to the transparent laminates using pressure-sensitive tape adhesive 68 , and a urethane backfill 70 , in accordance with an embodiment of the present invention. The urethane backfill 70 surrounds the outer perimeter of the desiccant-filled structural spacer 66 and extends between the transparent laminates 62 to provide additional sealing for the air gap 64 .
[0040] In other embodiments, a separate inner desiccant seal is used. With reference to FIG. 4 , there is shown a partial cross-sectional view of a spaced transparent armor structure 80 having a pair of transparent laminates 82 , an air gap 84 defined therebetween, a solid structural spacer 86 bonded to the transparent laminates using pressure-sensitive tape adhesive 88 , and an inner desiccant seal 90 bonded to the solid structural spacer using pressure-sensitive tape adhesive, in accordance with an embodiment of the present invention. Wither reference to FIG. 5 , there is shown a partial cross-sectional view of a spaced transparent armor structure 100 having a pair of transparent laminates 102 , an air gap 104 defined therebetween, a solid structural spacer 106 bonded to the transparent laminates using pressure-sensitive tape adhesive 108 , and an inner desiccant seal 110 bonded to the solid structural spacer using pressure-sensitive tape adhesive, and a urethane backfill 112 , in accordance with an embodiment of the present invention. The urethane backfill 112 surrounds the outer perimeter of the solid structural spacer 106 and extends between the transparent laminates 102 to provide additional sealing for the air gap 104 .
[0041] In some embodiments, the urethane backfill extends partially between the structural spacer and the transparent laminates. With reference to FIG. 6 , there is shown a partial cross-sectional view of a spaced transparent armor structure 120 having a pair of transparent laminates 122 , an air gap 124 defined therebetween, a structural spacer 126 bonded to the transparent laminates using pressure-sensitive tape adhesive 128 , an inner desiccant seal 130 bonded to the structural spacer using pressure-sensitive tape adhesive, and a urethane backfill 132 that extends partially between the structural spacer and the transparent laminates, in accordance with an embodiment of the present invention. Wither reference to FIG. 7 , there is shown a partial cross-sectional view of a spaced transparent armor structure 140 having a pair of transparent laminates 142 , an air gap 144 defined therebetween, a structural spacer 146 bonded to the transparent laminates using pressure-sensitive tape adhesive 148 , an inner desiccant seal 150 bonded to the structural spacer using pressure-sensitive tape adhesive, and a urethane backfill 152 that extends around the edges of both transparent laminates as well as partially between the structural spacer and the transparent laminates, in accordance with an embodiment of the present invention.
[0042] As noted above, the transparent laminates can be potted into a frame, or a gasket can be bonded to the edges of the transparent laminates and the structural spacer. With reference to FIG. 8 , there is shown a partial cross-sectional view of a spaced transparent armor structure 160 having a pair of transparent laminates 162 , an air gap 164 defined therebetween, a structural spacer 166 bonded to the transparent laminates using pressure-sensitive tape adhesive 168 , an inner desiccant seal 170 bonded to the structural spacer using pressure-sensitive tape adhesive, and an elastomer gasket 172 configured to extend around the edges of both transparent laminates and bonded thereto with a urethane adhesive 174 , in accordance with an embodiment of the present invention. With reference to FIG. 9 , there is shown a partial cross-sectional view of a spaced transparent armor structure 180 having a pair of transparent laminates 182 , an air gap 184 defined therebetween, a structural spacer 186 bonded to the transparent laminates using pressure-sensitive tape adhesive 188 , an inner desiccant seal 190 bonded to the structural spacer using pressure-sensitive tape adhesive, and a metal frame 192 into which the transparent laminates are potted using a urethane adhesive 194 , in accordance with an embodiment of the present invention.
[0043] It should be appreciated from the foregoing disclosure that the present invention provides environmental seal technology for spaced transparent armor that combines a strong, durable seal with a means for keeping the air between the glass laminate blocks clean and dry, the seal functioning without the need for inert gas or a vacuum in the gap between the glass laminate blocks.
[0044] Although the invention has been disclosed with reference only to the presently preferred embodiments, those of ordinary skill in the art will appreciate that various modifications can be made without departing from the invention. Accordingly, the invention is defined only by the following claims. | The present invention is embodied in environmental seal technology incorporated into a double-paned window, the environmental seal technology comprising an inner desiccant seal and a structural spacer. The subject invention solves the problem of moisture between the window panes by keeping the internal gap dry using a desiccant system. The invention also incorporates a durable structural spacer that will not rupture under normal military vehicle loads and environmental conditions. The spacer is bonded to the window panes using pressure-sensitive adhesives, thus allowing for easy manufacture. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to tractors and front loaders, and more particularly to a bracket for attaching a front loader to a tractor.
It is common practice for tractors to include loaders to which a large variety of attachments can be connected to provide a wide range of applications in the agricultural, industrial and construction fields. Such loaders are usually mounted on the front end of a tractor and generally include a bracket, acting as the interface between the tractor and the loader, a loader frame assembly, boom arms pivotally mounted to the frame, an attachment mounted across the forward ends of the boom arms, tilt cylinders coupled between the attachment and the boom arms, and a lift cylinder or cylinders coupled between the frame assembly and the boom arms. An exemplary structure of this general type loader/tractor/bracket is shown in U.S. Pat. No. 5,895,199 to Baumert, III et al.
The normal commercial practice for providing a tractor with a loader to an end customer is to build the tractor and ship it to a local dealer where the bracket and loader are then affixed to the tractor prior to delivery. Alternatively, in the case of a later decision, this process may occur in the field after purchase and use of the tractor by the customer. The problems associated with dealer installation of the loader are significant in the practical world. For instance, dealer installation in most cases requires extensive removal of tractor components to complete, and thus takes considerable time. Time is money. Additionally, dealer installation requires clamping/friction loads on the joint between the front and rear pieces. It is preferable that the loading on the bolts be in tension and compression. Dealer installation also requires periodic hardware torque checks to maintain integrity.
It would be of significant advantage to develop a simple, yet reliable mounting bracket that reduces or eliminates the above-described problems and difficulties.
SUMMARY OF THE INVENTION
Accordingly, it is an important object of the present invention is to provide a method to reduce the complexity, time required and cost of adding a loader to a tractor after its manufacture.
It is another object of the present invention to provide a method to simplify the process of adding a loader to a tractor after or at the time of sale of the tractor to an end customer.
It is another object of the present invention to provide a two-piece loader bracket for greatly reducing the complexity, labor and cost of adding a loader to a tractor after the tractor has been manufactured.
It is another object of the present invention to provide a two-piece bracket for mounting a loader to a tractor, each piece having a generally vertical planar surface with bolt holes therethrough in matching patterns to permit a rigid connection between the pieces.
It is a still further object of the present invention to provide a loader bracket comprised of a front piece and a rear piece. The rear piece is rigidly affixed to the tractor during the manufacturing process and the front piece is selectively added later when it is determined to incorporate a loader.
It is another object of the present invention to provide a two-piece bracket for mounting a loader to a tractor, each piece having a generally vertical planar surface with bolt holes therethrough in matching patterns to permit a rigid connection between the pieces.
It is another object of the present invention to provide a mounting bracket for a loader that is durable in construction, inexpensive to manufacture, carefree of maintenance, facile in assemblage, and simple, versatile and effective in use.
These and other objects are achieved by providing method and apparatus to simplify the process of adding a loader to a tractor after the manufacturing process. A pair of mounting brackets, one on each side of the tractor, each comprise a front piece and a rear piece. The rear piece is affixed to the tractor during the manufacturing process and the front piece, including a bearing surface for a transverse support axis of a loader, is selectively affixed to the respective rear piece and tractor when a decision to incorporate a loader is taken.
DESCRIPTION OF THE DRAWINGS
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a partial left side elevational view of a tractor with a break-away showing the mounting bracket of the instant invention with a cut-out portion showing the construction of the front piece;
FIG. 2 is a perspective exploded view of a right side bracket of the instant invention;
FIG. 3 is a front plan view of the front piece of FIG. 2 ; and
FIG. 4 is a top plan view of the front piece of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art, and they will not therefore be discussed in significant detail. Also, any reference herein to the terms “left” or “right” are used as a matter of mere convenience, and are determined by standing at the rear of the machine facing in its normal direction of travel. Furthermore, the various components shown or described herein for any specific application of this invention can be varied or altered as anticipated by this invention and the practice of a specific application of any element may already by widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail.
FIG. 1 shows an exemplary tractor to which the instant invention may be incorporated. Generally, tractor 10 has a longitudinal axis (not shown) extending through the tractor in a direction corresponding to a line defined generally by the direction of movement of the tractor. A generally longitudinal main frame 11 supported by wheel pairs 12 , 14 may be incorporated as a primary structural element of tractor 10 and to which many of the tractor components are attached. Alternatively, the rear axle and transmission assembly could fill the need for structural strength, and as the support for other tractor components, such as an engine 16 and cab 18 . Of course, one of skill in the art will understand that other structural arrangements are possible and in use.
For purposes of clarity, it should be appreciated that the bracket of the instant invention will be described and shown as a left-hand bracket. In most cases, two brackets will be required, one on each side of the tractor, to support an axis for the loader. The left and right-hand brackets, particularly the front pieces thereof, while similar are in reality mirror images of each other.
Referring still to FIG. 1 , mounting bracket 20 comprises a rear piece 22 and a front piece 24 . Front piece 24 has a generally vertical member 26 with a semi-circular upward-opening bearing surface 28 holding a bushing 29 (best seen in FIG. 2 ). Exemplary loader 30 has a plurality of linkages (most not numbered) terminating forwardly with bucket 32 and rearwardly with attachment assembly 31 . Attachment assembly 31 may be a single structure or two interconnected structures, one adjacent each side of the tractor 10 . From each side of attachment assembly 31 a transverse axis or pin 34 extends outwardly to engage respective bearing surfaces 28 . Thus, the axle or pins 34 support the rear of loader 30 . Attachment assembly 31 is also bolted to front piece 22 , as at stop block 58 .
FIG. 2 provides a perspective representation of the rear and front pieces 22 , 24 . Rear piece 22 includes a generally vertical planar surface 40 , generally perpendicular to the longitudinal axis of tractor 10 , with a plurality of bolt holes 42 therethrough; holes 42 arranged in a symmetrical pattern of two rows of two holes each. Other patterns could be used without straying from the concepts of the instant invention. Rear piece 22 further includes a rearwardly extending flange 44 , also with bolt holes therethrough; flange 44 being generally perpendicular to surface 40 . The bolt holes through flange 44 are arranged in a second pattern that matches a pattern of holes on a structural member of tractor 10 , such as, for example, the transmission or rear axle housing (neither shown) to rigidly affix rear piece 22 by bolts 46 to the tractor. In practice, rear piece 22 may be the same for the left and right sides or they may be slightly different depending upon other tractor components that may interfere with the attachment of the rear piece to a structural member of the tractor.
Referring to FIGS. 2–4 , front piece 24 is comprised primarily of generally vertical member 26 and generally forwardly extending member 50 rigidly connect by gusset plates 52 , 54 and 56 welded into an assembly. Depending upon the design of the loader, other elements may be associated with front piece 24 . Forwardly extending member 50 may be formed to fit the specific tractor to which it is to be attached. For example, as best seen in FIGS. 2 and 4 a sloping step-like bend 60 is formed in member 50 to properly interface with a particular tractor structure while maintaining the vertical member 26 in proper alignment with the pivot pins on axis 34 . Bolts 62 affix the front piece to a structural member of tractor 10 .
A generally vertical planar surface 64 on gusset plate 56 , best seen in FIG. 4 , has a plurality of bolt holes 66 therethrough arranged in the same pattern as the bolt holes through surface 40 . A similar pattern of bolts holes extend through gusset plate 54 such that bolts 68 extend through both gusset plates and the holes through surface 40 of rear piece 22 to draw surfaces 40 , 64 together, forming a rigid connection between rear and front pieces 22 , 24 .
Mounting bracket 20 provides considerable flexibility and efficiency in the commercial arena. A tractor may be assembled at the factory with the relatively inexpensive rear piece 22 in position, and then shipped to a dealer for sale. If a customer decides to purchase the tractor with a loader, or later decides to add a loader, the dealer's installation efforts and costs are significantly reduced because the installation of the front piece and loader requires much less effort than the installation of the full bracket and loader. Tractors are complex assemblies of thousands of parts and components, with many on, over or adjacent the area where the rear pieced is located. With the rear piece attached during assembly of the tractor, there is no need to remove or loosen most of those parts and components during installation of the front piece and loader.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the inventions. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | Method and apparatus to simplify the process of adding a loader to a tractor after the manufacturing process. A pair of mounting brackets, one on each side of the tractor, each comprises a front piece and a rear piece. The rear piece is affixed to the tractor during the manufacturing process and the front piece, including a bearing surface for a transverse support axis of a loader, is selectively affixed to the respective rear piece and tractor when a decision to incorporate a loader is taken. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 61/562,517, filed Nov. 22, 2011, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to an inflow dish for a sanitary sewer system and more particularly to a two-piece dish assembly designed to be used in enlarged manhole openings.
BACKGROUND OF THE INVENTION
[0003] For a number of reasons, including the obesity of some workmen and the necessity to move larger equipment and supplies through a manhole opening to gain access to the manhole, it has been necessary to increase the diameter of manholes. Inflow dishes are designed to fit below the manhole cover and to prevent rainfall and debris that may find its way past the manhole cover from entering the sanitary sewer system.
[0004] Inflow dishes designed to fit standard manhole openings, of course, do not fit manholes with enlarged diameters. Providing an inflow dish enlarged to accommodate the larger size manhole openings has not proven to be a satisfactory solution. Using standard materials to construct a single piece enlarged inflow dish has provided an inflow dish that is either too weak to accommodate rain and debris without collapsing or too heavy to be easily handled. Also very often it would not be necessary to remove the entire inflow dish if it could be removed in sections.
SUMMARY OF THE INVENTION
[0005] The present invention provides a two-piece inflow dish assembly which includes an outside dish with a central opening and an insert dish which nests within the outside dish to completely close the manhole below the manhole cover. The outside dish has the diameter of an enlarged manhole opening so that the two-piece dish can fit within and close the enlarged manhole opening. The insert dish is substantially the diameter of a standard manhole opening so that it can be used by itself to serve as an inflow dish for a standard size manhole.
[0006] The construction permits the inflow dish assembly to be removed in two pieces. It may only be necessary to remove the insert dish to dispose of debris captured by the inflow dish. Where access to the manhole is required, it may be necessary to remove both pieces.
[0007] A problem with using commonly used materials, such as polyethylene, for inflow dishes is that such material is not sufficiently strong and, especially in the larger diameters required by the enlarged manholes, can result in sagging of the dish and the possibility of the dish, and the debris carried by the dish, falling into the manhole. A preferred construction, however, would be that, rather than being formed of polyethylene, either or both of the dishes of the inflow dish constructed is constructed of polycarbonate or a material having the characteristics of polycarbonate. Polycarbonate has the necessary strength to function as an inflow dish even with large diameter dishes. It has been found that acrylic is also sufficiently strong to support the dishes over the span of an enlarged manhole opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Reference will be made herein to various drawings, wherein like reference numerals refer to like parts throughout and wherein:
[0009] FIG. 1 is a fragmentary cross sectional view of the upper part of a manhole with a two-piece inflow dish assembly of the present invention shown in place;
[0010] FIG. 1 a is an enlarged view of a portion of the structure shown in FIG. 1 ;
[0011] FIG. 2 is top perspective view of the outside dish of the present invention; and
[0012] FIG. 3 is top perspective view of the two piece dish assembly of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring now to the drawings an inflow dish assembly 10 of the present invention is shown which includes an outside dish 14 having a central opening 13 which receives an insert dish 12 to provide the two-piece inflow dish assembly 10 . The inflow dish assembly 10 , as can best be seen in FIG. 1 , is dimensioned to fit within a manhole opening 16 of a manhole 17 and below a manhole cover 18 . The manhole opening 16 is of a diameter which is larger than the diameter of a standard manhole opening and the cover 18 is therefore larger than the standard manhole cover to fit within and close the manhole opening 16 . Inflow dishes are commonly provided to be mounted below the manhole cover 18 in the manhole opening 16 to collect rainwater and debris passing the cover 18 and before the rainwater can make its way into the sanitary sewer system and thereby causing the system to overflow.
[0014] The inflow dish assembly 10 of the present invention is of a diameter to fit within an enlarged manhole opening 18 of a manhole 19 and with the insert dish assembly 10 in place within the central opening 13 it is operable to fully block the manhole opening 16 below the manhole cover 18 . With the inflow dish assembly 10 in place as shown in FIG. 1 , debris and rainwater that has made its way past the manhole cover 18 can, in many instances, be removed by removing the cover 18 and then removing only the insert dish 12 .
[0015] The insert dish 12 is preferably dimensioned to fit within a standard manhole where it can be used without the outside dish 14 .
[0016] As can best be seen in FIGS. 1 and FIG. 3 the insert dish 12 removably nests within the center of the outside dish 14 to close the central opening 13 ( FIG. 2 ) formed within outside dish 14 to form the inflow dish assembly 10 . As seen in FIG. 1 the inflow dish assembly 10 is intended to be inserted in the manhole opening 16 with an outwardly extending flange 22 of the outside dish 14 supported by a flange 20 formed in the wall 17 of the manhole 19 . A slot 21 is preferably formed in the flange 20 to receive the flange 22 of the outside dish 14 .
[0017] Still referring to FIGS. 1 , 2 and 3 the outside dish 14 is provided with an offset internal flange 23 formed about the central opening 13 which supports an outer rim 24 ( FIG. 3 ) of the insert dish 12 to receive a central portion 25 of the insert dish 12 within the central opening 13 to nest the insert dish 12 within the outside dish 14 to close the central opening 13 .
[0018] It should be apparent that then an inflow dish assembly has been provided which includes an insert dish mounted within an outside dish to form an assembly which fits within a manhole that has been enlarged from the conventional size.
[0019] If access to the enlarged manhole is required any debris and rainwater can be removed by removing the inflow dish assembly in sections. If access through the enlarged manhole is not required it may only be necessary to remove the insert dish to gain access.
[0020] Inflow dishes have heretofore been commonly constructed of polyethylene or a similar plastic material. Applicant has found that polycarbonate and similar plastic material as well as acrylic possess the strength necessary to prevent the dish from sagging and thereby risking debris and rainwater and even the dish itself from falling into the manhole and into the sanitary system.
[0021] Having thus described the disclosed two-piece inflow dish assembly of the present invention, other embodiments for the present invention that do not depart from the scope of the claims will become apparent to those of skill in the art. | A two piece inflow dish assembly for installation in an enlarged manhole opening to prevent debris from entering the manhole to clog the sewer system and to permit the inflow dish assembly to be removed from the manhole in separate pieces. |
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] A faucet body such as a spout having exterior and interior surfaces formed so that the faucet body does not trap and retain liquids during the processes used to manufacture the faucet body and provide finishes on the exterior surface of the faucet body.
[0002] Modern faucet bodies, particularly those cast of base metals such as brass, etc., are coated with various finishes for both aesthetic and durability reasons. These finishes are applied by moving the faucet body sequentially through a series of baths containing the finishes which finishes are usually in liquid form. The faucet bodies are conventionally moved through each bath and on to the next bath using a conveyor apparatus. Each faucet body is suspended from the conveyor by a hook with the faucet body oriented so that its water outlet is located above its base and the body is generally supported in a generally upright position relative to its longitudinal axis.
[0003] Prior faucet bodies have trapped liquids which required hand manipulation to remove the trapped liquids. If the liquids were not removed, they many times resulted in contamination of downstream baths. The retention of liquids in the faucet bodies has been due to the interior construction of the faucet bodies. Faucet bodies are, of necessity, formed with interior partitions or septums which separate the water passage cavity from the drain plug rod cavity. These partitions, in conjunction with the exterior walls of the faucet bodies, form pockets which trap or retain liquids when the faucet bodies are supported in a generally upright orientation.
[0004] This invention is directed to a faucet body having interior partitions arranged to allow drainage of all liquids which enter the hollow interior of the body as it is moved into and out of process baths during its finishing and coating processes without the need for manual manipulation of the faucet bodies.
[0005] Another object of this invention is a faucet body having interior partitions and exterior walls that slope without obstruction to the base end of the faucet body when the faucet body is oriented in a generally upright direction relative to its longitudinal axis.
[0006] Yet another object of this invention is a faucet body having a water chamber connected to the base end of the faucet by a water inlet passage which water inlet passage is formed to permit complete drainage of liquid from the water chamber when the faucet body is in a generally upright position.
[0007] Still another object of this invention is a faucet body having a drain rod compartment which is open at its base end to permit complete drainage of liquid from the drain rod compartment when the faucet body is supported in a generally upright position.
[0008] Another object of this invention is to allow the complete drainage of metal-bearing electroplating solutions from the faucet body as it is being processed by automatic electroplating equipment, so that the solutions drain completely into their respective original process tanks. this allows for the reuse of those solutions, saving substantial chemical makeup costs.
[0009] Yet another object of this invention is that it allows for the complete drainage of metal-bearing electroplating solutions from the faucet body as it is being processed by automatic plating equipment so that the solutions drain completely into their respective original process tanks. This minimizes the transfer of those electroplating solution into subsequent processes, where they are a contaminant that must be removed. This reduces the waste treatment and process purification costs, saving substantial costs.
[0010] An additional object of this invention is that it allows for the complete drainage of metal-bearing electroplating solutions from the faucet body as it is being processed by automatic plating equipment, so that the solutions can be completely rinsed from the interior of the faucet body. This eliminates the solutions being trapped within the faucet body, where they could come in contact with the end user. This results in a safer faucet body through which to pass potable water, as the water cannot be contaminated by residual electroplating solutions.
[0011] Other objects of the invention will be found in the following specification, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention is illustrated more or less diagrammatically in the following drawings wherein:
[0013] [0013]FIG. 1 is a side elevational view of a faucet body embodying the novel aspects of this invention supported in a generally upright or vertical position by a hook;
[0014] [0014]FIG. 2 is a bottom plan view of the faucet body of FIG. 1;
[0015] [0015]FIG. 3 is a longitudinal cross section view of the faucet body of FIG. 1;
[0016] [0016]FIG. 4 is a side elevational view of another embodiment of the invention with the faucet body supported in a vertical position by a hook;
[0017] [0017]FIG. 5 is a bottom plan view of the faucet body of FIG. 4; and
[0018] [0018]FIG. 6 is a longitudinal cross sectional view of the faucet body of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIGS. 1 - 3 of the drawings shows a first form of this invention embodied in a faucet spout body 11 . This body, which is cast of a base metal, usually brass, is treated during the course of its manufacturing and finishing processes in numerous baths. Some of the baths are for cleaning, some apply plating and others apply protective coatings, generally to the outside surfaces of the spout body. The spout body includes a distal or far end 13 and a base end 15 . The faucet body is elongated and has a generally longitudinal axis shown by line 17 .
[0020] The hollow faucet spout body includes a top wall 21 and a bottom wall 23 as are shown most clearly in FIG. 3 of the drawings. A septum 25 , which is an extension of the top wall 21 , divides the hollow faucet spout body into a water passage compartment 27 and a plunger rod compartment 29 . The plunger rod compartment has a dome 31 with a flat top wall 33 . The flat top wall has a plunger rod slot 35 and a rear wall 37 completes the faucet spout body.
[0021] A recessed portion 41 of the bottom wall 23 forms a water outlet passage 43 near the distal end 13 of the faucet spout body. Threads 45 are formed around the water outlet passage to receive an aerator which is customarily installed on faucet spouts but is not shown in these drawings.
[0022] The bottom wall 23 of the faucet spout body 11 has a base end opening 49 which is shown most clearly in FIG. 2 of the drawings. A web 51 located at the base end opening connects to the septum 25 , front wall 21 and rear wall 37 of the faucet spout body. A rib 53 connects the bottom wall 23 of the faucet spout body with the septum 25 while a rib 55 connects the septum to the rear wall 29 of the faucet spout body. As can best be seen in FIGS. 2 and 3 of the drawings, a water inlet passage 57 is formed in rib 53 and a threaded plunger rod passage 59 is formed in rib 55 . Later in the process of manufacturing the faucet spout body, a sleeve with exterior threads will be threaded into the threaded plunger rod passage 59 , but that will be after the liquid coating processes with which this application is concerned will have been completed. A groove 61 for receiving a trim ring is formed in the base end 15 of the faucet spout body.
[0023] A tethered hook 65 supports the faucet spout body 11 during its movement between the various plating baths such as the liquid bath 67 in container 69 shown in FIG. 1 of the drawings. Due to the shape of the exterior walls of the faucet spout body, the interior septum 25 and the provision of openings, such as opening 49 , at the base end of the faucet spout body, liquid accumulated during its passage through the baths is not retained in the faucet spout body. When the body is hanging in its upright position relative to its longitudinal axis 17 as shown in the drawings, liquid will flow out of the opening 49 between the septum 25 and the rib 55 . The water inlet passage 57 and the threaded plunger rod passage 59 are both inclined to drain to the exterior when the faucet spout body is held in a generally upright position as can be seen most clearly in FIG. 3 of the drawings. Thus, the faucet spout body of this invention provides complete drainage of the interior compartments above the water passage chamber 27 and the plunger rod chamber 29 without interfering with any of the functions of these compartments during use of the faucet spout body while functioning as a plumbing fixture.
[0024] FIGS. 4 - 6 of the drawings shows a second form of this invention embodied in a faucet spout body 11 . This body, which is cast of a base metal, usually brass, is treated during the course of its manufacturing and finishing processes in numerous baths. Some of the baths are for cleaning, some apply plating and others apply protective coatings, generally to the outside surfaces of the spout body. The spout body includes a distal or far end 113 and a base end 115 . The faucet body is elongated and has a generally longitudinal axis shown by line 117 .
[0025] The hollow faucet spout body includes a top wall 121 and a bottom wall 123 as are shown most clearly in FIG. 6 of the drawings. A septum 125 , which is an extension of the top wall 121 , divides the hollow faucet spout body into a water passage compartment 127 and a plunger rod compartment 129 . The plunger rod compartment has a dome 131 with a flat top wall 133 . The flat top wall has a plunger rod slot 135 and a rear wall 137 completes the faucet spout body.
[0026] A recessed portion 141 of the bottom wall 123 forms a water outlet passage 143 near the distal end 113 of the faucet spout body. Threads 145 are formed around the water outlet passage to receive an aerator which is customarily installed on faucet spouts but is not shown in these drawings.
[0027] The bottom wall 123 of the faucet spout body 111 has a base end opening 149 which is shown most clearly in FIG. 5 of the drawings. A web 151 located at the base end opening connect to the septum 125 , front wall 121 and rear wall 137 of the faucet spout body. A rib 153 connects the bottom wall 123 of the faucet spout body with the septum 125 while a rib 155 connects the septum to the rear wall 129 of the faucet spout body. As can best be seen in FIGS. 4 and 5 of the drawings, a water inlet passage 157 is formed in rib 153 and a threaded plunger rod passage 159 is formed in rib 155 . Later in the process of manufacturing the faucet spout body, a sleeve with exterior threads will be threaded into the threaded plunger rod passage 159 , but that will be after the liquid coating processes with which this application is concerned will have been completed. A groove 161 for receiving a trim ring is formed in the base end 115 of the faucet spout body.
[0028] A tethered hook 165 supports the faucet spout body 111 during its movement between the various plating baths such as the liquid bath 167 in container 169 shown in FIG. 4 of the drawings. Due to the shape of the exterior walls of the faucet spout body, the interior septum 125 and the provision of openings, such as opening 149 , at the base end of the faucet spout body, liquid accumulated during its passage through the baths is not retained in the faucet spout body. When the body is hanging in its upright position relative to its longitudinal axis 117 as shown in the drawings, liquid will flow out of the opening 149 between the septum 125 and the rib 155 . The water inlet passage 157 and the threaded plunger rod passage 159 are both inclined to drain to the exterior when the faucet spout body is held in a generally upright position as can be seen most clearly in FIG. 6 of the drawings. Thus, the faucet spout body of this invention provides complete drainage of the interior compartments above the water passage chamber 127 and the plunger rod chamber 129 without interfering with any of the functions of these compartments during use of the faucet spout body while functioning as a plumbing fixture. | A faucet spout having interior surfaces sloping in the direction of its base so that any liquid in its interior will drain when the faucet spout is supported in a generally upstanding position with its outlet end above its base. |
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FIELD OF THE INVENTION
This invention relates in general to pool cleaning devices and more particularly to a device that enables convenient attachment of a pool debris skimming net to a cylindrically shaped object.
BACKGROUND OF THE INVENTION
The present invention relates to a device for skimming debris off the surface of a body of water and, more particularly, for skimming debris such as dead leaves, twigs, insects and scum off of the surfaces of pools prior to their sinking and forming a sludge at the bottom of the pool.
Skimming debris from the water surface of pools is done either manually, by hand, using a net attached to a long handle and manipulated by a person, or by positioning a debris skimming net in a location where water currents flowing around the pool urge the floating debris to move along fairly well defined paths created by the moving currents. A generally circular flow of water from pump inlet to outlet creates the current flows in the pool.
A variety of devices are known in the prior art for mounting a pool debris skimming net over a swimming pool. In many instances, the net mounting devices are bulky, lacking in flexibility to orient the net at a desired attitude or angle, difficult to install and some are quite expensive to produce. Ideally, a pool net mounting device is adaptable for use with all pool installations be they in-ground or above-ground pools. In addition the ideal device should include net positioning features that enable a multitude of net positioning options, is small and lightweight, is easily removed for storage purposes, and is inexpensive to produce. What is needed is a pool net mounting device that incorporates all of these desirable features.
SUMMARY OF THE INVENTION
A device for removably mounting a pool net having a tubular shaft, according to one aspect of the present invention, comprises mounting means adapted to be removably attached to a cylindrical mounting surface, net holding means for securely receiving the tubular shaft of the pool net and maintaining the shaft at a desired angular orientation, and attachment means for attaching the mounting means to the net holding means in one of a plurality of predetermined angles, the attachment means having a portion thereof disposed on the mounting means and a portion thereof disposed on the net holding means.
One object of the present invention is to provide an improved pool net mounting device.
Another object of the present invention is to provide a pool net mounting device that is less expensive yet provides enhanced configurations over the prior art.
Still another object of the present invention is to provide a pool net mounting device that is easily installed and removed from a cylindrical object such as a pool ladder.
Yet another object of the present invention is to provide a pool net mounting device that may be removably attached to a cylindrical object and provides multiple angular and height positioning features for attaching a debris net shaft thereto.
These and other objects of the present invention will become more apparent from the following figures and description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a pool net mounting device according to the present invention.
FIG. 2 is a partial cut-away front elevational view of the pool net mounting device of FIG. 1 .
FIG. 3 is a side elevational view of the ladder clip shown in FIG. 1 .
FIG. 4 is a side elevational view of the net mount adapter shown in FIG. 1 .
FIG. 5 is a front elevational view of the spline connector.
FIG. 6 is an end elevational view of the spline connector
FIG. 7 is an illustration depicting the pool net mounting device of FIG. 1 attached to a pool ladder and including a debris skimming net attached thereon.
FIG. 8 is a plan view of a pool net mounting device according to another aspect of the present invention.
FIG. 9 is a cut-away exploded front elevational view of the pool net mounting device of FIG. 8 .
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 embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to FIGS. 1 and 2 , a plan view ( FIG. 1 ) and a front elevational view ( FIG. 2 ) of a pool net mounting device 10 according to the present invention is shown. Pool net mounting device 10 includes ladder clip 12 , net mount adapter 14 , and spline connector 16 (see FIGS. 5 and 6 ) used to internally attach or join clip 12 to adapter 14 . Cylindrical portion 18 defines a partial cylindrical aperture 20 that is sized to receive and securely snap onto a cylindrical object such as the metal tubing used in the fabrication of a pool ladder. Adapter 14 includes a cylindrical aperture 22 therethrough sized to receive the shaft of a debris skimming net (see FIG. 7 ). A number of circular apertures 24 extend through the cylindrical portion 26 of adapter 14 . Apertures 24 are in fluid communication with aperture 22 and are sized to receive a spring-pin (shown in FIG. 7 ) of a debris net. Slots 28 are also size to receive a spring-pin of a debris net. Anti-slip material 30 , typically made of a rubber-like compound, is adhesively attached to cylindrical portion 18 to provide an anti-rotational gripping force between cylindrical portion 18 and pool ladder tubing (shown in FIG. 7 ).
Referring now to FIGS. 3-6 , a side elevational view of clip 12 ( FIG. 3 ), a side elevational view of adapter 14 ( FIG. 4 ) and a front ( FIG. 5 ) and side elevational view ( FIG. 6 ) of spline connector 16 are shown. Spline connector 16 includes a plurality of splines that serve to define a multitude of angular positions for connecting clip 12 to adapter 14 . Spline 16 is inserted into mating spline apertures 34 and 36 to assemble or connect clip 12 to adapter 14 . Spline connector 16 is sized so that insertion of connector 16 is achieved with a moderate insertion force into apertures 34 and 36 attributable to a fairly small interference fit. It is contemplated that connector 16 may be formed or molded as a part of either clip 12 or adapter 14 rather than as a separate component part of device 10 . Also shown in FIG. 4 is set screw 31 installed in a threaded aperture in adapter 14 . Set screw 31 is useful when the debris net does not include a locating pin or spring-pin feature. The threaded aperture into which screw 31 is inserted may require additional reinforcement such as a threaded metal insert (not shown) to increase the mounting thread strength and thereby enable larger forces created when rotating set screw 31 into the threaded aperture of adapter 14 . Set screw 31 may be replaced by a nut and bolt, wherein the nut and bolt assembly extends through opposing apertures 24 and the shaft of the net when the net is disposed in aperture 22 .
It is also contemplated that a number of design approaches may be taken for attachment of clip 12 to adapter 14 to achieve a device that provides a multitude of angular configurations of various relationship between clip 12 and adapter 14 . Spline connector 16 may be integrally formed or molded as a part of either clip 12 or adapter 14 thereby eliminating a molded part. Alternatively, the spline engagement design of device 10 could be replaced by a concentric cylindrical sleeve design with an engaging spring-loaded locking pin quite similar to the manner that a debris net shaft extension slides over and clips onto a pool debris net. Such an embodiment is shown in FIGS. 8 and 9 . Further, a simple concentric cylindrical interface with a small molded protrusion (such as a plastic dimple) on one concentric cylinder and small indentations sized to receive and engage the dimple in the other concentric cylinder would enable multiple assembly positions for clip 12 versus adapter 14 . In practice, a large number of multi-angular assembly approaches could be taken for the clip 12 to adapter 14 connection, the important aspect being to provide flexibility in the angular assembly relationship between clip 12 and adapter 14 . It is also contemplated that clip 12 and adapter 14 may be machined or molded as a single piece unit without any angular adjustment therebetween. Velcro, wire-ties, hose clamps, nylon tie-wrap straps, and rubber o-ring grommets (a rubberized gripping device) may also be used to more securely attach clip 12 to a cylindrical object such as a pool ladder.
Referring now to FIG. 7 , and operationally speaking, device 10 is shown attached to a cylindrical object such as pool ladder 32 (also shown in cross-section in FIG. 1 ). Device 10 conveniently and easily snaps onto ladder 32 by positioning the c-shaped cross-sectional aperture 20 of ladder clip 12 against ladder 32 and applying a horizontal force thereto. It should be readily recognized that ladder clip 12 is easily removed at a later time by applying a horizontal force to separate ladder clip 12 from ladder 32 . Anti-slip material 30 provides a frictional gripping force between clip 12 and ladder 32 preventing undesirable rotation of clip 12 versus ladder 32 . Ladder 32 is attached to the pool wall 33 (shown in cross-section). Clip 12 may be rotated to any desired angular position versus ladder 32 to position debris net 38 in a desired location such as a current flow path in the pool water 42 . The angular orientation of clip 12 versus adapter 14 is selected by the user during assembly of the clip 12 and adapter 14 using spline connector 16 . The handle of debris net 38 is inserted into aperture 22 , and the angular orientation of debris net 38 is established by rotating the net so that a spring-pin 40 extending radially outward from within the pool net shaft engages one of the circular apertures 24 or one of the slots 28 . As shown, spring-pin 40 is located in one of the slots 28 , however it should be readily recognized that spring-pin 40 may also be situated in any of the apertures 24 to angularly position the net at a desired angle and depth in the pool water 42 .
The standard outer diameter of debris net poles is known to be 1.125 inches, thus aperture 22 is typically dimensioned to 1.15 inches. It is contemplated that other net shaft diameters may be accommodated with corresponding dimensional changes to adapter 14 and the diameter at aperture 22 wherein a small clearance spacing is provided to allow the net shaft to slide easily in and out of aperture 22 . Debris nets 38 typically include internal spring-pins 40 to engage mating holes in tubular extension shafts.
Ladder clip 12 and net mount adapter 14 are preferably manufactured from thermoplastic materials such as PVC (polyvinyl chloride) or any other suitable material having some resiliency and rust resistance. Alternative materials include polyethylene and polypropylene. Anti-slip material 30 is made of rubber or man-made equivalent.
Referring now to FIGS. 8 and 9 , another embodiment of a pool net mounting device 50 according to the present invention is shown. FIG. 8 is a plan view of device 50 and FIG. 9 is an exploded cut-away front elevational view thereof. Features of device 50 that are identical to those shown in device 10 are numbered with like numerals in FIGS. 8 and 9 . Mount device 50 replaces the spline connector with a spring-pin and concentric cylindrical mating member. Mounting device 50 is comprised of a ladder clip 52 and a net mount adapter 54 . Clip 52 and adapter 54 are shown in exploded fashion in FIG. 9 so that the details of spring-pin 56 and spring 58 are readily seen. Spring-pin 56 is attached to spring 58 via a rivet 60 . Rivet 62 attaches spring 58 to the internal surface of cylindrical portion 66 of adapter 54 . Assembly of device 50 requires insertion of hollow cylindrical member 66 of adapter 54 into hollow cylindrical member 68 of clip 52 . Spring 58 enables pin 56 to be displaced radially inward on cylindrical member 66 so that cylindrical member 66 is insertable within cylindrical member 68 . Upon insertion of cylindrical mating member 66 into cylindrical mating member 68 , adapter 54 is rotated to a desired angular relationship versus clip 52 and spring-pin 56 engages one of apertures 70 sized to receive spring-pin 56 . Apertures 70 are equi-angularly spaced about the cylindrical surface of cylindrical member 68 for a total of twelve apertures, yet more or less apertures 70 are contemplated. Spring 58 is a rectangular flat metal spring that urges pin 56 into the position shown in FIG. 9 . A circular recess is formed in cylindrical member 66 at 66 a so that rivet 62 does not interfere with mating of cylindrical mating members 66 and 68 . Also shown in FIGS. 8 and 9 are apertures 20 and 22 , cylindrical portion 18 , cylindrical portion 26 , apertures 24 , slots 28 , and anti-slip material 30 , each having identical properties and characteristics as the identically numbered items in FIGS. 1-7 . Device 50 functions identically to device 10 with the sole differences residing in the manner in which the two primary components, clip 52 and adapter 54 , are attached to one another. Materials used in the construction of device 50 are identical to those used in the fabrication of device 10 .
The embodiments shown utilize two different approaches for attaching clip 12 to adapter 14 , yet it should be readily apparent that screws, nuts and bolts or pop rivets are equally suitable to attach these two components to one another. The embodiments shown are more convenient in that no tools are required for assembly of the two primary components of the invention.
While the invention has been illustrated and described in detail in the drawings and foregoing description of the preferred embodiments, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A pool net mounting device is disclosed. The mounting device includes a pool net holding portion having a hollow cylindrical tube adapted to receive and secure a pool net in a plurality of angular orientations. The pool net mounting device also includes a mounting portion adapted to be removably attached to a cylindrical object such as a pool ladder rail. The net holding portion and the mounting portion are removably attached to each other in a variety of angular positions so that a wide range of configurations is achieved for orienting a pool debris net at a desired angular orientation and height. The net holding portion includes a number of apertures and slots therein for receiving a spring loaded pin, a common feature of pool nets. Alternative pool net attachment features are also disclosed. |
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BACKGROUND OF THE INVENTION
The present invention pertains to ice handling systems and more particularly to systems where the removal of dangers presented by icebergs to marine platforms or marine vessels located on the open seas.
Presently, icebergs present a constant danger to not only vessels on high seas but also offshore oil rigs or platforms located as far as several hundred miles from the coast.
Icebergs come from glaciers which end at the seashore. A glacier is a moving mass of ice that travels across the land and terminates at the ocean. As the glacier moves to the ocean, portions break off and are termed icebergs. Icebergs are primarily fresh water ice since they are composed of packed ice and snow which has been compressed over hundreds of years. The compression of snow over a large period of time results in a cohesive structure which has small bubbles or pockets of air trapped within.
Icebergs are irregular in shape, each being unique. As an iceberg travels through the ocean, it is constantly melting, at various rates dependent on the temperature of the air and water surrounding the iceberg. As such, the center of gravity will slowly change and the iceberg may roll in the water, presenting further dangers to personnel and equipment working near the iceberg.
Although icebergs are commonly encountered in the North Atlantic from the glaciers in Greenland and Canada, icebergs in smaller quantities are encountered in the Pacific from the Alaskan glaciers. Additionally, large masses of ice are encountered in the Southern Hemisphere from the Coast of Antarctica. These ice masses are similar to the icebergs located in the Northern Hemisphere, although they have a larger surface area and lower height above the water line. Many icebergs will melt at sea and never present a problem, however, many travel towards the equator along the coast line of one of the continents. These icebergs cause dangers to ships when they travel in a shipping lane or to offshore platforms, such as oil rigs, when they travel along the coast.
The danger posed to offshore platforms was not a major concern when the world oil supply was plentiful on land. However, since oil production has moved offshore, particularly in places such as the North Sea or the Hybernia Oil Field off the Coast of Newfoundland, the danger of icebergs has become a significant problem in oil production. An iceberg may weigh as much as a hundred million tons and have a water speed of one half knot. The force with which an iceberg may collide with a platform is devastating.
Under normal conditions, an iceberg watch is kept to monitor iceberg movement. Icebergs which are within one hundred miles of a platform are checked daily to determine whether they pose a danger to a production platform. If the iceberg approaches the platform, a tow line is placed around the iceberg and an attempt is made to maneuver the iceberg to avoid collision with the platform. If the threat of collision cannot be safely avoided, a floating platform may be disconnected from the subsea wellheads and moved out of the path of the iceberg. The disconnection of a production platform may require a loss of a weeks production time. Since the disconnection may require as much as 48 hours, a wide safety margin must be left to assure the prevention of a collision.
The disconnection of a production platform does not remove all detrimental effects of icebergs since flowlines are connected between an onshore storage area and the offshore production platform. Icebergs, because of their specific gravity, float with their majority of their mass beneath the surface o& the water. As such, their draft or depth below the water line, may be several hundred feet. Flowlines may be in only several hundred feet of water and can be damaged or severed by icebergs dragging bottom.
To reduce the draft of an iceberg, many methods have been attempted, such as blasting the iceberg apart. This method has proven unsatisfactory due to the nature of an iceberg. An iceberg is similar to a very densely packed snowball with a great amount of air trapped and compressed within as small air bubbles or pockets of air. The force of an explosive charge is absorbed by the generally deformable structure of the ice.
The method of moving icebergs by placing a tow rope around the peripheral at water level has several disadvantages. First, an iceberg is extremely unstable as it floats in the water and may roll or tip over when towing proceeds. Second, an iceberg generally decreases in size with respect to height out of the water and the tow rope may slide up and over the top of the iceberg.
Other ice masses have similar difficulties in movement by tow ropes circling the ice mass. First, the overall size of the surface area may render the length of the tow line prohibitive. Second, an ice mass having a flat surface and a low height above water may not allow the tow rope to securely rest around the ice mass.
Monitoring icebergs by aircraft iceberg watch has several deficiencies. Aircraft watch or marine vessel watch is weather related. Inclement weather or fog may inhibit aircraft availability. Either inclement weather or fog renders iceberg watch by marine vessel extremely dangerous. As a result, an iceberg may travel for several days while monitoring is impossible. If the iceberg has approached an offshore platform during the inclement weather, conditions may render the detachment and movement of the platform extremely dangerous if not impossible.
SUMMARY OF THE INVENTION
The present invention provides a safe, reliable method and apparatus for monitoring the movement of large masses of ice such as icebergs. A borehole is drilled into an ice mass by a specially designed erosion type water drill. The drill housing having a drillhead at one end and a connection point at the deployment end is configured to contain a cooling system for refreezing the housing when the drill has penetrated the ice mass a predetermined distance. A line is attached to the connection point to secure a floatation member to the ice mass. The floatation member has provision for holding a metallic structure for reflecting electromagnetic waves, such as those used in radar. In an alternate embodiment, a transmitter is secured to the floatation device to transmit electromagnetic signals such as RF (radio frequency) waves. By the use of either, the location of the ice mass may be determined without the requirement of visual contact with the ice mass.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectionalized plan view of an ice drill.
FIG. 2 is a front view of a deployment apparatus.
FIG. 3 is a side view of FIG. 2.
FIGS. 4A through 4C are plan views of the deployment of an ice anchoring device.
FIGS. 5A through 5C are plan views of an ice identification system.
FIG. 6 is a plan view of an ice fracturing device.
FIG. 7 is a plan view of an iceberg.
FIGS. 8A through 8C are plan views of the operation of the device of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides solutions to many ice related problems which create hazzards to not only equipment but also to human life. The use of the present invention removes the requirement of personnel in dangerous situations.
Referring now to FIG. 1, a side sectional view of an ice drill 12 is illustrated in iceberg 13 as having an external housing 14 and an internal concentric housing 16 connected at a deployment end 18 and a drill head end 20 by connectors 22. A rotatably mounted drill head 24 is mounted at drill head end 20 having water lines 26 providing fluid flow to drill head 24 and hydraulic fluid lines 28 to a hydraulic motor 30. The overall length of ice drill 12 is preferably fifteen feet, however, a longer or shorter length may be used with satisfactory results. External housing 14 is preferably steel, chosen for its rigidness and ability to conduct heat. However, any rigid conduit may be used and ability to conduct heat is not required if drill 12 is to be removed when a hole is complete. Under certain conditions ice drill 12 is to be left in the ice mass, drill and the ability of housing 14 to conduct heat is preferred. As such, a metallic conductive material is preferred in the construction of housing 14.
As illustrated in FIG. 1, a fluid refrigerant hose 32 may be added with expansion nozzles 34 connected between hose 32 and an expansion area 36 defined by external housing 14 and internal housing 16. This addition may be used to freeze the drill in place to provide a solid anchor to the ice mass being drilled. Threading 37 may be machined onto external housing 14 to provide greater freezing area. A clevis 38 is provided at deployment end 18 of external housing 14. A tow line (not shown) or the like may be attached to clevis 38.
Drill head 24 has water passages (not shown) angularly drilled therein to provide water streams at angles with face 40 of drill head 24 as indicated by arrows A and B. In operation, high pressure water, or similar liquid, is provided to the passages in drill head 24 through water line 26. The high pressure water has an eroding effect on iceberg 13. Hydraulic motor 30 rotates drill head 24. As hydraulic motor 30 is driven by fluid pressure from fluid line 28, exhaust from hydraulic motor 30 exits through annular opening 40 defined by the space between end 20 of housing 14 and drill head 24. As drill head 24 rotates, water streams A and B travel in a circular path, eroding a borehole 42 in iceberg 13 without grinding or producing tailings to block the efficiency or progress of drill head 24.
In operation ice drill 12 is placed in position at the edge of the ice along the axis of a desired borehole. Pressurized fluid is fed to drill head 24 through water line 26 to provide eroding water streams A and B. A fluid flow is fed to hydraulic motor 30 through fluid line 28 to rotate drill head 24. As water streams A and B rotate with the movement of drill head 24, ice is melted in a generally arcuate area. Melted ice as well as overflow from streams A and B is exhausted with hydraulic fluid from hydraulic motor 30 along the space between outer housing 14 and a borehole 42 provided thereby. Forward motion, that is motion into the iceberg, is exerted on deployment end 18 of external housing 14. This forward motion forces exhaust fluids and melted or eroded ice out of borehole 42.
Whenever ice drill 12 is to be left in iceberg 13 or some other ice mass, inner concentric housing 16 is used to provide expansion area 36.
A compressed fluid such as carbon dioxide may be fed to expansion area 36 through hose 32 to nozzle 34. The compressed fluid expands when leaving nozzle 34 into expansion area 36 causing a significant reduction in temperature. The heat absorbed in the expansion process reduces the surface temperature of external housing 14 causing exhaust fluid from hydraulic motor 30 and drilling head 24 along with melted ice to freeze. Threading 37 provides a greater surface area to extract heat from the fluid between external housing 14 and borehole 42 and also provides a gripping surface once the exhaust fluid is frozen.
As indicated previously, a clevis 38 may be fixed on deployment end 18 of external housing 14 with provision to receive a tow line or cable etc.
Referring now to FIG. 2, a front view of a deployment sled 50 is illustrated as having frame members 52 and ballast tanks 54A through 54D. Mounted on a lower support frame 56 is a track 58 and continuous link chain drive 60. Track 58 is adapted for deployment of ice drill 12 and has brackets 62A and 62B (see FIG. 3) to guide ice drill 12 in track 58. Brackets 62A and 62B may be standard brackets attached to chain drive 60 to move drill 12 into iceberg 13 as borehole 42 is drilled. As ice drill 12 advances, bracket 62A releases and drill 12 is supported by borehole 42 and bracket 62B.
Illustrated in phantom above deployment sled 50 is a remotely operated vehicle 64. Remotely operated vehicle 64 may be of any type currently used in the art, the only requirement being that it may be adapted to grip onto deployment sled 50 without greatly restricting its maneuverability.
Referring now to FIG. 3, side view of the deployment sled of FIG. 2 illustrates ballast tanks 54A through 54D as running the full length of deployment sled 50. As ice drill 12 is deployed into the ice mass or iceberg which is being drilled, the weight of the deployment system comprising remotely operated vehicle 64 and deployment sled 50 is reduced in weight. To prevent dipping or pitching of deployment sled 50, ballast is released to maintain a predetermined bouyancy and to assure the deployment of ice drill 12 on a generally horizontal plane. Ballast release may be controlled electrically by a gyroscope (not shown) or the like. Ballast is released automatically when the pitch or slope of deployment sled 50 exceeds a predetermined amount.
Referring now to FIGS. 4A through 4C, deployment of ice drill 12 and its use for an anchor for towing purposes are illustrated. In FIG. 4A remotely operated vehicle 64 approaches iceberg 13 with deployment sled mounted thereunder. Ice drill 12 is illustrated as mounted on deployment sled 50 having deployment end 18 with clevis 38 mounted to the rear of deployment sled 50 and drill head end 20 mounted towards the front of sled 50. A tow line 70 is attached to clevis 38 to provide a towing connection between ice drill 12 and a marine vessel (not shown). Water lines 26 and 28 and compressed fluid line 32 are connected to tow line 70 in a manner that allows all tension between clevis 38 and a marine vessel to be absorbed by tow line 70. A tether line 72 is attached to remotely operated vehicle 64 in the event of malfunction of the controls. In the event that remotely operated vehicle 64 malfunctions, the tether line 72 may be used to retrieve remotely operated vehicle 64 once ice drill 12 is in place.
FIG. 4B illustrates ice drill 12 as having initiated borehole 42. Ballast from ballast tanks 54A through 54D has been released to permit maintaining ice drill 12 in a generally horizontal plane. In FIG. 4C, ice drill 12 has been deployed and has drilled borehole 42. Ice drill 12 proceeded into iceberg 13 a predetermined distance such that clevis 38 extends out of the surface of iceberg 13. A compressed fluid is fed through fluid line 32 to expansion area 36 through nozzle 34 to provide quick freezing of external housing 14 of ice drill 12 into borehole 42. Remotely operated vehicle 64 together with deployment sled 50 is retrieved, leaving ice drill 12 having tow line 70 attached to clevis 38 solidly anchored into iceberg 13. In FIGS. 4A through 4C, ice drill 12 is illustrated as being deployed significantly below the surface of the water in which ice mass or iceberg 13 is floating. For best results, ice drill 12 is deployed in a horizontal plane on which the approximate center of gravity of iceberg 13 is located. Thus, iceberg 13 may be towed by exerting a pulling force on tow line 70 with a minimum amount of rolling and drag to provide additional safety and less stress on the towing vehicle.
FIGS. 5A through 5C illustrate an iceberg identification system. FIG. 5A is similar to FIG. 4A differing only in the line attached to clevis 38. Line 74 attached to clevis 38 is preferably a much lighter nylon line attached to an identification balloon 76. Remotely operated vehicle 64 together with deployment sled 50 and ice drill 12 are operated much in the same manner for an ice identification system as for the ice towing system. However, clevis 38 is of a much smaller size to permit its entrance into borehole 42. Ice drill 12 is placed approximately 100 to 120 feet inside iceberg 13 to assure that line 74 remains attached to iceberg 13 despite a significant amount of melting over a period of several weeks.
Identification balloon 76 may either use an active or a passive identification system. In the active identification system, a transmitter (not shown) is attached to identification balloon 76 to continually transmit a signal, preferably in the radio frequency range. By assigning a distinct radio frequency to each of a plurality of icebergs, acurate monitoring of individual icebergs is possible.
For a passive identification balloon, balloon 76 may be coated with a metalic foil of a type which will reflect microwaves such as radar. Although iceberg 13 will not be apparent on a radar sweep of the area, balloon 76, when covered with a metallic foil, will provide a positive indication of the location of iceberg 13. If identification balloon 76 becomes detached from iceberg 13, detachment is determined by the height of balloon 76.
As illustrated in FIG. 5C, ice drill 12 has been deployed approximately 100 feet into iceberg 13 while identification balloon 76 remains attached to clevis 38 through line 74. As iceberg 13 travels through the water, it will be constantly melting. As indicated previously, the ice below the surface of the water and above the surface of the water will melt at different rates, depending on whether the air or water is warmer. As such, iceberg 13 will occassionally roll due to the uneven melting. Line 74 is provided with enough length to allow identification balloon 76 to remain above the surface of the water despite rolling and shifting of iceberg 13. Identification balloon 76 is preferably filled with a lighter than air gas such as hellium. By constructing identification balloon 76 in a manner similar to weather balloons, a useful life of several months is assured.
As illustrated in FIG. 5B, ice drill 12 may be deployed in iceberg 13 at any location whereas in FIGS. 4A through 4C, ice drill 12 must be deployed in approximately the same horizontal plane as the center of gravity of iceberg 13 for towing purposes.
Referring now to FIG. 6, a modified ice drill 80 is illustrated as being similar to ice drill 12 differing only insofar as external housing 14 contains a bore packer 82 mounted close to drill head end 20. Drill head end 20 contains a vertical drill nozzle 84 in addition to drill head 24. Five fluid lines instead of three lines are illustrated as feeding ice drill 80. In addition to water lines 26 providing fluid flow to drill head 24 and hydraulic fluid lines 28 to hydraulic motor 30, fluid line 86 is illustrated to provide fluid flow to vertical drill nozzle 84, fluid line 88 is illustrated to provide expansion fluid to bore packer 82 and a high pressure line 90 is illustrated to supply internal pressure in iceberg 13.
Referring now to FIG. 7, a plan view of iceberg 13 is illustrated. Iceberg 13 has its center of gravity 92 approximately half way between iceberg top 94 and iceberg bottom 96. In a system for splitting an iceberg, ice drill 80 must be deployed approximately one third of the height of iceberg 13 from bottom 96 in order to assure a simultaneous cracking above and below ice drill 80. This is due to the hydrostatic head of the water in which iceberg 13 is floating.
Referring now to FIGS. 8A through 8C, the deployment of an ice fracturing system is illustrated. Ice drill 80 is deployed into iceberg 13 to its approximate horizontal center at a predetermined depth, preferably two thirds of the distance from top 94 of iceberg 13. Upon reaching the approximate center of iceberg 13, fluid flow to drill head 24 is stopped and fluid flow to vertical drill nozzle 84 is begun to provide a vertical air space within iceberg 13. When a vertical area 98 is achieved, borepacker 82 is energized through fluid lines 88 to seal drill 80 into position. As illustrated in FIG. 8C, high pressure is provided through pressure line 90 to drill head end 20 of ice drill 80. This pressurizes vertical cavity 98 with air causing iceberg 13 to split. In the preferred embodiment, approximately 150 psig air pressure is used to cause iceberg 13 to fracture. Due to the hydrostatic head or external pressure of the water in which an iceberg 13 floats, fracturing will progress vertically upward approximately twice as rapidly as vertically downward. By initiating the fracture approximately one third of the distance from the bottom of iceberg 13, a fracture will reach top 94 and bottom 96 of iceberg 13 simultaneously, splitting iceberg 13 in two parts.
By fracturing a large iceberg, two smaller icebergs are produced which may easily be moved from a position where they endanger personnel and equipment by use of the ice towing system described previously.
The present invention illustrates a method and apparatus for drilling into an ice mass such as iceberg. In one example, a drill may be refrozen into position in the horizontal plane containing the center of gravity of the iceberg to permit towing the iceberg to a location where it no longer endangers personnel and equipment. In another example, a method and apparatus for identification of icebergs has been illustrated using an ice drill to provide a connection deep within an iceberg to provide a reliable monitoring system despite weather conditions. Additionally, a method and apparatus for providing a centralized area to internally pressurize an iceberg causing it to fracture has been illustrated. While the present invention has been described by way of preferred embodiment, it is to be understood that this was for illustration purposes only and that the present invention should not be limited thereto but only by the scope of the following claims. | A method and apparatus is disclosed for monitoring ice masses wherein a signal transmitter is attached to an ice mass and receivers are used to detect the location of the transmitter. |
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BACKGROUND
[0001] In the hydrocarbon recovery industry, seals are often required in the downhole environment for a plethora of reasons that are familiar to one of ordinary skill in the art. Setting of these seals can be accomplished in a number of ways including mechanical axial compression, inflation, etc. While mechanical compression is reliable, the seals tend to be regularly annular and may not always seal well in an open hole or irregularly shaped cased hole because the setting environment is other than regularly annular. Inflatables are more conformable to the exact shape of the setting hole but suffer from temperature induced pressure changes that can, under some conditions, deleteriously affect the sealing contact pressure and therefore promote leaks. Since sealing in the downhole environment is both important and not likely to be supplanted in the foreseeable future, alternate configurations to create and maintain a seal are always well received by the art.
SUMMARY
[0002] A seal includes a mandrel having a plurality of radially directed openings therethrough; a plurality of members disposed within the openings and radially displacable therein; and an element disposed about the mandrel and radially displacable by the plurality of members.
[0003] A method for creating a seal includes running into a downhole environment a mandrel having a plurality of radially directed openings therethrough; a plurality of members disposed within the openings and radially displacable therein; and an element disposed about the mandrel and radially displacable by the plurality of members; causing the plurality of members to radially displace thereby contacting the element; and urging the element into loaded contact with a separate structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0005] FIG. 1 is a schematic cross-sectional representation of a radially supported seal as disclosed herein in a run-in position;
[0006] FIG. 2 is the configuration of FIG. 1 in a deployed position;
[0007] FIG. 3 is a schematic cross-sectional representation of a radially supported backup for a seal as disclosed herein in a run-in position; and
[0008] FIG. 4 is the configuration of FIG. 3 in a deployed position.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , a configuration 10 capable of mechanically producing a radially supported seal structure is illustrated in the run-in position. The configuration 10 includes a mandrel 12 , upon which is mounted an element 14 . Element 14 may be mounted upon mandrel 12 in a number of commercially recognizable ways, one of which being by end rings 16 and 18 that limit ends of the element against unintended axially or radially movement relative to the mandrel 12 . The foregoing sentence should be understood to indicate that fixation can be achieved or that intended movement can be achieved while unintended movement is inhibited. It will be appreciated that in some constructions of element 14 , axial shortening or the run-in length dimension between rings 16 and 18 is required for the element 14 to move radially outwardly as is necessary for sealing against an open or cased hole in which the configuration is intended to be set. Whether or not this is the case depends upon the type of element and its mode of action. More specifically, if the element itself is not substantially elastic in at least the axial direction, shortening will be necessary. Alternatively, if elasticity is available in the element 12 , axial movability may be reduced or eliminated.
[0010] In either case, the configuration 10 utilizes a plurality of radially extensible members 20 . The members are each positioned in openings 22 extending through the mandrel in a substantially radial direction. In one embodiment, the openings are smooth bore structures while in other embodiments, the openings are configured to allow movement of the members 20 therethrough in a single direction. As illustrated, the direction is radially outward although it will be appreciated that they could be configured for radially inward movement.
[0011] As illustrated, the members 20 are actuatable in a radially outward direction based upon the application of a force at a radially inward end 24 of each member 20 . This force may be applied via a fluid pressure or may be applied via a mechanical or electrical actuator such as a ramped structure (e.g. a cone), or a solenoid, respectively, for example. In the event that a smooth bore is exhibited in openings 22 , a radial force must be maintained on the members 20 to keep them in position. Alternatively, if they are not smooth but rather are configured to allow movement of the members 20 in only one direction, such as in the case of a ratchet profile and suitable ratchet following structure on the members 20 , then the radial force on the members need only be maintained until the setting procedure is complete whereafter because the members 20 would not be able to retract, there is no reason to maintain the radial force thereon.
[0012] The members 20 , regardless of smooth or profiled bore embodiments, are positioned to be capable of contacting an inside dimension of the element 14 and urging that element radially so that it comes into loaded contact with a casing or open hole with which the element is intended to create a seal. Reference is made to FIG. 2 wherein the deployed or sealed position of the configuration 10 is illustrated. The members 20 are intended to remain in the extended position illustrated in FIG. 2 for the duration of the life of the seal. This will ensure that the element 14 remains in contact with the casing or open hole even with changes in temperature in the wellbore.
[0013] In a variation of this embodiment, the element 14 includes at a surface 26 thereof with which the members 20 are to come in contact, a force spreading arrangement. This is because the members 20 are contemplated to be about 1 to about 2 inches in diameter meaning they are relatively small and will thus cause a significant point load on the element 14 if not used with a force spreading arrangement. At least one of the members is configured to contact the force spreading arrangement. One force spreading arrangement contemplated includes a number of traditional packer ribs, while another arrangement includes a reinforcing fabric or mesh material. Further, combinations of such force spreading arrangements are also contemplated.
[0014] Referring to FIGS. 3 and 4 , an alternate embodiment is illustrated wherein the concept discussed in connection with FIGS. 1 and 2 is applied as a backup configuration for an element in a seal configuration. One seal configuration that can benefit from the embodiment of FIGS. 3 and 4 is a swellable element 114 . Swellable elements are by nature composed of relatively soft material. Because, hereof, they are also subject to being swabbed off the mandrel on which they are mounted. Such a condition, of course, will defeat any seal the swellable material had previously created when set. As this is clearly undesirable, configurations capable of backing-up the swellable element are useful. The concept as described above employing radially moving members to support a material in loaded contact with a wall, is utilized for this backup purpose as is illustrated in FIGS. 3 and 4 .
[0015] Several members 120 are positioned at each axial end of the configuration 110 . The members 120 are actuated identically to those discussed hereinabove. Because of the mechanical backup of the backup elements 130 , the element 114 cannot be extruded easily. In addition hereto, it is further noted that the element 14 may also comprise a swellable material for additional sealing capability.
[0016] 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 seal includes a mandrel having a plurality of radially directed openings therethrough; a plurality of members disposed within the openings and radially displacable therein; and an element disposed about the mandrel and radially displacable by the plurality of members and method. |
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BACKGROUND AND SUMMARY
[0001] The present invention relates to cutting tools used to cut through soft ground or through relatively soft material that has been laid on the ground, such as asphalt roadways.
[0002] Mining, excavating, and road resurfacing operations are typically performed by forcing rotary cutting bits through the material being cut. The cutting bits are mounted on a driven support, such as a rotary drum, fixed beam, or the like to be forced through the material. A typical cutting bit comprises a hard cemented carbide tip that is brazed to the front surface of a steel shank. The shank is to be mounted in a holder by means of a retainer sleeve which permits the bit to rotate freely relative to the holder about the bit's center axis, while being restrained against axial dislodgment from the holder. Due to being freely rotatable, the tip is basically self-sharpening.
[0003] It should be understood that cutting mechanisms of the type described above have been used to cut through hard materials, such as rock and ice, in addition to cutting through softer materials such as asphalt. During the cutting of rock, the highest rate of bit wear occurs at the carbide tip, so the wear life of the bit is determined by the carbide tip. However, during the cutting of relatively softer material, such as asphalt, coal, and salt, the highest rate of wear occurs at the shank, i.e., erosion caused by cut asphalt rubbing and impacting against the shank. Thus, when cutting asphalt during a road resurfacing operation, the wear life of the cutting bit is determined by the shank.
[0004] It would be desirable to provide a cutting bit that has an increased wear life when used for cutting softer materials such as asphalt.
[0005] Disclosed in U.S. Pat. No. 4,725,098, which is incorporated by reference, is a cutting bit in which a groove is machined in a tapering side surface of the bit head closely behind a carbide tip mounted in the bit head. Hardfacing is deposited into the groove to form an erosion-resistant annular ring which can be flush with, or project slightly radially beyond, the side surface. Despite being formed of hard material, the ring will be subjected to considerable erosion by cuttings and thus will have a somewhat limited life.
[0006] U.S. patent application Ser. No. 10/058,387, filed Jan. 30, 2002, entitled Rotary Cutting Bit with Material-Deflecting Ledge, naming Kent Peay and Timothy J. Shean as inventors, which is incorporated by reference, discloses a cutting bit having a tapered side surface with a ledge projecting from the tapered surface. The ledge can be integral with the rest of the bit body or formed as a separate ring held on the body. The ledge is of sufficient diameter relative to the portion of the body above it that material cut tends to accumulate on the ledge and shields the body material underneath from erosion. However, it has been found that the ledge in such a cutting bit is highly prone to wear.
[0007] It would be desirable to provide a cutting bit with an erosion-resistant structure which has an enhanced life. It would also be desirable to provide a cutting bit that is simple to manufacture and involves relatively few manufacturing operations.
[0008] In accordance with an aspect of the present invention, a cutting bit includes a body having a front surface and a side surface, the side surface including a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, the body being no larger in diameter above the shoulder than at the shoulder, and a ring that is harder than the body attached to the body at a front surface of the shoulder.
[0009] In accordance with another aspect of the present invention, a cutting bit includes a body having a front surface and a cylindrical side surface portion, the cylindrical side surface portion including a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, and a ring that is harder than the body attached to the body at a front surface of the shoulder. A distance between the front surface and a top of the ring divided by a distance between the front surface and a bottom surface of the body is 0.15 to 0.5.
[0010] In accordance with yet another aspect of the present invention, a cutting bit includes a body having a front surface and a cylindrical side surface portion, the cylindrical side surface portion including a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, a cutting tip attached to the front surface, and a ring that is harder than the body attached to the body at a front surface of the shoulder. A diameter of a bottom of the cutting tip divided by the diameter of the body at the bottom of the cuffing tip is 0.72 to 0.95.
[0011] In accordance with yet another aspect of the present invention, a cutting bit includes a body having a front surface and a cylindrical side surface portion, the cylindrical side surface portion including a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, a cutting tip attached to the front surface, and a ring that is harder than the body attached to the body at a front surface of the shoulder. A diameter of the cutting bit divided by an outside diameter of the ring is 0.60 to 0.80.
[0012] In accordance with yet another aspect of the present invention, a cutting bit includes a body having a front surface and a side surface, the side surface including a first shoulder below the front surface and extending substantially perpendicular to a central axis of the body, the body being no larger in diameter above the first shoulder than at the first shoulder, and a second shoulder below the first shoulder, the body being no larger in diameter above the second shoulder than at the second shoulder, and a first ring and a second ring attached to the body at a front surface of, respectively, the first shoulder and the second shoulder.
[0013] In accordance with still another aspect of the present invention, a cutting tip for being attached to a cutting bit includes a base portion, a tip portion, the tip portion being generally convex in shape, and a side portion extending between the base portion and the tip portion, the side portion being generally concave in shape.
[0014] In accordance with still another aspect of the present invention, a cutting bit includes a cutting tip having a base portion, a tip portion, the tip portion being generally convex in shape, and a side portion extending between the base portion and the tip portion, the side portion being generally concave in shape and intersecting with the tip portion at a junction. The cutting bit also includes a body having a front face to which the cutting tip is attached, a bottom portion, and a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, and a ring that is harder than the body attached to the body at a front surface of the shoulder. An imaginary cone is defined by the junction and the bottom portion and the ring is disposed inside of the cone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The objects and advantages of the invention will become apparent from the following detailed description of preferred embodiments thereof in connection with the accompanying drawings in which like numerals designate like elements and in which:
[0016] FIG. 1 is a side elevational view of a rotary cutting bit according to an embodiment of the present invention;
[0017] FIG. 2 is a side elevational view of a rotary cutting bit according to an embodiment of the present invention showing an accumulation of cut material on the bit; and
[0018] FIG. 3 is a side elevational view of a rotary cutting bit according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0019] A cutting bit 21 according to an embodiment of the present invention is shown in FIGS. 1 and 2 . The cutting bit 21 includes a body 23 having a front surface 25 and a side surface 27 . The side surface 27 includes a shoulder 29 below the front surface 25 and extending substantially perpendicular to a central axis of the body. A cutting tip 31 is preferably attached to the front surface 25 , usually by brazing, the cutting tip preferably being harder than the body 23 .
[0020] A ring 33 that is preferably harder than the body 23 is attached to the body at a front surface 35 of the shoulder 29 , such as by brazing. The body 23 is preferably no larger in diameter above the shoulder 29 than at the shoulder and, preferably, at least a portion 37 of the side surface 27 of the body 23 is cylindrical, more preferably circularly cylindrical, above the shoulder 29 so that a ring having a circular inside diameter can be slid over the body to the shoulder. Because the body 23 is preferably no larger in diameter above the shoulder 29 than at the shoulder, it is not necessary to incur machining costs for machining a groove in the body. Also, the body 23 can be cold formed. The ring 33 is preferably positioned above the shoulder 29 and brazed to the body 23 in the same operation, which can minimize manufacturing costs, particularly when compared with bits wherein a groove must be formed. If desired or necessary, however, the shoulder 29 can be part of a groove in the side surface and the ring can be, for example, a split ring that is held in place by upper and lower surfaces of the groove. The ring 33 is illustrated as being a substantially circular shape, however, it will be appreciated that the ring can be any desired shape, such as hexagonal, octagonal, etc.
[0021] In the cutting bit 21 ′ shown in FIG. 3 , the body 23 ′ includes a second shoulder 39 below the first shoulder 29 . Again, the body 23 ′ is preferably no larger in diameter above the second shoulder 39 than at the second shoulder to facilitate sliding a second ring 41 over the body to the second shoulder where it is attached to the body at a front surface of the second shoulder. Again, if desired or necessary, however, the shoulder 39 can be part of a groove in the side surface and the ring 41 can be, for example, a split ring that is held in place by upper and lower surfaces of the groove.
[0022] A distance A between the front surface 25 and a top 43 of the ring 33 divided by a distance B between the front surface and a bottom surface 45 of the body is preferably 0.15 to 0.5. It is intended that material being cut will accumulate on the ring 33 and the material will prevent erosion of the body 23 between the ring and the cutting tip 31 by deflecting further material. A flange 47 , which is preferably integral with the body, is preferably provided at the bottom of the body 23 . Cut material tends to accumulate on the flange 47 in a manner similar to the manner in which material accumulates on the ring 33 .
[0023] In the past, a wear pattern between a cutting tip and a bottom flange on a body would tend to approximate the “golf tee” shape shown by the dotted line X in FIG. 2 . It has been found that providing the ring 33 in a region that would ordinarily be subject to significant erosion results in a substantially reduced volume loss of material from the body 23 and tends to approximate the double “golf tee” shape shown as the shaded area Y in FIG. 2 . While it is desirable to prevent body wear, it is also desirable to ensure that the ring 33 is at a sufficient distance from the cutting tip 31 to avoid a dulling of the cutting action, which can be achieved by keeping the relationship between distance A and distance B in the range of 0 . 15 to 0 . 5 . If a second shoulder 39 and ring 41 are provided as in FIG. 3 , it is preferred that a distance A′ between the front surface 25 and a top 49 of the second ring 41 divided by the distance B between the front surface and a bottom surface 45 of the body is, as with the first ring 33 , 0.15 to 0.5. This tends to place both the first ring 33 and the second ring 41 in what would otherwise be a region of maximum erosion on the body 23 .
[0024] A diameter C of the cutting tip 31 divided by a diameter D of the body 23 at the bottom of the cutting tip is preferably 0.72 to 0.95. The front surface 25 is preferably recessed to define a dam wall 51 in which the cutting tip 31 is attached by brazing. Purposes of the dam wall 49 include preventing brazing liquid from flowing out from between the cutting tip 31 and the front surface 25 and acting as a stress reliever when the body 23 cools off. As C/D becomes closer to 1, the thickness of the dam wall 49 is reduced and less material is needed to form the body 23 . As C/D moves from 1 toward 0, the body 23 has more material and its useful life span tends to approach that of the cutting tip 31 made of harder material.
[0025] The diameter C of the cutting tip 31 divided by an outside diameter E of the ring is preferably 0.60 to 0.80. As seen in FIGS. 1-3 , the cutting tip 31 preferably has a bottom surface 52 that is brazed to the front surface 25 inside the dam wall 49 , a concave surface portion 53 extending upwardly to a break point 55 , and a tip portion 57 that is generally convex. As seen in FIGS. 2 and 3 , an imaginary cone 59 extends through a point 61 on the outer edge of the flange 47 and the break point 55 to a point 63 above the tip portion 57 along the center axis of the body 23 . It has been found desirable to keep all points on the cutting bit 21 , including points on the ring 33 , inside or at least substantially inside of this cone 59 . Points extending outwardly beyond the cone tend to be too vulnerable to erosion. By keeping C/E in the range of 0.60 to 0.80, particularly when A/B is 0.15 to 0.50 and C/D is 0.72 to 0.95, the outermost point on the ring 33 tends to fall on or inside of the cone 59 and is less subject to wear. The relationships described above in connection with the cutting bit having only the ring 33 are preferably also true for bits having two or more rings, e.g., the bit 21 ′ including the ring 41 shown in FIG. 3 .
[0026] Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departing from the spirit and scope of the invention as defined in the appended claims. | A cutting bit includes a body having a front surface and a side surface, the side surface including a shoulder below the front surface and extending substantially perpendicular to a central axis of the body, and a ring that is harder than the body attached to the body at a front surface of the shoulder. Wear life of the cutting bit is enhanced by maintaining particular dimensional relationships regarding the position of the ring on the body, and the diameter of portions of the body. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to devices for drilling and boring through subterranean formations. More specifically, this invention relates to polycrystalline diamond compacts (“PDCs”), also known as cutting elements or diamond inserts, which are intended to be installed as the cutting element of a drill bit to be used for boring through rock in any application, such as oil, gas, mining, and/or geothermal exploration, requiring drilling through geological formations. Still more specifically, this invention relates to polycrystalline diamond inserts which have a surface topography formed integral to an otherwise spherical, conical, or other uniform geometric shape, to increase stress at the insert/rock interface, thereby inducing the rock to fail while requiring the expenditure of less overall energy and introducing little, if any, additional internal stresses to the insert.
[0003] 2. Description of Related Art
[0004] Three types of drill bits are most commonly used for penetrating geologic formations. These are: (1) percussion bits; (2) rolling cone bits, also referred to as rock bits; and (3) drag bits, or fixed cutter rotary bits. Each type of bits may employ polycrystalline diamond inserts as the primary cutting device.
[0005] In addition to the drill bits discussed above, polycrystalline diamond inserts may also be used with other down hole tools, including but not limited to: reamers, stabilizers, and tool joints. Similar devices used in the mining industry may also use this invention.
[0006] Percussion bits penetrate through subterranean geologic formations by an extremely rapid series of impacts. The impacts may be combined with a simultaneous rotations of the bit. An exemplary percussion bit is shown in FIG. 1 b . The reader is directed to the following list of related art patents for further discussion of percussion bits.
[0007] Rolling cone bits currently make up the largest number of bits used in drilling geologic formations. Rolling cone bits have as their primary advantage the ability to penetrate hard geologic formations while being generally available at a relatively low cost. Typically, rolling cone bits operate by rotating three cones, each oriented substantially transverse to the bits axis and in a triangular arrangement, with the narrow end of each cone facing a point in the direct center of the bit. An exemplary rolling cone bit is shown in FIG. 1 a.
[0008] A rolling cone bit cuts through rock by the crushing and scraping action of the abrasive inserts embedded in the surface of the rotating cone. These abrasive inserts are generally composed of cemented tungsten carbide, but may also include polycrystalline diamond coated cemented tungsten carbide, where increased wear performance is required.
[0009] The primary application of this PDC invention is currently believed to be in connection with percussion and rolling cone bits, although alternative embodiments of this invention may find application in connection with other drilling tools.
[0010] A third type of bit is the drag bit, also known as the fixed cutter bit. An example of a drag bit is shown in FIG. 2. The drag bit is designed to be rotated about its longitudinal axis. Most drag bits employ PDCs which are brazed into the cutting blade of the bit. The PDCs then shear the rock as the bit is rotated about its longitudinal axis.
[0011] While it is expected that this invention will find primary application in percussion and rolling cone bits, some use in drag bits may also be feasible.
[0012] A polycrystalline diamond compact (“PDC”), or cutting element, is typically fabricated by placing a cemented tungsten carbide substrate into a refactory metal container (“can”) with a layer of diamond crystal powder placed into the can adjacent to one face of the substrate. The can is then covered. A number of such can assemblies are loaded into a high pressure cell made from a soft ductile solid material such as pyrophyllite or talc. The loaded high pressure cell is then placed in an ultra-high pressure press. The entire assembly is compressed under ultra-high pressure and temperature conditions. This causes the metal binder from the cemented carbide substrate to become liquid and to “sweep” from the substrate face through the diamond grains and to act as a reactive liquid phase to promote the sintering of the diamond grains. The sintering of the diamond grains causes the formation of a polycrystalline diamond structure. As a result the diamond grains become mutually bonded to form a diamond mass over the substrate face. The metal binder may remain in the diamond layer within the pores of the polycrystalline structure or, alternatively, it may be removed via acid leeching and optionally replaced by another material forming so-called thermally stable diamond (“TSD”). Variations of this general process exist and are described in the related art. This detail is provided so the reader may become familiar with the concept of sintering a diamond layer onto a substrate to form a PDC insert. For more information concerning this process, the reader is directed to U.S. Pat. No. 3,745,623, issued to Wentorf Jr. et al., on Jul. 7, 1973.
[0013] Existing PDCs often exhibit durability problems in cutting through tough geologic formations, where the diamond working surface may experience high but transient stress loads. Under such conditions, existing PDCs have a general tendency to crack, spall, and break. Similarly, existing PDCs are relatively weak when placed under high loads from a variety of angles. These problems of existing PDCs are further exacerbated by the dynamic nature of both normal and torsional loading during the drilling process, during which the bit face moves into and out of contact with the uncut material forming the bottom of the well bore.
[0014] For optimal performance, the interface between the diamond layer and the tungsten carbide substrate must be capable of sustaining the high residual stresses that arise from thermal expansion and bulk modulus mismatches between the two materials. These differences create high residual stress at the interface as the materials are cooled from the high temperature and pressure process. Residual stress can be deleterious to the life of the PDC cutting elements, or inserts, during drilling operations, when high tensile stresses in the substrate or diamond layer may cause fracture, spalling, or complete delamination of the diamond layer from the substrate.
[0015] Typical prior PDCs have a relatively thin diamond layer, generally between 0.020 and 0.040 inches in thickness. The cylinder of carbide to which the diamond layer is attached is generally at least three times thicker than the diamond layer.
[0016] Diamond is used as a drilling material primarily because of its extreme hardness and abrasion resistance. However, diamond also has a major drawback. Diamond, as a cutting material, has very poor toughness, that is, it is very brittle. Therefore, anything that further contributes to reducing the toughness of the diamond, substantially degrades its durability.
[0017] A number of other approaches and applications of PDCs are well established in related art. The applicant includes the following references to related art patents for the reader's general familiarization with this technology.
[0018] U.S. Pat. No. 4,109,737 describes a rotary drill bit for rock drilling comprising a plurality of cutting elements mounted by interference-fit in recesses in the crown of the drill bit.
[0019] U.S. Pat. No. 4,604,106 reveals a composite polycrystalline diamond compact comprising at least one layer of diamond crystals and precemented carbide pieces which have been pressed under sufficient heat and pressure to create a composite polycrystalline material wherein polycrystalline diamond and the precemented carbide pieces are interspersed in one another.
[0020] U.S. Pat. No. 4,694,918 describes an insert that has a tungsten carbide body and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and the remaining layers adjacent to the polycrystalline diamond layer are transition layers containing a composite of diamond crystals and precemented tungsten carbide, the composite having a higher diamond crystal content adjacent to the polycrystalline diamond layer and a higher precemented tungsten carbide content adjacent to the tungsten carbide layer.
[0021] U.S. Pat. No. 4,858,707 describes a diamond insert for a rotary drag bit consists of an insert stud body that forms a first base end and a second cutter end.
[0022] U.S. Pat. No. 4,997,049 describes a tool insert having a cemented carbide substrate with a recess formed in one end of the substrate and having abrasive compacts located in the recesses and bonded to the substrate.
[0023] U.S. Pat. No. 5,154,245 relates to a rock bit insert of cemented carbide for percussive or rotary crushing rock drilling. The button insert is provided with one or more bodies of polycrystalline diamond in the surface produced by high pressure and high temperature in the diamond stable area. Each diamond body is completely surrounded by cemented carbide except the top surface.
[0024] U.S. Pat. No. 5,217,081 relates to a rock bit insert of cemented carbide provided with one or more bodies or layers of diamond and/or cubic boron nitride produced at high pressure and high temperature in the diamond or cubic boron nitride stable area. The body of cemented carbide has a multi-structure containing eta-phase surrounded by a surface zone of cemented carbide free of eta-phase and having a low content of cobalt in the surface and a higher content of cobalt next to the eta-phase zone.
[0025] U.S. Pat. No. 5,264,283 relates to buttons, inserts and bodies that comprise cemented carbide provided with bodies and/or layers of CVD- or PVD-fabricated diamond and then high pressure/high temperature treated in the diamond stable area.
[0026] U.S. Pat. No. 5,304,342 describes a sintered product useful for abrasion- and impact-resistant tools and the like, comprising an iron-group metal binder and refractory metal carbide particles.
[0027] U.S. Pat. No. 5,335,738 relates to a button of cemented carbide. The button is provided with a layer of diamond produced at high pressure and high temperature in the diamond stable area. The cemented carbide has a multi-phase structure having a core that contains eta-phase surrounded by a surface zone of cemented carbide free of eta-phase.
[0028] U.S. Pat. No. 5,370,195 describes a drill bit having a means for connecting the bit to a drill string and a plurality of inserts at the other end for crushing the rock to be drilled, where the inserts have a cemented tungsten carbide body partially embedded in the drill bit and at least two layers at the protruding drilling portion of the insert. The outermost layer contains polycrystalline diamond and particles of carbide or carbonitride.
[0029] U.S. Pat. No. 5,379,854 discloses a cutting element which has a metal carbide stud with a plurality of ridges formed in a reduced or full diameter hemispherical outer end portion of said metal carbide stud. The ridges extend outwardly beyond the outer end portion of the metal carbide stud. A layer of polycrystalline material, resistant to corrosive and abrasive materials, is disposed over the ridges and the outer end portion of the metal carbide stud to form a hemispherical cap.
[0030] U.S. Pat. No. 5,544,713 discloses a cutting element with a metal carbide stud that has a conic tip formed with a reduced diameter hemispherical outer tip end portion of said metal carbide stud. A corrosive and abrasive resistant polycrystalline material layer is also disposed over the outer end portion of the metal carbide stud to form a cap, and an alternate conic form has a flat tip face. A chisel insert has a transecting edge and opposing flat faces, which chisel insert is also covered with a polycrystalline diamond compact layer.
[0031] U.S. Pat. No. 5,624,068 describes buttons, inserts and bodies for rock drilling, rock cutting, metal cutting and wear part applications, where the buttons or inserts or bodies comprise cemented carbide provided with bodies and/or layers of CVD- or PVD-fabricated diamond and then HP/HT treated in a diamond stable area.
[0032] Each of the aforementioned patents and elements of related art is hereby incorporated by referenced in its entirety for the material disclosed therein.
SUMMARY OF THE INVENTION
[0033] In drill bits which are used to bore through subterranean geologic formations, it is desirable to provide an insert which has increased durability. This invention provides this increased durability by increasing the diamond layer thickness to decrease the spalling failure of the diamond layer from the non-planar upper surface of the insert and to reduce the residual stresses within the insert, thereby permitting the insert to withstand greater service loads.
[0034] Therefore, it is an object of this invention to improve cutter durability by increasing the thickness of the diamond layer.
[0035] It is a further object of this invention to improve cutter durability by providing a diamond layer which provides full cutter surface coverage.
[0036] It is a further object of this invention to provide a cutter with improved ability to resist spalling failure of the diamond layer.
[0037] It is a further object of this invention to provide a cutter which is capable of withstanding greater service loads.
[0038] These and other objectives, features and advantages of this invention, which will be readily apparent to those of ordinary skill in the art upon review of the following drawings, specification, and claims, are achieved by the invention as described in this application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] [0039]FIG. 1 a depicts an exemplary related art roller cone earth boring bit.
[0040] [0040]FIG. 1 b depicts an exemplary related art percussion bit.
[0041] [0041]FIG. 2 depicts an exemplary related art drag or fixed cutter bit.
[0042] [0042]FIG. 3 depicts a preferred embodiment of the invention showing a full diamond cap.
[0043] [0043]FIG. 4 depicts a preferred embodiment of the invention showing an increased diamond layer thickness.
[0044] [0044]FIG. 5 depicts a preferred embodiment of the invention showing an increased diamond layer thickness in the center of the insert.
[0045] [0045]FIG. 6 depicts a preferred embodiment of the invention showing an increased diamond layer thickness in the periphery of the insert.
[0046] [0046]FIG. 7 depicts a preferred embodiment of the invention showing a full diamond cap on a generally conically shaped insert.
[0047] [0047]FIG. 8 depicts a preferred embodiment of the invention showing an increased diamond layer thickness on a generally conically shaped insert.
[0048] [0048]FIG. 9 depicts a preferred embodiment of the invention showing an increased diamond layer thickness in the center of a generally conically shaped insert.
[0049] [0049]FIG. 10 depicts a preferred embodiment of the invention showing an increased diamond layer thickness in the periphery of a generally conically shaped insert.
DETAILED DESCRIPTION OF THE INVENTION
[0050] This invention is intended for use in cutting tools, most typically roller cone bits, as shown in FIG. 1 a , and percussion bits, as shown in FIG. 1 b . The typical rolling cone bit 101 includes three rotating cones 102 , 103 , 104 . Each rotating cone 102 , 103 , 104 has a plurality of cutting teeth 107 . Each insert (also known as a drill insert, compact or PDC) is pressed into the drill bit such that the diamond surface is exposed outside the bit. FIG. 1 b shows a standard percussion bit 109 with cemented carbide button drill inserts 108 , for percussion rock drilling. The diamond coated inserts of this invention can be substituted for the carbide button inserts 108 shown in FIG. 1 b.
[0051] [0051]FIG. 2 depicts the top view of an example of a typical drag bit 201 . A number of inserts, which also could be of the type described in this invention are shown 201 a - t arranged in rows emanating in a generally radial fashion from the approximate center 205 of the bit. It is expected by the inventor that the inserts of this invention could be used on rolling cone, percussion and drag bits of virtually any configuration.
[0052] In each embodiment of this invention the insert is composed of essentially two materials: polycrystalline diamond, which covers the cutting surface of the insert; and tungsten carbide. The tungsten carbide region is the area of the insert that is brazed or pressed into the bit body, while the polycrystalline diamond region is the area of the insert that comes in contact with the geologic formation during the drilling operation. In the present invention, the quantity of diamond in the polycrystalline diamond layer is significantly greater than used in prior art inserts. The present invention also has a non-linear, hemispherical or conical shape and is designed to cover the entire cutting surface of the insert. In some embodiments of the invention the polycrystalline diamond layer interfaces with the tungsten carbide region using a generally flat interface, a generally convex interface, an extension of diamond into the tungsten carbide region, and/or an extension of the tungsten carbide into the diamond region. Each interface has its own advantages and applications. Although the interfaces between the diamond region and the substrate regions are shown as generally smooth, it would also be possible to include in the interface a variety of mechanical modifications (e.g., ridges, undulations or dimples, or chemical modifications to enhance both the adhesion between the regions, as well as the transfer of stress between the diamond region and the substrate region. The polycrystalline diamond regions of the present invention are thicker than typically used because a thicker diamond layer provides a greater insert life. As the drill is operated the diamond region of the insert comes into direct physical contact with hard rock. The polycrystalline diamond regions of the various embodiments of the present invention are all essentially symmetrical around the center axis of the insert. This symmetry permits the installation of the insert without regard to the bit face.
[0053] The inserts, as described in this invention, although typically constructed with polycrystalline diamond on a tungsten carbide substrate, can, alternatively, use other materials, such as cubic boron nitride or some other superabrasive material in place of the polycrystalline diamond. Similarly, titanium carbide, tantalum carbide, vandium carbide, niobium carbide, hafnium carbide, or zirconium carbide can be used in place of the tungsten carbide for the substrate. Such superabrasive materials and substrate materials suitable for use in inserts are well known in the art.
[0054] Typically, the inserts of this invention are formed by sintering the diamond layer under high temperature and high pressure conditions to the substrate, using a metal binder or reactive liquid phase such as cobalt. The substrate may be brazed or otherwise joined to an attachment member such as a stud or to a cylindrical backing element to enhance its affixation to the bit face. The cutting element may be mounted to a drill bit either by press-fitting or otherwise locking the insert into a receptacle on a steel-body drag bit, percussion bit or roller cone bit, or by brazing the insert substrate (with or without cylindrical backing) directly into a preformed pocket, socket or other receptacle on the face of a bit body, as on a matrix-type bit.
[0055] An insert, as described in this invention, is preferably fabricated by placing a preformed cemented carbide substrate into a container or cartridge with a layer of diamond crystals or grains loaded into the cartridge adjacent to one face of the substrate. A number of such cartridges are then loaded into an ultra-high pressure press simultaneously. Next, the substrates and adjacent diamond crystal layers are subjected to ultra-high temperature and ultra-high pressure conditions. Such ultra-high pressure and ultra-high temperature conditions cause the metal binder from the substrate body to become liquid and to sweep from the region behind the substrate face next to the diamond layer, through the diamond grains and then to act as a reactive liquid phase to promote a sintering of the diamond grains thereby forming the polycrystalline diamond structure. As a result, the diamond grains become mutually bonded together forming a diamond mass over the substrate face. This diamond mass is also bonded to the substrate face. Alternatively, the diamond layer may be formed as above, but separately from the substrate, and may be subsequently bonded to the substrate material by brazing with a tungsten or titanium-base braze. Yet another alternative method is to deposit the diamond layer on the substrate by chemical vapor deposition (CVD) processing. The metal binder may remain in the diamond layer within the pores existing between the diamond grains or may be removed and optionally replaced by another material, as known in the art, to form a so-called thermally stable diamond. Where the binder is removed by leaching a diamond table is formed with silicon, or alternatively another material having a coefficient of thermal expansion similar to that of diamond. Variations of this general process exist in the art, but this detail is provided so that the reader will understand the concept of sintering a diamond layer onto a substrate on order to form a cutter or insert.
[0056] In a case of the present invention, the desired surface shape of the diamond layer is achieved by utilizing preformed cans. Alternatively, the surface shape can be formed by grinding or even through the use of etching, EOM, EDG, etc.
[0057] Eight examples of the inventive insert design are now described. Further modifications may be made without departing from the essential nature of the invention and such modifications should be considered to fall within the scope of this patent.
[0058] [0058]FIG. 3 depicts the top 301 and section 302 view of a single preferred embodiment of the invention. It can be seen that inserts of this invention are generally cylindrical in shape, with a generally hemispherical diamond surface 306 , the apex of which is at the center axis 307 of the insert. This diamond insert is composed of a layer of polycrystalline diamond 303 bonded to a tungsten carbide substrate 304 . The polycrystalline diamond layer 303 serves as the cutting surface. The interface region 305 is shown where the polycrystalline diamond layer 303 is joined to the substrate 304 . In this embodiment of the invention the interface region 305 is essentially flat. Alternatively, the interface region can have an irregular geometry imposed on it.
[0059] [0059]FIG. 4 depicts the top 401 and section 402 view of a second embodiment of the invention. Again, the insert is generally cylindrical in shape, with a generally hemispherical diamond surface 406 . Alternatively, the apex of the hemisphere could be offset from the center of the insert. This diamond insert is composed of a layer of polycrystalline diamond 403 bonded to a tungsten carbide substrate 404 . The polycrystalline diamond layer 403 serves as the cutting surface. The interface region 405 is shown where the polycrystalline diamond layer 403 is joined to the substrate 404 . In this embodiment of the invention the interface region 405 is curved with the apex 407 of the curve at the center axis 408 of the insert. Alternatively, the interface region 405 may be positioned such that the diamond layer is relatively thinner or relatively thicker.
[0060] [0060]FIG. 5 depicts the top 501 and the section 502 view of another embodiment of the invention. Again, the insert is generally cylindrical in shape, with a generally hemispherical diamond surface 506 . This diamond insert is composed of a layer of polycrystalline diamond 503 bonded to a tungsten carbide substrate 504 . The polycrystalline diamond layer 503 serves as the cutting surface. The interface region 505 is shown as the region where the polycrystalline diamond layer 503 is joined to the substrate 504 . In this embodiment of the invention the interface region 505 includes a trough 507 in the substrate 504 in which the diamond layer 503 extends. This trough 507 intersects and runs perpendicular to the center axis 508 of the insert. Alternatively, the trough 507 can be revolved about the center axis 508 of the insert.
[0061] [0061]FIG. 6 depicts the top 601 and the section 602 view of another embodiment of the invention. Again, the insert is generally cylindrical in shape, with a generally hemispherical diamond surface 606 . This diamond insert is composed of a layer of polycrystalline diamond 603 bonded to a tungsten carbide substrate 604 . The polycrystalline diamond layer 603 serves as the cutting surface. The interface region 605 is shown as where the polycrystalline diamond layer 603 is joined to the substrate 604 . In this embodiment of the invention, the interface region 605 includes a protrusion 607 of the substrate 604 into the polycrystalline diamond 603 layer. This protrusion 607 intersects and runs perpendicular to the center axis 608 of the insert. Alternatively, the protrusion 607 can be revolved about the center axis 608 of the insert.
[0062] [0062]FIG. 7 depicts the section 701 view of an alternative embodiment of the invention. In this embodiment the insert has a generally conic shaped polycrystalline diamond region 702 bonded to a cylinder which is the tungsten carbide substrate 703 . The polycrystalline diamond region 702 serves as the cutting surface. The interface region 704 is shown where the polycrystalline diamond region 702 is joined to the substrate 703 . In this embodiment of the invention the interface region 704 is generally flat. Alternatively, the interface region 704 may have irregularities imposed upon it. The apex of the cone 705 is formed along the center axis 706 of the insert.
[0063] [0063]FIG. 8 depicts the section 801 view of an alternative embodiment of the invention. In this embodiment the insert has a generally conic shaped polycrystalline diamond region 802 bonded to a generally conic shaped tungsten carbide substrate region 803 . The polycrystalline diamond region 802 serves as the cutting surface. The interface region 804 is shown where the polycrystalline diamond region 802 is joined to the substrate 803 . In this embodiment of the invention, the interface region 804 is of a generally conical shape. The apex of both the diamond region cone 805 and the interface region cone 806 is formed along the center axis 807 of the insert.
[0064] [0064]FIG. 9 depicts the section 901 view of an alternative embodiment of the invention. In this embodiment, the insert also has a generally conic shaped polycrystalline diamond region 902 bonded to a generally cylindrically shaped tungsten carbide substrate region 903 . The polycrystalline diamond region 902 serves as the cutting surface. The interface region 904 is shown as the area where the polycrystalline diamond region 902 is joined to the substrate 903 . In this embodiment of the invention, the interface region 904 includes a trough 905 in the substrate 903 in which the diamond region 902 extends. This trough 905 intersects and runs perpendicular to the center axis 906 of the insert. Alternatively, the trough 905 can be revolved about the center axis 906 of the insert.
[0065] [0065]FIG. 10 depicts the section 1001 view of an alternative embodiment of the invention. In this embodiment, the insert also has a generally conic shaped polycrystalline diamond region 1002 bonded to a generally cylindrically shaped tungsten carbide substrate region 1003 . The polycrystalline diamond region 1002 serves as the cutting surface. The interface region 1004 is shown where the polycrystalline diamond region 1002 is joined to the substrate 1003 . In this embodiment of the invention, the interface region 1004 includes a protrusion 1005 of the substrate 1003 into the polycrystalline diamond 1002 layer. This protrusion 1005 intersects and runs perpendicular to the center axis 1006 of the insert. Alternatively, the protrusion 1005 can be revolved about the center axis 1006 of the insert.
[0066] Alternative embodiments of the invention employing a combination of one or more of the features of the foregoing inserts should be considered within the scope of this invention.
[0067] The described embodiments are to be considered in all respects only as illustrative of the current best mode of the invention known to the inventor at the time of filing the patent application, and not as restrictive. Although several of the embodiments shown here include a trough or protrusion in the interface region, interface region geometry is not intended to be limited to a single trough or protrusion or to a particular interface region shape. The scope of this invention is, therefore, indicated by the appended claims rather than by the foregoing description. All devices which come within the meaning and range of equivalency of the claims are to be embraced as within the scope of this patent. | A cutting element, or insert, is provided for use with drills used in the drilling and boring of subterranean formations. This new insert has improved wear characteristics while maximizing the manufacturability and cost effectiveness of the insert. This invention accomplishes these objectives by employing a superabrasive diamond layer of increased depth and by making use of diamond layer surface shape that is generally convex. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates in general to mineral recovery wells, and in particular to an apparatus and method for supporting a tensioned tubular assembly.
[0003] 2. Brief Description of Related Art
[0004] Tubular members such as wellbore risers are often placed under tension. A riser, for example, can extend from a subsea wellhead upward to a drilling platform. It is often necessary to place a certain amount of tension on the riser. The tension can be applied by, for example, latching the riser into place on the wellhead, and then drawing it upward through an opening in a drilling platform until the riser is subject to the desired amount of tension. The riser can then be latched into place by a latching mechanism on the drilling platform to maintain the tension. Conventional methods of tensioning and latching a riser have numerous problems.
[0005] For example, it can be difficult to center the riser assembly within the opening of the drilling platform or within the latching mechanism. If the riser is offset within the opening, then it can be difficult, or even unsafe, to latch the riser in position with conventional latching mechanisms. Those conventional latching mechanisms can include segmented dogs that can engage the riser assembly. It is difficult to engage in the riser with segmented dogs when the riser is offset. Engaging the riser with the segmented dogs can also require personnel to be present on the drilling platform to operate heavy equipment. Safety can be an issue any time personnel are operating heavy equipment, especially in close proximity to a tensioned riser. Furthermore, heavy equipment must be lifted and operated in order to engage the riser with the segmented dogs, which can further present safety issues. Additionally, the conventional latching mechanisms have a large number of moving parts. Those moving parts can be expensive and can have mechanical failures.
[0006] Another problem with conventional latching techniques is that they are not able to prevent upward movement of the riser assembly. Under some circumstances, risers can be subjected to upward force that can cause the riser assembly to thrust upward from the drilling platform. Conventional risers are not suited to provide downward support to prevent a riser assembly from thrusting upward.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention include a method and apparatus for applying tension to a tubular conductor, such as a riser for subsea well drilling operations. Specifically, a tension latch can sit atop a conductor, such as a riser assembly, or on a deck of an offshore platform. As the riser is made up, all segments of the riser system must pass through a rotary or a spider. One constraint for the riser is that the greatest outer diameter (“OD”) on the riser must be less than the inner diameter (“ID”) of the spider. The same limitation is also present at the tensioner; the largest OD must be able to pass through the tension latch. In the past the tension latch is a segmented ring that pivots backwards inside a housing and leaves an opening to allow the largest member of the riser to pass. Once the riser has moved to the proper location, then the segmented latches can be rotated into position and made up to complete the tensioner system. The segmented latch design in the past has also presented some make up obstacles, such as making up with an offset on the riser due to loading.
[0008] In embodiments of the present design, the latch ring includes two separate components. There is a lower latch that can be a segmented ring design that is configured as a single piece component. The upper latch is a solid ring latch that is run on the tension joint. As the riser is run, the lower latch ring and housing assembly are retracted by a spider like device so it does not interfere with the riser running. This allows the riser to pass with no ID limitations once it is through the spider. The tension joint is run with a solid piece latch pre-installed at a pre-determined position. Once the riser is close to the landed position the lower latch ring and housing assembly is actuated into place by, for example, a hydraulic powered system (similar to a spider) and fixed in the final position. A c-ring is installed on the upper latch ring, which can provide retaining force should there be an upward force on the tension latch. The lower latch ring and housing assembly can now accept the solid upper latch ring, as it is lowered into place. As the upper latch lands out on the lower latch it compresses the c-ring; once it is fully landed the c-ring will snap back inward into a groove in the lower latch. This c-ring can provide the capability to support an upward force.
[0009] The method of operating the system can include inserting a c-ring into a solid upper tension latch and installing the upper tension latch on the tension joint (prior to welding). The tension joint can be passed down through the tensioner with a centralizer ring attached to keep the tension joint (riser) in the correct position. Once the exact location of the upper tension latch is determined, the latch can be rotated on the threads on the tension joint to determine the exact position and be brought to that position. The upper tension latch outer diameter is small enough to pass through the rotary or spider. The lower tension latch is actuated, for example hydraulically, outward while the riser is being (using a device similar to a spider), which allows the riser to pass through easily. Once the tension joint is in the appropriate location the upper tension latch is in place), the lower tension latch is actuated into the proper position. The geometry of the upper tension latch allows it to self-center as it is lowered over the lower tension latch, regardless of initial offset. This will centralize even when the tension joint is at the maximum offset allowed by the tension ring. The upper tension latch lowers over the lower tension latch and compresses the c-ring attached to the upper tension latch and the upper tension latch lands out on the lower tension latch. At the same time, the c-ring snaps into a groove in the lower tension latch. The c-ring provides the necessary area to prevent axial movement of the upper latch, relative to the lower latch, in response to an upward force in the tension joint.
[0010] The “Self centering” feature makes installation and running the equipment easier and safer. For example, embodiments of the design do not include dogs or dog teeth to center and engage the riser and, thus, do not require rig personnel to be in the immediate vicinity of the latch and riser during tensioning. The operation is also safer because there is no need for manual labor to move dogs and the lower tension latch is not actuated hydraulically when the riser is under tension. In embodiments having hydraulic actuators, they can be actuated before the riser is placed under tension. Additionally, the self-centering function can center the upper latch and riser more quickly and more consistently than conventional tensioning systems.
[0011] Furthermore, embodiments of the tension latch assembly can handle a large load if the tension joint were to generate an upward force, which was not previously possible. In addition to being safer and handling upward force, embodiments of the tension latch assembly use fewer parts than conventional latch designs.
[0012] An embodiment of an apparatus for providing tension to a riser includes a platform having a bore therethrough, a tubular member extending through the bore, an annular upper latch member connected to an outer diameter of the tubular member, the upper latch member having a downward facing latch recess on a bottom surface, and a retractable lower latch ring connected to the platform, the lower latch ring being movable from an open position to a latch position. The open position allowing the upper latch member to pass through and the latch position stopping downward axial movement of the upper latch member, the lower latch ring having a cylindrical guide extending upward in an axial direction and having an outer diameter that is less than an inner diameter of the latch recess when the lower latch ring is in the latch position so that the cylindrical guide can fit inside the latch recess.
[0013] Embodiments of the apparatus include a downward and inward facing tapered surface extending downward from the latch recess. The tapered surface can center the upper latch member on the lower latch ring when the cylindrical guide enters the latch recess. Embodiments can include an annular lock ring recess on each of an outer diameter surface of the cylindrical guide and an inner diameter surface of the upper latch member, and a resilient lock ring initially positioned in one of the annular lock ring recesses, the lock ring expanding to engage the other annular lock ring recess when the cylindrical guide is positioned inside the upper latch member. The resilient ring can be a c-ring. The lock ring can be initially positioned in the annular lock ring recess of the upper latch member. The resilient ring can engage the latch recess and, thus, prevent the upper latch member from moving axially upward.
[0014] In embodiments of the apparatus, the upper latch member threadingly engages the outer diameter of the riser. In embodiments, the upper tension latch is a solid member free of moving parts. Embodiments include a hydraulic actuator connected to the lower latch ring, the hydraulic actuator causing the lower latch ring to move between the open and the closed positions.
[0015] In embodiments of a method for tensioning a riser, the method includes the steps of connecting an upper tension latch to a tension joint, the tension latch having a downward facing annular receptacle and the tension joint being a segment of a riser assembly; passing the tension joint downward through an inner diameter of a lower latch assembly to determine the desired amount of tension, then tensioning the riser assembly by drawing the tension joint upward through the lower latch assembly; moving the lower latch assembly from an open position to a latch position, the inner diameter of the lower latch assembly being less than an outer diameter of the upper tension latch when the lower latch assembly is in the latch position; and lowering the tension joint onto the lower latch assembly until a portion of the lower latch assembly occupies the annular receptacle and engages a downward facing surface at the uppermost portion of the annular receptacle to prevent further downward movement of the lower latch assembly.
BRIEF DESCRIPTION OF DRAWINGS
[0016] So that the manner in which the features, advantages and objects 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 a preferred embodiment of the invention and is therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
[0017] FIG. 1 is an environmental view of an embodiment of the tension latch assembly.
[0018] FIG. 2 is a partial environmental view of the tension latch assembly of FIG. 1 , showing the latch support and lower latch in the closed position.
[0019] FIG. 3 is a partial sectional side view of the tension latch assembly of FIG. 1 .
[0020] FIG. 4 is a partial sectional side view of the tension latch assembly of FIG. 1 showing an offset condition.
[0021] FIG. 5 is a partial sectional side view of the tension latch assembly of FIG. 1 showing partial engagement of the lower and upper latch assemblies.
[0022] FIG. 6 is a partial sectional side view of the tension latch assembly of FIG. 1 showing the upper latch landed on and lockingly engaged to the lower latch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The present invention will now be described more fully hereinafter with reference to the accompanying drawings which illustrate embodiments of the invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and the prime notation, if used, indicates similar elements in alternative embodiments.
[0024] Referring to FIG. 1 , a tension latch system 100 is shown. Tension latch system 100 can be used in a variety of applications requiring tension to be applied to a tubular member including, for example, the application of subsea well drilling operations. As shown in FIG. 1 , tension latch system 100 is used to apply tension to riser 102 , which is a riser extending from a wellhead (not shown) at the ocean floor up to a drilling platform 104 and through bore 106 of drilling platform 104 . Riser 102 , which can be conventional, is an assembly made up of tubular riser segments. Tension joint 108 is installed as one or more segments of riser 102 . Tension joint 108 is a tubular member having threads 110 on an outer diameter surface. Upper latch 112 is installed on tension joint 108 by way of threads 114 ( FIG. 3 ) on an inner diameter surface which threadingly engage threads 110 . Upper latch 112 can, thus, be positioned anywhere along the threaded portion of tension joint 108 by rotating upper latch 112 . Other techniques can be used to engage and position upper latch 112 on tension joint 108 . For example, upper latch 112 can have a ratcheting mechanism (not shown) which can engage threads or wickers (not shown) on tension joint 108 . Upper latch 112 has an outer diameter that is smaller than the inner diameter of bore 106 so that upper latch 112 , as well as riser 102 and tension joint 108 , can pass through bore 106 .
[0025] Lower latch 116 is a segmented annular ring having segments 118 and 120 . In the embodiment shown in FIG. 1 , lower latch 116 includes two such segments 118 and 120 , each of which is semi-circular. Embodiments can have a greater number of segments which can be assembled to create an annular lower latch assembly. Lower latch 116 is connected to latch support 122 . Latch support 122 can be any structure and mechanism that can support segments 118 and 120 as they move between the open and latched position. In the open position, segments 118 and 120 are spaced apart such that upper latch 112 can pass between segments 118 and 120 . Segments 118 and 120 move linearly or pivotally between the open and the latch position. The movement can be in response to, for example, a hydraulic actuator, an electric actuator, or any other type of mechanism sufficient to move latch support 122 and latch segments 118 and 120 .
[0026] Referring now to FIG. 2 , lower latch 116 is shown in the latched position. In the latched position, the segments of latch support 122 have moved toward each other so that segments 118 and 120 are brought together to form lower latch 116 . Latch 116 has an inner diameter 126 , which is larger than the outer diameter of riser 102 so that riser 102 can extend through latch 116 when latch 116 is in the latch position.
[0027] Referring now to FIG. 3 , lower latch 116 has a guide 128 extending upward to define the uppermost portion of lower latch 116 . Guide 128 is a cylinder and having the same inner diameter 126 as the rest of tower latch 116 . Top surface 130 defines the uppermost portion of guide 128 . Top surface 130 can be generally flat or can have a profile. Shoulder 132 , the transition from the outer diameter of guide 128 to top surface 130 , has an upward and outward facing tapered surface. Guide 128 is shown as a cylindrical guide having a solid cylindrical body, but other configurations of cylindrical guide can be used guide upper latch 112 into concentric alignment with lower latch 116 . For example, a plurality of posts or a plurality of arc-shaped segments (not shown) can be spaced apart around lower latch 116 , each of the posts or segments (not shown) extending upward from lower latch 116 and having a generally vertical portion for engaging upper latch 112 .
[0028] The surface of outer diameter 134 of lower latch 116 includes an annular groove 136 , which can be located somewhere between the upper and lower boundaries of guide 128 . The body of lower latch 116 also includes support groove 142 . As shown in FIG. 3 , support groove 142 is an upward facing annular groove. Support groove 142 has a v-shaped cross section so that the axial depth increases from the deepest part of the groove when moving radially inward and radially outward.
[0029] Still referring to FIG. 3 , upper latch 112 has a generally frustoconical shape with an outer surface that generally faces outward and upward, and has a bore therethrough. As discussed above, threads 114 are located on the inner surface of the bore. Upper latch 112 is not limited to a frustoconical shape. The outer surface can be, for example, cylindrical, octagonal, or a variety of other profiles. In embodiments, upper latch 112 can be a solid member free of moving parts.
[0030] Latch recess 146 faces downward from the bottom end of upper latch 112 . Latch recess 146 is a bore having a bore sidewall 148 , the diameter of which is the same is or slightly greater than the outer diameter of guide 128 . The opening of latch recess 146 includes a downward and inward facing taper 150 . In embodiments, taper 150 can extend at an angle of about 10-80 degrees relative to the axis of upper latch 112 . In embodiments, taper 150 can extend at an angle of about 30 degrees to about 60 degrees relative to the axis of upper latch 112 . In embodiments, taper 150 can extend at an angle of about 45 degrees relative to the axis of upper latch 112 . Outward taper 152 faces downward and outward and is located at the bottom of upper latch 112 , proximate to taper 150 . The profile of taper 150 and outward taper 152 , combined, can be an inverse of the profile of support groove 142 .
[0031] The upper portion of latch recess 146 includes a downward facing shoulder 156 . Shoulder 156 can be generally flat or can have a profile. The shape of shoulder 156 can be the inverse of the shape of top surface 130 . The axial length from the uppermost portion of taper 150 to shoulder 156 is about equal to or greater than the axial length from the uppermost portion of the inner leg of support groove 142 to top surface 130 of guide 128 . In embodiments wherein that axial length is the same, tapers 150 and 152 can land in and be supported by support groove 142 , and downward facing shoulder 156 can land on top surface 130 , when tension joint 108 lands on lower latch 116 , as best shown in FIG. 5 .
[0032] Annular lock ring recess 154 is a groove located on bore sidewall 148 , such that the diameter of lock ring recess is greater than the diameter of bore sidewall 148 . The axial height of lock ring recess 154 is approximately the same as the axial height of groove 136 . A resilient lock ring 138 is installed in groove 136 . In embodiments, lock ring 138 can be a c-ring. Lock ring 138 , in its relaxed state, has an outer diameter greater than the outer diameter of guide 128 and in inner diameter greater than the outer diameter of groove 136 . The cross-sectional width of lock ring 138 is less than or equal to the depth of groove 136 . Lock ring 138 is installed in groove 136 so that it protrudes outward from the surface of guide 128 but can be compressed into groove 136 until it is flush or nearly flush with the outer diameter surface of guide 128 . The upper and outer shoulder 1140 of lock ring 138 is a tapered surface. In some embodiments (not shown), the lock ring can initially be installed in an annular groove on the lower latch such that it expands and engages a corresponding groove on the upper latch when the upper latch lands on the lower latch.
[0033] Access ports 158 are passages from the exterior of upper latch 112 to the outer diameter surface of lock ring recess 154 . As best shown in FIG. 5 , when tension joint 108 is landed on lower latch 116 , lock ring recess 154 is axially aligned with groove 136 . When latch 112 is positioned on lower latch 116 , lock ring 138 expands outward to permit outer diameter 134 of lower latch 116 to pass into latch recess 146 . Latch 112 moves downward onto lower latch 116 until lock ring recess 154 is aligned with annular groove 136 , at which time lock ring 138 collapses inward to engage annular groove 136 . When engaging annular groove 136 , lock ring 138 still partially resides in lock ring recess 154 and, thus, prevents axial movement of latch 112 relative to lower latch 116 .
[0034] Referring to FIG. 4 , in the event that riser 102 is offset in bore 106 , lower latch 116 functions as a centralizer to center latch 112 , and thus riser 102 , as it is latched into place. FIG. 4 illustrates an offset condition. As latch 112 moves downward, taper 150 contacts shoulder 132 . Due to the angle of taper 150 , taper 150 slidingly engages the contact point of shoulder 132 , thereby forcing latch 112 into concentric alignment with lower latch 116 as latch 112 moves downward.
[0035] Referring now to FIG. 5 , as upper latch 112 is lowered onto lower latch 116 , taper 150 urges lock ring 138 inward into annular groove 136 . Upper latch 112 moves axially downward so that guide 128 of lower latch 116 enters lock recess 146 . In embodiments having other configurations of guide 128 , such as spaced apart upward extending posts or arc-shaped segments, the posts or arc-shaped segments enter lock recess 146 . Referring now to FIG. 6 , continued downward movement of latch 112 , relative to lower latch 116 , causes upper latch 112 to land on lower latch 116 . Tapers 150 and 152 land in support groove 142 . In embodiments, shoulder 156 can also land on top surface 130 . The landed surfaces prevent further downward movement of upper latch 112 relative to lower latch 116 and, thus, prevent downward movement of riser 102 relative to platform 104 . Upon landing, lock ring 138 radially expands outward to engage both lock ring recess 154 and annular groove 136 , thereby preventing upward movement of upper latch 112 relative to lower latch 116 .
[0036] Furthermore, the v-shape profile of support groove 142 reduces or eliminates lateral movement of upper latch 112 relative to lower latch 116 , thus centralizing riser 102 in bore 106 . For example, downward and inward facing taper 150 can engage support groove 142 to prevent lateral movement of riser 102 toward the axis of bore 106 , and outward taper 152 can engage support groove 142 to prevent lateral movement of riser 102 away from the axis of bore 106 . Because the interlocking surfaces are annular, they prevent lateral movement of riser 102 in any direction relative to bore 106 .
[0037] 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. | A tensioner assembly for applying tension to a tubular member, such as a riser, can include an upper latch connected to the tubular member, a platform with a bore, and a lower latch ring. After applying tension to the tubular member, the lower latch ring can be closed around the tubular member so that when the tension is released, the upper latch lands on and engages the lower latch. The assembly can include a locking mechanism that prevents axial movement of the upper latch, relative to the lower latch, after engagement. The upper latch can self-center on the lower latch as it is moved into the latching position. |
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RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 61/676,774, filed on Jul. 27, 2012, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to non-explosive mining techniques for mining operations.
[0004] 2. Description of the Related Art
[0005] Non-explosive mining techniques offer an alternative to the increasing costs associated with explosive excavation. Explosive excavation is a cyclic process requiring several steps: blast holes are drilled into a rock face, explosive charges are loaded into the blast holes, the surrounding area is evacuated, the explosives are detonated, and the area is ventilated and cleared. Explosive excavation incurs significant costs associated with security and environmental damage, such as the generation of toxic gases.
[0006] Mechanized non-explosive mining may be carried out with fewer personnel and reduce the security and environmental costs of high explosives. This approach also increases processing efficiency by allowing selective mining of the ore veins. Mechanical impact hammers can be used to excavate hard rock, but the process is slow; the hammers and support equipment are very heavy and the impact tools wear out quickly.
[0007] Another example of mechanized non-explosive mining is an impact piston water cannon, in which compressed air drives a heavy piston that impacts and pushes a quantity, or slug, of water. The water slug impacts the rock face to cause erosion and excavation. While impact piston devices have been shown to generate high pressures, their use in commercial excavation work has been limited due to the significant wear on the pistons and cylinders of the devices. Further, the mechanical system that must be maneuvered at the rock face is prohibitively bulky.
[0008] As an alternative to an impact piston cannon, a compressed water cannon designed for hard rock mining is described in “A Hydraulic Pulse Generator for Non-Explosive Excavation,” by Kolle, J. J., in Mining Engineering , July 1997, pg. 64-72, which is herein incorporated by reference in its entirety. The compressed water cannon comprises a heavy pressure vessel charged to very high pressures (100-400 MPa, or 14,500-60,000 psi). At these pressures, the water is substantially compressed and stores a considerable amount of energy. After charging, the water is discharged through a fast-opening valve, which causes the resulting pulse of water to impact the rock face. Discharge of a 100 to 400 MPa pulse onto the face of hard rock will have little or no effect in rock fragmentation. To perform rock fragmentation, the compressed water cannon nozzle must be inserted and discharged into a pre-drilled blast hole. Discharge of the pulse into the blast hole generates tensile stresses in the rock and allows effective excavation. The productivity and flexibility of this approach, called bench blasting, is limited because drilling is the most time-consuming aspect of the operation.
[0009] As reported by Mauer, W. C. in Advanced Drilling Techniques , pg. 302-348, Petroleum Publishing Inc., 1980, hyper-pressure pulses that are over 1 GPa, or 145,000 psi, have been shown to efficiently excavate hard rock by cratering, eliminating the need for a pre-drilled blast hole. Accordingly, it would be desirable to enable a compressed water cannon to be employed without the need for a pre-drilled blast hole.
SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, the problems above are addressed with a hyper-pressure water cannon. The hyper-pressure water cannon, or pulse excavator, is able to discharge fluid pulses at extremely high velocities to fracture a rock face in excavation applications. A compressed water cannon can be used to generate hyper-pressure pulses by discharging the pulse into a straight nozzle section which leads to a convergent tapered nozzle. The water cannon design is relatively compact, and the pulse generator can readily be maneuvered to cover the face of an excavation as part of a mobile mining system. As an alternative, the pulse could be generated by a propellant gun.
[0011] Hyper-pressure pulse excavation, or cratering, is an application of the water cannon that eliminates the need for drilling a blast hole. The high-velocity water pulse is discharged into a combination straight and tapered nozzle that can amplify the peak pulse pressure by a factor of 10 or more.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various aspects and attendant advantages of one or more exemplary embodiments and modifications thereto will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0013] FIG. 1A illustrates a cross-sectional schematic view of a complete hyper-pressure pulse excavator 100 including an electrical trigger, vent valve assembly 150 , pressure vessel 110 , and two-part nozzle assembly ( 120 and 132 );
[0014] FIGS. 1B-1E illustrate the hyper-pressure pulse excavator 100 in various stages of preparing to fire a water pulse;
[0015] FIGS. 2A-2C illustrate exemplary measurements for various sizes of the hyper-pressure pulse excavator 100 ;
[0016] FIGS. 3A-3C show nozzle inlet pulse measurement charts based on a 230 MPa discharge from the exemplary embodiment shown in FIG. 2A ;
[0017] FIG. 4 illustrates the process of unsteady flow acceleration of a water pulse through straight and tapered nozzle sections;
[0018] FIG. 5A-5C illustrate the hyper-pressure outlet pulse measurement charts; and
[0019] FIG. 5D shows a chart displaying an exemplary exponentially convergent tapered nozzle profile.
[0020] FIG. 5E shows a chart displaying the internal pressure profiles inside an exponentially tapered nozzle at three locations of the fluid pulse.
DETAILED DESCRIPTION
[0021] It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
[0022] FIG. 1A illustrates a schematic of an exemplary hyper-pressure pulse excavator 100 , shown after firing a water pulse. The pulse excavator 100 includes a pressure vessel 110 and a two-part nozzle assembly, which includes a straight nozzle section 120 and a tapered nozzle section 132 within a nozzle housing 130 . The pressure vessel 110 includes a supply tube 112 , a poppet sleeve 114 , a sleeve port 116 , and a poppet 118 . When poppet 118 is closed, it sits against poppet seat 119 at the end of pressure vessel 110 . When the poppet 118 is opened, or pushed away from the poppet seat 119 , the poppet 118 and poppet seat 119 together act as a dump valve, and pressurized fluid in the pressure vessel 110 is discharged into the straight nozzle section 120 . The junction of the pressure vessel 110 and the straight nozzle section 120 includes an opening connected to an air compressor 126 and a second opening connected to a metering pump 122 and a gel supply 124 . The electrical subsystem of the pulse excavator 100 includes a push button switch 170 , arm light 172 , arm switch 174 , relay switch 176 , and the solenoid valve 180 (including battery power for the solenoid).
[0023] Fluids within the hyper-pressure pulse excavator 100 build to extremely high pressures and must be discharged very quickly to effectively crater rock. Additionally, an excavating tool such as the pulse excavator 100 should not be so unwieldy and large as to prevent moving the tool around the rock face. Off-the-shelf valve systems offering suitable performance in both size and speed for such operation are typically not available. Instead, as shown in FIG. 1A , a series, or system, of cascading valves leading to the pressure vessel 110 can be used. Each subsequent stage the handles progressively larger volumes and pressures, and the final stage opens the poppet 118 in the pressure vessel 110 . While FIG. 1A shows an exemplary series of cascading valves, different types and arrangements of valves may be used to operate the poppet 118 in the pressure vessel 110 .
[0024] The series of cascading valves includes the solenoid valve 180 , the hydraulic pump return valve 146 , the pressurized water supply valve 184 , and the vent valve assembly 150 . In operation, the accumulator 140 , return tank 142 , and hydraulic pump 148 , and isolator piston 144 serve to maintain a pressure on the vent valve assembly 150 until the solenoid valve 180 can open. In the discharged state after firing, the hydraulic pump return valve 146 is open, resulting in water pressure from pressurized water supply 182 moving the isolator piston 144 to its upper position. The hydraulic pump 148 is also shown with a return tank 142 and an accumulator 140 . Additionally, the pressurized water supply valve 184 is open, and the solenoid valve 180 to the tank 178 is closed and unarmed. Additional details of the valve operation can be seen in U.S. Pat. No. 5,000,516 to Kolle, entitled “Apparatus for rapidly generating pressure pulses for demolition of rock having reduced pressure head loss and component wear,” issued Mar. 19, 1991, which is incorporated herein in its entirety.
[0025] In a preferred embodiment of the invention, the pulse excavator 100 further includes a vent valve assembly 150 . The vent valve assembly 150 includes a vent valve housing 158 with vent valve vents 160 . Although the pressurized water supply valve 184 is open, the vent valve piston 156 in the vent valve housing 158 is not pressurized to a sufficient level to tightly hold the poppet 154 against its seat 152 . The vent valve assembly 150 is connected to the supply tube 112 of the pressure vessel 110 . An ultra-high pressure pump 162 with a water inlet 164 is also coupled to the vent valve assembly.
[0026] FIG. 1B shows the system ready to fire a water, or water-based, pulse. The pressurized water supply valve 184 is closed. The hydraulic pump return valve 146 of the hydraulic pump 148 is closed, and the hydraulic pump 148 has been actuated, pressurizing the top of the isolator piston 144 with oil, water, or another fluid. The other side of the isolator piston 144 contains water. When the top of the isolator piston 144 is pressurized, the left side of the vent valve piston 156 is pressurized, causing the vent valve piston 156 to push against and hold the vent valve poppet 154 against the vent valve poppet seat 152 . The ultra-high pressure pump 162 is then actuated and used to charge the pressure vessel 110 through the supply tube 112 into the cavity between the poppet sleeve 114 and poppet 118 within the pressure vessel 110 . This pressurization pushes the poppet 118 against its seat 119 at the outlet of the pressure vessel 110 , closing the fluid path to the straight nozzle section 120 . With the poppet 118 seated against the straight nozzle section 120 , the sleeve port 116 is exposed, allowing water to flow into the pressure vessel 110 through the supply tube 112 . As more water is pumped into the pressure vessel 110 , the pressure within the pressure vessel 110 builds, typically to 100 to 400 MPa.
[0027] In parallel, the air compressor 126 may supply compressed air to the straight nozzle section 120 . This helps to empty the straight nozzle section 120 and tapered nozzle section 132 of any residual water (for example, from the previous water pulse firing). In one embodiment, a small volume of a gelled fluid 125 such as agar, polyacrylamide, or bentonite gel may be metered using the metering pump 122 from into the straight nozzle section 120 immediately below the poppet seat 119 . This precharges the straight nozzle section 120 with the gelled fluid 125 , allowing the gelled fluid 125 to be on the leading edge of the fluid pulse when the pulse excavator 100 fires. This gelled fluid may also be weighted with a substance such as salt to increase its density. The arm switch 174 electrical circuit is then armed, the air valve of the air compressor 126 is closed, and the system 100 is ready to fire.
[0028] FIG. 1C illustrates the start of the firing sequence. The push button switch 170 is closed or depressed, causing the relay switch 176 to close and the solenoid valve 180 to open. As the solenoid valve 180 opens, the isolator piston 144 moves down at constant pressure. The opening time of the solenoid valve 180 is preferably very short, such as on the order of 100 milliseconds so, but there is a limit to the opening speed of solenoid valves. The isolator piston 144 and accumulator 140 assembly give the solenoid valve 180 time to open fully by maintaining pressure on the vent valve poppet 154 before the isolator piston 144 reaches the end of its travel. As soon as the isolator piston 144 reaches the end of its travel, the left side of the vent valve piston 156 is depressurized, and the ultra-high pressure on the face of the vent valve poppet 154 causes it to open.
[0029] FIG. 1D illustrates the continuation of the firing sequence, with the vent valve poppet 154 fully open. This depressurizes the water in the supply tube 112 and the volume of water in the cavity between the poppet 118 and poppet sleeve 114 in the pressure vessel 110 . Because the section area of the poppet 118 is larger than the seal area of the poppet seat at the base of the straight nozzle section 120 , a large force lifts the poppet 114 from its seat. The poppet 118 opens very quickly, acting like a fast-opening dump valve and discharging the compressed water from the body of the pressure vessel 110 . Once the poppet 118 is open, the water contained in the pressure vessel 110 begins accelerating through the straight nozzle section 120 . As mentioned above, if gel has been metered out into the straight nozzle section 120 , the gel slug is also pushed by the accelerating water pulse. The gel slug and water slug are pushed through the straight nozzle section 120 as well as the nozzle housing 130 , as shown in FIG. 1E . The nozzle housing 130 contains a tapered nozzle section 132 , which tapers from the diameter of the opening of the straight nozzle section 120 .
[0030] Due to the unsteady flow phenomenon, the gel and water slugs are extruded though the tapered nozzle section 132 at extremely high velocities. The process of unsteady flow acceleration is illustrated in FIG. 4 . When a fluid pulse moving at uniform velocity, U o , enters a tapered nozzle, the leading edge of the pulse accelerates (U e ), while the trailing edge of the pulse slows (U b ). The velocities can be calculated for a given nozzle profile based on the principles of continuity of momentum and volume. If no gel is used, then the water will be at the leading edge of the pulse. In a preferred embodiment of the invention, the tapered section 132 is exponential.
[0031] Due to the extreme pressures generated in employing this technique, nozzle wear and fatigue of the cannon body are concern for long-term operation. The tapered nozzle section 132 is preferably fabricated from a hard erosion-resistant material such as hardened steel or carbide. This material may be held by a nozzle housing 130 made of high strength steel. The two part construction of the tapered nozzle allows the use of hard, erosion-resistant materials that may have low tensile strength. Conversely, the tapered nozzle can be fabricated from one part if a sufficiently high strength steel is used.
[0032] FIGS. 2A-2C illustrate exemplary dimensional measurements for various sizes of the hyper-pressure pulse excavator 100 . The productivity of hyper-pressure pulse excavation can be expressed in terms of specific energy, which is the ratio of the pulse energy to the volume of rock removed. Increasing the scale of the system increases efficiency substantially, since the specific energy required for breaking is inversely proportional to the rock fragment size. As described above, impact piston cannons provide a means of generating hyper-pressure pulses, but the mechanism for these devices is very bulky and generates large reaction forces. Further, as also described above, their use in commercial excavation work has been limited due to the significant wear on the pistons and cylinders of the devices. The compressed water cannon as described herein can provide the similar pressure levels more efficiently. As described above, the pulse excavator 100 uses the system of cascaded valves to build to sufficient pressure levels. In a smaller embodiment, such as the one seen in FIG. 2A , alternate valve systems, such as a hand valve or a large solenoid valve, may be used. This may allow the pulse excavator 110 to be operated with a single- or dual-level valve system. For larger embodiments, such as the ones seen in FIGS. 2B and 2C , single- or dual-level valve systems will likely not provide the performance required for operation. Additionally, the cascaded valve system allows for smaller valves to be used at the various stages, further allowing for the use of smaller batteries to actuate the solenoid valve 180 .
[0033] The specifications for the exemplary embodiment shown in FIG. 2A of the compressed water cannon for use in hyper-pressure pulse excavation are as follows:
1.8-liter internal volume; 15 kJ @ 240-MPa charge pressure; and 12.7-mm-diameter discharge nozzle.
[0037] The operating pressure of the pressure vessel 110 alone is limited by practical considerations to 100-400 MPa (14,500-60,000 psi). However, the pressure required to effectively break harder rock requires fluid pulses with stagnation pressures above 2 GPa (300,000 psi). As mentioned above, the straight nozzle section 120 and tapered nozzle section 132 are used to amplify the velocities of fluid pulses to achieve the stagnation pressures required to effectively break rock. The diameter of the straight nozzle section 120 may be equal to the diameter of the discharge valve of the pressure vessel 110 . The diameter of the straight nozzle section 120 is smaller than the diameter of the pressure vessel 110 bore—typically, around 20% to 30% of the bore is preferred, though the range could be 10% to 50%.
[0038] The length of the straight nozzle section 120 is determined by observing the discharge characteristics of the pressure vessel 110 without the nozzle section attached. FIG. 3A shows the observed stagnation pressure from a water pulse discharged from the exemplary embodiment shown in FIG. 2A (without the attached nozzle) when the pressure vessel 110 is charged to 230 MPa versus time. Note that the peak stagnation pressure is substantially less than the charge pressure of 230 MPa. Further, the rise time of the pressure release is very fast, on the order of 1-2 ms. The fast rise time is facilitated by the presence of the fast-opening dump valve, such as the poppet valve 118 . FIG. 3B shows the velocity of the pulse as a function of pulse length as calculated from the stagnation pressure profile. A uniform-velocity slug of water is needed to generate a hyper-pressure pulse in a tapered nozzle section 132 . In practice, the velocity of water exiting the cannon valve varies continuously, however a pulse of about 0.5 m length with a velocity of over 500 m/s is generated. The kinetic energy of the pulse rises linearly up to around 0.5 m and then increases at a lower rate. The velocity is slow as the valve opens, peaks after the valve is opened, and then drops as the cannon decompresses. A straight nozzle section 120 accumulates the water in the leading edge of the pulse and allows the higher-velocity fluid to catch up, forming a uniform-velocity slug. Once the slug velocity starts to drop, the slug will stretch and break up.
[0039] Based on a measurement of the discharge pressure of the pressure vessel 110 at 230 MPa, the velocity of the water pulse can be measured against the length of the pulse. To reach efficiencies, pulse velocity and length should be maximized. For the pressure vessel 110 of the exemplary embodiment shown in FIG. 2A , a pulse length of 0.5 meters was chosen based on the chart shown in FIG. 3B . The point representing the pulse length of 0.5 meters in FIG. 3B was selected as maximizing both pulse velocity and length because the pulse velocity begins to decrease more substantially after the pulse length of 0.5 meters. Accordingly, the length of the straight nozzle section 120 was set at 0.5 meters. The final volume of the straight nozzle section 120 may be preferably between 2-10% of the volume of the pressure vessel 110 .
[0040] Given a 20 inch long (i.e., roughly 0.5 meter) slug with a diameter of 0.5 inch, the tapered nozzle parameters may be determined. As mentioned above, the tapered nozzle section 132 accelerates the leading edge of the pulse to hyper velocity through unsteady flow dynamics. Given a convergent tapered nozzle 132 with an arbitrary profile, it is possible to calculate the velocity of the slug of water everywhere as the slug is extruded though the taper by solving the equations for continuity of volume and momentum. This may be determined using a numerical simulation of these continuity equations for various nozzle profiles. The internal pressure along the length of the nozzle can also be calculated from the local acceleration. The details of this calculation are described in Glenn, Lewis A. (1974) “On the dynamics of Hypervelocity liquid jet impact on a flat rigid surface,” Journal of Applied Mathematics and Physics ( ZAMP ), vol. 25.
[0041] A numerical analysis indicates that the exemplary compressed water cannon tool from FIG. 2A can produce a compressed water pulse that is 300-mm in length, traveling at a velocity of about 520 m/s, as shown FIG. 5A . The theoretical profile agrees reasonably well with the observed profile shown in FIG. 3B . The theoretical velocities of the leading and trailing edges (shown as U e and U b , respectively) of this water slug as it moves through the tapered nozzle are shown in FIG. 5B . The leading edge accelerates to over 2000 m/s, while the trailing edge decelerates. The peak velocity drops rapidly, to under 1000 m/s after 200 μsec. In this time the leading edge of the pulse will travel 0.4 m (16 in.). The nozzle should be located at a fraction of this distance from the target to maximize effectiveness. The velocity profiles may be calculated by assuming that the water is an incompressible fluid, although water is compressible at such velocities. The peak velocity of the discharged jet may be limited by the speed of sound in water (around 1500 m/s), which may limit the peak velocities to values lower than those shown in FIG. 5B . The compressed water pulse will convert to a 2-GPa pressure spike in a 150-mm-long convergent tapered nozzle, as shown in FIG. 5B , with 80% energy conversion above 1 GPa, as shown in FIG. 5C .
[0042] An example of the internal pressure profiles inside an exponentially tapered nozzle at three locations of the pulse is provided in FIG. 5E . The internal pressure builds as the pulse enters the tapered section. The peak pressure occurs at the moment that the pulse reaches the exit of the nozzle. The peak internal pressure is less than 1 GPa (145,000 psi) which is within the capacity of the nozzle materials available. In a preferred embodiment of the invention, the nozzle comprises a carbide inner section that is pressed into a sleeve to provide a preload on the carbide. Those skilled in the art will understand that a composite nozzle of this type provides higher internal pressure capacity than a monobloc nozzle.
[0043] The cross-sectional area of the tapered nozzle section 132 is denoted as A(x), and it decreases exponentially along the length of the tapered nozzle section 132 , which is denoted as x. The relationship between the length and cross-sectional area of the tapered nozzle section 132 is shown according to the following exponential equation:
[0000]
A
(
x
)
=
A
i
exp
(
-
x
ln
(
R
)
l
t
)
[0000] In this equation, R is the inlet/outlet area ratio; and I t is the total length of the tapered nozzle section 132 . An example of a nozzle profile is as shown in FIG. 5D , which is derived from the data in the following Table 1.
[0000]
Length, in.
Diameter, in.
Straight
20
0.500
Taper
0
0.500
2
0.429
4
0.369
6
0.316
8
0.272
10
0.233
12
0.200
[0044] An exponential tapering is used for the tapered nozzle section 132 , as opposed to a linear tapering, to prevent the tapered section from being blown off from the pressure release during a firing. An external nut may be used to clamp the tapered nozzle section 132 to the straight nozzle section 120 . This nut may be attached with a torque of about 2000 ft-lbf. Based on the configuration of the straight nozzle section 120 and tapered nozzle section 132 , a water cannon may be converted into the hyper-pressure water cannon 100 suitable for use in excavation applications.
[0045] Although the concepts disclosed herein have been described in connection with the preferred form of practicing them and modifications thereto, those of ordinary skill in the art will understand that many other modifications can be made thereto. Accordingly, it is not intended that the scope of these concepts in any way be limited by the above description. | A hyper-pressure water cannon, or pulse excavator, is able to discharge fluid pulses at extremely high velocities to fracture a rock face in excavation applications. A compressed water cannon can be used to generate hyper-pressure pulses by discharging the pulse into a straight nozzle section which leads to a convergent tapered nozzle. The hyper-pressure water cannon design is relatively compact, and the pulse generator can readily be maneuvered to cover the face of an excavation as part of a mobile mining system. |
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This is a continuation of application Ser. No. 06/783,553 filed Oct. 3, 1985 now abandoned.
SCOPE OF THE INVENTION
The present invention relates to a sanitary equipment for a clean room, which is provided in a toilet sttached to the clean room in an integrated circuit production plant, a food production or processing plant or the like.
DESCRIPTION OF THE PRIOR ART
In a conventional toilet attached to a clean room, a grating, a punched metal plate or the like is laid on the floor of the toilet to provide numerous air discharge ports. The air in the toilet is sucked out of it through the air discharge ports by a fan installed outside the toilet and is returned into the toilet through an air filter mounted on the ceiling of the toilet, so that dust or the like should not stay or accumulate in the toilet. The dust or the like might thus be prevented from being carried into the clean room. However, since a toilet stool, for example, provided as a sanitary equipment in the toilet has a recess on the side surface of the lower part of the toilet stool and is fixed at the bottom on the floor of the toilet by bolts or the like, the circulating air flowing down in the toilet is disturbed around the toilet stool so that an air flow stays near said recess. If the staying air flow contains dust or the like, the dust or the like is likely to stay and cling to the clothes of the user of the toilet so that the dust or the like is carried into the clean room. If a toilet bowl for urine or a washstand is provided, in stead of the toilet stool, in the toilet, the circulating air flowing down in the toilet is disturbed because the toilet bowl or the washstand projects from the wall of the toilet, so that an air flow stays in the toilet. If the staying air flow contains dust or the like, the dust or the like is likely to stay and accumulate on the top of the toilet bowl or the washstand in particular, fly off again and cling to the clothes of the user of the toilet so that the dust or the like is carried into the clean room.
In addition, since a water feeder is manually handled for each of the above-mentioned sanitary equipments to supply washing water to the pot-shaped portion of the equipment, dirt from the hand of the user is likely to cling to the handling portion of the water feeder, fly off in the form of particles from the handling portion, float in the air and cling to the clothes or the like of the user so that the particles are carried into the clean room.
SUMMARY OF THE INVENTION
The first purpose of the present invention is to provide a sanitary equipment for a clean room, which does not cuase dust or the like to stay in a chamber furnished with the equipment.
The second purpose of the present invention is to provide a sanitary equipment for a clean room, which enables the user of the equipment to supply washing water without putting a hand into contact with the equipment.
The first purpose of the present invention is attained by making the side surface of the body of the sanitary equipment almost vertical and by furnishing fixation elements for fastening the body of the equipment onto a wall, so that the fixation elements do not project into the chamber furnished with the equipment.
The second purposed of the present invention is attained by furnishing a sensor to open and close a water feeder for supplying the washing water to the body of the equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
Other purposes and features of the present invention are clarified in the following description with reference to the drawings.
FIG. 1 shows a longitudinal sectional side view of a sanitary equipment for a clean room, which is an embodiment of the present invention and whose body is a toilet stool.
FIG. 2 shows a plan view of the sanitary equipment.
FIG. 3 shows a sectional view of the sanitary equipment along a line III--III shown in FIG. 2.
FIG. 4 shows an oblique view of the sanitary equipment.
FIG. 5 shows a longitudinal sectional view of a sanitary equipment for a clean room, which is another embodiment of the present invention and whose body is toilet bowl for urine.
FIG. 6 shows a partially cutaway front view of the latter sanitary equipment.
FIG. 7 shows a partially cutaway plan view of the latter sanitary equipment.
FIG. 8 shows a side view of a sanitary equipment for a clean room, which is still another embodiment of the present invention and whose body is a toilet bowl for urine.
FIG. 9 shows a longitudinal sectional side view of a sanitary equipment for a clean room, which is still another embodiment of the present invention and whose body is a washstand.
FIG. 10 shows a partially cutaway front view of the sanitary equipment whose body is the washstand.
FIG. 11 shows a sectional view of the sanitary equipment along a line XI--XI shown in FIG. 10.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiment shown in FIG. 1, 2, 3 and 4 is hereinafter described. The body (a) of the sanitary equipment shown in these four drawing is a toilet stool of the blowout type. The body (a) is made of ceramic or synthetic resin so that the side surface of the body is made almost vertical and does not have a large recess or protrusion though the side surface may have a small recess or protrusion or may be slightly oblique. The bottom a1 of the body (a) is placed on the floor A1 of a toilet as shown in the drawings, the floor A1 is provided with openings, i.e., either in the form of a grate or as a punched metal plate, so as to provide numerous air discharge ports in the floor to ensure circulation of the air through the chamber. The rear a2 of the body (a) is put in tight contact with the wall A2 of the toilet. Fixation elements 1 such as T-shaped bolts are inserted in the rear of the body (a) and the wall A2 and tightened with nuts 2 so that the body (a) is secured
A pot-shaped portion a3 is provided in the front part of the equipment body (a). A water feed chamber a4 is formed in the upper section of the rear part of the body (a). A water drain passage a6 is formed at the bottom of the pot-shaped portion a3 so that the passage a6 obliquely extends up along the rear of the pot-shaped portion, is cranked halfway and communicates with a water drain port a5 opened in the rear of the equipment body (a).
A water feed port a7 is opened into the rear of the water feed chamber a4. The water feed port a7 is connected to a water feed pipe 3 which is embedded in the wall A2 and communicates with a water feeder (b). The water feed chamber a4 is connected through a communication hole a8 to a water passage a9 formed along the brim of the pot-shaped portion a3 and is also connected through a communication passage a10 to a water passage a11 formed under the water drain passage a6.
Numerous water ejection holes a12 are opened at appropriate intervals into the bottom of the water passage a9. A portion of washing water supplied from the water feeder (b) is discharged from the water ejection holes a12 on the inside surface of the post-shaped portion a3 to wash it.
The water passage a11 is provided with a first jet hole a13 at the bottom of a bent portion at the inlet port of the water drain passage a6 and with a second jet hole a14 above the first jet hole a13. The first and the second jet holes a13 and a14 are opened toward the outlet port of the water drain passage a6. Another portion of the washing water supplied from the water feeder is jetted from the jet holes a13 and a14 into the water drain passage a6 to send excrements together with accumulated water to the water drain port a5 to drain them to the exterior of the toilet through a water drain pipe 4 connected to the water drain port a5.
The water feeder (b) is made up of an electromagnetic flush valve, for example. The operation of the water feeder is controlled through an infrared sensor (c) provided on the wall a2. When it is detected by the sensor (c) that the user of the sanitary equipment has approached the body (a) of the equipment, a prescribed quantity of washing water is supplied to the water feed chamber a4. When the user has stood up after using the equipment, another quantity of washing water is supplied to the water feed chamber a4.
A toilet seat (d) made of synthetic resin or the like and shape similarly to the top of the equipment body (a) is integrally fitted on the top of body (a). An open portion d1 is provided in the front part of the toilet seat (d) so that the open portion d1 adjoins the pot-shaped portion a3. Air discharge passages d2 are formed in the right and left portions of the rear part of the toilet seat (d). A housing portion d3, in which an excretive organ washer 5 which ejects warm water to the excretive organ of the user of the sanitary equipment to wash the organ is provided, is formed in the center of the rear part of the toilet seat (d). A right and a left warm air passages d4 are formed between the housing portion d3 and the right and the left air discharge passage d2.
The front ends of the right and the left air discharge passages d2 are connected to a pair of right and left air discharge ports d5 opened in the bottom of the front of the open portion d1 toward the pot-shaped portion a3. Air discharge pipes 6, which communicate with the exterior of the toilet, are connected to the rear ends of the air discharge passage d2. An air discharge fan 7 is provided halfway in the air discharge pipes 6 to suck smelly air out of the pot-shaped portion a3 through the air discharge ports d5 and evacuate the smelly air to the exterior of the toilet through the air discharge passages d2 and the air discharge pipes 6. In this embodiment, the operation of the air discharge fan 7 is controlled through the sensor (c). When the user of the sanitary equipment has appropriated the body (a) of the equipment, the fan 7 is rotated. In a prescribed time after the user has moved away from the equipment body (a) after using the equipment the fan 7 is stopped.
The front ends of the right and the left warm air passages d4 are connected to a pair of right and left blowoff ports d6 opened in the rear of the open portion d1. The rear ends of the passages d4 are connected to air feed pipes 8 communicating with the interior or exterior of the toilet. An air feed fan 9, a heater 10 and an air filt 11 such as a sterilizing filter for removing dust or the like from to air and removing oxides or the like flying off from the surface of the heater 10 are sequentially provided halfway in the air feed pipes 8 so that the heater and the air filter are located downstream to the fan 9.
The air obtained from the interior or exterior of the toilet and heated by the heater 10 is blown off from the blowoff ports d6 to the user's excretive organ washed by the excretive organ washer 5, through the filter 11 by the air feed fan 9 to dry the excretive organ. The operation of the air feed fan 9 and the excretive organ washer 5 are regulated through a control panel 2 mounted on the wall A2.
Although the equipment body (a) is a blowout-type toilet stool in the above-mentioned embodiment, the equipment body (a) may be a toilet stool of any type.
The embodiment shown in FIG. 5, 6 and 7 is hereinafter described. In this embodiment, the equipment body (a) is a toilet bowl for urine. The equipment body (a) is made of ceramic or synthetic resin so that the outside surface of the body (a) is almost vertical the upper part of the body is made slightly larger and larger downward, and the form of the body as seen from the front is similar to that of the longitudinal section of a bullet or bomb. The bottom a1 of the body (a) is placed on the floor A1 of a toilet. The rear a2 of the body (a) is made flat and put in tight contact with the wall A2 of the toilet. Fixation elements 1 such as T-shaped bolts are inserted in the rear a2 of the equipment body (a) and the wall A2 and tightened with nuts 2 so that the body (a) is secured.
An open portion a15 is provided in the upper section of the front part of the equipment body (a) so that the open portion a15 adjoins a pot-shaped portion a3. A water feed chamber a4 is formed over the pot-shaped portion a3 so that a rear wall a16 extends between the water feed chamber a4 and the pot-shaped portion a3. A water drain port a5 is opened into a trap a17 under the pot-shaped portion a3. A water drain pipe 4 embedded in the wall A2 is connected to the water drain port a5.
A water feed port a7 is opened into the rear of the water feed chamber a4. The water feed port a7 is connected to a water feed pipe 3 embedded in the wall A2 and communicating with a water feeder (b) such as an electromagnetic flush valve. Communication holes a8 are opened into the right and left portions of the rear of the water feed chamber a4 so that the holes a8 communicate with water spreading chambers a17 extending continuously to the bottom of the water feed chamber a4. The right and left portions of the front of the water feed chamber a4 communicate with water passages a9 formed along the brim of the open portion a15.
The operation of the water feeder (b) is controlled through a sensor (c) provided on the upper part of the front of the equipment body (a). In a prescribed time after it is detected by the sensor (c) that the user of the sanitary equipment has approached the body (a) of the equipment, a prescribed quantity of washing water is supplied to the water feed chamber a4 and then sent to the water spreading chambers a17 and the water passage a9.
Plural water spreading holes a18 are opened at appropriate intervals into the bottoms of the water spreading chambers a17 at the rear wall a16. A portion of the washing water introduced into the water feed chamber a4 through the water feed port a7 is discharged from the water spreading holes a18 on the inside surface of the rear wall a16.
Plural water ejection holes a12 are opened at appropriate intervals into the water passages a9 toward the pot-shaped portion a3. Another portion of the washing water introduced into the water feed chamber a4 is discharged from the water ejection holes a12 on the inside surface of the pot-shaped portion a3.
FIG. 8 shows the other embodiment in which the rear a2 of the body (a) of a sanitary equipment is embedded in a wall A2.
FIG. 9, 10 and 11 shows still another embodiment in which a washstand is provided as a sanitary equipment body (a). The body (a) is made of ceramic or synthetic resin so that the outside surface of the front of the body (a) is almost vertical or slightly oblique as shown in FIG. 9. The rear a2 of the equipment body (a) is embedded in a wall A2 so that an annular engaging stepped portion a19 vertically formed on the outer part of the body (a) is fitted, from the interior of a chamber furnished with the equipment, into a fitting hole A2' opened in the wall A2. The bottom a1 of the equipment body (a) is placed on a pedestal (e) located outside the chamber. A fixation element 1 such as a bolt is inserted in the bottom a1 and the pedestal (e) and tightened with a nut 2 so that the body (a) is secured.
An open portion a15 is provided in the upper part of the front of the equipment body (a) so that the open portion adjoins a pot-shaped portion a3. A dome-shaped cover a20 is formed on the upper part of the rear of the body (a) so that the cover a20 extends over the rear part of the pot-shaped portion a3. A water passage a9 is formed at the brim of the pot-shaped portion a3 along the total circumference thereof.
When the equipment body (a) is secured, the upper edge of the open portion a15 is made nearly flush with the surface of the wall A2 so that only the front of the pot-shaped portion a3 project from the wall A2.
A feed port a7 is opened into the rear of the water passage a9 so that a water feed pipe 3 communicating with a water feeder (b) such as a solenoid valve is connected to the water feed port a7. Numerous water ejection holes a12 are opened at appropriate intervals into the bottom of the water passage a9. Washing water supplied from the water feeder (b) is discharged from the water ejection holes a12 on the inside surface of the pot-shaped portion a3 to make a water film to wash hands.
A water drain port a5 is opened in the bottom of the pot-shaped portion a3 so that a water drain pipe 4 is connected to the water drain port a5. The diameter of the drain port a5 is made such that no water accumulates at the bottom of the inside of the pot-shaped portion a3 even if the maximum quantity of washing water is discharged from a water ejector 13 mentioned below. The inlet port of an air discharge passage a21 is opened above the water drain port a5 and beside (behind as to FIG. 9) it.
The air discharge passage a21 obliquely extends up from said inlet port along the rear of the pot-shaped portion a3. An air dischar pipe 6, which communicates with the exterior of the chamber furnished with the sanitary equipment, is connected to the outlet port of the air discharge passage a21. An air discharge fan 7 is provided in the halfway portion of the air discharge pipe 6.
When the air discharge fan 7 is rotated, the air in the pot-shaped portion a3 is sucked out of it through the inlet port of the air discharge port a21, turned as U along the bottom of the inside surface of the pot-shaped portion and evacuated to the exterior of the chamber through the air discharge pipe 6. In this embodiment, the operation of the air discharge fan 7 is controlled through a sensor (c) mentioned below, so that the quantity of the air discharged by the fan is changed in a prescribed time after the start of the operation. In other words, the rotational frequency of the air discharge fan 7 is low while the washing water is discharged from the water ejector 13; and the rotational frequency of the fan is heightened to increase the quantity of the sucked air when hot air is blown off from a blowoff port 14 mentioned below.
The water ejector 13 for washing the hands of the user of the sanitary equipment, the blowoff port 14 for drying the already washed hands and the sensor (c) for control both the washing and the drying are provided through the cover a20.
A water ejection pipe 15 ramified from the secondary side of the water feeder (b) for supplying the washing water to the water passage a9 connected to the upper end of the water ejector 13. The lower end of the ejector 13 is protruded in the over a20 so that the drops of the washing water supplied from the water feeder (b ) do not fly out of the equipment body (a).
A air feed pipe 8 is connected to the blowoff port 14. An air feed fan 9 is provided in the halfway portion of the air feed pipe 8 so that the air inside or outside the chamber furnished with the sanitary equipment is rapidly blown off from the port 14. A heater 10 and an air filter 11 such as a sterilizing filter for removing dust or the like from the air and removing oxides or the like flying off from the surface of the heater are sequentially provided downstream to the air feed fan 9.
The sensor (c) is a conventional photoelectric infrared sensor which sends a detection signal to a controller 16 when the user of the sanitary equipment has inserted his hand into the pot-shaped portion a3 through the open portion a15.
The controller 16 is electrically connected to the water feeder (b), the air discharge fan 7, the sensor (c), the air feed fan 9 and the heater 10. When the detection signal is sent from the sensor (c) to the controller 16, the water feeder (b) is opened and the air discharge fan 7 is rotated at the low rotational frequency for 10 to 15 seconds, for example. After that, electricity is applied to the heater 10 to cause it to heat, the air feed fan 9 is rotated and the air discharges fan 7 is rotated at the heightened rotational frequency, for 30 seconds to 1 minute, for example.
When the user of the washstand has inserted his hands into the pot-shaped portion a3 through the open portion a15, washing water is discharged from the ejection holes a12 of the water passage a9 to make a water film on the inside surface of the pot-shaped portion, other washing water is jetted as a shower bath from the water ejector 13 to wash the hands of the user, and the air in the pot-shaped portion is evacuated out of it. When the discharge and the jetting of the washing water and the evacuation of the air are stopped, hot air is rapidly blown off from the blowoff port 14 to remove water drops from the hands to dry them, and the quantity of the air sucked through the air discharge passage a21 is increased to suck dust or the like flying off from the hand-washing user and his clothes, to evacuate the air and the dust or the like to the exterior of the chamber furnished with the sanitary equipment.
Although the quantity of the air sucked by the air discharge fan 7 is changed in a prescribed time in the above-mentioned embodiment, the rotation of the fan 7 may be started at the same time as the blowoff of the hot air from the blowoff port 14. | The present invention relates to a sanitary equipment which is provided in a toilet attached to a clean room. The side surface of the body of the sanitary equipment is made almost vertical, and fixation elements for fastening the body of the equipment onto the wall of the toilet do not protrude into the toilet. As a result, air is circulated through the toilet in such a manner that the air flowing down in the toilet is not disturbed. |
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FIELD OF THE INVENTION
The present invention relates to an anti-frost concrete mould.
BACKGROUND OF THE INVENTION
The use of forms, casings, moulds and shells is well known in the construction of cast-in-place concrete footings, piers and piles. These footings, piers and piles are used to transfer the loads of buildings, bridges, decks, porches, raised walkways, ramps, mini-home supports, highway sign posts and add-ons of existing structures to the underlying supporting soil. The concrete of a cast-in-place pile or footing is cast inside a mould that usually consists of a tin metal, plastic or paper shell left in the ground. The mould is usually so thin that its strength is disregarded in evaluating the structural capacity of the pile or footing. However, the mould must have adequate strength to resist collapse under the pressure from the surrounding backfill before it is filled with concrete. Similarly, if the mould is filled with concrete without the support of backfill, the mould must have sufficient strength to resist bursting pressures.
In northern latitudes, such as those which encompass Canada, northern Europe and the northern portions of the United States, soils, and particularly fine grained water saturated soils, are susceptible to the formation of ice lenses and frost heave. These phenomena can greatly diminish the stability and integrity of structures embedded in such soils. Therefore, footings are placed at a depth of not less than the depth of normal frost penetration. This prevents damage to the footing from the swelling and shrinkage of the surrounding soil caused by freeze-thaw cycles or displacement from frost heaving. However, while placing the footing below the depth of frost penetration will protect the footing from the effects of frost action, the pier that transfers the loads from the supported structure to the footing remains above the frost line and therefore remains vulnerable to frost and ice action.
The mechanisms of frost heave and frost action are well known to persons skilled in the art. The main phenomenon of concern to the construction industry is the displacement, laterally and vertically, of foundation members due to loads placed upon them from frost action. Where surrounding soil is frozen to a pier connecting a supported structure to a supporting footing, movement of the soil frozen to the pier will displace the pier. This will diminish the stability of the footing and structure to which it is attached no matter the depth of the footing below the frost line. In northern climates, a pier must be of a significant length to connect a footing placed below the frost line to the structure on the surface. Most of the entire length of the pier embedded in frost susceptible soil will be vulnerable to frost action.
Many examples of concrete moulds are known. However, none of these addresses the problem of being able to resist upward displacement due to frost heave in the surrounding soil. The problem is particularly acute in climates where the footing must be placed at a significant depth below the surface to remain unaffected by frost. One example of the known art is described in U.S. Pat. No. 5,271,203 issued to Nagle on Dec. 21, 1993 and entitled “Support Form For A Setable Material”. Nagle recognizes the problems associated with frost heave and compares the advantages of his invention over conventional thin-walled constant diameter moulds, such as the SONATUBE™, which he states are vulnerable to tipping and leaning due to lateral forces caused by frost heave in surrounding soil. While the Nagle invention relies upon its conical shape to resist frost heave, it possesses longitudinal ribs that could permit water to collect and freeze therein thus allowing localized frost action to act detrimentally upon the mould.
Furthermore, the dimensions of the Nagle invention, specifically its height to width ratio, approaches unity. Therefore, for deep frost line applications, where the mould would have to be embedded deeply into the soil and remain connected to the above surface supported structure, the resulting mould of the Nagle design would have to be very large. This would result in greater expense and the mould would require a significant volume of setable material to fill it.
An additional disadvantage of the Nagle invention is that it is of a fixed height and cannot be adjusted at the work site to adapt to the variable depth of excavations. Furthermore, the Nagle invention does not possess anchoring means to prevent the mould from shifting as the concrete is poured. Furthermore, if the Nagle invention is left exposed to the elements for several days before the setable material is poured, there are no means to anchor the Nagle invention to the ground to prevent wind and rain forces from displacing the Nagle invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved concrete mould that resists the detrimental action of frost heave.
In accordance with an aspect of the present invention there is provided an anti-frost concrete mould that resists the adhesion of frost, ice and frozen soils. The mould generally resembles a cone and comprises an upper frustoconical portion coaxially aligned with a lower drum portion whose outer surface extends outwardly and downwardly from a transitional shoulder. The shoulder connects the upper portion of the mould with the lower portion of the mould. The mould has opposed top and bottom ends and a continuous and smooth exterior surface. The mould is manufactured from recycled material bound with a binding agent. The bottom end of the mould has an integral anchor flange extending horizontally from it. The anchor flange is apertured at regular intervals for holding anchoring means in the form of pins, nails, dowels and other hold-down devices. The mould is sufficiently resilient and rigid to withstand the pressure from surrounding soil attempting to collapse the mould inwardly. The mould is further able to withstand fluid pressures from the fluid setable material contained therein attempting to burst the mould outwardly. The mould has a smooth outer and inner surface.
In a further aspect of the present invention there is provided an inexpensive and simple method of manufacturing the mould comprising the steps of: determining the appropriate dimensions of the mould to suit the intended purpose; producing a die in obedience to the desired dimensions of the mould; covering said die with a non-stick fabric; applying a plurality of layers of a mixture of binding agent and recycled material to the fabric covering the die until a mould of the desired thickness is formed; finishing the mould with a smooth surface of binding agent.
In a further embodiment of the invention, the mould may be manufactured using injection moulding techniques.
In yet another aspect of the present invention it is contemplated that the mould be manufactured from resilient, rigid and light weight recycled materials, such as, wood, plastic, cloths, fabrics or other synthetic or natural materials bound together using a binding agent. The outer surface of the mould will have a smooth surface with frost and ice adhesion resistant properties.
Yet another aspect of the present invention contemplates a method of using the mould comprising the steps of: excavating a cavity in the earth; placing a mould of desired dimensions into the cavity; anchoring the mould through the anchoring flange using anchoring means; adjusting the height of the mould as necessary by cutting away excess mould along the grooves at the top end of the mould; backfilling the excavation around the mould; if necessary, capping the open top end of the mould with capping means to prevent water from collecting within the mould; when convenient, filling the mould with a setable material, generally concrete; insert the desired structure to be supported by the concrete before setting or alternatively allow the concrete to set and then affix the concrete mould to the structure to be supported; and, leaving the mould in place.
Advantages of the present invention are that the mould can be used in locations where there is a deep penetration of frost and a frequent cycle of soil freezing and thawing without being displaced. The mould is also easy and inexpensive to manufacture being made from recycled materials.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be further understood from the following description with references to the drawings in which:
FIG. 1 illustrates an example of the known art.
FIG. 2 illustrates in perspective view one embodiment of the present invention.
FIG. 3 illustrates in sectional side view another embodiment of the present invention.
FIG. 4 illustrates a side-view of one embodiment of the present invention.
FIG. 5 illustrates a top view of one embodiment of the present invention.
FIG. 6 illustrates a bottom view of one embodiment of the present invention.
FIG. 7 illustrates a sectional side view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
FIG. 8 illustrates a top view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
FIG. 9 illustrates a bottom view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
DETAILED DESCRIPTION
An example of a known concrete mould is shown in FIG. 1 and has been previously discussed.
FIG. 2 shows one embodiment of the present invention ( 10 ) comprising a hollow rigid elongated mould ( 12 ) generally resembling a cone. The mould has opposed top ( 14 ) and bottom ( 16 ) ends. In a preferred embodiment of the present invention the diameter of the top end is approximately 33% the diameter of the bottom end. The mould ( 12 ) has a continuous and smooth exterior surface ( 18 ). The mould is manufactured from material which resists the adhesion of frost, ice and frozen soils.
The bottom end of the mould has an integral anchor flange ( 20 ) perforated at regular intervals ( 22 ) to hold anchoring means.
FIG. 3 shows another embodiment of the present invention in sectional side view in which the mould ( 12 ) comprises an upper frustoconical portion ( 30 ) coaxially aligned with a lower drum portion ( 34 ) whose outer surface extends outwardly and downwardly from a transitional shoulder ( 32 ) connecting the upper portion with the lower portion of the mould. In a preferred embodiment of the present invention, the diameter of the top opening ( 14 ) of the conical upper portion ( 30 ) is approximately 50% of the diameter of the bottom opening ( 15 ) of the upper conical portion ( 30 ). In a preferred embodiment of the present invention, the height of the upper conical portion ( 30 ) represents approximately 85% of the total height of the mould. Therefore, the upper conical portion ( 30 ) of the mould ( 12 ) acts as a pier connecting the supported structure to the supporting soil. In a preferred embodiment of the present invention, the interior angle ( 17 ) of the wall of the upper conical portion ( 30 ) of the mould ( 12 ) is approximately 85 degrees from a horizontal plane bisecting the bottom end ( 15 ) of conical portion ( 30 ). In a preferred embodiment of the present invention, the thickness of the mould ( 12 ) at the top end ( 14 ) of the upper conical portion ( 30 ) is approximately ⅜ inches and the thickness at the bottom end ( 15 ) of the upper conical portion ( 30 ) is approximately ½ inches.
Attached and integral to the bottom ( 15 ) of the upper conical portion ( 30 ) is transitional shoulder ( 32 ). Transitional shoulder ( 32 ) is also attached and integral to the upper end of the drum portion ( 34 ) of the mould ( 12 ). As seen from inside the mould, and from the top to the bottom of the transitional shoulder, transitional shoulder ( 32 ) comprises a first convex ( 32 a ) surface and a second concave surface ( 32 b ) joined together. In a preferred embodiment of the present invention, each surface ( 32 a & 32 b ) has a radius of approximately 1 inch. The resulting effect of the transitional shoulder ( 32 ) is to expand the diameter of the mould ( 12 ) by approximately 50% from the lower end of the conical portion ( 30 ) to the lower end of the drum portion ( 34 ). In a preferred embodiment of the present invention, the height of the transitional shoulder ( 32 ) is approximately 4% of the total height of the mould ( 12 ).
Stacking supports ( 36 ) are attached to the mould ( 12 ) at the shoulder ( 32 ) and are spaced equidistantly about the circumference of the mould. In a preferred embodiment of the present invention, there are four stacking supports equidistantly spaced about the circumference of the mould, approximately ½ inches wide by 1 ¼ inches long by approximately 3½ inches in height.
The lower drum portion ( 34 ) of the mould ( 12 ) extends downwardly and outwardly from the transitional shoulder ( 32 ). In a preferred embodiment of the present invention, the interior angle formed by the wall of the drum portion to a horizontal plane bisecting the lower drum portion at ( 16 ) is approximately 85 degrees so that the walls of the upper conical portion ( 30 ) and the walls of the lower drum portion ( 34 ) are substantially parallel. In a preferred embodiment of the present invention, the height of the drum portion ( 34 ) is approximately 10% of the total height of the mould ( 12 ). The diameter of the mould at the bottom end ( 16 ) of the drum portion is approximately 300% of the diameter of the top portion ( 14 ).
The anchor flange ( 38 ) is attached and integral to the bottom of the drum portion ( 34 ) of mould ( 12 ). The anchor flange ( 38 ) is sufficiently dimensioned to withstand potential shearing forces which may be developed between the anchor flange and the anchor means ( 40 ) fixing the mould to the soil. The anchor means may comprise nails, hold-downs, pins, bolts, dowels and similar devices inserted through the apertures in the anchor flange which anchor means are of sufficient length to fix the mould in the desired location. In a preferred embodiment of the present invention, the outer diameter of the anchor flange is approximately 125% the inner diameter of the lower end of the drum portion ( 34 ) and the thickness of the mould from the transitional shoulder to the tip of the anchor flange is approximately ½ inches.
While FIG. 3 shows an embodiment of the present invention with the bottom end ( 16 ) of mould ( 12 ) open so that the setable material is in direct contact with the supporting soil, it may also be closed. Whether open or closed, the diameter of the lower end ( 16 ) of the drum portion ( 34 ) is adequately large enough to transfer the loads from the supported structure to the underlying soil.
As shown in FIG. 3, the present invention must be sufficiently rigid and resilient to resist crushing pressure from surrounding soil and bursting pressure from the setable material contained therein before setting.
Referring to FIG. 4, one embodiment of the present invention shows the plurality of spaced concentric rings ( 41 ) located at the top of the frustoconical portion ( 30 ) of mould ( 12 ) which circumscribe the outer surface of the cone. In the preferred embodiment of the present invention, these rings are spaced at two inch intervals from the top of the cone down to approximately 18 inches from the top of the cone. A worker uses these rings as a guide to remove excess material from the top of the cone. In a preferred embodiment of the invention these rings comprise a series of raised dots approximately ⅛ inches in height.
FIG. 5 shows a top view of one embodiment of the present invention illustrating the spacial relationship between the top of the cone ( 14 ); the concentric rings ( 41 ); the stacking shoulders ( 36 ); and the anchor flange ( 38 ). Also shown is a plurality of holes ( 22 ) through which anchoring means are placed.
FIG. 6 shows a bottom view of one embodiment of the present invention illustrating the spacial relationship between the anchor flange ( 38 ); the holes through which the anchor means are placed ( 22 ); the drum portion of the mould ( 34 ); the transitional shoulder ( 32 ); between the drum portion ( 34 ); and, the frustoconical cone portion ( 30 ) of the mould ( 12 ). While FIG. 6 shows an embodiment of the present invention with an open bottom, it is contemplated that the bottom may be sealed.
Although it is understood by a person skilled in the art that the size and dimensions of the mould can be varied to suit the intended purpose, FIGS. 7, 8 and 9 show examples of the dimensions of embodiments of the present invention to suit a specific application.
The present invention contemplates that the mould is to be manufactured from resilient, rigid and light weight recycled materials, such as, wood, plastic, cloths, fabrics or other synthetic or natural materials bound together using a binding agent. The outer surface of the mould will have a smooth surface with frost and ice adhesion resistant properties.
Numerous modifications, variations, and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims. | An anti-frost concrete mold having an upper frustoconical portion, a transitional shoulder portion and a lower drum portion. The top portion of the mold is adjustable in height. The mold is fabricated simply by molding it over a die. The mold is fabricated from various suitable recycled materials bound with a binding agent. |
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CONTINUATION STATEMENT
This application claims priority to U.S. Provisional Application No. 60/085,620, filed May 15, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of isolation systems and gravel pack assemblies for use in a wellbore. More particularly, the invention provides an improved system and method for zone isolation following gravel pack completions installed in a wellbore.
2. Description of the Prior Art
Typical prior art isolation systems involve intricate positioning of tools which are installed down-hole after the gravel pack. An example of this type of system is available from Baker. This system utilizes an anchor assembly which is run into the well bore after the gravel pack. The anchor assembly is released by a shearing action, and subsequently latched into position.
Certain disadvantages have been identified with these systems. For example, prior conventional isolation systems have had to be installed after the gravel pack, thus requiring greater time and extra trips to install the isolation assemblies. Also, prior systems have involved the use of fluid loss control pills after gravel pack installation, and have required the use of thru-tubing perforation or mechanical opening of a wireline sliding sleeve to access alternate or primary producing zones. Since multiple trips into the well are required for gravel pack and isolation, these systems are time consuming methods and provide less flexibility and reliability.
An example of an isolation washpipe for well completions is disclosed in U.S. Pat. No. 5,343,949, incorporated herein by reference. In this system, there is an expansion joint which is used to push a closing sleeve into a closed position over the production screen.
More recently, isolation systems have been developed which do not require the running of tailpipe and isolation tubing separately. Instead, the system uses the same pipe to serve both functions: as tailpipe for circulating-style treatments and as production/isolation tubing. An example of this type of isolation system is disclosed in U.S. Pat. No. 5,865,251, incorporated herein by reference. An isolation sleeve is installed inside the production screen at surface and placed in the wellbore simultaneously with the service tool. The isolation sleeve is thereafter controlled in the wellbore by means of the inner service string. This system is adapted for well control purposes and for well bore fluid loss control. It combines simplicity, reliability, safety and economy, while also affording flexibility in use.
However, '251 provides only small orifices for circulation of the gravel pack fluid through the isolation sleeve. Further, '251 allows debris to become trapped between the production screen and the isolation sleeve. Further, because the washpipe extends through the isolation sleeve during the gravel pack operation, there is the possibility that debris will become lodged between the isolation sleeve and the wash pipe. This debris could cause the washpipe to hang or jam upon withdrawal so that the entire service string is permanently lodged in the isolation sleeve. Therefore, there is a need for a system which allows the isolation sleeve to be closed without a washpipe extending through the isolation sleeve. Further, there is a need for an isolation sleeve which does not allow debris to become accumulated between the isolation sleeve and the production screen and which allows fluid to freely pass through the isolation sleeve during the gravel pack operation.
SUMMARY OF THE INVENTION
The present invention is a system and method for providing full fluid flow through the production screen during a gravel pack operation and which does not allow debris to accumulated between the isolation system and the production screen. Further, the isolation system is closeable immediately upon completion of the gravel pack operation by the service tool which performed the gravel pack. Closure of the isolation system may even be accomplished without a wash pipe extending through the isolation system. The system comprises an activation tool which allows the isolation system to operate between the open and closed positions.
According to one aspect of the invention, there is provided an isolation system having: an isolation string, wherein the isolation string has a packing assembly which secures the isolation string in a wellbore casino, wherein the isolation string has a production screen which allows production fluid to pass into the isolation string; an isolation sleeve which slides within the isolation string between open and closed positions; a locking device which locks and unlocks the isolation sleeve in an open position; and an activation tool which allows the isolation sleeve to move to a closed position, wherein the open position allows fluid communication between the production screen and an interior portion of the isolation string and the closed position prevents fluid communication between the production screen and an interior portion of the isolation string.
According to a further aspect of the invention, there is provided an isolation system having: an isolation string, wherein the isolation string has a packing assembly which secures the isolation string in a wellbore casing, wherein the isolation string has a production screen which allows production fluid to pass into the isolation string; an isolation sleeve which slides within the isolation string between open and closed positions, wherein the open position allows fluid communication between the production screen and an interior portion of the isolation string and the closed position prevents fluid communication between the production screen and an interior portion of the isolation string, wherein the isolation sleeve comprises at least one isolation valve which is coupled within the isolation sleeve, wherein the at least one isolation valve is movable between open and closed positions; a locking device which locks and unlocks the isolation sleeve in an open position, wherein the locking device comprises a trigger that secures the isolation sleeve to the isolation string before the trigger is activated and releases the isolation sleeve from the isolation string after the trigger is activated, wherein the trigger comprises: a piston collar having a solid cylindrical portion attached to the isolation sleeve and a finger portion having at least one finger, wherein the at least one finger has a head at a distal end; and at least one recess in the isolation string, wherein the head of the at least one finger is engaged in the at least one recess; a cylindrically shaped pop lock positioned adjacent the head of the at least one finger so that the head is between the pop lock and the recess, wherein the pop lock secures the head relative to the recess; and a latch attached to the service tool which couples with the pop lock, wherein the trigger is activated by removing the pop lock from the position adjacent the head; and an activation tool which allows the isolation sleeve to move to a closed position, wherein the activation tool is a piston driven by a hydrostatic chamber which comprises lower pressure within the hydrostatic chamber than without, and wherein the piston moves the isolation sleeve from the open to the closed position.
According to an even further aspect of the invention, there is provided a process for isolating a production zone within a well, the process having the steps of: installing an isolation string and a service tool simultaneously within the well adjacent the production zone, wherein the isolation string comprises an isolation sleeve; locking the isolation sleeve in an open position during the installing an isolation string, wherein the open position allows fluid communication between the production screen and an interior portion of the isolation string; unlocking the isolation sleeve with the service tool; and moving the isolation sleeve to a closed position, wherein the closed position prevents fluid communication between the production screen and an interior portion of the isolation string.
Other and further features and advantages will be apparent from the following description of presently preferred embodiments of the invention, given for the purpose of disclosure and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is better understood by reading the following description of non-limitative embodiments, with reference to the attached drawings wherein like parts in each of the several figures are identified by the same reference character, and which are briefly described as follows.
FIGS. 1A and 1B are cross sectional views of a service tool with a locking stick joint, in the run-in position in combination with an isolation string, of the present invention;
FIGS. 2A and 2B are cross sectional views of a service tool with a locking stick joint in the set position, in combination with an isolation string, of the present invention;
FIG. 3 is a cross sectional view of an alternative embodiment of a service tool with a locking stick joint in the run-in position, in combination with an isolation string, of the present invention;
FIG. 4 is a cross sectional view of an alternative embodiment of a service tool with a locking stick joint in the set position, in combination with an isolation string, of the present invention;
FIG. 5 is a cross sectional view of the sleeve components of the locking stick joint of the present invention;
FIGS. 6 (A-G) through 12 (A-J) represent cross sectional views of an alternative isolation system in various stages of operation of the present invention;
FIGS. 13 through 15 represent enlarged cross sectional views of the alternative isolation system of the present invention; and
FIG. 16 represents a cross sectional view of an additional alternative isolation system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, the details of preferred embodiments of the present invention are graphically and schematically illustrated. Like elements in the drawings will be represented by like numbers, and similar elements will be represented by like numbers with a different lower case letter suffix.
Referring now to FIGS. 1A and 1B, a first embodiment of the invention is illustrated in which depict a cross sectional view of a service tool 10 in combination with an isolation string 20 inside of a well casing 5 . The service tool 10 and isolation string 20 are designed to work in tandem to perform completion functions and leave the production zone in an isolated state for subsequent production. The service tool 10 comprises a crossover assembly 40 , a fracture port assembly 41 , and an activation tool. In embodiment depicted in FIGS 1 A and 1 B, the activation tool is a locking slick joint 30 . Significant characteristics of this first embodiment are that there is no wash pipe which extends below the service tool 10 and through the isolation string 20 . Also, the locking slick joint 30 may be manipulated to open a through channel which allows fluid to travel from below the service tool 10 , up through the channel in the service tool 10 , and up through the service string. This prevents the service tool 10 from becoming “stuck” in the isolation string 20 after closure of the concentric isolation sleeve 21 due to vacuum pressure below the service tool 10 . The service tool 10 is first described and then the isolation string 20 .
Near the top of the significant portion of the service tool 10 , there is the crossover assembly 40 which is typical of those known in the art. An example is disclosed in Rebardi et al. U.S. Pat. No. 5,865,251. The crossover assembly 40 provides control of fluid flow paths in cooperation with other components inserted into the wellbore. It has an inner pipe 44 that extends for a portion of the proximal part of an outer pipe 46 . The proximal end of the outer pipe 46 has outer holes 47 which allow fluid communication from the exterior of the outer pipe 46 to the interior. The inner pipe 44 defines a central lumen 48 which communicates through an aperture 45 to the exterior of the outer pipe 46 at a location intermediate the length of the outer pipe 46 . As is known, the cross over assembly is used during gravel pack operations to deposit “gravel” between a production screen 26 of the isolation string 20 and perforations 52 in the well casing 5 .
The fracture port assembly 41 defines a fracture port chamber 42 in communication with a plurality of fracture ports 43 which provide fluid communication with the locking slick joint 30 . The fracture port assembly 41 may be shifted between an open position and a closed position. In the open position, fluid is allowed to flow through the fracture ports 43 during circulation of the gravel pack fluids. When it is desirable to fracture a production zone, the fracture port assembly 41 is shifted to a closed position so that the fracture ports 43 are closed. In the closed position, high pressure may be generated below the fracture port assembly 41 to fracture a production zone, as is well known.
The locking slick joint 30 comprises a locking slick joint outer sleeve 31 , a locking slick joint female sleeve 32 , and a locking slick joint male sleeve 33 . The locking slick joint outer sleeve 31 is positioned around the outer radius of the locking slick joint female sleeve 32 and secures the locking slick joint female sleeve 32 around the locking slick joint male sleeve 33 . A recess 35 is located on the outer radius of the locking slick joint male sleeve 33 formed to receive the mating ledge 34 . The mating ledge 34 is located along a proximal, open end 36 of the locking slick joint female sleeve 32 . Attached to the distal, closed end 37 of the locking slick joint female sleeve 32 is the locking slick joint tip 38 . The locking slick joint male sleeve 33 is hollow in the inside and defines an annular passage 60 . At the center of the annular passage 60 there is a locking slick joint plug 61 which extends, in the run-in position (see FIGS. 1 A and 1 B), from the distal end of the service tool 10 where the locking slick joint 30 is attached, through the center of the annular passage 60 , and through a tip aperture 62 . Within the tip aperture 62 there are tip seals 63 which completely seal the locking slick joint tip 38 when the locking slick joint plug 61 is in the tip aperture 62 . In the extended position (see FIGS. 2A and 2B) the locking slick joint 30 provides a fluid passage from below the service tool 10 to above, as is described more fully below.
The isolation system of the present invention is comprised of an isolation string 20 , a concentric isolation sleeve 21 , an upper packer 18 , and a lower packer 19 . The isolation string 20 is formed to have an outer diameter capable of being positioned inside the well casing 5 and formed to have an inner diameter capable of receiving the service tool 10 inside the inner diameter of the isolation string 20 . The isolation string 20 is comprised of an upper seal bore 15 , a lower seal bore 16 , an isolation pipe 23 a production screen 26 , and a base seal bore 17 . The upper packer 18 is positioned concentrically around the upper seal bore 15 of the isolation string 20 , and the lower packer 19 is positioned concentrically around the base seal bore 17 of the isolation string 20 ; on opposite ends of the isolation string 20 . The upper packer 18 and the lower packer 19 prevent fluid flow adjacent each packer in the region bounded by the outer radius of the isolation string 20 and the inner radius of the casing 5 . The concentric isolation sleeve 21 is comprised of an isolation string collar 22 , which is axially connected to an isolation tube 29 . Affixed to the inner radius of the concentric isolation sleeve 21 are isolation sliding sleeves 24 . Positioned on the outer radius of the isolation tube 29 are exterior concentric seal assemblies 28 . The exterior concentric seal assemblies 28 are formed to provide a sealing surface between the outer radius of the isolation tube 29 and downhole of the base seal bore 17 . The concentric isolation sleeve 21 is positioned within the isolation string 20 , proximate to the production screen 26 .
FIGS. 3 and 4 illustrate an alternative concentric isolation sleeve 21 a . The alternative concentric isolation sleeve 21 a is comprised of an isolation tube 29 a which is open at one end, and connected at its other end to an isolation string collar 22 a . Seal assemblies 28 a are positioned on the outer radius of the isolation tube 29 a . A glass disk 39 is positioned inside the isolation tube 29 a and prevents fluid flow through the isolation tube 29 a . The alternative concentric isolation sleeve 21 a is typically used on the producing zone that is located furthest downhole, i.e. no additional hydrocarbon producing zones exist past the point where the alternative concentric isolation sleeve 21 a will be positioned.
Operation of the locking slick joint tool is typically performed during a gravel pack operation. Since gravel pack operations are well known in the art, a detailed description of gravel pack operations will not be provided herewith. A description of such operations is provided in Rebardi et al., U.S. Pat. No. 5,865,251, incorporated herein by reference. After gravel pack operations have been completed, and it is desired to isolate the section of the well that has been gravel packed or fractured, the locking slick joint tool is adjusted from the run-in position to the set or extended position.
The change in position is accomplished by retracting the service tool 10 up the well hole until the locking slick joint outer sleeve 31 contacts a shoulder of the lower seal bore 16 . Additional force is then applied in retracting the service tool 10 until the locking slick joint outer sleeve 31 is moved along the locking slick joint female sleeve 32 towards the locking slick joint tip 38 . Moving the locking slick joint outer sleeve 31 towards the locking slick joint tip 38 allows the mating ledge 34 of the locking slick joint female sleeve 32 to move out of the recess 35 formed on the outer radius of the locking slick joint male sleeve 33 . Once the mating ledge 34 of the locking slick joint female sleeve 32 is moved out of the recess 35 the force being applied to retract the service tool 10 will slide the locking slick joint female sleeve 32 along the locking slick joint male sleeve 33 , thereby extending the locking slick joint tool into the set position. The locking slick joint 30 is locked in the set position when the mating ledge 34 snaps into upper set recess 64 (see FIG. 5 ). The locking slick joint 30 is further held in the set position by lower mating ledge 65 which snaps into lower set recess 66 . The lower mating ledge 65 is firmly held in the lower set recess 66 by the locking slick joint outer sleeve 31 when the outer sleeve 31 is moved into a lock position (see FIG. 2 B). The locking slick joint outer sleeve 31 is shown in an unlock position in FIG. 5 .
If it is desired not to actuate the concentric isolation sleeve 21 after the locking slick joint 30 has been placed in the set position, the locking slick joint 30 may be returned to its original run-in position. This is done by pulling up on the service tool 10 to draw the locking slick joint 30 up through the lower seal bore 16 and slacking back off to push the locking slick joint 30 back through the lower seal bore 16 from above. Since the locking slick joint outer sleeve 31 indicates on the lower seal bore 16 , this action slides the outer sleeve 31 from a lock position (see FIG. 2B) to an unlock position (see FIG. 5 ). As the locking slick joint 30 moves further through the lower seal bore 16 , this action dislodges the mating ledge 34 and lower mating ledge 65 from the upper set recess 64 and the lower set recess 66 , respectively. The locking slick joint female sleeve 32 then slides axially along the locking slick joint male sleeve 33 until the mating ledge 34 snaps into recess 35 . The locking slick joint outer sleeve 31 then squeezes through the lower seal bore 16 and the locking slick joint 30 is fully returned to the run-in position.
If it is desired to actuate the concentric isolation sleeve 21 , the locking slick joint 30 is placed in the set position as described above. Once the locking slick joint tool is in the set position (see FIGS. 2 A and 2 B), the service tool 10 is then moved downward towards the concentric isolation sleeve 21 . As seen in FIGS. 2 and 4, the locking slick joint tip 38 contacts the isolation string collar 22 (or 22 a ) and forces the concentric isolation sleeve 21 downward until the exterior concentric seal assemblies 28 are in contact with the base seal bore 17 . In the case of the alternative embodiment, the exterior concentric seal assemblies 28 a contact the intermediate seal bore 17 a . Engaging the exterior concentric seal assemblies 28 (or 28 a ) with the base seal bore 17 (or intermediate seal bore 17 a ) prevents flow from the perforations 52 into the well bore 84 , thereby isolating the hydrocarbon producing zone adjacent the perforations 52 .
With the production zone completely scaled, the service tool 10 is withdrawn from the isolation string 20 by simply retracting the service string up through the wellbore. Since the locking slick joint plug 61 is withdrawn from the tip aperture 62 when the locking slick joint 30 is in the set position 30 , a fluid flow channel is created within the service tool 10 . As the service tool 10 is withdrawn, fluid flows from outside the service tool 10 , above the upper packer 18 . In particular, fluid flows through the outer holes 47 to the interior of the outer pipe 46 of the crossover assembly 40 . This fluid then flows to the fracture port chamber 42 of the fracture port assembly 41 . Next, the fluid passes through the fracture ports 43 (if the ports are open as shown in FIG. 2A) and into the annular passage 60 of the locking slick joint 30 . Finally, the fluid flows from the annular passage 60 , through the tip aperture 62 , and into the space within the closed concentric isolation sleeve 21 (see FIG. 2 B). This prevents the service tool 10 from “sticking” in the isolation string 20 due to a vacuum created below the service tool 10 when removal of the service string is attempted.
If hydrocarbons are later desired to be produced from the zone adjacent the perforations 52 the isolation sliding sleeves 24 can be moved until the isolation sliding sleeve apertures 25 are in alignment with the isolation tube apertures 27 . If the perforations 52 are located next to the alternative concentric isolation sleeve 21 a then the glass disk 39 will can be broken thus allowing fluid flow through the glass disk 39 into the well bore 84 . The glass disk 39 may be broken by hydraulic pressure, dropping a ball, acoustics, intelligent methods, etc.
At any time after the production is isolated with the isolation string 20 as described above, the isolation string 20 of the first embodiment of the invention may be withdrawn from the wellbore with a separate retrieval tool which run into the wellbore on a subsequent trip.
FIGS. 6 (A-G) through 12 (A-J) depict, in cross sectional view, a second embodiment of the invention. In this embodiment, the activation tool is a release tool 100 . This second embodiment also comprises a hydrostatic chamber 104 which enables movement of the isolation sleeve 102 from an open to a closed position upon release of the sleeve by the release tool 100 . A trigger is used to hold the isolation sleeve 102 in an open position, until the trigger is activated to allow the hydrostatic chamber 104 to push the isolation sleeve 102 into a closed position. FIGS. 6A through 6G illustrate the invention at the initial stage of operation. FIGS. 7A through 7G illustrate the invention at a subsequent stage of operation and so forth. These stages of operation will be described more fully below. Briefly, the isolation sleeve 102 is shown in an open position in FIGS. 10E-10J and shown in a closed position in FIGS. 11E-11J.
The isolation system of the second embodiment is comprised of an isolation string 101 , and a service tool 138 . Like the first embodiment, the service tool 138 and isolation string 101 are run into the wellbore simultaneously. Once the production screen 26 of the isolation string 101 is adjacent the perforated portion of the casing, the isolation string 101 is set in the casing with an upper packer 18 and a lower packer (not shown).
In the second embodiment of the invention, the service tool 138 is similar to that of the first embodiment in that the upper or proximal parts comprise devices necessary for the gravel pack processes. In a lower or more distal portion of the service tool 138 , the release tool 100 is attached (see FIG. 6 C). The release tool 100 is connected to the service tool 138 by a release tool shear pin 142 . Of course, since the release tool 100 is connected to the service tool 138 , the release tool 100 is positioned within the isolation string 101 in the run-in position and during gravel pack procedures. In the embodiment shown, a wash pipe 112 extends from the distal or lower end of the service tool 138 . In the run-in position, the end of the wash pipe 112 extends to about the bottom of the production screen 26 ; the remainder of the service tool 138 is above the production screen 26 .
The isolation string 101 is secured to the well casing (not shown) by packers in a manner that is usual and customary in the art. In a lower portion of the isolation string 101 there is a production screen 26 (see FIGS. 8 G- 8 H). Inside the isolation string 101 and adjacent the production screen 26 , there is an isolation sleeve 102 (see FIGS. 8 E- 8 H). The isolation sleeve 102 comprises a piston 126 , a hydraulic dampener 118 , seal tubing 124 , and a wrap screen 128 . All of these parts are axially connected to form an elongated tubular section.
In this embodiment, the trigger is comprised of a piston collar 106 that is secured to the upper portion of the piston 126 , and is positioned on the outer radius of the piston 126 , thus forming a band between the isolation string 101 and the piston 126 (see FIGS. 6 E- 10 E). A more detailed drawing of the piston collar 106 is shown in FIG. 13. A lower section 106 a of the piston collar 106 is completely cylindrical while the upper portion 106 b of the piston collar 106 has a plurality of upwardly projecting fingers 107 . At the upper distal ends of the fingers 107 , the fingers 107 each have a head 107 a with threads thereon which mate with threads on shoulder 105 of the isolation string 101 . The heads 107 a of the fingers 107 are impinged against the shoulder 105 of the isolation string 101 by a pop lock 108 . By impinging the heads 107 a against the isolation string 101 , the isolation sleeve 102 is secured to the isolation string 101 , thereby preventing axial movement of the isolation sleeve 102 with respect to the isolation string 101 . If the pop lock 108 is moved vertically from within the fingers 107 of the piston collar 106 , the heads 107 a are released and the piston collar 106 and the rest of the isolation sleeve 102 connected thereto are free to slide within the isolation string 101 . The lower portion 106 a of the piston collar 106 occupies a space between the isolation string 101 and the piston 126 . Seals 109 are placed between the piston collar 106 and the isolation string 101 , and between the piston 126 and the piston collar 106 .
The outside diameter of the piston 126 is smaller than the adjacent inside diameter of the isolation string 101 so that the space between forms a hydrostatic or atmospheric chamber 104 (see FIGS. 8 E- 8 F). The top end of the hydrostatic chamber 104 is sealed by the piston collar 106 as described above. The lower end of the hydrostatic chamber 104 is sealed by a ring seal 119 (see FIGS. 6 F- 12 F). The ring seal 119 has seals on its inner diameter and outer diameter surfaces for sealing against the piston 126 and the isolation string 101 , respectively. Since the piston 126 and the isolation string 101 are assembled at the surface before the system is lowered into the wellbore, the air inside the hydrostatic chamber 104 is at or close to standard atmospheric pressure. Once lowered into the wellbore, surrounding pressures become significantly greater than standard atmospheric pressure. This pressure differential provides a closure force for sliding the isolation sleeve 102 into a closed position as described below.
The seal tubing 124 of the isolation sleeve 102 defines the section of the isolation sleeve 102 that is downhole of the ring seal 119 and “seals” the inside of the isolation sleeve 102 from fluid flow through the production screen 26 (see FIG. 8 F- 8 H). According, a particular section of the isolation sleeve 102 could be defined as the piston 126 during one stage of operation, and defined as seal tubing 124 during a subsequent stage of operation (see FIG. 8 F- 12 F). Below the seal tubing 124 , the wrap screen 128 extends to form the lowest most distal end of the isolation sleeve 102 . In the open position, seal tubing seals 130 engage the seal surface 157 to ensure that all production fluids flow through the wrap screen 128 . A hydraulic dampener 118 is located below the hydrostatic chamber 104 between the seal tubing 124 and the isolation string 101 (see FIGS. 8 G- 12 G). The hydraulic dampener 118 serves to regulate the speed at which the isolation sleeve 102 closes upon release by the pop lock 108 . The hydraulic dampener 118 comprises two parts, a dampening ring 151 and a lock ring 152 , both of which are secured to the outer diameter of the seal tubing 124 . When locked, these rings are unable to slide in the axial direction relative to the seal tubing 124 . When locked in the position shown in FIGS. 8G-12G, fingers with heads (similar to the piston collar 106 described above) of the dampening ring 151 are positioned so that the heads protrude into an annular slot in the outside diameter of the seal tubing 124 . The lock ring 152 is placed around the heads of the dampening ring 151 to secure the heads in the slot. The outer diameters of the dampening and lock rings 151 and 152 are slightly smaller than the inside diameter of the adjacent portion of the isolation string 101 . This difference in diameters allows a small amount of fluid to pass from below the hydraulic dampener 118 to above while the isolation sleeve 102 slides from the open to the closed position. Since fluid flow is restricted through the narrow annular space, movement of the isolation sleeve 102 is restricted. This reduces opportunities for the isolation sleeve 102 to become damaged during closure.
The process for isolating the production zone after the gravel pack operation will now be described.
FIGS. 6A through 6G illustrate as position of the service tool 138 relative to the isolation string 101 immediately after “gravel” is packed around the outside of the production screen 26 . In fact, since the service tool 138 has been pulled up relative to the isolation string 101 , the gravel pack sleeve 153 is closed (see FIG. 6 B).
In FIGS. 7A through 7G, the service tool 138 is shown in a reversing position. As is known in the art, completing fluid is cycled down the outside of the service tool 138 to flush the gel/propant of the gravel pack procedure back up through the inside of the service tool 138 . In this position, gravel pack collet 154 has indicated on a gravel packer shoulder 155 so the operator will know the exact location of the service tool 138 . After completion of the reversing procedure, the operator pulls the service tool 138 further up in the wellbore until the release tool indicator collet 144 indicates against the seal port shoulder 136 (see FIG. 7 C). When the release tool indicator collet 144 contacts the seal port shoulder 136 the service tool 138 operator is informed as to the location of the release tool 100 . Continued upward force on the service tool 138 , against the unmoving seal port 136 , causes the release tool shear pin 142 to fracture thereby freeing the release tool 100 from the service tool 138 allowing the release tool 100 to “free float” inside the well bore (see FIG. 8 D).
The position of the devices immediately after release of the release tool 100 is shown in FIG. 8A-8J. Due to the force of gravity, the release tool 100 has fallen in the space between the wash pipe 112 and the isolation string 101 .
In FIGS. 9A-9J, the release tool 100 is shown reattached to the service tool 138 . To reattach the release tool 100 to the washpipe 112 of the service tool 138 , the service tool 138 is raised until a wash pipe collet 114 contacts a release tool capture collet 116 (see FIG. 9 C). The service string 138 is raised until the release tool indicator collet 144 , which is on the outside diameter of the release tool 100 , indicates against the seal port shoulder 136 on the isolation string 101 . Continued upward movement of the service tool 138 results in the wash pipe collet 114 fully mating with the release tool capture collet 116 to secure the release tool 100 to the wash pipe 112 . This position is shown in greater detail in FIG. 14 .
In FIGS. 10A-10J, the service tool 138 is again set down in the wellbore to activate the trigger. In this embodiment, the service tool 138 is lowered to a position where the release tool 100 is inserted into the upper rim of the pop lock 108 (see FIG. 10 E). The service tool 138 comprises a release tool latch 140 which contacts the pop lock 108 (FIG. 10 E). The upper ring of the pop lock 108 has a pop lock lip 111 which is engaged by a release tool latch 140 on the release tool 100 . When the release tool latch 140 is inserted into the pop lock lip 111 , the parts snap into engagement so that the opposing shoulders of the parts prevent slippage of the parts when the service tool 138 is again pulled back up the wellbore. These parts are shown in greater detail in FIG. 14 . With the release tool 100 and the pop lock 108 engaged, the operator closes the isolation sleeve 102 to isolate the gravel packed production zone by pulling the service tool 138 further up the wellbore. This action pulls the pop lock 108 upward relative to the piston collar 106 to release the fingers 107 of the piston collar 106 as described above. Shearing the pop lock shear pin 110 disengages the pop lock 108 from the isolation string 101 thus allowing the pop lock 108 to slide upward with the release tool 100 . The isolation sleeve 102 is forced downward by gravitational forces in addition to the pressure differential between the wellbore pressure and the standard atmospheric pressure inside the hydrostatic chamber 104 .
In alternative embodiments, a trigger is activated by any means known in the art. For example, different mechanical tools may be used to release a latch sleeve to unlock the isolation sleeve similar to the trigger shown in the second embodiment of the invention. Next, hydraulic pressure sensitive devices may be used as a trigger so that the operator controls the trigger through downhole pressure differentials. Further, a ball seat trigger is possible so that the trigger is activated by a dropped ball. A still further illustrative embodiment uses intelligent methods, such as acoustics, pressure signals, battery packs, electronics, etc. to communicate with and activate a trigger. Examples of intelligent methods are disclosed in patent disclosures WO 96/10123 and U.S. Pat. No. 5,558,153, incorporated herein by reference.
Referring again to the second embodiment shown in FIGS. 11A-11J, the tool positions are shown immediately after the released isolations sleeve 102 has moved to a closed position. At the end of the isolation sleeve's 102 downward stroke threads located on lower, more distal end of the outside diameter of the piston collar 106 mate with threads formed on the inner radius of the C-ring 134 (see FIG. 11 F). Mating the threads on the outer radius of the piston collar 106 with the threads on the inner radius of the C-ring 134 secure the isolation sleeve 102 in the isolating position. In the closed position, lower seals 156 on the seal tubing 124 engage with the seal surface 157 in the isolation string 101 (see FIG. 11 I). This isolates the lower end of the production screen 26 while the upper end is isolated by the ring seal 119 (see FIG. 11 F). In the isolating position, the isolation sleeve 102 prevents fluid flow from the production zone through the production screen 26 .
With the isolation sleeve 102 in the closed position, the service tool 138 is ready for removal from the isolation string 101 . In this second embodiment of the invention, the washpipe 112 is long enough for the service tool seal 160 to clear the upper packer 18 (see FIG. 10A) when the release tool 100 engages the pop lock 108 (see FIG. 10 E). When the isolation sleeve 102 becomes closed, this clearance prevents a vacuum from developing below the service tool 138 . As noted above, if a vacuum develops below the service tool 138 , the service tool 138 will be effectively stuck in the isolation string 101 .
In FIGS. 12A-12J, the isolation sleeve 102 is again shown in a closed position. Further, the service tool 138 is removed and a removal tool 120 is inserted in the wellbore (see FIG. 12 F). Should it become necessary or desirable to raise the isolation sleeve 102 in the future, a piston collet 103 is provided on the inner radius of the top of the piston 126 for mating with a removal tool 120 . Of course, if the isolation sleeve 102 is to be removed, the hydraulic dampener 118 must be unlocked from the isolation sleeve 102 . This is accomplished by pulling the isolation sleeve 102 upward relative to the isolation string 101 until the lock ring 152 indicates against the ring seal 119 . Upon indication, the lock ring 152 will slide relative to the dampening ring 151 to release the dampening ring 151 from the isolation sleeve 102 . The isolation sleeve 102 may then be taken from the wellbore.
FIG. 16 depicts a third embodiment of the invention in cross sectional view. While this embodiment uses a hydrostatic chamber to close the isolation sleeve 202 as described above, it does not utilize a release tool 100 . Instead, the alternative pop lock 208 has a relatively smaller inner diameter. Similar to the second embodiment, this embodiment is assembled at the surface before the service tool and isolation string is placed in the wellbore. This prior assembly allows the wash pipe (not shown) to extend below the alternative pop lock 208 . The wash pipe of this embodiment is equipped with a wash pipe latch 240 (shown in FIG. 14) which catches the alternative pop lock 208 as the wash pipe 112 is pulled up in the wellbore. In all other respects, this embodiment is the same as the second embodiment.
When it is desirable to produce from the isolated zone, a production string is inserted in the wellbore to mate with the isolation string 101 . Then the isolation sleeve 102 may be perforated as is know in the art, or sleeve valves placed on the seal tubing 124 may be operated from a closed to open positions. Sleeve valves are described in U.S. Pat. No. 5,865,251, the disclosure of which is incorporated herein by reference.
According to a fourth embodiment of the invention, there is provided a service tool 10 similar to that of the first embodiment (see FIGS. 1 A- 2 B). At the distal end of the service tool 10 there is a locking slick joint 30 similar to that of the first embodiment. However, this fourth embodiment of the invention has a release tool 100 attached to the distal end of the locking slick joint 30 . The isolation sleeve 102 comprises a piston 126 , a hydraulic dampener 118 , and seal tubing 124 as in the second embodiment. Further, the piston 126 is driven by a hydrostatic chamber 104 as described above. Therefore, rather than pushing the isolation sleeve 102 with the locking slick joint 30 , the isolation sleeve 102 is activated by lowering the release tool 100 with the locking slick joint 30 to trip a trigger. Of course, the trigger releases the piston 126 which pushes the isolation sleeve 102 to a closed position. An advantage of this embodiment is that there is no need for a wash pipe 112 to extend below the locking slick joint 30 . Also, the reliability of the hydrostatic chamber 104 ensures complete closure of the isolation sleeve 102 . It is also possible to use various isolation sleeves with this fourth embodiment of the invention, including: the concentric isolation sleeve 21 shown in FIG. 1 B and having isolation sliding sleeves 24 , and the concentric isolation sleeve 21 a having a glass disk 39 shown in FIG. 3 .
According to a fifth embodiment of the invention, the service tool 138 has a configuration similar to that shown relative to the second embodiment. In this fifth embodiment, the washpipe is removed and the service tool 138 is modified to allow fluid to pass through the service tool 138 immediately subsequent closure of the isolation sleeve 102 by a hydrostatic chamber 104 . The modification could be to provide a mechanism to open the fracture valve 161 (see FIG. 7B) when the release tool 100 is positioned adjacent the pop lock 108 . Other means for opening a passage within the service tool 138 are also possible as known by persons of skill in the art.
The present invention, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes in the details of procedures for accomplishing the desired results will readily suggest themselves to those skilled in the art, and which are encompassed within the spirit of the invention and the scope of the appended claims.
5 well casing
10 Service tool
15 upper seal bore
16 lower seal bore
17 base seal bore
17 a Intermediate seal bore
18 upper packer
19 lower packer
20 Isolation string
21 Concentric isolation sleeve
22 Isolation string collar
24 Isolation sliding sleeves
25 Isolation sliding sleeve apertures
26 Production screen
27 Isolation tube apertures
28 Exterior concentric seal assemblies
29 Isolation tube
30 Locking slick joint
31 Locking slick joint outer sleeve
32 Locking slick joint female sleeve
33 Locking slick joint male sleeve
34 Mating ledge
35 Recess
36 open end
37 closed end
38 Locking slick joint tip
39 glass disk
40 Crossover assembly
41 Fracture port assembly
42 Fracture port chamber
43 Fracture ports
44 inner pipe
45 Aperture
46 outer pipe
47 outer holes
48 central lumen
52 Perforations
60 Annular passage
61 Locking slick joint plug
62 tip aperture
63 tip seals
64 upper set recess
65 lower mating ledge
66 lower set recess
84 well bore
100 Release tool
101 Isolation string
102 Isolation sleeve
103 piston collet
104 Hydrostatic chamber
105 Shoulder
106 piston collar
106 a lower section
106 b upper portion
107 Fingers
107 a Head
108 poplock
109 Seals
110 pop lock shear pin
111 pop lock lip
112 wash pipe
114 wash pipe collet
116 Release tool capture collet
118 Hydraulic dampener
119 ring seal
120 Removal tool
124 seal tubing
126 Piston
128 wrap screen
130 seal tubing seals
134 C-ring
136 seal port shoulder
138 Service tool
140 Release tool latch
142 Release tool shear pin
144 Release tool indicator collet
151 Dampening ring
152 lock ring
153 gravel pack sleeve
154 gravel pack collet
155 gravel packer shoulder
156 lower seals
157 seal surface
160 Service tool seal
161 Fracture valve
202 Isolation sleeve
208 Alternative pop lock
240 wash pipe latch | An isolation system having: an isolation string, wherein the isolation string has a packing assembly which secures the isolation string in a wellbore casing, wherein the isolation string has a production screen which allows production fluid to pass into the isolation string; an isolation sleeve which slides within the isolation string between open and closed positions, wherein the open position allows fluid communication between the production screen and an interior portion of the isolation string and the closed position prevents fluid communication between the production screen and an interior portion of the isolation string, wherein the isolation sleeve comprises at least one isolation valve which is coupled within the isolation sleeve, wherein the at least one isolation valve is movable between open and closed positions; a locking device which locks and unlocks the isolation sleeve in an open position, wherein the locking device comprises a trigger that secures the isolation sleeve to the isolation string before the trigger is activated and releases the isolation sleeve from the isolation string after the trigger is activated, wherein the trigger comprises: a piston collar having a solid cylindrical portion attached to the isolation sleeve and a finger portion having at least one finger, wherein the at least one finger has a head at a distal end; and at least one recess in the isolation string, wherein the head of the at least one finger is engaged in the at least one recess; a cylindrically shaped pop lock positioned adjacent the head of the at least one finger so that the head is between the pop lock and the recess, wherein the pop lock secures the head relative to the recess; and a latch attached to the service tool which couples with the pop lock, wherein the trigger is activated by removing the pop lock from the position adjacent the head; and an activation tool which allows the isolation sleeve to move to a closed position, wherein the activation tool is a piston driven by a hydrostatic chamber which comprises lower pressure within the hydrostatic chamber than without, and wherein the piston moves the isolation sleeve from the open to the closed position. |
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to portable shelters, more particularly to tents.
BACKGROUND OF THE INVENTION
A tent is intended to provide one or more users with a shelter which is fairly easily transported to be erected at various desired locations. Traditionally, tents have required poles, lines and/or stakes, all of which add weight to the tent (making the tent more cumbersome to transport), and all of which are readily misplaced (making the tent difficult to erect). Recent improvements in tent design have sought to eliminate these cumbersome elements.
One example of a pole-less tent is found in U.S. Pat. No. 4,876,829, incorporated by reference herein, which describes an inflatable tent structure comprising a plurality of pneumatically interconnected, elongate inflatable tubes defining the perimeter of the tent structure for being inflated in unison. A valve is provided for inflating the tubes, and a plurality of wall panels are suspended from and between the tubes to define the enclosure of the tent whereby the tubes define a support structure exterior to the enclosure of the tent. The tubes define a dome-shaped structure, the tubes converging in pneumatic interconnection with each other in a single plane at the apex of the dome-shaped structure. The valve includes a manifold in which all of the tubes interconnect at the apex of the dome-shaped structure. Among the shortcomings of such a tent, as described in this patent, are the dome shape and the interconnection of all of the tubes to a single valve. For example, failure of the single valve at the apex could result in the entire tent collapsing. Further, the location of the inflating valve on the exterior of the tent does not allow the user to re-inflate a partially inflated tent without exiting the tent.
The present invention is specifically directed at a tent for accommodating one person, that is lightweight (easy to transport), durable, weatherproof, reliable, and easy to use.
The following U.S. patents are referenced by way of background information, and are incorporated by reference herein: U.S. Pat. Nos. 5,205,086; 4,707,953; 3,629,875; 4,317,315; 3,759,277; 4,251,959; and 4,114,325.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved tent.
It is a further object of the present invention to provide a tent that is optimized for use by one person.
It is a further object of the present invention to provide a tent that lightweight (easy to transport), durable, weatherproof, reliable, and easy to use.
According to the invention, a generally semi-cylindrical cover portion is provided atop a generally rectangular base portion.
In one embodiment, the cover portion is closed at least one end by generally quarter-circular flaps, which are separable to allow ingress into the tent. The cover portion may be closed at one end by a non-separable, semi-circular flap.
The cover portion is provided with a plurality of semi-circular, inflatable ribs, extending circumferentially at axially spaced-apart positions. Preferably, the ribs are interconnected to one another in two groups, so that there are two valves (one valve per group of ribs) for inflating the totality of the ribs. Preferably, the valves are disposed so as to be inside the erected tent.
In one embodiment of the invention, the base portion is formed as an air mattress, inflatable with a single valve by the user.
According to an aspect of the invention, the two valves for inflating the cover portion are disposed at a location interior the erected tent, near the ends of the cover portion, so as to be accessible from exterior the tent for commencing inflating the cover portion and accessible from interior the tent for completing inflating the cover portion and/or re-inflating a partially-deflated the cover portion.
According to an aspect of the invention, the cover portion is joined to the base portion with zipper type fasteners, and said zipper type fasteners are covered by flaps on (e.g., peripheral regions of) the cover portion which are secured to edges of the base portion, such as with elongated Velcro (tm), hook and loop type fasteners. In this manner, the tent will exhibit a high degree of weatherproofness. The tent, with the cover portion joined to the base portion, resembles a quonset hut.
Among the advantages of the tent of the present invention are that the tent may be re-inflated from the inside. This is important in the event that the tent begins sagging, and completely avoids the necessity of the user exiting the tent to perform the re-inflation.
Other objects, features and advantages of the invention will become apparent in light of the following description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generalized, perspective, exploded view of the tent of the present invention, showing the cover portion and the base portion. Several details of construction are omitted from this view, for illustrative clarity.
FIG. 2A is a plan view of the cover portion of the tent of the present invention.
FIG. 2B is a cross-sectional view of a portion of a cover portion attaching to a portion of a base portion, of the tent of the present invention.
FIG. 3 is an end view of the tent of the present invention.
FIGS. 4A, 4B 4C are cross-sectional views of a portion of the cover portion of the tent of the present invention, detailing methods of connecting air-passageways to the cover portion.
FIGS. 5A, 5B, 5C and 5D are plan views of the cover portion of the tent of the present invention, showing various embodiments for isolating rib air-passageways from one another.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates, in a generalized manner, the tent 100 of the present invention. A cover portion 102 is generally semi-cylindrical, having a length "L" a width "W" and a height "H". A base portion 104 is generally rectangular, having a length "L" (approximately equal to the length of the cover portion), a width "W" (approximately equal to the width of the cover portion) and a thickness "T".
An exemplary length "L" for the cover and base portions is six-to-seven feet (72-84 inches). An exemplary width "W" for the cover and base portions is three-to-four feet (36-48 inches). An exemplary height "H" of the cover portion is three-to-four feet (36-48 inches), and an exemplary thickness "T" of the base portion is three-to-four inches. As is evident from these exemplary dimensions, the width "W" is suitably approximately equal to the height "H" and the thickness "T" is suitable approximately one tenth (e.g., one-twelfth) of the height "H".
These exemplary dimensions are suitable to provide a tent for accommodating one person, along with a modest amount of personnel effects, with head room, foot room and side room.
The cover portion 102 has a front edge 102a, two opposite side edges 102b and 102c, a back edge 102d, an inside surface 102e and an outside surface 102f.
The base portion 104 has a front edge 104a, two opposite side edges 104b and 104c, a back edge 104d, a top (inside) surface 104e and a bottom (outside) surface 104f.
As described in greater detail hereinbelow, the tent is lightweight, inflatable and waterproof.
FIG. 2A is a flattened-out (plan) view of the cover portion 102, with the inside surface 102e of the cover portion 102 exposed (facing the viewer), according to a simple embodiment of the invention. The cover portion 102 is shown in a flaccid state, which it would be in prior to erecting or inflating the cover portion 102. FIG. 2B is a detail view of a side edge 102b of the cover portion 102 connecting to a corresponding side edge 104b of the base portion 104.
As best viewed in FIG. 2A, the uninflated cover portion 102 is rectangular, having two opposite side edges 102b and 102c, each side edge having a length "L". The `flattened` width "FW" of the cover portion 102 is evidently larger than its erected width "W", for example three times its erected width, and may be approximately equal to the length "L" (i.e., FW˜L). The flattened width "FW" of the cover portion is initially greater than the width "W" of the base portion (which corresponds to the erected width "W" of the cover portion).
The cover portion 102 is provided with a plurality of tubular, elongate air passageways 114a, 114b, 114c, 114d, 114e (five shown, may be fewer or more), extending across the width of the cover portion at longitudinally (axially) spaced-apart positions, including one passageway (114a, 114e) disposed adjacent each end of the cover portion. When inflated, these passageways (114a . . . 114e) act as "ribs" to support the cover portion in its semi-cylindrical configuration.
The cover portion 102 is provided with two tubular, elongate air passageways 120, 122, each extending inward of and parallel to a respective side edge 102b, 102c of the cover portion 102. The rib air-passageways extend across the cover portion between the two edge air-passageways (as shown, perpendicular thereto). The ends of the rib air passageways (114a . . . 114e) are connected to the edge air passageways (120, 122). In this manner, by providing air into the edge air passageways (120, 122), air is communicated into the rib air passageways (114a . . . 114e). Were the side edges 102b, 102c of the cover portion unconstrained, this would result in the various air passageways being inflated, but would not result in the cover portion being erected into a semi-cylindrical configuration. In order to achieve the semi-cylindrical configuration of the cover portion, it is necessary to constrain the side edges of the cover portion to be less than "FW" (its flattened width), namely to be equal to the width "W" of the erected tent.
The side edges 102b, 102c of the cover portion are each provided with two distinct fastening systems for connecting the cover portion 102 to the base portion 104.
A first fastening system, disposed approximately three-to-four inches within the perimeter (i.e., within a side edge) of the cover portion, and immediately outside of the respective edge air passageway (120, 122), comprises one elongate component 130, 132 of a two-component zipper-type fastener.
As best viewed in FIG. 2B, each side edge 104b, 104c (only one of the two side edges are shown in this figure) of the base portion is provided with a corresponding (mating) elongate component 134 of a zipper-type fastener. In use, prior to inflating the cover portion, the component 130 is connected to the component 134, and the component 132 is connected to a similar component (not shown) on the opposite side edge 104c of the base portion 104. The zipper components comprise the first fastening system, and constrain the cover portion to the width "W" so that the rib air passageways, when inflated, will cause the cover portion 102 to be erected (i.e., to be generally semi-cylindrical and to have a height "H"). The fasteners (e.g., 130/134, and 132) secure the cover portion 102 to the base portion 104.
In order to ensure that there is a weatherproof connection between the cover portion 102 and the base portion 104, a second fastening system comprises elongate strips 140, 142 of one component of a Velcro (tm), hook and loop type fastener system disposed along each side edge 102b, 102c of the cover portion, just inside the perimeter of the cover portion and outside the location of the zipper component. Another corresponding elongate component 144 (only one shown in FIG. 2B) is disposed on the side edges 104b (and 104c, not shown) of the base portion 104. In use, after the cover portion 102 is zipped to the base portion 104, the Velcro-type fasteners are brought securely together so that a peripheral region of the cover portion extends over the zippers, thereby weatherproofing the junction between the cover portion 102 and the base portion 104.
Although the cover portion 102 has been described as semi-cylindrical, it is within the scope of this invention that the cross-section of the cover section not be perfectly semi-circular, but rather it can be semi-elliptical--the general idea being that it is three-dimensional and is curved.
FIG. 2A shows an air (inflation) valve 150 suitable for inflating the rib air passageways, such as by the user blowing air into the air valve. Generally, it is preferred that this air valve 150 be disposed at a location that is interior the erected tent so that a partially-deflated tent (e.g., a sagging, previously-erected cover portion) can be re-inflated by the user without exiting the tent. In FIG. 2A, all of the rib air-passageways are connected to one another. Evidently, a hole in one rib air-passageway would cause deflation of all of the rib air-passageways. Alternate embodiments of the rib air-passageways are shown and described with respect to FIGS. 5A-5D.
FIG. 3 shows a representative one end (e.g., the `front end`) of the tent 100. Preferably, both (front and back) ends of the tent are constructed in an identical manner. The front end of the tent comprises two quarter-circular flaps 302 and 304, each extending from the front edge 102a (see FIG. 1) of the cover portion 102. The front (and rear) flaps are advertently omitted from the illustrations of FIGS. 1 and 2A, for illustrative clarity.
Each end flap (302,304) is provided with a vented window 306. The vented window may be opaque, and may be secured only at its top edge to the respective end flap. Preferably all (four) end flaps are provided with a similar window.
As shown in FIG. 3, one end flap 302 is in a closed position, and one end flap 304 is in an open (furled) position. The inflating valve 150 (compare FIG. 2A) is visible behind the open flap 304.
The front edge 104a of the bottom portion 104 is provided with one component 308 of a two-component, Velcro(tm)-type fastening system. The corresponding bottom edge 310 of each end flap (304) is provided with another component 312 of the two-component, Velcro(tm)-type fastening system. In this manner, when the end flaps are closed, the ends of the tent can be sealed against weather. Any suitable fastening system (such as a zipper or Velcro(tm); not shown) is provided on the side edges 314, 316 of the end flaps 302, 304, respectively, so that the two quarter-circular end flaps can be joined to form a semi-circular end panel for the tent, and separated to allow ingress into the tent.
FIGS. 4A, 4B and 4C illustrate various (alternate) ways of forming the tubular air-passageways (e.g., 114a . . . 114e, 120, 122; see FIG. 2A) integrally with the cover portion (102).
In FIG. 4A, a representative tubular air passageway 402 (representing the edge and rib air-passageways) is formed as a nearly complete circle (in cross-section), the ends 402a and 402b of which are folded back (outward from the circle) and joined (with a suitable adhesive, or the like) to a representative (e.g., inner) surface 404 of the cover portion (102). This may be the inner surface 102e (compare FIG. 2A), or may be the outer surface (102f), but is preferably the inner surface.
In FIG. 4B, the cover portion is formed having a double thickness, represented by the surfaces 410 and 412. A representative air-passageway 414 is formed by a void between the two surfaces 410, 412. In areas where there is not an air-passageway (414) the two surfaces are joined (e.g., laminated) by a suitable adhesive (not shown).
In FIG. 4C, the air-passageway is formed as two semi-circular elements 420 and 422. The ends of each semi-circular element extend radially away from the semi-circular element, and are spaced apart so that ends of regions 424 and 426 or the cover portion can be sealed within these ends. This is similar to known methods of joining tubular air-passageways, as shown in FIG. 18 of U.S. Pat. No. 4,317,315.
FIGS. 5A, 5B, 5C and 5D illustrate various (alternate) ways of interconnecting the edge air-passageways (e.g., 120, 122; see FIG. 2A) with the rib air-passageways (114a . . . 114e, see FIG. 2A). It is generally preferred that the rib air-passageways are isolated from one another, and so that the failure of one rib air-passageway will not adversely affect at least a portion of the remaining rib air-passageways. In these figures, two edge air-passageways 502 and 504 are illustrated, and a plurality of (in this case, six) rib air-passageways 506, 508, 510, 512, 514 and 516 are illustrated. The cover portion 102 is shown in dashed lines, and its edges (102a . . . 102d) are indicated consistent with the illustration of FIG. 2A. As in FIG. 2A, in this figure the edge air-passageways are disposed on the cover portion, each edge air-passageway disposed on the cover portion inward of a corresponding opposite side edge of the cover portion. As will be evident, the rib air-passageways are discussed as being in two groups (two pluralities) disposed on the cover portion. Generally, both pluralities of rib air-passageways extending widthwise across the cover portion between the two edge air-passageways and are connected to the two elongate edge air-passageways. Throughout these figures, an inflation valve (see, e.g., 150, FIG. 2A) is associated with each edge air-passageway (disposed near the end of each edge air-passageway).
As shown in FIG. 5A, the first plurality (506, 510, 514) of rib air-passageways are interleaved with the second plurality (508, 512, 516) of rib air-passageways. The first plurality (506, 510, 514) of rib air-passageways are connected solely to a one of the edge air passageways (502). The second plurality (508, 512, 516) of rib air-passageways are connected solely to an other of the edge air passageways (504). In this manner, should there be a leak in any one of the edge air-passageway 502 or the rib air-passageways (506, 510, 514) connected thereto, the other edge air-passageway 504 and the other rib air-passageways (508, 512, 516) connected thereto would not lose their structural (inflated) integrity, and vice-versa. This arrangement (of the rib air-passageways) has the advantage that if one group fails, the user would still have a semi-cylindrical (cover portion) tent enclosure, albeit a bit saggy at certain locations.
As shown in FIG. 5B, the first plurality (506a, 508a, 510a, 512a, 514a, 516a) of elongate rib air-passageways are connected to a one of the edge air-passageways 502, and are disposed in line with the second plurality (506b, 508b, 510b, 512b, 514b, 516b) of rib air-passageways which are connected to the other of the edge air-passageways 504. In this manner, one `group` of rib air-passageways can fail without compromising the integrity of the other group of rib air-passageways. Each rib air-passageway (e.g., 506) is divided into two widthwise segments (e.g., 506a and 506b). This arrangement (of the rib air-passageways) has the advantage that if one group fails, the user is left with a quarter-cylindrical (cover portion) tent enclosure.
As shown in FIG. 5C, the first plurality (506, 508, 510) of rib air-passageways are in communication with a one of the edge air-passageways 502, and are arranged towards one end 102a of the cover portion. The second plurality (512, 514, 516) of rib air-passageways are in communication with an other edge air-passageway 504, and are arranged at another, opposite end 102d of the cover portion. This arrangement (of the rib air-passageways) has the advantage that if one group fails, one (or the other) one half of the length of the tent enclosure (i.e., the cover portion thereof) will remain fully supported by three (half the total number) of inflated rib air-passageways. Presumably, the user would lay down with their head at the erected (inflated) end of the tent.
As shown FIG. 5D, the first plurality of rib air-passageways are "staggered" with the second plurality of rib air-passageways. In other words, the pattern is not strictly interleaved (e.g., one rib to the left, next rib to the right, next rib to the left, etc.), but rather is interleaved in the following manner. The first two rib air-passageways (506, 508) and the fourth rib air-passageway (512) are connected to a one of the edge air-passageways (502). The third (510) and the last two (514,516) rib air-passageways (506, 508) are connected to an other of the edge air-passageways (504). This arrangement (of the rib air-passageways), is similar to the arrangement shown in FIG. 50 in that if one group (or rib air-passageways) fails, the one end of the tent will remain erected (in this case, a third of the tent's length).
The base portion 104 (see, e.g., FIG. 1) is preferably formed as an air-mattress, having its own inflation valve. Certain salient features of the base portion 104 have been shown and discussed with respect to FIGS. 2B and 3 (e.g., zipper-type fasteners and hook-and-loop tope fasteners disposed on the side edges of the base portion).
The cover portion (102) and the base portion (104) are formed of any material suitable for such a tent, such as plastic, nylon, polyester, plasticized fabric, etc. Evidently, the material of the elongate tubes (edge and rib air-passageways) should be airtight.
Although 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 preferred embodiments have been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A portable, inflatable tent has a semi-cylindrical cover portion that fastens to a planar base portion. The cover portion is provided with rib air-passageways that, when inflated, support the cover portion in its semi-cylindrical configuration. Various configurations of the rib air-passageways connecting to edge air-passageways provided with air inflation valves are described. Generally, the rib air-passageways are segregated into two groups, so that the failure of a single rib air-passageway will not cause the deflation of all of the rib air-passageways. The inflation valve(s) are preferably disposed on a surface of the cover portion that will be interior the erected tent, so that the user may reinflate the tent without exiting the tent. The tent is sized and shaped so as to provide convenient, weatherproof, portable shelter for a user. |
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This application is a division of application No. 09/244,983 filed Feb. 4, 1999, now U.S. Pat. No. 6,237,295.
FIELD OF THE INVENTION
The present invention is directed to a flooring assembly and fastener therefor and, in particular, to recycled plastic lumber decking and unitary clips to retain the decking in a stable and level manner on a plurality of horizontal joists.
BACKGROUND OF THE INVENTION
The present invention relates to an innovative flooring assembly and method, as well as several embodiments of a unitary fastener clip used to secure the flooring assembly to a plurality of horizontal support members, such as joists, so as to construct a platform, patio or a raised deck. This flooring assembly and fastener clip find particular utility by providing homeowners and building contractors with a relatively simple, secure and reliable means to construct a platform or a deck with a minimum number of component parts, and without specialized tools or expertise. The preferred embodiment of the flooring assembly employs recycled plastic lumber as the flooring component, which promotes the conservation of resources and the environment.
In the prior art, various fasteners have been proposed to retain flooring or decking in place, none of which approach the simplicity, economy and ease of use of the present invention. For instance, U.S. Pat. No. 5,660,016 to Erwin et al. discloses a foam-filled extruded decking plank and decking attachment system. This system includes clamps to hold down blocks which are secured onto a structure that supports the planks. The blocks permit relative motion between the planks. U.S. Pat. No. 4,599,842 to Counihan discloses a fastening system for fastening planar sections such as flooring boards to a base surface. The system includes fastening strips that interlockingly engage in a set of grooves cut in the ends of the boards. While the system of Erwin et al. recognizes that joist and decking fabricated from different construction materials may expand or contract at differing rates, this system is rather complex and especially adapted for extruded decking. In light of these complexities, a need has developed to provide an improved system for assembling flooring or decking planks which uses fewer components parts, is easier to assemble and is less expensive. In response to this need, the present invention provides an assembly and a fastener therefor which is simple but effective in securely retaining flooring planks to a support structure such as joists.
SUMMARY OF THE INVENTION
Accordingly, it is a first object of the present invention to provide consumers and building contractors with a relatively cost effective, secure and low maintenance flooring assembly, particularly for recycled plastic lumber.
Another object of the present invention is to provide an improved, easily-manufactured and cost-effective unitary fastener clip to securely retain flooring or decking in place.
A related object of the present invention is to provide a unitary fastener clip what will securely connect a series of flooring planks so that they are maintained flat and level with one another, while allowing the individual planks to expand and contract longitudinally according to weather and atmospheric condition.
A further object of the present invention is to provide a method if installing flooring using interconnecting flooring and the inventive unitary flooring fastener, with a minimum number of necessary components, and without specialized tools or expertise.
To achieve these objects and in accordance with the purposes of the invention, as embodied and broadly described herein, the present invention is directed to a flooring assembly comprising: a plurality of elongated flooring planks, wherein each of the elongated flooring planks has on opposing ends at least one of a tongue-containing first longitudinal edge and a groove-containing second longitudinal edge. This flooring assembly is arranged on a plurality of supporting members so that the tongue-containing first longitudinal edge of a first elongated flooring plank engages the groove-containing second longitudinal edge of a second flooring plank.
In addition, a plurality of clip units are utilized, wherein each of the clip units is fastened to the supporting members and are arranged between the elongated flooring planks. A distal end portion of each clip positioned between a lower face of said tongue-containing first longitudinal edge of the first elongated flooring plank and an upper face of the groove-containing second longitudinal edge of said second flooring plank. Each of the clip units exerts a force normal to the lower face of the tongue-containing first longitudinal edge of said first plank and the upper face of the groove-containing second longitudinal edge of a second flooring plank so as to retain said elongated flooring planks to the supporting members latitudinally, while permitting the elongated flooring to expand and contract longitudinally.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the drawings of the invention wherein:
FIG. 1 is a sectional view of one embodiment of the inventive assembly in exploded form to show greater detail;
FIG. 2 shows the assembly of FIG. 1 in a partially assembled state;
FIG. 3 shows a perspective view of one embodiment of the inventive fastener;
FIG. 4 shows a perspective view of a second embodiment of the inventive fastener;
FIG. 5 shows a perspective view of a third embodiment of the inventive fastener; and
FIG. 6 shows a connection between adjacent planks; and
FIG. 7 shows a side view of the inventive fastener.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the inventive flooring assembly and fastener unit of the present invention is shown in FIGS. 1, 2 and 3 and is represented by reference numeral 1. The flooring assembly includes a plurality of elongated flooring planks 2 , 3 , and 4 . These elongated flooring planks 2 , 3 or 4 may be constructed of an extruded recycled plastic material, or other suitable flooring materials commonly used in construction. Each of the elongated flooring planks 2 , 3 and 4 , have on opposing ends at least one of a tongue-containing first longitudinal edge 5 and a groove-containing second longitudinal edge 6 . The elongated flooring planks 2 , 3 and 4 are arranged along a plurality of supporting members 7 , so that the tongue-containing first longitudinal edge 5 an elongated flooring plank 3 or 4 engages the groove-containing second longitudinal edge 6 of a second flooring plank 2 or 3 . The supporting members 7 may take the form of joists and may be constructed of wood.
A plurality of clip units 8 are used to fasten the plurality of flooring planks 2 , 3 or 4 to the supporting members 7 . Each of said clip units 8 may have a z-shape in vertical cross section. The base 8 a of each of the clip units 8 is fastened to a supporting member 7 and is arranged between the flooring planks, 2 , 3 , or 4, with a leg 8 c extending vertically therefrom. In an alternative embodiment, each clip unit 8 is comprised of a pair of prongs 10 a and 10 c extending downward from the base portion 8 a of the clip units 8 . The pair of prongs 10 b and 10 c engage the supporting member 7 when the clip units 8 are fastened thereto.
A free, distal end portion 8 d of each clip unit 8 is attached perpendicular to the vertical leg 8 c and parallel to the base 8 a . The distal end portion 8 d is positioned between a lower face 5 a of the tongue-containing first longitudinal edge 5 of elongated flooring planks 3 or 4 and an upper face 6 a of the groove-containing second longitudinal edge 6 of second flooring planks 2 or 3 . Each of the clip units 8 used to construct flooring assembly 1 is usually fastened to each of the supporting members 7 in a spaced apart relationship.
When the flooring is fully assembled as shown in FIGS. 1, 2 and 3 , each of the clip units 8 exerts a force perpendicular to the lower face 5 a of the tongue-containing first longitudinal edge 5 of the first plank 3 or 4 and to the upper face 6 a of the groove-containing second longitudinal edge 6 of the second plank 2 or 3 , so as to retain the elongated flooring planks 2 , 3 or 4 to said supporting members 7 latitudinally, while permitting the elongated flooring planks 7 to expand and contract longitudinally according to usage, weather or atmospheric conditions.
Referring now to FIGS. 1, 3 , 6 and 7 , the preferred embodiment of the 8 is described. In FIGS. 1 and 3, the clip units 8 used to fasten the elongated flooring planks 2 , 3 and 4 to a support surface 7 are comprised of a base 8 a and at least one fastening means 8 b to secure the base 8 a to support surface 7 . A leg 8 c extends vertically from the base 8 a . A free, distal end portion, 8 d extends perpendicular to the leg 8 c , and is spaced apart from, and parallel to, the base 8 and is sized to engage a groove-containing second longitudinal edge 6 of a plurality of flooring planks 3 or 4 to retain the flooring planks 3 or 4 against the support surface 7 .
Again referring to FIGS. 1, 2 , 6 and 7 , the clip unit 8 is fastened to the supporting member 7 by a screw 8 b , which is inserted through a single aperture 8 e in the base 8 a , through which the screw 8 b engages the support member 7 and the base 8 a . The single aperture 8 e in the base 8 a of clip unit 8 may be offset from the center point represented by the intersection of broken reference lines 12 , so as to be positioned in close proximity to leg 8 c . This is an important feature of the present invention, as it prevents clip 8 from bending upward during use, which allows a smaller clip 8 to be used to secure the elongated flooring 2 , 3 and 4 to the supporting members 7 . This feature may also be incorporated into the alternative embodiments of the clip units 9 and 10 shown in FIGS. 4 and 5.
The single aperture 8 e may be countersunk 8 f in order to allow the head of the screw 8 b to rest flush and level with the upper surface of the base 8 a . This feature allows the elongated flooring planks 2 , 3 and 4 to lie flat and level with each other on the supporting members 7 , thus enhancing the utility and aesthetic desirability of the flooring assembly 1 .
In alternative embodiments of the invention shown in FIGS. 2, 4 and 5 , the clip units 9 and 10 include fastening means comprised of two apertures 9 e and 10 b arranged adjacent to one another in the base 9 a and 10 a , and through which two screws 9 b and 10 c engage the support surface 7 and the base 9 a and 10 a . Each of the two apertures may be countersunk (not shown), in order to allow the heads of the screws 9 b and 10 c to rest flush and level with the upper surface of the base 9 a and 10 a . This allows the elongated flooring planks 2 , 3 and 4 to lie flat on the supporting members.
Referring now to FIG. 5, the clip unit 10 includes an additional fastening means comprised of two prongs 10 d and 10 e attached to opposing sides of the base 10 a and extending downward therefrom. As shown in FIG. 2, the prongs 10 d and 10 e are inserted into the material of the supporting member 7 in order to prevent movement of the clip unit 8 .
The present invention also includes a method, shown in FIG. 3, of constructing a flooring assembly I which comprises the steps of providing a plurality of elongated floor planks 2 , 3 and 4 with opposing longitudinal edges 5 and 6 , clip units 8 and supporting members 7 and fastening the clips 8 units in spaced apart relationship along the supporting members 7 to support the plurality of elongated floor planks 2 , 3 and 4 . This method also includes the steps of arranging the elongated floor planks 2 , 3 and 4 on the supporting members 7 in a side-by-side relationship to create a substantially flat, level flooring.
The preferred embodiment of this method also requires the positioning of the clip units 8 between the opposing longitudinal edges 5 and 6 of the adjacent elongated floor planks 2 , 3 and 4 to retain these floor planks 2 , 3 and 4 on the supporting members.
In alternative embodiments of this method, shown in FIG. 2, clip unit 8 may include means, such as prongs 10 d and 10 e , which securely affix the clip unit 8 to supporting member 7 . As a result, the clip units 8 are fastened in such a way as to further prevent rotation thereof.
Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims. | A flooring assembly and fastener therefor comprises flooring planks, preferably made of recycled lumber, and a clip fastener arranged between opposing longitudinal edges of the planks. The planks, in one embodiment, use tongue and groove construction. The clip is Z-shaped in cross section, one end portion of the clip catching the groove of a plank with the other end portion acting as a base for fastening to the joist. The clip fasteners are spaced along each joint and adjacent joints to retain the planks on the joists while permitting the planks to expand and contract at rates different than the joists themselves. |
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TECHNICAL FIELD
[0001] The application relates generally to communications. In particular, the application relates to a wireless sensor in a downhole operation.
BACKGROUND
[0002] During drilling operations for extraction of hydrocarbons, measurement of different downhole parameters. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The drill string used to perform the drilling operations typically includes a downhole tool having a number of sensors to measure such parameters. Some of these sensors may need to make contact with the formation using pivoting arms using mechanical/hydraulic devices. These mechanical/hydraulic devices allow the sensors to make required measurements in a variety of borehole conditions, shapes and diameters.
[0003] Because these devices include electronics (e.g., the sensors) to obtain these measurements, the devices typically need insulated wiring to transmit the data back to the electronics within the downhole tool that is part of the drill string. There may be reliability issues because this device is moving, under potentially high pressure and temperature and in a potentially conductive environment. Moreover, the wiring can restrict the potential flexibility of the sensor movements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The numbering scheme for the Figures included herein are such that the leading number for a given reference number in a Figure is associated with the number of the Figure. For example, electronics 102 can be located in FIG. 1 . However, reference numbers are the same for those elements that are the same across different Figures. In the drawings:
[0005] FIG. 1 illustrates a wireless communication sensor attached to a pivot arm of a downhole tool, according to some embodiments of the invention.
[0006] FIG. 2 illustrates a wireless communication sensor attached to a hydraulically activated part of a downhole tool, according to some embodiments of the invention.
[0007] FIG. 3 illustrates a tethered or deployed unattached sensor in a downhole operation, according to some embodiments of the invention.
[0008] FIG. 4 illustrates a wireless sensor that has been fired or deployed into the formation or the borehole, according to some embodiments of the invention.
DETAILED DESCRIPTION
[0009] Methods, apparatus and systems for a wireless sensor in a downhole operation are described. In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the understanding of this description.
[0010] FIG. 1 illustrates a wireless communication sensor attached to a pivot arm of a downhole tool, according to some embodiments of the invention. FIG. 1 includes electronics 102 and an antenna array 104 , which that may be part of a downhole tool for drilling operations. The downhole tool may be part of a wireline system or a Measurement While Drilling (MWD)/Logging While Drilling (LWD) system. A sensor/pad 106 having a pad transceiver 108 is coupled to the downhole tool through a pivot arm 110 . The sensor/pad 106 may make measurements of various parameters downhole. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The pad transceiver 108 wirelessly communicates with the antenna array 104 . For example, the pad transceiver 108 may use electromagnetic communications through the borehole and or the body of the downhole tool.
[0011] The antenna array 104 operates at a band of frequencies or frequencies that are selected to optimize transmission in a downhole logging or drilling environment. The antenna array 104 is selected to provide data flow at the desired variable distance from the sensor/pad 106 . The antenna array 104 is selectable, either manually or automatically, to suit the individual environments of operation. Operating environment may include conductive or nonconductive fluids, air, gas or any hydrocarbon-based fluid. The sensor/pad 106 may be powered using external wires, a self-powered by localized electromagnetic field and/or an internal power source.
[0012] The antenna array 104 may be pressure compensated and/or exposed to the borehole fluid. The antenna array 104 may include a single individual antenna or a series of antennas. The data rate of transfer between the pad transceiver 108 and the antenna array 104 may be set by the individual sensor requirement. The data rate of transfer may vary depending on the type of measurement. The antenna array 104 may be used for a multiple sensor assembly for separate sections of the downhole tool.
[0013] FIG. 2 illustrates a wireless communication sensor attached to a hydraulically activated part of a downhole tool, according to some embodiments of the invention. FIG. 2 includes electronics 202 and an antenna array 204 , which that may be part of a downhole tool for drilling operations. The downhole tool may be part of a wireline system or a Measurement While Drilling (MWD)/Logging While Drilling (LWD) system. A sensor/pad 206 having a pad transceiver 208 is coupled to the downhole tool through a hydraulically activated arm 215 . The sensor/pad 206 may make measurements of various parameters downhole. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The pad transceiver 208 wirelessly communicates with the antenna array 204 . For example, the pad transceiver 208 may use electromagnetic communications through the borehole and or the body of the downhole tool.
[0014] FIG. 3 illustrates a tethered or deployed unattached sensor in a downhole operation, according to some embodiments of the invention. FIG. 3 includes electronics 302 and an antenna array 304 , which that may be part of a downhole tool for drilling operations. The downhole tool may be part of a wireline system or a Measurement While Drilling (MWD)/Logging While Drilling (LWD) system. A sensor/pad 306 includes a pad transceiver 308 . The sensor/pad 306 may be tethered or deployed unattached in the borehole. The sensor/pad 306 may make measurements of various parameters downhole. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The pad transceiver 308 wirelessly communicates with the antenna array 304 . For example, the pad transceiver 308 may use electromagnetic communications through the borehole and or the body of the downhole tool.
[0015] FIG. 4 illustrates a wireless sensor that has been fired or deployed into the formation or the borehole, according to some embodiments of the invention. FIG. 4 includes electronics 402 and an antenna array 404 , which that may be part of a downhole tool for drilling operations. The downhole tool may be part of a wireline system or a Measurement While Drilling (MWD)/Logging While Drilling (LWD) system. A sensor 406 may be fired or deployed into the formation or into the borehole. The sensor 406 may make measurements of various parameters downhole. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The sensor 406 wirelessly communicates with the antenna array 404 . For example, the sensor may use electromagnetic communications through the borehole and or the body of the downhole tool.
[0016] In the description, numerous specific details such as logic implementations, opcodes, means to specify operands, resource partitioning/sharing/duplication implementations, types and interrelationships of system components, and logic partitioning/integration choices are set forth in order to provide a more thorough understanding of the present invention. It will be appreciated, however, by one skilled in the art that embodiments of the invention may be practiced without such specific details. In other instances, control structures, gate level circuits and full software instruction sequences have not been shown in detail in order not to obscure the embodiments of the invention. Those of ordinary skill in the art, with the included descriptions will be able to implement appropriate fimctionality without undue experimentation.
[0017] References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
[0018] A number of figures show block diagrams of systems and apparatus for a wireless sensor in a downhole operation, in accordance with some embodiments of the invention. A number of figures show flow diagrams illustrating operations for a wireless sensor in a downhole operation, in accordance with some embodiments of the invention. The operations of the flow diagrams are described with references to the systems/apparatus shown in the block diagrams. However, it should be understood that the operations of the flow diagrams could be performed by embodiments of systems and apparatus other than those discussed with reference to the block diagrams, and embodiments discussed with reference to the systems/apparatus could perform operations different than those discussed with reference to the flow diagrams.
[0019] In view of the wide variety of permutations to the embodiments described herein, this detailed description is intended to be illustrative only, and should not be taken as limiting the scope of the invention. What is claimed as the invention, therefore, is all such modifications as may come within the scope and spirit of the following claims and equivalents thereto. Therefore, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | An embodiment includes an apparatus comprising a downhole tool that includes a body that includes electronics and an antenna array. The downhole tool also includes a sensor that includes a wireless transceiver that is coupled to the body of the downhole tool through a pivot arm. The sensor is to measure a downhole parameter and to wirelessly transmit the downhole parameter to the electronics through the antenna array. |
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TECHNICAL FIELD
[0001] The present disclosure relates generally to plugs for downhole cementing and other completion operations, and, more particularly, to a plug capable of performing multiple functions downhole.
BACKGROUND
[0002] Hydrocarbons, such as oil and gas, are commonly obtained from subterranean formations that may be located onshore or offshore. The development of subterranean operations and the processes involved in removing hydrocarbons from a subterranean formation typically include a number of different steps such as, for example, drilling a wellbore at a desired well site, treating the wellbore to optimize production of hydrocarbons, and performing the necessary steps to produce and process the hydrocarbons from the subterranean formation.
[0003] The steps of completing the well, including well stimulation, well enhancement, zonal isolation, sand control, and other completion steps often use tubular downhole tools to perform a variety of functions. These downhole tools are often operated with a ball or plug. The plug or ball lands and seals on a sleeve or seat internal to the tool, allowing pressure to be generated. The pressure build up enables the sleeve or seat to slide from one position to another position. The sleeve or seat can thus move from a closed position to an open position, whereby casing ports are opened, thus allowing fluids to flow into the annulus or subterranean formation. Downhole plugs are a fairly simple and generally reliable means of activating downhole tools.
[0004] One of the drawbacks of downhole plugs, however, is that after a particular downhole operation has been performed, the plug needs to be moved out of the way to continue operations. One technique for doing this involves drilling the plug out of the downhole tool. Another technique involves pumping fluid downhole at such a high pressure that the plug is forced down and sometimes out of the downhole tool.
[0005] Recent develops have led to efforts to optimize the use of the downhole plugs, for example, by reusing them in subsequent wellbore operations. Such efforts include designing the seats that the plugs set into to shear at high pressures. This enables the plugs to travel downhole for subsequent use. This solution, however, is less than optimal because there are a number of restrictions within the casing, including the inner diameter of the casing itself and coupling transitions, which can interfere with the dislodged seats.
[0006] The present disclosure is directed to a multi-function plug, which includes a detachable member, which enables the plug to engage with at least two seats to perform at least two separate downhole operations. By employing a detachable member, the plug have a reduced outer diameter, which enables to continue downhole with minimal chance of forming an obstruction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
[0008] FIG. 1 is an isometric view of a plug in accordance with the present disclosure;
[0009] FIG. 2 is an isometric view of the plug shown in FIG. 1 illustrating separation of a shear ring from the body of the plug (with the pins shown intact for clarity);
[0010] FIG. 3 is cross-sectional view of the plug shown in FIG. 1 ;
[0011] FIG. 4 is a partial cut-away view of an upper tool seated with the plug shown in FIG. 1 taken along a longitudinal plane;
[0012] FIG. 5 is a partial cut-away view of the upper tool shown in FIG. 4 illustrating the plug shifting the tool from a closed position to an open position;
[0013] FIG. 6 is a partial cut-away view of the upper tool of FIG. 4 shown in the open position with only the shear ring of the plug remaining in the seat; and
[0014] FIG. 7 is a partial cut-away view showing the plug seated in a lower tool.
DETAILED DESCRIPTION
[0015] Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve developers' specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure. Furthermore, in no way should the following examples be read to limit, or define, the scope of the disclosure.
[0016] A multi-function downhole plug 10 in accordance with the present disclosure is shown in FIG. 1 . The plug 10 is defined by a main body portion 12 , which is generally tubular shaped. The main body portion 12 of the plug has a center bore section 14 which is hollow along approximately ⅔rds of the length of the main body 12 , as shown in FIG. 3 . The hollow section opens at the tip or nose of the plug 16 . A cap 18 is placed at the tip or nose 16 of the plug 10 .
[0017] The cap 18 covers the open end of the main body 12 and prevents fluids and other downhole elements from entering into the hollow portion of the plug 10 . The cap 18 may be formed of an elastomeric or other suitable material known to those of ordinary skill in the art. The main body 12 may be formed of any suitable material which can withstand the harsh downhole environment, such as, for example, a metal alloy or rigid thermoplastic material.
[0018] The plug 10 is further defined by a hub 20 , which is attached to the distal end of the main body 12 , with the tip 16 being at the proximal end as a point of reference. The hub 20 has the shape of some car tire hubs, namely, generally circular with a forward taper, as best illustrated in FIGS. 1-2 . The forward taper allows the hub 20 to have generally aerodynamic shape in the rear portion of the plug 10 thereby enabling it to move through casing or work string with minimal resistance. The main body 12 of the plug has a slightly smaller diameter at the distal end to enable the hub 20 to be secured over the distal end of the main body, as illustrated in FIG. 3 . The hub 20 can be secured to the main body 12 using known mounting techniques, including, but not limited to welding, cementing, and the like. The hub 20 may be formed of the same material used to form the main body 12 , but alternatively, may be formed of a different material, for example, a less rigid material.
[0019] The hub 20 has a generally flat section at its distal end which enables a ring 22 to be secured to it. The ring 22 has a greater diameter than the largest diameter portion of the hub 20 , which is at the distal end. The ring 22 is secured to the end of the hub 20 may any one of a variety of known attached means. In one exemplary embodiment, the ring 22 is secured to the distal end of the hub using a plurality of shear pins 24 equally disposed around the circumferential surface of the ring 22 and hub 20 . In the exemplary embodiment illustrated in FIGS. 1-3 , ten shear pins 24 are illustrated. Those of ordinary skill in the art will understand and be able to determine the optimum number of shear pins to use, and their optimum size and grade, depending upon the particular application that the plug 10 will be used in. The ring 22 may be formed of the same material used to form the hub 20 and/or main body portion 12 . The ring 22 also has a generally cylindrical shape with a forward facing taper, as best illustrated in FIG. 2 . The forward facing taper is employed to continue the aerodynamic shape of the hub 20 at its distal end where the ring 22 is attached. As will be explained further below, the ring 22 enables the plug 10 to engage itself in at least two different downhole seats, which in turn enables the plug 10 to carry out at least two separate downhole operations. Furthermore, as those of ordinary skill in the art will appreciate, a plurality of nested rings 22 may be utilized with each layer of nested rings shearing off from the previous layer as downhole functions are performed. Thus, more than two downhole operations can be performed if multiple rings 22 are utilized.
[0020] The downhole plug 10 may have other optional features common among downhole plugs. For example, the downhole plug 10 may further include one or more wiper cups 26 and 28 as illustrated in FIGS. 1-3 . The wiper cups 26 and 28 are known in the art and are used to wipe the inner walls of the casing string as the plug 10 is deployed downhole. In particular, the wiper cups 26 and 28 may be used to wipe the casing ID of mud cake and other debris. They can also be used as a mechanical separator between two separate and distinct types of fluid being pumped downhole, e.g., mud and cement. The wiper cups 26 and 28 have a generally cylindrical shape with a forward facing taper, which like the forward facing taper on the hub 20 and ring 22 , enhance the aerodynamics of the plug 10 has a travels through one or more fluids downhole. The wiper cups 26 and 28 are generally formed of an elastomeric or rubber material, but can be formed of other suitable flexible materials which can withstand downhole conditions as well as have the ability to flex to conform to the non-uniform profile encountered by the plug 10 as it travels downhole.
[0021] An additional optional feature that the plug 10 may include are centralizers. FIGS. 1-3 shown two centralizers, one secured to the proximal end 30 and another secured to the distal end 32 . As those of ordinary skill in the art, one or more or no centralizers may be employed depending upon the applications. The specific centralizers 30 and 32 that are illustrated, are generally star-shaped and have six equally spaced arms. Again, the number of arms used may be varied. The centralizers 30 and 32 aid in maintaining the plug in a generally centralizer axial position as the travels downhole. This helps to minimize the possibility that the plug 10 may get stuck in an undesirable location. The centralizers 30 and 32 may be formed of a suitable elastomeric or similar material, which can withstand downhole conditions, but also have enough rigidity to allow maintain the plug 10 in a centralized orientation. The proximal centralizer 30 is held in place onto the main body 12 by the elastomeric end cap 18 . It may also be cemented or otherwise bonded to the main body 12 to ensure it does not separate from the main body. Likewise, the end cap 18 may be bonded to the tip 16 of the main body 12 . Similarly, the distal centralizer 32 is held in place onto the distal end of the plug 10 by an elastomeric distal end cap 34 , as best shown in FIG. 3 . The distal centralizer 32 and end cap 34 may also be bonded to the main body 12 using a cement or other similar bonding agent.
[0022] With reference to FIGS. 4-7 , the present disclosure will now discuss how the multi-function downhole plug 10 may operate. The plug 10 is deployed downhole through a section of casing string 36 until it reaches a section of the casing string identified as upper tool 38 , shown in FIG. 4 . The upper tool 38 is a section of the casing string which performs a downhole function, for example, injecting downhole fluid into the wellbore and/or formation through ports 40 . The plug 10 lands in a two part seat 42 a and 42 b . Seat 42 a may also be referred to as a closing seat and seat 42 a may also be referred to as an opening seat 42 b . Seats 42 a and 42 b are both secured to the inner circumferential surface of the upper tool 38 using a plurality of shear pins 44 a and 44 a , respectively. Shear pins 44 a and designed to withstand higher shear forces than shear pins 44 b.
[0023] The plug 10 lands in seat 42 b wherein ring 22 of the plug engages with and seals against a tapered end of the opening seat. Fluid is substantially blocked from flowing downhole by the seal formed between the ring 22 of the plug and the tapered end of opening seat 42 b . As the fluid is continued to be pumped downhole, pressure builds up. Upon reaching a high enough pressure the shear pins 44 b shear, thereby causing opening seat 42 b to slide downward to a position whereby the ports 40 are no longer cover the opening seat 42 b . In this position, fluids pumped from the surface are allowed to be injected into the wellbore and/or subterranean formation. At a later time another plug (not shown) can be sent downhole to seat with closing seat 42 a so as to activate the shearing of pins 44 a and thereby slide closing seat 42 a into a position whereby the ports 40 are once again blocked, i.e., into a position whereby the flow of fluid into the wellbore and/or subterranean formation is closed.
[0024] In the next step, after the plug 10 has activated the opening seat 42 b into position, the plug 10 may be moved further downhole for subsequent operation. This can be accomplished by increasing the pressure of the fluid being pumped downhole so as to cause the shear pins 24 attaching the ring 22 to the hub 20 to fail. Upon shearing of the pins 24 , the ring 22 will separate from the hub 20 and remaining part of the plug 10 . This enables the plug 10 to continue traveling downhole for subsequent use is activating another downhole tool. Once the ring 22 separates from the plug 10 , it remains engaged with the tapered portion of opening seat 42 b . More specifically, the generally tapered/concave shape of the ring 22 allows the fluid being pumped downhole to force the ring into engagement with the tapered portion of the opening seat 42 b . FIG. 6 illustrates the condition where the plug 10 has separated from the ring 22 and forced downhole leaving the ring engaged in the opening seat 42 b.
[0025] Once the plug 10 separates from the ring 22 and moves further downhole it eventually engages with a seat 44 attached to a lower tool 46 , as shown in FIG. 7 . In particular, the hub 20 engages with a tapered inner surface of the seat 44 to form a seal between the seat 44 and plug 10 . The seal formed between the seat 44 and the hub 20 of the plug 10 blocks the flow of fluid further downhole. As the fluid is continued to be pumped under this blocked condition, pressure builds up enabling the plug 10 and/or seat 44 to activate an operation of the lower tool 46 . The seat 44 may optionally be a moveable sleeve. Once the downhole operation of the lower tool 46 has completed, the plug 10 may be removed, or in the case where the lower tool 46 is at the end of the casing string, the plug 10 may simply remain in place. There are a number of ways to remove the plug 10 , which are known in the art, including but not limited to drilling out the plug, and utilizing a degradable material.
[0026] Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims. | A downhole plug and method of activating multiple downhole tools in a subterranean formation are disclosed. The plug includes a detachable ring that enables the plug to land in and engage at least two different seats, each seat having a different profile. This in turn enables the plug to activate at least two separate downhole devices, one in an upper downhole tool and one in a lower downhole tool. The ring separates from the plug once a certain pressure is reached in the wellbore enabling the plug to travel downhole from the upper tool to the lower tool to activate the device in the lower downhole tool. |
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BACKGROUND OF THE INVENTION
This invention is concerned with flooding of underground formations, such as oil-bearing strata and the like, and is more particularly concerned with an improved pump installation for pumping sub-surface water to an oil-bearing formation, and with improved control valve apparatus.
In the secondary recovery of fluid hydrocarbons, such as oil, it is common practice to flood the hydrocarbon-bearing formation with water pumped through a bore hole, thereby applying fluid pressure which increases the yield of the desired hydrocarbon from its underground formation. Both surface water and sub-surface water have been employed for this purpose. In the employment of sub-surface water, two schemes have been utilized -- (1) pumping the water upwardly to the surface through a first bore hole, then downwardly to the hydrocarbon-bearing formation through a second bore hole, and (2) pumping the water through a single bore hole communicating with both the water-bearing zone and the hydrocarbon-bearing zone. As will appear more fully hereinafter, the present invention is principally concerned with the second technique.
The following patents are typical of the prior art dealing with flooding oil-bearing strata and the like: Krueger; U.S. Pat. No. 2,808,111 Van Den Beemt; U.S. Pat. No. 2,706,526 Gray et al; U.S. Pat. No. 2,551,434 Heath; U.S. Pat. No. 2,347,779 Arutunoff; U.S. Pat. No. 3,170,520 Engle; U.S. Pat. No. 3,354,952 Hassler; U.S. Pat. No. 2,352,834 Chenoweth; U.S. Pat. No. 3,455,382.
Krueger, Van Den Beemt, and Gray et al pump water downwardly through a bore hole and through a packer to flood an oil-bearing zone communicating with the bore hole at a lower level. Heath employs a similar technique, but in which the water pressure is high enough to avoid the need for a pump. The flow rate is regulated by a mechanically adjusted valve. Arutunoff and Engle pump upwardly through a bore hole for flooding. Hassler and Chenoweth are broadly concerned with regulation of the flow of the flooding medium.
As will appear more fully hereinafter, underlying the present invention is the discovery of the need for a critical type of flow control, by means of a special flow control valve in conjunction with a submergible pump. Valves of various types in wells and/or in conjunction with pumps have of course been known for many years. See, for example, the following prior patents: O'Rourke, U.S. Pat. No. 3,807,894; Miller, U.S. Pat. No. 3,084,898; Page, U.S. Pat. No. 3,477,507; Baker, U.S. Pat. No. 1,631,509; Garrett, U.S. Pat. No. 3,698,411; Litchfield et al, U.S. Pat. No. 3,698,426; Vincent, U.S. Pat. No. 3,294,174; Pistole et al, U.S. Pat. No. 3,007,524; Bows, U.S. Pat. No. 3,747,618; Verheul, U.S. Pat. No. 3,640,303; Reaves, U.S. Pat. No. 3,610,569; Kruse et al, U.S. Pat. No. 1,829,704; Natho, U.S. Pat. Re. No. 25,109; and Canadian Pat. No. 749,740. However, the prior art is devoid of a teaching of the type of pump discharge flow control in flooding or the type of flow control valve required by the invention.
SUMMARY OF THE INVENTION
It is accordingly a principal object of the invention to provide improved secondary recovery apparatus and methods, improved apparatus and methods for flooding, improved pump installations, and improved control valves.
Briefly stated, in a preferred embodiment of the invention sub-surface water is pumped downwardly through a bore hole to an oil-bearing formation by a pump installation in the bore hole including a submergible pump and an adjustable control valve at the discharge side of the pump. The control valve closes automatically when the pump is not operating and is controlled hydraulically from the surface of the earth to vary the flow to the oil-bearing formation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments, and wherein:
FIG. 1 is a truncated vertical sectional view illustrating a flooding installation in accordance with the invention; and
FIG. 2 is a truncated vertical sectional view illustrating the preferred control valve of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, in accordance with the illustrated application of the invention it is desired to flood an oil-bearing zone 10 with sub-surface water pumped from a water-bearing zone 12, which, in the example shown, is at a higher sub-surface level than the oil-bearing zone. Both zones communicate with a bore hole 13, which in the example shown, contains a casing 14.
To pump water from zone 12 to zone 10, a pump installation 16 is provided. As shown, the pump installation 16 may be suspended by tubing 18 from the well head 20 at the surface of the earth, successive colinear housing sections of the installation being bolted together. The down-hole end of the installation engages and traverses a conventional packer 22, which divides the casing 14 into an upper zone above the packer and a lower zone below the packer.
Water from the water-bearing zone at 12 enters casing 14 via perforations 24 and flows downwardly to the intake head 26 of a submergible pump 28, which may be of the centrifugal type having a tubular housing containing diffusers and a shaft carrying impellers. The pump is driven by an electric motor 30 energized by power supplied from the surface via cable 32. The electric motor is preferably of the oil-filled type, and the drive shaft of the motor extends through a combined protector and thrust section 34 to engage the impeller shaft of the pump 28. The thrust section 34 is also filled with oil in the manner of the protector described in Arutunoff U.S. Pat. No. 2,783,400, for example, and preferably contains a plurality of thrust bearings to accommodate both upward and downward thrust of the drive shaft. At its upper end the motor 30 may be provided with an expansion chamber 36 containing a flexible bag, one side of which is exposed to the ambient pressure in the bore hole via a vent 38, the other side of which is exposed to the oil pressure in the motor 30. By this arrangement the thrust section 34 may be kept completely isolated from the fluid in the bore hole and need not include the check valves that are conventionally employed in protectors.
The discharge end 40 of the submergible pump is coupled to a flow meter 42, such as the turbine type manufactured by the Halliburton Company, the flow meter being coupled in turn to pressure sensors 44, such as the type employed in the Lynes Sentry Systems manufactured by Baker Division of Baker Oil Tools Inc. The pressure sensors may measure the discharge pressure of the pump as well as the ambient bore hole pressure, if desired. Electrical output signals from the pressure sensors 44 and the flow meter 42 are transmitted to indicators (not shown) at the surface of the earth via cables 46 and 48.
Coupled in turn to the pressure sensors 44 is a flow control valve 50 in accordance with the invention. The discharge pipe 52 of the flow control valve extends through packer 22. As will be seen hereinafter, operation of the flow control valve requires a hydraulic fluid connection to the surface, and in the form shown this connection is provided by a conduit 53 connecting the flow control valve 50 to the tubing 18, by which the pump installation may be suspended. Tubing 18 and conduit 53 may be pressurized with hydraulic fluid supplied from the surface by a hand pump 54, and the pressure may be relieved by a valve indicated diagrammatically at 56. An indicator 58 shows the pressure in tubing 18.
FIG. 2 illustrates the structure of the control valve. The valve comprises a cylindrical housing 60, which in the form shown is constituted by several consecutive parts threaded together and provided with suitable O-rings 62 to prevent leakage. The housing contains a large-diameter longitudinal passageway 64, one end of which (the upper end in the form shown) is adapted to be closed by engagement of the head or plug 66 of a valve member with a seat 68. The valve head is preferably tapered and engages a seat of complementary taper, thereby isolating a first space above the valve head from a second space below the valve head. The valve head is supported at one end of a stem or shaft 70, which reciprocates in a bearing 72 supported by the center portion of an apertured disk or spider 74. The lower end of the valve stem carries a further apertured disk or spider 76 connected to one end of a plurality of circumferentially spaced rods 78 (only two of which are shown). At their opposite end the rods are connected to an annular piston 80 which reciprocates in an annular cylinder or chamber 82 formed in the wall of the valve housing and isolated from the main passage 64 of the valve by means of seals 84 and 86. Piston 80 may be provided with internal piston rings 88 and external piston rings 90. Coil compression springs 92 surrounding the rods 78 urge the piston 80 upwardly in the chamber 82 and hence tend to close the valve head 66 against the seat 68. The upper end of chamber 82 is vented to the exterior of the housing of the valve (to the ambient pressure in the bore hole) by means of a vent 94, while the lower end of chamber 82 is connected to conduit 53 for the supply of hydraulic fluid thereto from the surface, so that a pressure differential can be provided across the piston and so that an adjustable force can be selectively applied to the valve member.
When the pump is not operating, springs 92 have sufficient force to close the control valve 50. When it is desired to pump water from zone 12 to an oil-bearing zone 10 for flooding, the pump is energized with the valve closed, sufficient hydraulic pressure having been built up in the conduit 53 to maintain the valve closed even when the pump is started. This insures that the pump will start against adequate back pressure to prevent runaway and damage to the pump. As the pump discharge pressure builds up, indicated by the pressure sensors 44, the operator at the surface relieves the pressure in conduit 53, so that the pump discharge pressure gradually forces the valve head 66 away from the seat 68 against the force of springs 92. Water discharged from the pump then begins to flow through passage 64 of the valve, the flow being indicated by the output of the flow meter 42. The operator relieves the pressure in conduit 53 enough to provide the desired pressure and flow conditions for flooding. With the large diameter passage 64 through the valve, flow is minimally restricted by the valve per se when it is desired to provide maximum flow to the oil-bearing zone 10. The ambient pressure in the bore may vary considerably, particularly as the head of water drops, and the hydraulic pressure in conduit 53 can be reduced further to compensate for lower ambient pressures.
When the pump is de-energized, springs 92 will close the valve 50 automatically, since the discharge pressure on the valve head 66 will no longer tend to open the valve. Springs 92 may have sufficient force to maintain the valve closed against any column or water above the valve. Even if a substantial ambient pressure develops above the packer when the pump is not operating, the valve will remain closed if sufficient pressure is maintained in conduit 53, the ambient pressure being insufficient to overcome the combined force of the springs 92, the pressure in conduit 53, and the pressure exerted upon the underside of valve head 66. The valve configuration prevents reverse flow (upwardly) through the bore once the valve is closed, insuring against loss of flooding pressure, flow of oil through the flooding bore, and windmilling of the pump (free reverse rotation) which would prevent safe starting of the pump in the required rotational direction.
While a preferred embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that changes can be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims. | Sub-surface water is pumped through a bore hole to an oil-bearing formation by a pump installation in the bore hole including a submergible pump and an adjustable control valve at the discharge side of the pump. The control valve closes automatically when the pump is not operating to prevent reverse flow and loss of flooding pressure and to insure a back pressure on the pump during starting, and is controlled hydraulically from the surface of the earth to vary the flow to the oil-bearing formation. A novel control valve structure provides accurate and reliable control without unduly restricting the flow volume. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of the PCT Application No. PCT/GB2015/050219 filed on Jan. 30, 2015, which claims priority to and the benefit of GB Application No. 1401557.2, filed on Jan. 30, 2014, and further claims the priority to and the benefit of GB Application No. 1513876.1, filed Aug. 5, 2015 and GB Application No. 1522290.4, filed Dec. 17, 2015, and the disclosures of each of the applications above is incorporated herein by reference in its entirety.
BACKGROUND
Field of the Invention
[0002] The present invention relates to a plumbing device which allows a pressure and/or temperature relief valve for a fresh water system to be connected to a waste pipe or soil stack without the risk of back contamination or odours.
[0003] An example of the use of a relief valve is with an unvented domestic hot water storage system (UVHWSS) or unvented hot water heater (UVHWH). Such a system typically has a temperature and/or pressure relief valve connected to a discharge pipe. The regulations for connection of the discharge pipe to a waste water system are strict because of the risk of back contamination from the pathogenic water in the waste water system to the fresh water in the storage system. Typically, the regulations require a tundish to provide a visible point of discharge and an air gap (to provide backflow prevention) and the outflow from the tundish to be connected in a particular way to discharge above an external ground floor gulley. Such a connection requires careful engineering and is expensive to install.
[0004] In order to connect the vent valve to a soil stack within a building, arrangements need to be made to provide an odour trap to prevent any foul gases from the soil stack from entering the domestic location. On most domestic installations, a water trap would be used to prevent escape of gases and odours from the soil stack. Typically, a water trap comprises a bended tube in which water is trapped. A water trap allows passage of liquid and suspended solids but not gases. Generally speaking, a water trap is not suitable for use with a tundish as it will become ineffective through drying out. A water trap is also relatively bulky and is not suitable for use in all locations.
[0005] More recently, a product has been approved which provides an odour trap which allows the discharge pipe to be connected to a soil stack within a building. This product is designed to be used in association with a tundish and is not easy to use with an UVHWH because of its overall length.
[0006] A way of ameliorating these problems has been sought.
SUMMARY
[0007] According to the invention, there is provided a connector which connector comprises a chamber having an open upper chamber and a lower closable chamber, an inlet connector, an outlet connector formed in a floor of the lower chamber wherein the inlet connector is supported above the open upper chamber by one or more arms and wherein the lower chamber is closable by a non-return valve which is arranged to open at a pre-selected pressure.
[0008] In some embodiments, the pre-selected pressure is a pressure applied by a flow of liquid from the inlet such as may be produced by a pressure and/or temperature relief valve in operation. For example, the pre-selected pressure may be sufficiently high to prevent accidental opening of the non-return valve (for example due to dust or condensation on the valve) but not so high to restrict flow of liquid from the inlet such that liquid overflows from the open upper chamber. A skilled person would be able to determine a suitable pressure.
[0009] In some embodiments, the chamber has a tubular middle chamber arranged between the upper chamber and the closable lower chamber. In some embodiments, the pre-selected pressure is no more than the pressure from a volume of liquid which can fill the tubular middle chamber. The advantages of the middle chamber include that it reduces the risk of accidental opening of the non-return valve by providing a receptacle for collection of liquid; and that the presence of a non-return valve in a tundish does not interfere with the operation of the tundish because the risk of spillage of liquid from the tundish is reduced.
[0010] In some embodiments, the valve may be a non-return valve, for example a diaphragm check valve, a lift valve or a duck bill valve.
[0011] In some embodiments, the valve is a lift valve having a valve stem. In some embodiments, the upper chamber provides one or more ribs to support a valve guide for the valve stem. In some embodiments, the lift valve has a resilient member to bias it into a closed position. In some embodiments, the resilient member is arranged on the lift valve above the valve guide. Provision of a resilient member above the valve guide has the advantage of enabling the valve stem to be self-guiding such that only one valve guide is required.
[0012] In some embodiments, the chamber may be provided as a unitary component or single piece. Any or any, any combination or all of the open upper chamber, lower closable chamber, inlet connector, outlet connector and/or one or more arms may be unitarily formed or joined/fused, for example in a manner that prevents separation without breaking the chamber.
[0013] According to aspects of the invention, there is provided a shielded connector which comprises a shield and a connector which comprises: a chamber having an open upper chamber and a lower chamber, an inlet connector and an outlet connector formed in a floor of the lower chamber, wherein the inlet connector is supported above the open upper chamber by one or more arms; wherein the upper chamber has an upper chamber floor having an upper chamber outlet, the upper chamber is in fluid communication with the lower chamber by means of the upper chamber outlet; wherein the upper chamber outlet has a non-return valve which is arranged to open at a pre-selected pressure; wherein the lower chamber forms a flow conduit for receiving the valve when it is open; and wherein the shield is shaped to cover the open upper chamber.
[0014] According to aspects of the invention, there is also provided a connector which comprises: a chamber having an open upper chamber and a lower chamber, an inlet connector and an outlet connector formed in a floor of the lower chamber, wherein the inlet connector is supported above the open upper chamber by one or more arms; wherein the upper chamber has an upper chamber floor having an upper chamber outlet, the upper chamber is in fluid communication with the lower chamber by means of the upper chamber outlet; wherein the upper chamber outlet has a non-return valve which is arranged to open at a pre-selected pressure; wherein the lower chamber forms a flow conduit for receiving the valve when it is open.
[0015] According to aspects of the invention, there is further provided a shield for a connector having an open upper chamber wherein the shield is shaped to cover the open upper chamber.
[0016] According to aspects of the invention, there is also provided a valve assembly for use in sealing an outlet in a connector according to the invention wherein the valve assembly comprises a stem, a biasing member for biasing the valve assembly into a closed position, a valve disc for sealing the outlet, an upper washer and a lower washer wherein the upper and/or lower washer is shaped to support the valve disc such that the valve disc is not distorted in use. In some embodiments, the valve assembly additionally comprises an additional upper washer to provide extra support.
[0017] In some embodiments, the upper and/or lower washers of the valve assembly are shaped to support the valve disc such that the valve disc is not compressed in use. It has been found that without the shaped upper and/or lower washer, the valve disc can distort such that the amount of water required to open the valve may change. In some embodiments, the upper and lower washers and the valve disc form central apertures for mounting on the valve stem; wherein one of the upper and lower washers forms a projection around its central aperture and wherein the valve disc aperture is shaped to receive the projection such that valve disc is supported by the upper and lower washers.
[0018] The advantages of a connector according to the invention may include that as it is an adapted tundish, it may be compact and space saving such that it can be used in a restricted location such as with an under counter water heater. Its simple construction may enable it to have a rating for temperatures up to 100° C. Furthermore, by providing the lower chamber with a flow conduit for receiving the opened valve, the connector may offer an improved flow rate.
[0019] Further advantages may include that the shield may allow the connector to be used to vent a domestic boiler pressure relief valve to a waste water drain by preventing a user from inserting their fingers into the open upper chamber when the connector is in use. This is because the connector needs to be mounted on an outlet from the boiler which is visible but when it is in use, very hot water will be passed through the connector. Therefore the shield can provide protection for a user from that water.
[0020] In some embodiments, the shield has a window such that water flow through the upper chamber can be observed. In some embodiments, the shield may be formed partly or wholly from a transparent material.
[0021] In some embodiments, the shield has a loose fit on the upper chamber such that the connector provides a vent to atmospheric pressure. In some embodiments, the shield has a tolerance fit (for example, a water tight fit) to the upper chamber wherein the shield has an outlet which provides the shielded connector with a vent to atmospheric pressure. In some embodiments, the connector and/or shield may have a rubber seal to minimise water spillage where the shield fits to the upper chamber.
[0022] In some embodiments, the flow conduit is formed by a wall which is spaced from the valve in use so as to provide a volume for liquid flow. In some embodiments, the flow conduit allows the valve to open sufficiently to allow a high flow of water. In some embodiments, a high flow rate of water is a flow rate of over 12 litres per minute, for example a flow rate of from 12 litres per minute, optionally from 15 litres per minute, optionally from 18 litres per minute to 30 litres per minute, optionally to 25 litres per minute, optionally to 18 litres per minute. In some embodiments, the connector according to the invention is suitable for use in venting an unvented boiler or cylinder, particularly a cylinder having high discharge characteristics such as a Megaflo (registered trademark) unvented cylinder or modern design unvented boilers.
[0023] some embodiments, the lower chamber forms a first portion and the flow conduit wherein the first portion accommodates the upper chamber outlet and the valve when it is closed. In some embodiments, the first portion has a diameter which is greater than the diameter of the flow conduit such that there is a step between the first portion and the flow conduit. In some embodiments, the first portion has a diameter which is the same as the diameter of the flow conduit. In some embodiments, the floor of the lower chamber is a shelving floor. In some embodiments, the lower chamber floor is arranged between the flow conduit and the outlet connector.
[0024] In some embodiments, the pre-selected pressure is a pressure applied by a flow of liquid from the inlet such as may be produced by a pressure and/or temperature relief valve in operation. For example, the pre-selected pressure may be sufficiently high to prevent accidental opening of the non-return valve (for example due to dust or condensation on the valve) but not so high to restrict flow of liquid from the inlet such that liquid overflows from the open upper chamber. A skilled person would be able to determine a suitable pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will now be illustrated with reference to the following Figures of the accompanying drawings which are not intended to limit the scope of the invention claimed:
[0026] FIG. 1 shows a schematic vertical cross-sectional view of a first embodiment of the invention;
[0027] FIG. 2 shows a schematic overhead plan view of the first embodiment of the invention;
[0028] FIG. 3 shows a schematic horizontal cross-sectional view of the first embodiment of the invention taken along line marked A-A′ on FIG. 1 ;
[0029] FIG. 4 shows a schematic vertical cross-sectional view of a second embodiment of the invention;
[0030] FIG. 5 shows a schematic overhead plan view of the second embodiment of the invention;
[0031] FIG. 6 shows a schematic vertical cross-sectional view of a third embodiment of the invention;
[0032] FIG. 7 shows a schematic overhead plan view of the second embodiment of the invention
[0033] FIG. 8 shows a schematic vertical cross-sectional view of a third embodiment of the invention;
[0034] FIG. 9 shows a schematic vertical cross-sectional view of a further embodiment of the invention;
[0035] FIG. 10 shows a schematic vertical cross-sectional view of a further embodiment of the shielded connector according to the invention;
[0036] FIG. 11 shows a schematic horizontal cross-sectional view of the embodiment of the invention taken along line marked B-B′ on FIG. 10 ;
[0037] FIG. 12 shows a cross-sectional view of a shield according to the invention;
[0038] FIG. 13 shows a schematic perspective view of the parts from which a shielded connector according to an example of the invention may be constructed; and
[0039] FIG. 14 shows a schematic perspective view of a valve assembly for use in the invention.
DETAILED DESCRIPTION
[0040] A first embodiment of a connector according to the invention indicated generally at 100 is shown in FIGS. 1, 2 and 3 . Connector 100 has an inlet 105 , an upper chamber 162 , a middle chamber 177 , a lower chamber 182 and a lift valve indicated at 142 .
[0041] Inlet 105 is supported above upper chamber 162 by a pair of diametrically opposed arms 125 such that a vertical gap 107 is formed between the inlet and the upper chamber 162 . Inlet 105 has an outer thread 110 for engaging with a tap connector (or other pipe fitting) and forms a tapered beak drip 115 which projects downwards into the vertical gap 107 . Arms 125 are arranged so that the vertical gap 107 is of a height sufficient to provide an air gap of type AA which is typically at least about 20 mm.
[0042] Upper chamber 162 is shaped by circumferential upper chamber wall 165 and a shelving upper chamber floor 170 . Upper chamber 162 has an open mouth for receiving liquid from the inlet. The upper chamber wall 165 supports arms 125 . Upper chamber floor 170 forms upper chamber floor opening 175 which is the opening to tubular middle chamber 177 such that upper chamber floor 170 has an inverted truncated conical shape and such that the upper chamber floor 170 has a funnel shape for directing liquid to the upper chamber floor opening 175 . Upper chamber wall 165 has three inwardly projecting ribs 130 which support valve guide 135 which is arranged in the centre of the opening to upper chamber 162 .
[0043] The lift valve 142 has the following components: a valve stem 140 , a valve disc 145 , a valve disc fixing 150 , a valve spring 155 and a valve spring clip 160 . The valve stem 140 is arranged to run through valve guide 135 . At an upper part of the valve stem 140 above the valve guide 135 , valve spring 155 is arranged on the valve stem 140 and secured to an upper end of the valve stem 140 by valve spring clip 160 . At a lower end of the valve stem 140 , the valve disc 145 is secured by valve disc fixing 150 . Valve disc 145 is formed from a resilient material such as a plastics or rubber material, for example EPDM rubber. In an alternative embodiment, the valve spring 155 may be replaced by a suitable resilient member as would be known to a person of skill in the art.
[0044] The tubular middle chamber 177 has a lower opening which forms a valve seat for lift valve 142 and which lower opening is normally closed by valve disc 145 which is biased by the valve spring 155 into that position. The valve spring 155 is arranged to open the lift valve 142 at a pre-selected pressure on the valve disc 145 . A suitable pre-selected pressure may be that determined by when the tubular middle chamber 177 is full of liquid.
[0045] The lower chamber 182 has a ceiling 170 , 177 , a tubular lower chamber wall 180 and a shelving lower chamber floor 185 . The ceiling 170 , 177 of the lower chamber 182 is formed by the upper chamber floor 170 and middle chamber 177 and forms an opening which is normally closed by valve 142 . Lower chamber floor 185 shelves to form an opening for outlet 120 such that lower chamber floor 185 has an inverted truncated conical shape and such that the lower chamber floor 185 has a funnel shape for directing liquid to outlet 120 . Outlet 120 has a tubular shape and has an outer thread 110 for engaging with a tap connector (or other pipe fitting).
[0046] In an alternative embodiment, the diameter of valve disc 145 may be less than that for outlet 120 such that the valve spring 155 and/or valve disc 145 may be replaced by removing valve spring clip 160 , allowing the lift valve 142 to drop through outlet 120 and out of the connector 100 so that one or more of the components of lift valve 142 may be replaced.
[0047] The connector in any example of the invention may be formed such that the rigid connector body, i.e. excluding the moveable valve components, may be provided as a single piece. The connector body may be formed as a walled structure by moulding. The connector body may be formed as a plurality of sections fused together to provide a single piece. For example, ultrasonic welding or the like may be used to fuse the parts together as a single piece.
[0048] A second embodiment of a connector according to the invention indicated generally at 200 is shown in FIGS. 4 and 5 . Connector 200 has an inlet 205 , an upper chamber 262 , a middle chamber 277 , a lower chamber 282 and a diaphragm check valve 290 . The numbering of the reference numerals for features of the second embodiment corresponds to that for like features of the first embodiment.
[0049] Inlet 205 is supported above upper chamber 262 by a pair of diametrically opposed arms 225 such that a vertical gap 207 is formed between the inlet and the upper chamber 262 . Inlet 205 has an outer thread 210 for engaging with a tap connector (or other pipe fitting) and forms a tapered beak drip 215 which projects downwards into the vertical gap 207 . Arms 225 are arranged so that the vertical gap 207 is of a height sufficient to provide an air gap of type AA which is typically at least about 20 mm.
[0050] Upper chamber 262 is shaped by circumferential upper chamber wall 265 and a shelving upper chamber floor 270 . Upper chamber 262 has an open mouth for receiving liquid from the inlet. The upper chamber wall 265 supports arms 225 . Upper chamber floor 270 forms upper chamber floor opening 275 which is the opening to tubular middle chamber 277 such that upper chamber floor 270 has an inverted truncated conical shape and such that the upper chamber floor 270 has a funnel shape for directing liquid to the upper chamber floor opening 275 . The features of the upper part of connector 200 are shown in the overhead plan view depicted in FIG. 5 .
[0051] Diaphragm check valve 290 is formed from a resilient material and is shaped to be biased into a closed position. Diaphragm check valve 290 is shown in an open position by a partially occluded form shown on FIG. 4 . The tubular middle chamber 277 has a lower opening which forms a valve seat for lift valve 142 and which lower opening is normally closed by the diaphragm check valve 290 . The diaphragm check valve 290 is attached the lower opening of middle chamber 277 . The diaphragm check valve 290 is arranged to open at a pre-selected pressure. A suitable pre-selected pressure may be that determined by when the tubular middle chamber 277 is full of liquid.
[0052] The lower chamber 282 has a ceiling 270 , 277 , a tubular lower chamber wall 280 and a shelving lower chamber floor 285 . The ceiling 270 , 277 of the lower chamber 282 is formed by the upper chamber floor 270 and middle chamber 277 and forms an opening which is normally closed by diaphragm check valve 290 . Lower chamber floor 285 shelves to form an opening for outlet 220 such that lower chamber floor 285 has an inverted truncated conical shape and such that the lower chamber floor 285 has a funnel shape for directing liquid to outlet 220 . Outlet 220 has a tubular shape and has an outer thread 210 for engaging with a tap connector (or other pipe fitting).
[0053] A third embodiment of a connector according to the invention indicated generally at 300 is shown in FIG. 6 . Connector 300 has an inlet 305 , an upper chamber 362 , a middle chamber 377 , a lower chamber 382 and a duck bill valve 395 . The numbering of the reference numerals for features of the third embodiment corresponds to that for like features of the first and second embodiments.
[0054] Inlet 305 is supported above upper chamber 362 by a pair of diametrically opposed arms 325 such that a vertical gap 307 is formed between the inlet and the upper chamber 362 . Inlet 305 has an outer thread 310 for engaging with a tap connector (or other pipe fitting) and forms a tapered beak drip 315 which projects downwards into the vertical gap 307 . Arms 325 are arranged so that the vertical gap 307 is of a height sufficient to provide an air gap of type AA which is typically at least about 20 mm.
[0055] Upper chamber 362 is shaped by circumferential upper chamber wall 365 and a shelving upper chamber floor 370 . Upper chamber 362 has an open mouth for receiving liquid from the inlet. The upper chamber wall 365 supports arms 325 . Upper chamber floor 370 forms upper chamber floor opening 375 which is the opening to tubular middle chamber 377 such that upper chamber floor 370 has an inverted truncated conical shape and such that the upper chamber floor 370 has a funnel shape for directing liquid to the upper chamber floor opening 375 . The features of the upper part of connector 200 are shown in the overhead plan view depicted in FIG. 7 .
[0056] Duck bill valve 395 is formed from a resilient material biased to a closed position. Duck bill valve 395 is shown in an open position by the partially occluded form shown on FIG. 6 . Duck bill valve comprises two downwardly extending, opposed flexible impervious wall members of complementary shapes disposed face to face in surface contact so that there is no through passage between them in their normal state and where they are resiliently urged into the normal state.
[0057] The tubular middle chamber 377 has a lower opening on which the wall members of the duck bill valve 395 are mounted and which lower opening is normally closed by the duck bill valve 395 . Liquid at a pre-selected pressure will force the wall members of the duck bill valve 395 apart to permit flow between them from the middle chamber 377 into the lower chamber 382 . A suitable pre-selected pressure may be that determined by when the tubular middle chamber 377 is full of liquid. The duck bill valve 395 prevents liquid flow in the opposite direction by the close surface contact between its wall members.
[0058] The lower chamber 382 has a ceiling 370 , 377 , a tubular lower chamber wall 380 and a shelving lower chamber floor 385 . The ceiling 370 , 377 of the lower chamber 382 is formed by the upper chamber floor 370 and middle chamber 377 and forms an opening which is normally closed by diaphragm check valve 390 . Lower chamber floor 385 shelves to form an opening for outlet 320 such that lower chamber floor 385 has an inverted truncated conical shape and such that the lower chamber floor 385 has a funnel shape for directing liquid to outlet 320 . Outlet 320 has a tubular shape and has an outer thread 310 for engaging with a tap connector (or other pipe fitting).
[0059] A fourth embodiment of a connector according to the invention indicated generally at 400 is shown in FIG. 8 . Connector 400 has an inlet 405 , an upper chamber 462 , a middle chamber 477 , a lower chamber 482 and a lift valve indicated at 442 .
[0060] Inlet 405 is supported above upper chamber 462 by a pair of diametrically opposed arms 425 such that a vertical gap 407 is formed between the inlet and the upper chamber 462 . Inlet 405 has an outer thread 410 for engaging with a tap connector (or other pipe fitting) and forms a tapered beak drip 415 which projects downwards into the vertical gap 407 . Arms 425 are arranged so that the vertical gap 407 is of a height sufficient to provide an air gap of type AA which is typically at least about 20 mm.
[0061] Upper chamber 462 is shaped by circumferential upper chamber wall 465 and a shelving upper chamber floor 470 . Upper chamber 462 has an open mouth for receiving liquid from the inlet. The upper chamber wall 465 supports arms 425 . Upper chamber floor 470 forms upper chamber floor opening 475 which is the opening to tubular middle chamber 477 such that upper chamber floor 470 has an inverted truncated conical shape and such that the upper chamber floor 470 has a funnel shape for directing liquid to the upper chamber floor opening 475 . Upper chamber wall 465 has three inwardly projecting ribs 430 A which support valve guide 435 A which is arranged in the centre of the opening to upper chamber 462 .
[0062] The lower chamber 482 has a ceiling 470 , 477 , a tubular lower chamber wall 480 and a shelving lower chamber floor 485 . The ceiling 470 , 477 of the lower chamber 482 is formed by the upper chamber floor 470 and middle chamber 477 and forms an opening which is normally closed by valve 442 . Lower chamber floor 485 shelves to form an opening for outlet 420 such that lower chamber floor 485 has an inverted truncated conical shape and such that the lower chamber floor 485 has a funnel shape for directing liquid to outlet 420 . Outlet 420 has a tubular shape and has an outer thread 410 for engaging with a tap connector (or other pipe fitting). Lower chamber wall 480 has three inwardly projecting ribs 430 B which support valve guide 435 B which is arranged in the centre of lower chamber 482 .
[0063] The lift valve 442 has the following components: a valve stem 440 , a valve disc 445 , a valve disc fixing 450 , a valve spring 455 and a valve spring clip 460 . The valve stem 440 is arranged to run through valve guides 435 A, 435 B. At a lower part of the valve stem 440 above the valve guide 435 B and below valve disc 445 , valve spring 455 is arranged on the valve stem 440 and secured to a lower end of the valve stem 440 by valve spring clip 460 . In the middle of the valve stem 440 , the valve disc 445 is secured by valve disc fixing 450 . Valve disc 445 is formed from a resilient material such as a plastics or rubber material, for example EPDM rubber. In an alternative embodiment, the valve spring 455 may be replaced by a suitable resilient member as would be known to a person of skill in the art.
[0064] The tubular middle chamber 477 has a lower opening which forms a valve seat for lift valve 442 and which lower opening is normally closed by valve disc 445 which is biased by the valve spring 455 into that position. The valve spring 455 is arranged to open the lift valve 442 at a pre-selected pressure on the valve disc 445 . A suitable pre-selected pressure may be that determined by when the tubular middle chamber 477 is full of liquid.
[0065] In an alternative embodiment, the three inwardly projecting ribs 430 A and valve guide 435 A may be removed such that the valve stem 440 is only supported by valve guide 435 B.
[0066] Another embodiment of a connector according to the invention indicated generally at 100 is shown in FIG. 9 . Connector 500 has an inlet 505 , an upper chamber 562 , a lower chamber 582 and a lift valve indicated at 542 .
[0067] Inlet 505 is supported above upper chamber 562 by a pair of diametrically opposed arms 525 such that a vertical gap 507 is formed between the inlet and the upper chamber 562 . Inlet 505 has an outer thread 510 for engaging with a tap connector (or other pipe fitting) and forms a tapered beak drip 515 which projects downwards into the vertical gap 507 . Arms 525 are arranged so that horizontal gaps between the arms 525 and the vertical gap 507 are sufficient to provide an air break to drain, typical for a standard tundish.
[0068] Upper chamber 562 is shaped by circumferential upper chamber wall 565 and a shelving upper chamber floor 570 . Upper chamber 562 has an open mouth for receiving liquid from the inlet. The upper chamber wall 565 supports arms 525 . Upper chamber floor 570 forms upper chamber floor outlet 575 such that upper chamber floor 570 has an inverted truncated conical shape and such that the upper chamber floor 570 has a funnel shape for directing liquid to the upper chamber floor outlet 575 . Upper chamber wall 565 has three inwardly projecting ribs 530 which support valve guide 535 which is arranged in the centre of the opening to upper chamber 562 .
[0069] The lift valve 542 has the following components: a valve stem 540 , a valve disc 545 , a valve disc fixing 550 , a valve spring 555 and a valve spring clip 560 . The valve stem 540 is arranged to run through valve guide 535 . At an upper part of the valve stem 540 above the valve guide 535 , valve spring 555 is arranged on the valve stem 540 and secured to an upper end of the valve stem 540 by valve spring clip 560 . At a lower end of the valve stem 540 , the valve disc 545 is secured by valve disc fixing 550 . Valve disc 545 is formed from a resilient material such as a plastics or rubber material, for example EPDM rubber. In an alternative embodiment, the valve spring 555 may be replaced by a suitable resilient member as would be known to a person of skill in the art.
[0070] The upper chamber floor outlet 575 forms a valve seat for lift valve 542 and which outlet 575 is normally closed by valve disc 545 which is biased by the valve spring 555 into that position. The valve spring 555 is arranged to open the lift valve 542 at a pre-selected pressure on the valve disc 545 .
[0071] The lower chamber 582 has a ceiling 570 , a first tubular lower chamber wall 580 forming a first lower chamber portion 580 A, a horizontal step 581 , a second lower chamber wall 583 forming a lower chamber flow conduit 583 A, and a shelving lower chamber floor 585 . The ceiling 570 of the lower chamber 582 is formed by the upper chamber floor 570 . The first lower chamber portion 580 A provides a cylindrical volume which receives or accommodates the upper chamber floor 570 , upper chamber outlet 575 and valve 542 in its closed position, particularly valve disc 545 and valve disc fixing 550 . In an alternative embodiment, instead of being cylindrical, first portion 580 A may have a polygonal cross-sectional shape. The lower chamber flow conduit 583 A provides a cylindrical volume 583 A for receiving valve 542 in its open position, particularly valve disc 545 , valve disc fixing 550 and part of valve stem 540 . In an alternative embodiment, instead of being cylindrical, flow conduit 583 A may have a polygonal cross-sectional shape. Lower chamber floor 585 shelves to form an opening for outlet 520 such that lower chamber floor 585 has an inverted truncated conical shape and such that the lower chamber floor 185 has a funnel shape for directing liquid to outlet 5120 . Outlet 520 has a tubular shape, a diameter suitable for attachment to a waste pipe and has a smooth outer surface suitable for engaging with a push fit or universal fitting (not shown).
[0072] The first lower chamber portion 580 A provides a volume for receiving a liquid such as water discharged through the upper chamber floor outlet 575 when lift valve 542 is opened. Lower chamber flow conduit 583 A has a smaller diameter than the first portion 580 A because of step 581 . In an alternative embodiment, the diameter of the flow conduit 583 A may be the same as the diameter of the first portion 580 A such that there is no step 581 . The diameter of the flow conduit 583 A is substantially greater than the diameter of the valve disc 545 , for example 50% to 80% greater, particularly 66% greater such that a volume for liquid flow is provided between the lift valve 542 and the second lower chamber wall 583 . When lift valve 542 is opened, flow conduit 183 A receives lift valve 542 such that there is free flow of water around lift valve 542 within second lower chamber wall 583 . If lower chamber 582 had the typical shape of a tundish, there would be no flow conduit 583 A below first portion 580 A but instead there would be a shelving floor. The insertion of the flow conduit 583 A has surprisingly been found to increase flow rate of liquids through the connector 500 by 50% compared to the connector of FIG. 1 but with only a 20% increase in the overall length of the connector (the diameter of the connector 500 being the same as the diameter of the connector 100 .
[0073] In an alternative embodiment, the diameter of valve disc 545 may be less than that for outlet 520 such that the valve spring 555 and/or valve disc 545 may be replaced by removing valve spring clip 560 , allowing the lift valve 542 to drop through outlet 520 and out of the connector 500 so that one or more of the components of lift valve 542 may be replaced.
[0074] The increase in overall length of the connector 500 provides the connector with a push fit facility. Without the push fit connection, the length of the connector could be substantially the same as that disclosed in the previous embodiments.
[0075] An embodiment of a shielded connector according to the invention is shown in FIGS. 10, 11 and 12 . The shielded connector 600 comprises a connector substantially as described in relation to FIG. 5 . A corresponding sequence of reference numerals for connector 600 have been provided in FIG. 10 and like features will not be described again.
[0076] As shown in FIGS. 10 and 12 , the shielded connector 600 comprises a removable shield member 604 seated atop the connector body. The shield 604 has a frustroconical shape having an upper opening 601 which is shaped to fit over inlet 605 and a skirt 603 which is shaped to cover 662 and has a length approximately the same as the length of arms 625 . The shield thus covers the arms 625 and the air gap between the arms so as to block access thereto, whilst preserving the internal spacing required for operation of the device.
[0077] A further embodiment of the shielded connector according to the invention is indicated generally at 700 in FIG. 13 . The shielded connector 700 has a shield 704 and a connector 702 . FIG. 13 illustrates the five parts from which the connector 702 is constructed. The five parts are the upper chamber head 790 , the upper chamber body 791 , the upper chamber foot 792 , the lower chamber body 793 and the valve assembly 796 . The four parts 790 , 791 , 792 , 793 , may be joined together by ultrasonic welding or, in an alternate embodiment, by an equivalent technique as might be known to a person of skill in the art. The upper chamber head 790 comprises two circular plastic rings 710 , 712 which are joined by arms 725 . Upper ring 710 is smaller in diameter than lower ring 712 and forms inlet 705 such that upper ring 710 is arranged concentrically above lower ring 712 by arms 725 . Upper chamber body 791 comprises an outer circular plastic ring formed by upper chamber wall 765 , inwardly projecting ribs 730 mounted on an inner surface of upper chamber wall 765 and valve guide 735 which is supported by ribs 730 . The upper chamber foot 792 provides the upper chamber floor 770 and upper chamber floor outlet 775 . The lower chamber body 793 provides the lower chamber 782 as described above for the second embodiment.
[0078] The valve assembly 796 provides the lift valve 742 . Valve assembly 796 is shown in more detail in FIG. 14 . Valve assembly 796 comprises a valve stem 740 in the form of a shoulder bolt, a valve disc 745 , a valve disc fixing 750 in the form of a self-locking nut, a valve spring 755 , a first upper washer 797 , a second upper washer 794 and a lower washer 795 . The second upper washer 794 has an inverted top hat shape forming a lower projection 794 A. Valve disc 745 has a central aperture 745 A which is shaped to receive not only the shaft of shoulder bolt 740 but also lower projection 794 A such that in use, valve disc 745 is supported by second upper washer 794 and lower washer 795 such that the shape of valve disc 745 is not distorted when valve disc fixing 750 is tightened on shoulder bolt 740 . Additionally first upper washer 797 provides additional support by preventing second upper washer 794 from being pushed up past the shoulder of the threaded portion of the valve stem 740 . The inclusion of separate first upper washer 797 provides a washer function on an upper side of valve disc 745 , allowing second upper washer 794 to provide only a supporting function for the valve disc 745 . In an alternative embodiment, the first and second upper washers 794 , 797 might be arranged below the valve disc 745 .
[0079] Any of the alternative valve types of FIGS. 4-8 may be substituted for the valves shown in FIGS. 9-14 .
[0080] Any of the above described embodiments of the invention may be provided with a shield of the kind described above in relation to FIGS. 11-14 . | The invention provides a connector having:
a. a chamber having an open upper chamber and a lower chamber, b. an inlet connector and c. an outlet connector formed in a floor of the lower chamber.
The inlet connector is supported above the open upper chamber by one or more arms. The upper chamber has an upper chamber floor having an upper chamber outlet, the upper chamber being in fluid communication with the lower chamber by means of the upper chamber outlet. The upper chamber outlet has a non-return valve which is arranged to open at a pre-selected pressure and the lower chamber forms a flow conduit for receiving the valve when it is open. In some embodiments a shielded connector is provided in which a shield is shaped to cover the open upper chamber of the connector. A valve assembly may be provided for use in the connector or shielded connector wherein the valve assembly has a stem, a biasing member for biasing the valve assembly into a closed position, a valve disc for sealing the outlet. An upper washer and a lower washer are disclosed for support of the valve disc such that the valve disc does not distort in use. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
In the process of completing most oil wells, a string of conduit is placed into the open borehole and cemented in place by pumping a cement slurry down the annulus between the casing and the borehole wall.
The conduit or "casing" is run in the borehole in standard length sections joined together by threaded collars. The casing ends are threaded into the collars but the two ends are not in abutting relationship with each other leaving an axial annular space within each collar.
After the casing is cemented in the well, the casing may be perforated at the producing locations which have been located by sophisticated electronic, sonic, and radioactive logging methods. When lowering a perforating tool into the wellbore, it is desirable to have a quick, easy method to monitor how far down the borehole the tool has traveled so that it can be placed precisely adjacent the desired perforating location.
This can be accomplished roughtly by measuring the wireline or tubing carrying the tool into the well. To be more accurate, the operator needs to be able to correlate the depth with the well log. This he can do if he can know when the tool is at a specific casing collar near the formation to be perforated.
This knowledge can be ascertained by the use of a casing collar indicator. The prior art devices utilize electronic and magnetic sensing means to attempt to locate the collars. Other types utilize mechanical indicators which have fingers or blocks that must slide outward into engagement in the collar. These devices suffer reliability deficiencies because of their complexity and inability to distinguish collars from other types of discontinuities in the casing string.
The present invention provides a much less complex and more reliable apparatus to indicate when the tool has engaged a collar. Used in connjunction with a weight indicator on the tubing string, the present invention gives a precise indication of when the collar has been engaged.
The tool is also advantageous when lowering into the wellbore, a production or workover string containing packers, valves and other tools which need to be placed in close proximity to a producing formation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial cross-sectional view of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in partial cross-sectional view the casing collar indicator 10 having a main body 11 with an axial bore passage 12 passing centrally therethrough. Body 11 has an outer threaded portion 13 at its upper end and an inner threaded portion 14 at the lower end for threadably engaging a string of well tubing. Body member 11 also has an upper expanded shoulder area 15, a stepped shoulder area 16, and a recessed annular area 17.
A lower stepped portion 18 encircles body 11 at the lower end of recess 17 and a bottom recess 19 is located below shoulder 18. A threaded nut 20 is threaded on body 11 below recess 19. A slotted bowed sleeve 21 encircles body member 11 in contact with shoulders 16 and 18. Sleeve 21 is bowed outwardly and contains an annular outwardly projecting shoulder portion 22 having a curvilinear cross-sectional configuration.
A plurality of equi-spaced longitudinal slots 23 are formed through the wall of sleeve 21 and pass through annular shoulder 22. The provision of slots 23 results in the formation of a number of longitudinal arms 24 which are resiliently flexible in a radial direction. The amount of outward curvature of sleeve 21 is measured by the distance x illustrated in FIG. 1, which distance is the difference between the diameter of shoulders 16 and 18 and the greatest inner diameter of sleeve 21.
The casing collar indicator 10 is illustrated in a string of casing shown in break-away illustration at 26 and 27. A cylindrical casing collar 28 threadedly connects upper casing section 26 with lower casing section 27. Since the adjacent ends of the casing sections are not threaded into collar 28 sufficiently to abut each other, an annular space 30 is formed therebetween.
The annular space 30 has a radial dimension equivalent to the dimension t, which is the approximate thickness of the casing. In one embodiment, the amount of maximum outward curvature of sleeve 21 is relatively equivalent to the thickness t of the casing. Thus, when the apparatus 10 engages in a collar annulus 30, the projecting shoulder 22 will just contact the inner wall of collar 28 and the resilient force will be relaxed in sleeve 21.
In addition to the outward resilient force on shoulder 22 from the initial outward bowed configuration of sleeve 21, other resilient biasing means can also be used to complement the spring force of the bowedsleeve. One form of such additional springing force which may be advantageously utilized in this apparatus comprises a series of belleville spring washers 31 abutting the lower end of spring 21 and held in encircling relationship on member 11 by threaded nut 20.
In place of belleville spring washers, it would be possible to utilize other spring means, such as a coil spring, but the belleville washers are advantageous because they offer a high spring load in a short compression distance. If the dimension x is made substantially equal to dimension t, it can be seen that normally the action of spring means 31 is neutral in the radial direction and is acting solely in an axial direction thereby contributing nothing to the outward force of the arms 24.
The belleville spring load is thus not additive to the resilient spring load of arms 24, pressing projections 22 against the casing wall, as long as the apparatus 11 is not located in a collar area. Once the projection 22 passes from the casing section 26 into the collar annulus 30, the force of springs 31 is added to the outward force of spring fingers 24, thereby aiding in maintaining projections 22 engaged in the annulus 30.
Because of this relatively high force pushing the shoulders 22 outward against the collars 28, a strong indication is given at the weight indicator on the surface each time a collar is engaged by the tool 10. It can be seen that as projection 22 movesdownward in annular space 30 and contacts the upper end of casing section 27, a substantial portion of the weight of the tool string will be removed from the upper portion of the string and supported by the abutment of shoulder 22 on casing 27. This will give a sharp indication on the weight indicator at the surface that a weight reductionn in the string has occurred and the operator will realise that a collar has been engaged.
As weight is placed down on the string, the projection of 22 will be cammed radially inward until projection 22 slides inside casing 27. At this time, spring members 31 will be directing a spring force parallel to the central axis of body 11 and will add no further drag to projections 22 while traversing casing sections 27. Thus, the force arising from spring means 31 comes into play only while the tool passes through a joined section at the collar 28.
While this additive spring force further enhances the operation of the tool, it can be seen that the casing collar indicator will operate successfully without this secondary biasing spring means. In operation, the tool 10 is threadably inner connected into the work string at threaded ends 13 and 14 as the string is being lowered into the hole. Preferably the casing collar indicator 10 will be located in relatively close proximity to the perforating or treating tool which is to be placed in the desired location.
As the tool string is lowered into the borehole, the projections 22 will be forced radially inward while traversing each section of the casing. As the projections 22 pass out the bottom of each casing section, they will be biased radially outward into contact with the casing collars and upon passing to the length of the collar, annulus will abut the upper end of the next adjacent casing section. At this moment, a sharp weight reduction will register on the tool string weight indicator at the surface and the operator will know that a collar has been located by the tool 10.
When the tool has passed through the predetermined number of casing sections and has located the particular collar near the formation to be perforated or treated, the tool operator can then move the tool string the required distance from the collar to obtain a very accurate location on the desired underground formation.
The particular curvilinear surface for projections 22 may be selected to provide the desired weight indication with the given spring force arising from the elastic deflection of arms 24 from their initial outward bowed, relaxed position, and the spring members 31. In this embodiment, a parabolic curve is shown on member 22 but other type surfaces could be utilized, such as circular and elliptical. It would also be possible to provide angular shoulders on projections 22 although the curvilinear surfaces provide less wear and shock for sleeve member 21.
In addition, modifications of the ratio between the dimensions x and t can be made to alter the amount of drag force on the tool in the casing. For instance, if x is made greater than t, an increased drag force will be encountered by the tool while passing inside the casing. Conversely, making x smaller than t will result in a reduction of drag in the casing below that normally occurring in the neutral position where x equals t.
Although specific preferred embodiments of the present inventionhave been described in the detailed description above, the description is not intended to limit the invention to the particular forms or embodiments disclosed herein since they are to be recognized as illustrative rather than restrictive and it would be obvious to those skilled in the art that the invention is not so limited. For example, where belleville spring washers are utilized, it would be possible to use various other spring means such as coil springs. Also whereas parabolic curved surfaces are utilized on projections 22, it is clear that other configurations of the surfaces could be utilized also. Thus, the invention is declared to cover all changes and modifications of the specific example of the invention herein disclosed for purposes of illustration which do not constitute departures from the spirit and scope of the invention. | A tubing string device for giving an indication of the location of casing collars in a cased wellbore utilizes a tubular body having a resilient sleeve mounted thereon, and axial spring means abutting the resilient sleeve. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to an articulated sectional slat for an articulated curtain and to a closing curtain formed from these slats.
From the document FR-A-2,582,7l5, it is known how to obtain a curtain closure by means of sectional slats having on a longitudinal edge a male articulation element in closed cylinder form and on the opposite edge a female articulation element in open cylinder form. These two elements are adapted to cooperate with the corresponding elements of the adjacent slats. When the curtain is closed, its front face is substantially flat, and the front edges of two adjacent slats are separated by only a narrow gap.
However, when the slats of the curtain pivot relative to each other, the articulation elements permit a wide spacing between the two front edges of two adjacent slats. As a result, it is impossible to cover the front face of the curtain with a fabric or a decorative paper, which would be torn with the first opening of the curtain.
SUMMARY OF THE INVENTION
It is one of the objects of the present invention to provide a closure curtain with hinged slats, the front face of the curtain having substantially the same surface regardless of the relative position of the slats.
Another object of the invention is to provide curtain slats able to be articulated, forming an angle up to about 60°.
The subject of the present invention is a one-piece sectional slat for a curtain closure comprising two substantially symmetrical half-slats integrally joined by a flexible joint.
The half-slats and the joint are coextruded. Each half-slat presents in cross section a polygonal contour comprising a first side corresponding to the front face of the slat and a second side perpendicular to the first side and corresponding to a lateral face of the slat. The polygonal contour of each half-slat presents, at the joint, an acute angle between the first side and a fourth side. The fourth sides of the two half-slats of one and the same slat forming between them an angle of about 60°.
On each half-slat, the fourth side is separated from a third side by a substantially right angle whose outer wall alone ensures the support of each half-slat on a curtain slide.
The second side of one half-slat has a rib and the second side of the other joined half-slat has a groove so that two adjacent half-slats of two adjacent slats interlock by the cooperation of the rib and groove. The flexible joint presents on its outward face a V-shaped groove whose aperture angle is about 90°.
The invention has as its object also a slat curtain comprising slats rigidly linked together, the articulation occurring in the middle of each slat by means of the flexible joint.
BRIEF DESCRIPTION OF DRAWING
Other characteristics are evident from the description which follows with reference to the annexed drawing in which can be seen:
FIG. 1 is a top view of an articulated sectional slat for a curtain closure according to the invention;
FIG. 2 is an enlarged view of the flexible hinge joint of the slat of FIG, 1;
FIG. 3 is a top view of a closing curtain disposed in a slide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, it is seen that the slat according to the invention includes two half-slats 1, 2 joined by a flexible joint 3. Each half-slat is hollow and obtained, for example, by extrusion of a section of plastic material. Each half-slat presents, in cross section, a polygonal contour presenting an acute angle at the joint 3, that is, toward the middle of the slat.
Starting from this acute angle 4, the polygonal contour of the half-slat 2 has a first side 5 corresponding to the front face of the slat, a right angle 6, a second side 7 corresponding to the lateral face of the slat, an obtuse angle 8, a third side 9, a substantially right angle 10, and a fourth side 11. In this manner, the substantially right angle 10 is the point farthest away from the first side 5. When the curtain moves in a slide, the outer wall of this angle 10 alone ensures the support of the half-slat on the slide, thereby reducing friction
On the outside of the half-slat 2, the second side 7 carries a T-shaped rib 12 intended to cooperate with a corresponding groove 13 of the adjacent half-slat, which is identical with the half-slat 1 (FIG. 3).
The half-slat 1 is substantially symmetrical to the half-slat 2 relative to the median plane passing through the joint 3. It presents, in section, a polygonal contour with an acute angle 14, a first side 15, a right angle 16, a second side 17, an obtuse angle 18, a third side 19, a substantially right angle 20, and a fourth side 21. The second side 17 has a T-shaped groove 13, limited in depth toward the interior of the half-slat 1 by a partition 22.
In an assembled curtain, a half-slat 2 interlocks with the adjacent half-slat 1 by insertion of its T-shaped rib 12 in the corresponding T-shaped groove 13 of the adjacent slat (FIG. 3). The slats of the curtain are thus made integral with one another by means of the ribs 12 and grooves 13. The grooves are dimensioned so that the ribs slide in the grooves with a low level of friction. Two adjacent slats thus interlock efficiently and the articulation of the curtain occurs by means of the joints 3, that is, in the middle of the slats. The angle between the two fourth sides 11, 21 of the two half-slats 2, 1, respectively, is about 60°, thus allowing a bending angle of about 60° from one half-slat to the other in the direction that brings the rear corners 10, 20 toward each other.
It is seen in FIG. 2 that the joint 3 is disposed between the two facing sides 11, 21, in the immediate vicinity of the acute angles 4, 14 of the two half-slats. This joint may be effected by glue on the two half-slats, but it is advantageously coextruded with the two half-slats. It is flexible and plastic so as to be elastically deformable.
Preferably the joint 3 presents on the front face of the slat a V-shaped groove 23 whose opening angle is about 90° . This joint 3 permits bending of the slat both backward (FIG. 3) and forward. When the slat is bent backward, the V-shaped groove 23 ensures that the joint does not project forward. In this manner, the entire front face of the curtain can be covered with a fabric or a paper which will not tear in the course of opening or closing of a curtain. The aesthetic appearance of the curtain is thus improved as compared with a conventional curtain with slats articulated on one another by swivel pins that do not permit the placement of a continuous covering.
The curtain according to the invention, consisting of hollow half-slats coextruded with their hinge joint, behaves like a double walled rigid curtain, the flexible joints ensuring the articulation.
As the articulated slats are obtained by coextrusion, they can be cut to the desired length and assembled together to constitute a curtain of given dimensions.
Unlike conventional curtains with slats articulated by link pins, the curtain according to the invention is able to articulate in both directions.
The embodiments illustrated in FIGS. 1 and 2 are only illustrative, and the T-shaped ribs and grooves may be replaced by any type of attachment, for example, with tenon and mortise.
With a slat curtain according to the invention, the noise connected with operation of the curtain is much reduced and very easy operation is noted. | Two substantially symmetrical half-slats are joined by an integral flexible joint to form a one-piece articulated slat. Adjacent slats rigidly interlock by cooperation of a projecting rib on one slat and a correspondingly shaped groove on the other slat to form an articulated curtain. The flexible joints are bendable in two directions and coextruded with the half-slats. |
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FIELD OF THE INVENTION
The present invention relates to a process to enhance the recovery of crude oil and, more particularly, to a process of enhancing the flow of crude oil through a formation from injection holes to a recovery well.
BACKGROUND OF THE INVENTION
Many oil wells are subject to greatly reduced natural production as a result of heavy, low gravity crude oil deposits being combined with low porosity sands in the producing formation. In such shallow formations, crude oil is in equilibrium, and no natural differential pressure exists to drive the crude oil up to the surface. As a result, when crude oil is removed from a recovery well, high viscosity of the oil and low porosity of the formation prevent migration of the crude from the surrounding formation into the recovery well. The high pressure that exists in many deep wells usually does not exist in the shallower wells, such wells being within about one thousand feet of the surface. There are, however, many such stabilized, heavy crude oil deposits to be found in shallow formations. An example of such a heavy crude oil deposit can be found in the shallow San Miguel formation in the central part of Maverick County, northeast of the town of Eagle Pass, Texas.
Structurally, the shallow San Miguel formation is located on the northern, or tip portion of the Chittim anticline. The Olmos formation and underlying San Miguel formation outcrop over the northern portion of the Chittim anticline. This circumstance results in the oil-bearing reservoir sands within the shallow San Miguel formation lying as close as forty feet below the surface of the earth in many areas.
The San Miguel sands are estimated to contain in excess of one hundred one million barrels of heavy crude oil low in sulfur and ranging in gravity from about 10° A.P.I. to 20° A.P.I. depending upon depth. About half the heavy crude lies within one hundred feet of the surface of the earth.
Two methods have been used in an attempt to remove crude oil from the San Miguel sands. An in situ combustion project was attempted. Combustion was supported by injecting air through input wells. The project was abandoned when no significant quantity of oil was produced. In addition, steam injection was attempted with similar dissappointing results.
The prior art includes a number of patents related to the recovery of oil. For example, U.S. Pat. No. 2,286,724 (Garrison) discloses the heat treatment of an oil well by first heating wet sand above the producing formation to the boiling point of water to dehydrate the sand around the well. Garrison proposes heating to be done by an electric heater lowered into the well. Following deydration, the sand grains are coated with an oil wettable material. This converts an oil well that has contained water wet producing sand to one that is wettable by oil, and thereby increases the ratio of oil to water in the producing sand. By dehydrating the wet sand, oil can flow through the capillaries and crevices of the producing sand.
U.S. Pat. No. 3,385,359 (Offeringa, 1968) discloses a method for producing oil from a sub-surface producing formation that consists of very high viscosity tar-bearing sands. The method consists of injecting hot water into the formation, waiting for the formation to heat, then injecting steam and other condensable liquids into the formation. The viscosity of the tar is lowered, and it can be removed. Offeringa also discloses fracturing to reduce the pressure required to inject the water into the formation.
U.S. Pat. No. 3,372,750 (Satter et al., 1968) discloses a method directed to an environment in which oil sands overlay water-bearing sands. In Satter, heat is applied to a large volume of oil while steam is simultaneously used to a reduce viscosity and force migration to a recovery well.
Yet another method of enhancing crude oil recovery using heat is disclosed in U.S. Pat. No. 3,441,083 (Fitzgerald 1969). This method uses both steam drive and in situ combustion techniques in combination with a specific spacing between air and steam injection wells. In Fitzgerald, production wells surround a plurality of steam and air injection wells. Heat and pressure are created by in situ combustion at the top of the formation. Heat and fluid flow is initiated from the injection well to the production well by steam injection in the lower portion of the producing formation. This, in conjunction with gravity and thermal expansion, causes the crude oil to flow downward to the production wells. This method also anticipates fracturing of the producing formation near the bottom before steam injection.
Prior art also discloses processes for recovery of liquids other than liquid hydrocarbons from underground. For example, U.S. Pat. No. 3,759,328 (Ueber 1973) features a method for removing hydrocarbons from oil shale. This method discloses an underground cavern which is continually evacuated and in which shattered and crumbled oil shale is pyrolyzed, releasing hydrocarbons thereby. Pumps are used to inject steam and hot liquids, as well as to remove gas and fluid from the pyrolyzed shale in the underground chamber.
U.S. Pat. No. 461,445 (Monjeau 1891) discloses a process for forming subterranean filtering chambers for the recovery of clean water. The invention relates to enlarging subterranean areas to increase the amount of water obtainable from them. The method involves the injection into the well of steam in conjunction with hammering and thereby loosening particles of sand and gravel which are then removed by pumping.
SUMMARY OF THE INVENTION
The process consists of selecting a favorable site, such site determined by taking a full depth core for evaluation purposes. Assuming satisfactory core results, these core holes will become pilot holes for each recovery well. At the chosen location, a recovery well is drilled through the overburden into the bottom of the producing formation. Three shot holes are then drilled to the bottom of the producing formation in a triangular pattern around the recovery well. The shot holes are filled with a suitable blasting charge and a cast primer, and subsequently stemmed to the surface. The three shots are detonated simultaneously into the recovery well in the producing formation. The rubble that has been blasted loose is cleaned out as much as possible to increase the size of the recovery chamber. This will provide a place for crude oil to pool and also facilitate its pumping.
A fabricated casinghead is set in place on a cemented casing which extends into at least the top of the producing formation. A vacuum pump, submersible pump and monitoring instrumentation are hooked up and commissioned.
Approximately thirty to sixty feet away from the recovery well, injection holes are drilled into the producing formation, charges inserted, holes stemmed and blasted. The injection holes are then redrilled, and hot diesel fuel with a surfactant added is injected through injection lines lowered into each injection hole. The injection in each hole will sweep the producing formation in a half circle from a tangent on the circle towards the central casing and through the full depth of the formation. The heat of the diesel fuel will lower the viscosity of the crude oil, and the diesel fuel itself will slightly improve the gravity of the crude oil, with a surfactant included to promote separation of the oil from the formation water.
Vacuum of up to 25 inches of mercury will be drawn in the central casing to promote the flow of stimulated crude oil towards it.
All of these techniques will stimulate the flow of crude oil that previously was in equilibrium in the producing formation.
It is, therefore, the object of the present invention to initiate and enhance the flow of crude oil through a producing formation. More specifically, it is the object of the present invention to enhance the flow of crude oil through a producing formation from an injection well to a recovery well.
It is a further object of the present invention to initiate or enhance oil flow through a producing formation by the injection of a high pressure hydrocarbon solvent through an injection well to a recovery well which has been partially evacuated of air.
It is a further object of the present invention to enhance the flow of crude oil through a producing formation by fracturing the producing formation prior to imposing a pressure differential through the injection of a high temperature hydrocarbon solvent at an injection well and the evacuation of a central recovery well.
It is yet another object of the present invention to enhance the migration of crude oil through producing formation by utilizing hot hydrocarbon solvent mixed with a suitable surfactant to break down water-crude oil bond.
It is yet another object of the present invention to combine the aforementioned steps of heating, injecting, fracturing, and evacuating to enhance recovery of crude oil in a producing formation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a producing formation as it exists when the enhanced oil recovery process is in operation.
FIG. 2 is an overhead view of the surface of the ground and the location of drill noles when the enhanced oil recovery process is in operation.
FIG. 3 is an enlarged cross-section of an injection hole illustrating the injecting line as it crosses from the overburden through the producing formation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before the enhanced recovery process is begun, a suitable location must be found. In evaluating a proposed location, full depth cores should be taken. If the results are satisfactory, the core holes may become pilot holes for each central recovery well 18.
FIG. 1 illustrates the main features of the enhanced recovery process. To illustrate its application, assume crude oil 10 has been discovered in producing formation 12. However, because of high viscosity or other properties of crude oil 10, limited porosity in producing formation 12, and the shallow depth of producing formation 12, very little natural pressure exists to drive crude oil 10. Producing formation 12, therefore, is an excellent candidate for the enhanced recovery process. Producing formation 12 may be overlain by overburden 14, and underlain by underlying formation 16. For the sake of illustration, overburden 14 in FIG. 1 is limestone, producing formation 12 is sandstone, and underlying formation 14 is an impervious clay. Crude oil 10 is trapped within producing formation 12 by the impervious underlying formation 16.
As can be seen in FIG. 1, a number of drill holes penetrate producing formation 12. First, central recovery well 18 is drilled into the top of producing formation 12. In the preferred embodiment recovery well 18 is drilled through overburden 14 to a 24 inch diameter. It is from recovery well 18 that crude oil 10 will be withdrawn. After drilling recovery well 18 a casing 20, preferably made of steel, is set from the surface of the ground through overburden 14 and partially into producing formation 12. Preferably, casing 20 has an exterior diameter of 20 inches. Next, recovery well 18 is drilled approximately 18 inches in diameter through producing formation 12 into underlying formation 16.
Following the drilling of recovery well 18 and the setting of casing 20, shot holes 22 are drilled through overburden 14 and into producing formation 12. While the drilling diameter of recovery well 18 is generally in the order of 24 to 30 inches, shot holes need only be large enough to insert a blasting charge, preferably about 61/2 inches in diameter. Shot holes 22 are drilled within a close proximity to recovery well 18. Generally, shot holes 22 will be drilled within a 12-foot diameter of where the longitudinal axis of recovery well 18 intersects plane of surface 24.
The next step is a first blasting. Charges are inserted into producing formation 12 through shot holes 22. Following insertion of the blasting charges into producing formation 12, shot holes 22 are permanently stemmed from the top of producing formation 12 to surface 24. The stemming of shot holes 22 will prevent the escape of the blasting charge and debris during detonation. The charges will be packed into producing formation 12.
When the blasting charges are detonated, producing formation 12 is heavily fractured. Fractures 26 act as fluid channels for the migration of crude oil 10. In addition, detonating a blasting charge of sufficient magnitude will create rubble 28. Rubble 28 is illustrated underlying chamber 30. That is, after the first blasting, rubble 28 is physically removed from producing formation 12 to create chamber 30. Rubble 28 may be removed using drill bits that are known in the art, or by other mechanical means, such as tongs, grappling hooks, vacuum systems or a shallow pitch auger. For the sake of illustration, some rubble 28 is left in the bottom of chamber 30.
The purpose of the first blasting through shot holes 22 into recovery well 18 is two-fold. First, numerous fractures 26 are created which improves the flow of crude oil 10 through producing formation 12 by increasing the flow face. Second, the first blasting produces rubble 28 which may be removed from chamber 30 to create a vessel for the collection of crude oil 10 and underlying water 33. One example of an appropriate blasting charge is ANFO-Nitropel with a cast primer, though other charges are suitable.
It should be noted that the enhanced oil recovery process does not require shot holes 22. The purpose of shot holes 22 is to increase the volume of chamber 30 by introducing blasting charges several places within producing formation 12. That is, the use of shot holes 22 produces a larger chamber 30. The magnitude of the blasting charge and the location of shot holes 22 will help determine the amount of rubble 28 created and when removed, the size of chamber 30. The magnitude of blasting charge required will be a function of the type of charge and the manner it is used, as well as the properties of producing formation 12. In addition to blasting to create chamber 30, hydraulic fracturing or bell footing drilling techniques are appropriate for shallow formations.
As can be seen in FIG. 2, three shot holes 22 are drilled equally spaced along the circumference of a circle transcribed by a radius of 6 feet originating at the longitudinal axis of casing 20 where said longitudinal axis intersects surface 24. This distance, however, would vary with the properties of producing formation 12, magnitude of blasting charge, and size of evacuated chamber 30 desired.
The enhanced oil recovery process also requires drilling of at least one injection hole 32. Injection holes 32 are drilled at least partially into producing formation 12. In the preferred embodiment a plurality of injection holes 32 are drilled along the circumference of a circle extending outward from an origin located at the intersection of longitudinal axis of recovery well 18 and surface 24. This is illustrated in FIG. 2. The radius to first injection holes 32 is preferably 30 feet, and the radius to second injection holes 32 is 60 feet. These distances will vary with properties of producing formation 12. While FIG. 2 illustrates a circular pattern for injection holes 32, other patterns may be suitable, depending upon the properties of the formation. After flow of crude oil 10 is established, radii of injection holes 32 will increase in 30 foot increments.
Following drilling of injection holes 32, blasting charges are set within producing formation 12 and injection holes 32 are stemmed. A second blasting in producing formation 12 is then performed. The second blasting may be either simultaneous or sequential. That is, all charges may be fired simultaneously, or sequentially. The purpose of this blasting is to promote fracturing and gas generation in producing formation 12 and thereby create a free flow of crude oil 10 therethrough. In the preferred embodiment, sequential blasting promotes shock waves which assist in gas generation and fracturing of producing formation 12. When blasting sequentially, the charges closest to recovery well 18 are fired first, and the charges farthest away are fired last. Such sequential blasting focuses the blast's percussion at recovery well 18.
Following the second blasting, injection holes 32 are redrilled. Following redrilling, sleeves 34 are inserted at least through overburden 14. In the preferred embodiment, 51/2 inch steel is used for sleeve 34. At this stage, the physical drilling is completed.
The next step is to begin the recovery of crude oil 10. FIG. 1 and FIG. 3 are sufficient to illustrate the postdrilling steps required to produce crude oil 10 from producing formation 12. In brief overview, the recovery process requires the introduction by pressure injection of a hot, liquid hydrocarbon solvent/surfactant mixture through injection holes 32 into producing formation 12, evacuation by vacuum pump of chamber 30, and (optionally) using pump 38 to remove crude oil 10 pooled in chamber 30. The overall effect of the combination of the aforementioned, is to force crude oil 10 to migrate through producing formation 12, assisted by blast-created flow channels. The migration of crude oil 10 to evacuated chamber 30 is enhanced by the pressure differential created by the injection of hot, hydrocarbon solvent 36 under pressure through injection holes 32 combined with the vacuum created in chamber 30 by vacuum pump 40. The heating of hydrocarbon solvent 36 assists in lowering viscosity of crude oil 10 by raising its temperature. In preferred embodiment hydrocarbon solvent 36 is diesel fuel but other solvents may be used depending upon crude oil and formation properties. By using liquid hydrocarbon solvent 36, the viscosity of crude oil 10 is further decreased and the flow thereby increased.
Injection of hydrocarbon solvent 36 is performed by injection unit 42. Suitable injection units 42 are available through Bohanan Hot Oil Services, Jourdanton, Texas. Injection unit 42 heats diesel fuel and pumps it under pressure to a delivery point. In the preferred embodiment, hydrocarbon solvent 36 is injected at pressures up to 6,000 p.s.i. and a temperature of up to 250° F. The amount of solvent 36 injected into each hole preferably is a minimum of 5% and a maximum of 10% of the calculated volume of crude oil 10 in the formation swept from each injection hole 32. Optionally, a surfactant can be mixed with hydrocarbon solvent 36 prior to injection. A suitable surfactant is Hyflo IV (available through Halliburton Services, Duncan, Okla. 73536), a blend of oil soluble surfactants designed to help break water blocks and reduce the crude oil/water emulsions. By reducing interfacial tension and film viscosity between formation brines and crude oil 10, crude oil 10 flow is enhanced.
FIG. 3 shows injector line 45 connected to solvent injection/heater unit 42. Line 45 extends down through sleeved injector holes 32 and producing formation 12. Injector line 45 is attached to packer 52 which is affixed to spray nozzle assembly 54 which, in turn, extends into producing formation 12. Spray nozzles 56 are adapted to spray pressurized hydrocarbon solvent 36 in a variety of spray patterns. Nozzles 56 can spray sheets, cones, needles, or any other pattern desired. A source of different types of injector nozzles is Spraying Systems Co., Wheaton, Ill. 60188. In the preferred embodiment, numerous spray nozzles 56 are connected along nozzle assembly 54 below where injector line 44 is attached to packer 52. Injector line 44 and nozzle assembly 54 are capable of being rotated. This rotational feature allows injector spray nozzles 56 to direct spray. Spray nozzle assembly 54 may also be raised and lowered from surface 24 to allow injecting of entire producing formation 12. In the preferred embodiment, the injection is first directed toward chamber 30. Then, hydrocarbon solvent 36 may be sprayed in a 360° circle. The purpose of such directional injection is to initiate the migrating of crude oil 10 towards chamber 30.
Packer 52 will be inserted into injection well 32 seated at a point just above the interface of overburden 14 and producing formation 12. By using packer 52 with an outer diameter pressing firmly against inner diameter of sleeve 34 and an inner diameter of packer 52 carrying injector line 44 above and spray nozzle assembly 54 below, an effective seal is created between overburden 14 and producing formation 12. This seal allows restriction of pressure created by injector unit 42 to within producing formation 12 and prohibits backflow of solvent 36 up injection hole 32. An example of one such packer 52 is the Otis CP Packer with opposing cups designed to seal in both directions.
Recovery well 18 is sealed with casinghead 44. Gauges and monitoring instrumentation 46 are connected in communication with recovery well 18. Gauges and monitoring instrumentation 46 detect temperature (degrees F.), pressure (pounds per square inch and vacuum inches of mercury), hydrogen sulfide (H 2 S) and oxygen (O 2 ). These gauges and sensors are commercially available.
Vacuum pump 40 is connected with casinghead 44 to draw vacuum in recovery well 18. An example of a suitable vacuum pump is the Sogevac Rotary Vane Pump designed to produce at least 25 inches of mercury vacuum at a pumping capacity of approximately 375 cubic feet per minute. It is important that pump 40 is designed with blow-out protection for a sudden increase in pressure. In the preferred embodiment, vacuum pump 40 should pull recovery well 18 down to 25 inches of mercury vacuum maximum. In shallow wells, such a vacuum may be sufficient to cause crude oil 10 to rise up through casinghead. When this occurs, oil may be drawn off by valve 50 in flange of casinghead as indicated in FIG. 1. Valve 50 will draw off crude oil 10 when vacuum in chamber 30 is sufficient to draw crude oil 10 up to flange of casinghead 44. Optionally, pump 38 can be used in conjunction with vacuum pump 40 to remove crude oil 10 through casinghead 44. After a sufficient volume of crude oil 10 has accumulated, batch collection may be used. In the alternative, continuous removal of crude oil 10 through valve 50 or pump 38 is available. That is, a level sensor preset at a given level of crude oil 10 in chamber 30 will control pump 38 operation to maintain the preset level of crude oil 10.
The description set out above describes the preferred embodiment of the enhanced oil recovery process. It is intended, however, that this disclosure and the claims that follow include all obvious variations thereof. | A method to enhance oil production from producing formations using a pressure differential created by evacuating a recovery hole cased through the overburden into the producing formation, and directionally injecting under pressure, into an injection hole in communication with the producing formation, a heated hydrocarbon solvent with surfactant added a distance from the recovery hole. The heat, solvent, pressure differential and surfactant will increase the flow of crude into the recovery hole. |
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BACKGROUND OF THE INVENTION
One of the most essential ingredients for life is wholesome, palatable drinking water. Throughout the history of mankind, wars have been fought over the possession and ownership of bodies of potable water. Man may exist for weeks upon nothing but water and its essential value has always been recognized.
In modern times, through industrialization, urbanization and population growth, vast sources of clean water have been eliminated or so contaminated as to be rendered unfit for human consumption. The invention involves a system whereby available water supplies are more judiciously utilized by improved and more effective distribution, thus saving an additional twenty-five percent, or more, without harmful effect to the consumer or the community.
In household sinks and showers of conventional systems currently in use, the water is soiled by soap and material washed from a person's body, and discharged to a sewer drain. With laundry washing machines the sewer discharged water is soiled by the detergent and the dirt from the laundry. With rain water the detritus is largely leaves, twigs and air borne soot. Such water is commonly referred to as "gray water."
In water closets of toilets their proper functioning is predicated upon the provision of a proper liquid volumetric vehicle, usually several gallons of water are required to carry off the waste contained therein. It is not essential that the water used in these devices be potable in the strict sense. The waste entailed in conventional systems is not only of natural resources but also is an unnecessary drain on the user.
The invention provides a system where the liquid discharge from the sinks, showers and washing machines of a household is stored in a suitable reservoir, supplied to the water closets when needed and then ultimately discharged to the sewer.
DESCRIPTION OF THE PRIOR ART
A patent to Call, No. 3,112,497, issued Dec. 3, 1963, discloses a water conservation system where the same water is used for two purposes before being discharged. An O'Brien et al, U.S. Pat. No. 3,183,525, issued May 18, 1965 relates to a water conservation device for use in a fallout shelter. A patent issued Mar. 2, 1971, to Kemperer, 3,567,032, discloses a diaphragm type pump used in a recirculating sanitary system. A patent to Reid, U.S. Pat. No. 3,594,825, issued July 27, 1971, is directed to a system for storing water that has been used in a shower or basin and reusing it in a flush toilet. Of particular interest is a pamphlet entitled "Demonstration of Waste Flow Reduction from Households" EPA-670/2-74-071, September 1974, distributed by U.S. National Environmental Research Center, Office of Research and Development, U.S. Environmental Protection Agency Cincinnati, Ohio, 45268. This pamphlet discusses various means for the conservation of water and including consideration of systems for recycling water that has been used for washing and showering, so that it may be used for flush toilets or the like.
A patent to Lankton, U.S. Pat. No. 2,419,319, issued Apr. 22, 1947 relates to a portable housing unit adapted to be prefabricated as a factory item and mounted as a unit in a building.
BRIEF SUMMARY OF THE INVENTION
An object of this invention is, broadly, a practical household system wherein all or a portion of the water that is usually discharged to the sewer is treated and preserved for use in another facility before its ultimate disposal.
A further object of this invention is a waste water conservation system comprising a practicable process and apparatus for sanitizing and reusing the waste water from sinks, showers and washing machines for water closets of toilets.
Another object of this invention is a process and apparatus for the conservation of water, comprising the accumulation and storage of rain water from roof gutters, to be admixed with water from household sinks, showers or washing machines and ultimately used for water closets of toilets or garbage disposals.
A yet further object of this invention is a process and apparatus as above-mentioned, wherein a disinfectant material is added to the stored liquid prior to use in the water closet.
Alternatively, the salvaged water may be caused to flow through, or otherwise be exposed to, a supply of iodine crystals which cleanse the water.
Other objects, adaptabilities and capabilities of the invention will appear as the description progresses, reference being had to the accompanying drawings, which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view through a household illustrating one form of the invention;
FIG. 2 is a similar view illustrating a modification of the device;
FIG. 3 is an enlarged detail of the storm water sediment trap;
FIG. 4 discloses another modification for use with an outdoor tank;
FIG. 5 shows a further modification for use with a hydraulic ram;
FIG. 6 is an enlarged detail in secton illustrating the mixing of chlorine, or the like, and bluing with the previously used water;
FIG. 7 is a wiring diagram of the pressure responsive system for the tank;
FIG. 7A is a pump wiring diagram;
FIG. 8 illustrates an alternative water cleaning apparatus; and
FIG. 9 illustrates the apparatus of the invention in a self-contained transportable unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 the house 10 is provided with conventional float tank water closet 11, lavatory 12, tub 14 and washer 15. The lavatory, tub and washer are connected to a source of suitable clean uncontaminated water through a conventional piping system which forms no part of the invention as such and has not been illustrated for the sake of clarity. The waste lines from these facilities are not, however, connected directly to the sewer line as in a conventional system. Instead, inasmuch as this water, known as "gray water," after having been used, remains relatively clean, it can again be used for flushing toilets. Therefore waste lines 18 are connected to a settling storage tank 19. The washer 15 is provided with a discharge line 18a which discharges into an open-sight train 18b.
Storage tank 19 is provided with baffles 20 in its bottom portion and a valved drain system 21. The drain system is provided for the periodic removal of sediment, dirt and grit, and the like, which settles to the bottom thereof. It will be noted that the tank 19 is disposed at a level below the main or first household floor 22 and therefore conventional gravity flow to the tank suffices for the purpose of collecting the gray water. The tank and its essential components are preferably enclosed in a separate compartment or box-like holder as described hereafter with reference to FIG. 9. Deodorant pellets may be added to the contents of the tank to remove odors, impart an unpleasant taste to the water, or color same or any combination thereof. Thus an important feature of the invention is in the provision of a filtering, chlorinating and bluing system for this reused gray water. A deodorizing canister designated generally by reference numeral 23, is provided on an upper portion of the tank 19 and contains a supply of liquid sanitizer, deodorizer and soft blue coloring agent which is gravity fed into the gray water in tank 19 in controlled amounts. FIG. 6 shows an alternate embodiment wherein a canister 27 is supported in a container 23a which is mounted by a bracket 18a affixed to line 18 and is provided with a conduit 24 having a tip 25 disposed in the flow path of the gray water flowing through the waste lines 18, immediately prior to discharge into the settling storage tank. Tip 25 is split as at 26, the bisection being of a character and sufficiently thin that it normally prevents the flow of the liquid 27 from its interior, except that upon being wetted on its exterior by the water flowing in the waste lines 18 it permits the flow of the liquid 27 to intermix in selected amounts in the flowing water. Thus it will be seen that this chlorinating means functions only while the gray water is being added to the tank and the tip 25 is wetted.
A flow reversible pump designated generally by reference numeral 28 automatically functions to displace water from tank 19 into the gray water feed pipe line 29 and to maintain the desired pressure therein. Water in this pipe is pumped to an upper portion of the household into an upper storage tank 30 which is of diaphragm type to maintain pressure through the gray water feed system. The tank may be hidden in a closet or be in an attic or at any appropriate location where danger of the water therein freezing does not exist. A line pressure switch 53 is interposed between the pump 28 and the tank 30. Upon flushing water closet 11, gray water from the upper storage tank 30 flows through the conduit 29 thereto to replace water flushed from the tank of water closet 11. This flushed water and wastes are discharged to the sewer line 32. The drain system 21 of tank 19 also discharges to the sewer line 32. If desired, the upper storage tank 30 may be disposed in the general region of the main storage tank 19, as at 30a, for example, The function is essentially the same since the entire system is maintained under pressure by the pump 28 and by the head of pressure above the diaphragm whether in tank 30 or 30a. Tanks 30 or 30a also function as a reservoir for the several water closets. When the water closets are flushed, the fall in water level in the tank results in a lower pressure upon the line pressure switch 53 which, in turn actuates pump 28 to refill the tank 30 or 30a and repeat the cycle. Pump 28, as previously indicated, is preferably reversible to back-flush periodically, for example, every 24 hours. Piping arrangements, per se, for reversing pump 28 are well-known and therefore are now shown.
A tank pressure switch 54 acts as a safety cutoff for pump 28. If the water level in tank 19 drops too low, switch 54 breaks the circuit to the electric motor 55 of pump 28 which will not then operate. Further, the tank pressure switch 54, on a fall in pressure in tank 19, causes the fill solenoid 34 in conduit 37 to open. As shown in detail in FIGS. 1 and 7, this causes fresh water from the building's fresh water system via a fresh water inlet to fill tank 19. Conduit 37 also has a manually operated gate valve 36. The manual fill 35 which by-passes the automatic fill may be used if necessary. This manual fill comprises a gate valve 35b in a conduit 35a. Both conduits 35a and 37 carry fresh water to a tank fill funnel 38 and a furthe conduit 39 which leads into tank 19. It should be noted that there is an air break between the conduit 37 and the funnel 38 to prevent the least possibility of contamination of the fresh water system. Valve 36 in conduit 37 is preferably adjusted to ensure that the flow of fresh water provided therein is not at a rate to exceed the capacity of funnel 38 for drainage into tank 19.
The valved drain system 21 is opened for a few moments periodically to drain off any sediment from tank 19. Also inasmuch as the quantity of water flowing into tank 19 from the washers, showers, etc., is normally greater than the quantity pumped out for water closet use, the water level in tank 19 rises and the gray water passes through an overflow 39a and is discharged to sewer line 32. This action is utilized to remove any surface film which may accumulate on the surface ot the gray water. In larger buildings such as office buildings where this system can be incorporated, the reverse situation occurs and some makeup water is normally required.
Waste lines are vented conventionally as indicated by reference numeral 40 and check valves 41 are appropriately disposed in the system to prevent back flow. A strainer 42 is positioned in the pipe line 29 prior to pump 28 to prevent passage of solids therethrough. Reversing action of the pump 28 cleans the strainer.
Instead of utilizing the disinfecting system shown in FIG. 6, the system shown in FIG. 8 may be substituted. In this modification a receptacle 43 containing iodine crystals 44 is directly and removably interposed in the waste line 18 so that all gray water flowing to the settling storage tank must pass therethrough. The iodine crystals, like the chlorinating and bluing solution, function to deodorize as well as cleanse the stored water. The iodine crystals, in normal household use, have been found to remain effective up to a year before being replaced. The crystals may be added from time to time into receptacle 43 by removing a plug 43a. Line 18 which passes through the top of receptacle 44 almost touches the bottom of receptacle 43 whereby the crystals are slowly dissolved into the gray water passing therethrough.
In the arrangement shown in FIG. 1, the kitchen sink 16 with its garbage disposal unit 17 are connected to a waste line 45 and the material therefrom is discharged directly into the sewer line 32. Vent for the waste line 45 is designated by reference numeral 46. Lower level fixtures such as the lavatory 47 and a water closet 48 also discharge directly into sewer line 32; however, the water closet 48 receives its water through the pipe line 49 connected to the pipe line 29. The pipe providing the lines 29 and 49, which carry the recycled gray water, may, if desired, be of distinctive color and character such as yellow plastic. This provides an additional safeguard against accidental use of gray water for an undesired purpose.
In FIG. 7, the electrical components are shown diagrammatically. The main electric power supply (120 volt, 60 cycle) is designated by reference numerals 50 and 50a; the main disconnect switch by 51; magnetic starter for motor 55 by 52; line pressure switch by 53; tank pressure switch by 54 and pump motor by 55.
In FIG. 7A the pump wiring diagram is indicated whereby the power supply comprising 120 volt, sixty cycle AC conduits 107 and 108 feeds to a timer 106 which ordinarily retains in an opened or inactivated condition a further conductor which is a continuation of line 107 designated 107a. Solenoids 105 (for a valve 21a) and 105a (for a valve 42a) cause drainage from tank 19 for a predetermined period of time; say thirty seconds once in each twenty-four hour period, into sewer line 32 whereby sediment and the like which is collected in the bottom of the tank 19 and in the strainer 42 are discharged.
Line pressure switch 53 activates electric motor 55 when pressure in conduit 29 is sufficiently low as may be caused by the flushing of a toilet (FIG. 7). Tank pressure switch 54 in a like manner actuates the fill solenoid 34 and at the same time inactivates motor 55 when water in tank 19 is low. This condition continues until sufficient tank pressure has built up to open the tank pressure switch 54 which closes the circuit to the line pressure switch 53 and permits the pump 55 to operate. This provides a safety measure inasmuch as if the water in the tank 19 is so low as to actuate the tank pressure switch 54 the lack of water for suction may cause damage to an operating pump 28.
In FIG. 2, a modified arrangement for water conservation is illustrated. In conventional arrangements, storm water is either discharged directly to the soil or to a sewer line. In either instance its obvious usefulness as a liquid volumetric vehicle is lost. In FIG. 2 the storm water accumulated from gutters 56 is conducted by downspouts 57 to trap 58. The gutters are provided with screens 59 to eliminate leaves and twigs. Trap 58, shown in detail in FIG. 3, comprises a further debris trapping screen 60 of concave configuration and disposed atop the receptacle 61. A discharge conduit 62 connects to the receptacle at a point below the bottom of the screen. This conduit is in communication with pipe line 63 which carries the water to tank 64. A valve 65 is disposed in the line 63 to limit the flow of water as desired in case of a heavy storm condition or of a large roof area. A check valve 66 prevents the back flow of water from tank 64. In this arrangement the drains from the lavatory, tub and washer are as illustrated in FIG. 1. If, however, it be desired to use only storm water for the water closet, drain 67 may be entirely omitted. The lines from the tank 64 to the water closet 11 and 48 and therefrom to the sewer line are also the same as in FIG. 1. Further, where it is not desirable to discharge storm water to the sanitary sewer, or where a septic field is utilized, a high limit switch closes a solenoid 68 in the storm line. The solenoid is normally closed but opens at a low water point in the tank 64 and remains open until the tank is filled.
In FIG. 4, the system is further modified for use with an outdoor tank 69 mounted on a concrete base 70 disposed below ground. A manhole 71 is provided, and a suction pipe 72 and vent 73 are utilized for evacuating, as necessary, and venting the tank. The lavatory, tub and washer water are, as before, fed to tank 69 through pipes 74 similar to pipes 18. An overflow line 75 discharges excess water from the tank to the sewer, whereas pipe 76 feeds water from the tank to pump 28 for circulation to water closet 11 and the system otherwise as disclosed with reference to FIG. 1.
In FIG. 5 the salvaged gray water is recycled by a hydraulic ram or pumping device 77 which preferably comprises a water pump driven by a hydraulic motor of a type disclosed in U.S. Pat. No. 2,190,812, through the ram discharge line 78. This system is advantageous in the event of electric power failure or where no power is available. With the hydraulic device, as the water flows through the pipes 18a portion thereof is pumped through line 78 to storage tank 30 for reuse. The remainer flows into the tank 19. Preferably this system also includes electric motor 55 which drives pump 28. However, it will be appreciated that device 77 may be substituted for the pump 28, including motor 55, in the embodiment shown in FIG. 1 provided the necessary energy for pumping a portion of it needed for the water closets.
It should further be noted that in tall buildings which are provided with cooling tower water, such water may readily be utilized for water closet flushing. At present, this cooling water is usually wasted by being discharged to the sanitary sewer. The discharge from such a cooling tower may be connected to the downspout as is the gutter 56 in FIG. 2.
Referring to FIG. 9, apparatus in accordance with the invention is illustrated in a self-contained transportable unit. This unit, designated generally by reference numeral 80, is contained in a parallelepiped framework structure which has a width of approximately 30 inches, a length of approximately 60 inches, and an overall height of about 64 inches. The diameter of the holding tank 19 is 30 inches and the diameter of the pressure tank 30a is 20 inches. Although in FIG. 9 an overflow line 39a appears to extend beyond the length dimensions of the unit, in actuality, this line extends in the corner space defined between the outer circumference of the holding tank and the box-shaped frame 81. It will be noted from FIG. 9 that frame 81 includes a platform 81a which directly supports motor 55 for pump 28. Also supported on the frame 81 via a further platform 81b is pressure tank 30a, and on a backboard 85, an electric timer control box 82, and an electrical connection panel 84. Gray water supply line 18 terminates within tank 19 in a receptacle 43a which has at its bottom a plurality of small apertures 43b and is filled with a filtering agent which can be sand of a selected grade and may include a slowly soluble bluing agent or the like for coloring the water. Mounted on backboard 85 is a fresh water inlet 37a which includes a gate valve 36 controlled by solenoid 34. The manual fill by-pass 35 includes a gate valve 35b. The inlet 37a and bypass 35 lead to conduit 37 which is spaced above a funnel 38 which, in turn, leads into the interior of tank 19. Also mounted on backboard 85 is a filter 86 which has small diameter water conduit lines 86a and 86b leading from the upper and lower aspects thereof. Such lines connect to conduit 29 on either side of a gate valve 87 which is disposed in a conduit portion 29a that connects a pump discharge conduit portion 29b and the bottom of the pressure tank 30a. A further gate valve 90 is disposed in the discharge conduit portion 29c which connects pump discharge conduit portion 29b with the gray water outlet 29d.
In this embodiment the drain system 21 includes a gate valve 42c which is manually operated and a solenoid operated valve 21a. The valve 21b is a check valve to insure that the liquid flows in the system 21 in the direction of arrow 91 only. Strainer 42 is disposed between the inlet of pump 28 and the outlet conduit portion 29c of holding tank 19 in which a gate valve 92 is also disposed prior to the strainer. Within the tank 19, a float 94 is received which is connected by a rod 95 to a float valve switch mechanism 96. Stop 97 is secured to rod 95 proximate mechanism 96 whereby when the float 94 is lowered, switch mechanism 96 is actuated by a stop 97 to open solenoid 94 and admit fresh water through valve 34 and conduit 37 into funnel 38. Such water continues to flow until another stop 100 which is secured to rod 95 proximate to and under mechanism 96 rises to actuate mechanism 96 whereby the solenoid valve 34 is no longer energized. When such occurs, resilient means within the solenoid valve 34 causes it to close.
Unit 80 is installed usually in the basement of a dwelling in an appropriate location and connections are made with the gray water supply 18, a sewer line 32, the water closet gray conduit 29 and a fresh water conduit 37a. Also electrical connections are made to the control box 82 and connection panel 84. In operation, gray water supplied to the tank 19 is filtered and dyed by the material 44a contained in a receptacle 43a. In the event that amount of gray water supplied to the tank 19 exceeds its capacity, the excess overflows through line 39a to the sewer 32. If, on the other hand, not enough gray water for the purposes of the apparatus is retained in tank 19, the float 94 drops and as previously explained, fresh makeup water is added via the fresh water conduit 37. Water closets are supplied by means of the pumping action of the pump 28 whereby water is drawn from the holding tank outlet 29e and discharged through conduit portion 29d. Pressure is maintained on the system by the pressure tank 30a and motor 55 of pump 28 is actuated by the reduction of pressure in conduit 29 through a pressure responsive switch which connects into box 82 to activate motor 55 via electrical line 100. The pressure responsive switch involved is designated by reference numeral 101 and is connected to tank 30a via conductive line 102 and to the control box 82 via a further conductive line 104.
As pressure changes within pressure tank 30a a small amount of water passes through liquid conduit lines 86a and 86b and filter 86 which contains iodine crystals. By this means, iodine in the amount needed is introduced into the system. In this connection, although valve 87 is normally a gate valve, it can be a check valve which allows a surge of water from pump 27 to enter tank 30a via such valve but it requires that water passing in the opposite direction pass through filter 86.
Box 82 contains a 24 hour timer and at appropriate times of the day, preferably after holding tank 19 has been inactive for a period, say at 4:00 a.m. or 5:00 a.m., the valve 21a is caused to open by means of a solenoid 105 which is electrically connected to the timing device in box 82 and sediment and the like which is collected in the bottom of tank 19 and also in the strainer 42 is caused to drain via the line 21 (gate valves 42b and 42c being normally in an open condition). An appropriate period is provided to accomplish the necessary draining, say 30 seconds to 1 or 2 minutes. After such appropriate period, the timer box 82 causes the solenoid 105 to close valve 21a whereupon the drainage ceases.
Although the preferred embodiments of the invention are described above, it is to be understood that the invention is capable of other adaptations and modifications within the scope of the appended claims. | A system to be incorporated in new or in existing buildings where the waste lines of lavatory sinks, showers and clothes washing machines are connected to a storage reservoir for accumulation of water therein. This accumulated water is filtered and treated and thereafter used for the operation of water closets of toilets, the storage reservoir providing for the gravitational separation of solids from the water which are periodically flushed from the reservoir into the sewer. The pumping action which delivers the accumulated water to the water closets of toilets may be hydraulically operated by a portion of the water drained to the storage reservoir. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a keyless coupling arrangement for sliding two parts together to form a single unit.
[0003] 2. Description of Related Art
[0004] While the discussion hereinafter will make reference to construction equipment, such equipment is also referred to as demolition equipment, scrap handling equipment, and the like. The description of construction equipment is not intended to be restrictive of the equipment being referenced. Demolition equipment, such as heavy-duty metal cutting shears, plate shears, claws, hammers, buckets, grapples, and concrete crushers have been mounted on backhoes powered by hydraulic cylinders for a variety of jobs in the demolition field. This equipment provides for the efficient cutting and handling of scrap. For example, in the dismantling of an industrial building, metal scrap in the form of various diameter pipes, structural I-beams, channels, angles, sheet metal plates, and the like, must be efficiently severed and handled by heavy-duty metal shears. Such metal shears can also be utilized for reducing automobiles, truck frames, railroad cars, and the like. The shears must be able to move and cut the metal scrap pieces regardless of the size or shape of the individual scrap pieces and without any significant damage to the shears. In the demolition of an industrial building, concrete crushing devices, such as a concrete pulverizer or concrete cracker, are also used to reduce the structure to manageable components which can be easily handled and removed from the site. A grapple is often utilized where handling of debris or work pieces is the primary function of the equipment. Historically, all of these pieces of equipment represent distinct tools having significant independent capitol costs.
[0005] Each of these tools utilizes a jaw set pivotal about a pivot axis. Each of these jaw sets may be subjected to forces developed or generated on the magnitude of between less than 1 ton to more than 10,000 tons and, as a result, it is imperative that each of the jaws in the jaw set is fabricated, shaped, or cast to withstand such forces. However, certain jaw set designs may preferably require a portion of the jaw set to be disassembled in order to capture the pivot shaft between the lower jaw and the upper jaw. In the past, such a coupling arrangement was achieved by sliding the hub into the anvil and then inserting removable keys along the direction of insertion/removal to secure the anvil and the hub relative to one another. While this adequately secured the hub within the anvil, it is a relatively labor intense practice and, furthermore, the stress forces produced by this coupling tend to be concentrated within the keys such that there is not an equal stress distribution over the anvil and the hub.
[0006] A design is needed to slideably secure a hub within an anvil, whereby the design is relatively simple but, at the same time, eliminates the need for keys and provides effective redistribution of the stresses, such that localized forces are reduced and the stresses overall are more evenly distributed among the unified hub/anvil.
SUMMARY OF THE INVENTION
[0007] One embodiment of the invention is directed to a dovetail coupling arrangement for securing two removable parts along a coupling axis which are supporting segments of a shaft having a shaft axis. The coupling arrangement is suited to resist translational forces orthogonal to the coupling axis and has a first part having a receiver extending along the coupling axis, wherein the coupling axis is parallel to the shaft axis and, wherein the receiver has an inner wall with a receiver wall. The arrangement also has a second part with a projection extending along the coupling axis and an outer wall with a projection wall profile. A substantial portion of the outer wall of the projection corresponds to the inner wall of receiver, such that the projection mates with the receiver with a slip fit. The receiver and the projection define mating interlocking walls along the coupling axis to restrict movement of the projection within the receiver along directions orthogonal to the coupling axis.
[0008] A second embodiment of the invention is directed to a dovetail coupling arrangement for securing two removable parts along a coupling axis, wherein the coupling arrangement is suited to resist translational forces orthogonal to the longitudinal axis. The arrangement has a first part with a receiver extending along the coupling axis, wherein the receiver has an inner wall with a receiver wall. The arrangement also has a second part with a projection extending along the coupling axis and an outer wall with a projection wall. A substantial portion of the outer wall of the projection corresponds to the inner wall of receiver such that the projection mates with the receiver with a slip fit. The receiver and the projection define mating interlocking walls along the coupling axis to restrict movement of the projection within the receiver along directions orthogonal to the coupling axis. A removable shaft extends within the first part and the second part. The shaft is oriented in a direction generally orthogonal to the longitudinal axis to prevent relative movement between the first part and the second part along the coupling axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a hydraulically operated jaw utilizing a hub and anvil in accordance with the subject invention;
[0010] FIG. 2 is an exploded perspective view of the hub and anvil in accordance with the subject invention;
[0011] FIG. 3 is a different exploded perspective view of the hub and anvil in accordance with the subject invention;
[0012] FIG. 4A is a view of a section of the anvil along arrows 4 A- 4 A in FIG. 2 ;
[0013] FIG. 4B is a cross-section view of the hub along arrows 4 B- 4 B in FIG. 2 ;
[0014] FIG. 5 is an exploded perspective view similar to FIG. 2 but with securement bolts included;
[0015] FIG. 6 is an exploded perspective view similar to FIG. 3 but with securement bolts included;
[0016] FIG. 7A is a view of a section of the anvil along arrows 7 A- 7 A in FIG. 5 ;
[0017] FIG. 7B is a cross-section view of the hub along arrows 7 B- 7 B in FIG. 5 ;
[0018] FIG. 8A is an exploded cross-sectional view of the assembled hub/anvil along the plane defined by arrows 8 A- 8 A in FIG. 5 ; and
[0019] FIG. 8B is an assembled view of the arrangement illustrated in FIG. 8A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] For purposes of explaining the subject invention, an attachment 5 used for demolition may be associated with a hydraulic excavator (not shown) and includes a pair of movable jaws 10 , 11 which pivot about a main shaft 15 . In operation of the embodiment illustrated in FIG. 1 , the jaw 11 and the jaw 10 pivot toward one another, such that the tip 13 of jaw 11 passes through the opening 14 of jaw 10 .
[0021] Jaw 11 includes a jaw portion 17 having a bore extending therethrough, which pivots about the main shaft 15 . Furthermore, jaw 10 includes a jaw portion 19 and a jaw portion 21 which also have a bore (not shown) extending therethrough pivoting about the main shaft 15 .
[0022] Generally speaking, the main shaft 15 and the jaw 10 and jaw 11 pivoting thereabout define a jaw set 23 .
[0023] FIG. 1 illustrates a heavy-duty metal cutting shear, whereby the jaw set 23 is made up of a jaw 11 , which has a tip 13 that passes through the opening 14 of jaw 10 when the jaws 10 , 11 are closed. While this is one type of jaw set 23 , it should be appreciated that other jaw sets exist, and the subject invention may be applied to these jaw sets as well. In particular, the subject invention may be applied to jaw sets associated with concrete crushers, where the two opposing jaws have tips that abut with one another when the jaws come together or associated with grapples, which have two opposing jaws, each with tines that interlock with one another when the jaws come together. Overall, any discussion of jaw sets should not be limited to the functions of a particular jaw set, but should focus upon the arrangement by which the two opposing jaws are connected.
[0024] In order to assemble or disassemble the jaw set 23 , it may preferably be necessary to disassemble the jaw 10 . In particular, the jaw 10 is comprised of an anvil 25 and a hub 30 that is secured within the anvil 25 . It is this coupling arrangement between the anvil 25 and the hub 30 to which the subject invention is directed.
[0025] Although the following discussion will be directed to the hub 30 secured within the anvil 25 in the context of a jaw set 23 associated with demolition equipment 5 , it should be appreciated that this coupling arrangement has a wide range of applications and, therefore, should not be limited to the particular application discussed herein.
[0026] FIGS. 2 and 3 illustrate exploded views of the hub 30 relative to the anvil 25 , which are shown in their assembled state in FIG. 1 .
[0027] For ease in understanding this configuration, FIGS. 2 , 3 , 4 A, and 4 B will be discussed together.
[0028] As mentioned, the subject invention is directed to a coupling arrangement for removably securing the hub 30 within the anvil 25 . At least with respect to this arrangement, the hub 30 has a bore 32 extending therethrough and the anvil 25 has a bore 27 extending therethrough along a shaft axis 35 . The hub 30 slides within the anvil 25 along a coupling axis 40 . The coupling arrangement is suited to resist translational forces orthogonal to the coupling axis 40 .
[0029] The anvil 25 has a receiver 45 extending along the coupling axis 40 . As illustrated in FIGS. 2 and 3 , the coupling axis 40 may be parallel to the shaft axis 35 . The receiver 45 has an inner wall 47 with a receiver wall profile. The hub 30 has a projection 50 extending along the coupling axis 40 and an outer wall 52 with a projection wall profile. A substantial portion of the outer wall 52 of the projection 50 corresponds to the inner wall 47 of the receiver 45 , such that the projection 50 mates with the receiver 45 with a slip fit. The receiver profile and the projection profile define mating interlocking walls 47 , 52 along the coupling axis 40 to restrict movement of the projection 50 within the receiver 45 along directions orthogonal to the coupling axis 40 .
[0030] Directing attention to FIGS. 4A and 4B , when viewed along the coupling axis 40 from the end of the projection 50 (along arrows 4 B- 4 B), the profile of the projection 50 has a dovetail shape ( FIG. 4B ) with a bottom outer surface 54 and a primary outer top surface 56 . The bottom outer surface 54 and the primary top outer surface 56 are connected by opposing outer angled walls 58 , 60 . On the other hand, the receiver 45 has an open section 62 with an inner bottom surface 64 and opposed inner angled walls 66 , 68 extending upwardly therefrom, such that when the anvil 25 and the hub 30 are mated, the bottom outer surface 54 and the outer angled walls 58 , 60 of the projection 50 are engaged with the inner bottom surface 64 and the inner angled walls 66 , 68 of the receiver 45 .
[0031] As seen from an inspection of FIGS. 4A and 4B , the outer angled walls 58 , 60 of the projection 50 and the inner angled walls 66 , 68 of the receiver 45 extend upwardly and inwardly at a dovetail angle X of between 40 and 70 degrees, with respect to a line 70 . The line 70 extends perpendicular to the outer bottom surface 54 of the projection 50 and the inner bottom surface 64 of the receiver 45 . In a preferred embodiment, the dovetail angle X is approximately 57 degrees.
[0032] The receiver 45 , in a region adjacent to the open section 62 , further includes a primary enclosed section 75 formed with the inner bottom surface 64 and the opposing inner angled walls 66 , 68 common with the open sections 62 and, additionally, includes a primary inner top surface 77 connecting the inner angled walls 66 , 68 , thereby mating the anvil 25 with the hub 30 . Additionally, the primary outer top surface 56 of the projection 50 is engaged with the primary inner top surface 77 of the receiver 45 .
[0033] As illustrated in FIGS. 2 , 3 , 4 A, and 4 B, the receiver 45 further includes, along at least a portion of depth of the receiver 45 , a secondary enclosed section 80 formed by the inner bottom surface 64 and the inner opposing angled walls 66 , 68 with the open section 62 and additionally includes opposing inner extension walls 83 , 85 extending from the dovetail shape of the receiver 45 and connected by a secondary inner top surface 87 . The profile of the projection 50 further includes matching opposing outer extension walls 90 , 92 extending upwardly from the dovetail shape of the projection 50 and connected by a secondary outer top surface 94 , such that when the anvil 25 and the hub 30 are mated, the opposing inner extension walls 83 , 85 and the secondary inner top surface 87 of the receiver 50 mate with the opposing outer extension walls 90 , 92 and the second outer top surface 94 of the projection 50 .
[0034] The open section 62 of the receiver 45 may further include inner horizontal segments 97 , 99 extending from the dovetail shape and, wherein the projection 50 further includes outer horizontal segments 100 , 102 extending from the outer dovetail shape of the projection, such that when the anvil 25 is mated with the hub 30 , the inner horizontal surface 97 and inner horizontal surface 99 rest upon the outer horizontal surface 100 , 102 , respectively.
[0035] As illustrated in FIGS. 4A and 4B , the multitude of inner surfaces associated with the receiver 45 and outer surfaces associated with the projection are connected to adjacent surfaces with transition segments that are curved to eliminate sharp edges that may increase stress concentrations.
[0036] So far discussed have been the surfaces between the receiver 45 and the projection 50 that prevent translation in a direction orthogonal to the coupling axis 40 . However, it is also necessary to restrain the hub 30 , with respect to the anvil 25 , in the direction of the coupling axis 40 , even though the primary force is experienced by the anvil/hub assembly will be in a direction different than that of the coupling axis 40 .
[0037] Directing attention to FIGS. 5 , 6 , 7 A, and 7 B, to secure the hub 30 within the anvil 25 along the coupling axis 40 , one or more bolts 105 a , 105 b , 105 c extend through the inner bottom surface 64 through bores 107 a , 107 b , 107 c and into matching bores 109 a , 109 b , 109 c , which are threaded, extending into the outer bottom surface 54 of the hub 30 to secure the hub 30 within the anvil 25 along the coupling axis 40 . As illustrated in FIG. 5 , the bolt 105 a may further include a sleeve 110 a which extends through the bore 107 a of the anvil 25 and into an enlarged diameter portion of the bore 109 a of the hub 30 so that any shear loads produced between the hub 30 and the anvil 25 will be absorbed by the sleeve 110 a , which has a greater cross-sectional area than the bolt 105 a associated therewith. The bore 109 a has an enlarged diameter portion 112 a adjacent to the outer bottom surface 54 to accommodate the sleeve 110 a . This enlarged diameter is not threaded. The threaded portion of the bore 109 a begins beyond the enlarged diameter portion 112 a . In addition to providing additional cross-sectional area to absorb shear forces, the sleeve 110 a is also used to properly align the hub 30 within the anvil 25 prior to securing the bolts 105 a , 105 b , 105 c within their respective bores 109 a , 109 b , 109 c . Once secured within their respective bores, the bolts 105 b , 105 c and the sleeve 110 a absorb shear forces but, furthermore, the bolts 105 a , 105 b , 105 c retain the outer bottom surface 54 of hub 30 against the inner bottom surface 64 of the anvil 25 to minimize any twisting of the hub 30 within the anvil 25 .
[0038] Additionally, to secure the hub 30 within the anvil 25 , bolts 116 a , 116 b , 116 c , 116 d extend through bores 117 a , 117 b , 117 c , 117 d within the anvil 25 and into threaded bores 118 a , 118 b , 118 c , 118 d within the hub 30 . Sleeves 121 a , 121 b , associated with bolts 116 a , 116 b , fit within enlarged diameter portions 122 a , 122 b extending inwardly into the threaded bores 118 a , 118 b and with bolts 116 c and 116 d to provide additional cross-sectional area to resist shear forces in a direction perpendicular to the coupling axis 40 . Furthermore, all of the bolts 116 a , 116 b , 116 c , 116 d pull the front wall 119 of the hub 30 against the back wall 123 of the receiver 45 to provide additional stability to the projection 50 /receiver 45 coupling.
[0039] In order to disassemble the hub 30 from the anvil 25 , it is necessary to push the projection 50 of the hub 30 from the receiver 45 of the anvil 25 . To achieve this, an ejection bolt 114 ( FIGS. 5 , 8 A, 8 B) extends through a threaded bore 115 through the back wall 123 of the receiver 45 . The threaded bore 115 is aligned with the front wall 119 of the projection 50 . With all of the bolts 105 a , 105 b , 105 c , 116 a , 116 b , 116 c , 116 d and all of the sleeves 110 a , 121 a , 121 b removed from their respective bores, the ejection bolt 114 may be advanced within the threaded bore 115 against the front wall 119 of the projection 30 to urge the projection 50 from the receiver 45 , thereby separating the hub 30 from the anvil 25 .
[0040] As mentioned, the projection 50 has a front wall 119 and the receiver has a back wall 123 , wherein the receiver back wall 123 and the projection front wall 119 face one another. While what has been described is the ejection bolt 114 acting against the front wall 119 of the projection 50 , it is entirely possible for the ejection bolt 114 to extend through the hub and act upon the back wall 123 of the receiver 45 .
[0041] The embodiments so far discussed are directed to a single hub 30 with a projection 50 . The projection 50 is mounted within a receiver 45 of an anvil. It should be understood that more than one hub may be mounted to a single anvil. As an example, and directing attention to FIG. 5 , it is possible to form an additional receiver on the opposite side of the anvil 25 to accept a projection 50 on the opposite side of the anvil 25 . Under the circumstances, more than one hub may be mounted upon a single anvil.
[0042] While specific embodiments of the 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. The presently preferred embodiments described herein 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 appended claims and any and all equivalents thereof. | A dovetail coupling arrangement is disclosed for securing two removable parts along a coupling axis. The dovetail coupling arrangement includes multiple opposing surfaces between the receiver of a first member and the projection of a second member to provide resistance to forces transmitted in a direction orthogonal to the coupling axis. Such an arrangement may be utilized for jaw sets associated with hydraulic construction, demolition, and scrap handling equipment. |
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to drill bits and, in particular, to an improved system, method, and apparatus for a steel tooth drill bit having enhanced tooth breakage resistance.
2. Description of the Related Art
In the prior art, steel tooth drill bits are great tools for drilling multiple formations due to the ability of their teeth to flex when encountering hard formations. However, this ability to provide flexure can cause cracking at the base of the teeth in the weld deposit and carburized area under the iron-based hardfacing deposits. Moreover, the cracks can grow during service or can aggravate pre-existing thermal cracks from the initial manufacturing process.
The manufacturing cracks can be caused by a variety of sources, but are primarily from the thermal stresses induced during the welding process while using iron-based hardfacing materials at the base of the teeth and subsequent hardening and carburization of the cone. The hardfacing can relieve the stress in the form of a crack. The cracks can propagate directly into the base steel of the teeth and/or the cone shell. The extent of the cracking is dependent upon the thermal management of the cone during the heat-up, welding, and the cooling down of the cone. Another factor affecting the extent of the cracking is how brittle the carburized case is underneath the hardfacing deposit.
During operation, the combination of the flexing of the teeth, formations drilled, operating parameters, and the corrosive environment can cause the cracks to grow while the drill bit is in service. This crack propagation can cause the teeth to eventually break off or cause the cracks to grow into the cone shell, both of which impede performance.
It is known that nickel-based hardfacing minimizes the transport of carbon into the steel substrate and generally does not produce a carburized case in the steel underneath the hardfacing deposit. In addition, the thermal stresses in nickel-based hardfacing are not as great as in iron-based hardfacing, such that nickel-based hardfacing is less likely to have thermal cracks. Nickel-based hardfacing is also very corrosion resistant compared to iron-based hardfacing.
SUMMARY OF THE INVENTION
In general, if cracks occur in nickel-based hardfacing they typically arrest in the hardfacing deposit and generally do not propagate into the steel substrate. This is primarily due to the round blunt tip crack of nickel-based materials, contrasted with the sharp tip crack in iron-based materials. However, iron-based hardfacing materials are more durable than current nickel-based hardfacing materials. The area of the teeth that receives most of the damage due to impacting is at or near the top of the teeth. Therefore, the crest and a portion of the flanks require a highly durable iron-based hardfacing. Since the bases of the teeth do not receive significant impacting those portions are very suitable for nickel-based hardfacing. By placing the nickel-based hardfacing at least at the bases of the teeth and/or the surrounding cone shell, the overall durability of the drill bit is improved.
Typically, the hardfacing is applied by an oxygen acetylene welding process, but other welding or coating processes of applying the hardfacing material may be used. Some high-content nickel alloys with hard component materials also may be used.
The bases of the teeth are provided with nickel-based hardfacing to significantly reduce any potential cracking therein and in the adjacent areas of the cone. All other portions of the teeth are hardfaced with iron-based materials such that all surfaces of the teeth are protected with one or the other type of hardfacing. In addition, manufacturers of drill bits prefer to weld with nickel-based materials due to ease of heat management in the teeth base and cone surface areas of the cutting structure.
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
So that the manner in which the features and advantages of the present invention, 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 embodiments thereof that are illustrated in the appended drawings which form a part of this specification. It is to be noted, however, that the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is an isometric view of one embodiment of a drill bit constructed in accordance with the invention;
FIG. 2 is an enlarged photographic image of one embodiment of a cutter on the drill bit of FIG. 1 and is constructed in accordance with the invention;
FIG. 3 is an enlarged photographic image of another embodiment of a cutter on the drill bit of FIG. 1 and is constructed in accordance with the invention; and
FIG. 4 is a high level flow diagram of one embodiment of a method constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , one embodiment of a system, method, and apparatus for an earth boring bit 11 constructed in accordance with the invention is shown. Earth boring bit 11 includes a bit body 13 having threads 15 at its upper end for connecting bit 11 into a drill string (not shown). Bit 11 is depicted with three legs, and each leg of bit 11 is provided with a lubricant compensator 17 . At least one nozzle 19 is provided in bit body 13 for spraying cooling and lubricating drilling fluid from within the drill string to the bottom of the bore hole.
At least one cutter is rotatably secured to each leg of the bit body 13 . Preferably three cutters 21 , 23 (one cutter being obscured from view in the perspective view of FIG. 1 ) are rotatably secured to the bit body 13 . A plurality of teeth 25 are arranged in generally circumferential rows on cutters 21 , 23 . Teeth 25 may be integrally formed from the material of cutters 21 , 23 , which is typically steel.
Referring now to FIGS. 2 and 3 , two embodiments of earth boring bits having cutters 21 , 23 or roller cones that employ the novel elements of the invention are shown. Although the cutters 21 , 23 and teeth 25 are shown with certain types of geometry, those skilled in the art will recognize that the invention is not limited to the illustrated embodiments.
For example, in the enlarged view of FIG. 2 , the teeth 25 on the cutter 21 of the earth boring bit are shown with two different types of hardfacing materials 31 , 33 formed thereon. The invention may be applied to only some of the teeth or all of the teeth, and on one of the cutters or all of the cutters. Furthermore, the invention also may be applied to other teeth or other portions of the drill bit other than the cutters. The first type of hardfacing 31 is formed from a nickel-based material and is located on proximal or base portions 35 of at least some of the teeth 25 . Optionally, the first hardfacing may comprise an alloy, such as a nickel alloy, or an alloy having a high nickel content with some hard component materials such as, for example, monocrystalline WC, sintered WC (crushed or spherical), cast WC (crushed or spherical), and/or with a matrix of Ni—Cr—B—Si. In the embodiment of FIG. 2 , the first hardfacing 31 also is located on surfaces of the cutter 21 adjacent the aforementioned teeth 25 , such that the first hardfacing 31 smoothly transitions from the cutter 21 to the teeth 25 .
The second type of hardfacing 33 is formed from an iron-based material and is located on distal or upper portions of the same teeth with hardfacing 31 . Thus, all surfaces of the teeth 25 and, optionally, portions or the entire surface of the cutter 21 itself is protected with hardfacing materials. The second hardfacing 33 may be located at and adjacent to the top portions of the teeth 25 , such as on the crests and portions of the flanks of the teeth. Optionally, and as shown in FIG. 3 , only the base portions of teeth 45 on cutter 40 may be provided with the first hardfacing 41 (i.e., without application of hardfacing 41 directly to the surfaces of cutter 40 ). The remaining portions of teeth 45 are protected by the second hardfacing 43 , as described herein.
Referring now to FIG. 4 , the invention also comprises a method of fabricating a cutter for an earth boring bit. The method begins as indicated at step 51 , and comprises providing a cutter with teeth extending from the cutter (step 53 ); applying a first hardfacing on portions of at least some of the teeth (step 55 ); applying a second hardfacing that differs from the first hardfacing on other portions of said at least some of the teeth (step 57 ); before ending as indicated at step 59 .
Alternatively, the method may comprise one or more of the following steps, including: applying the first hardfacing on base portions of said at least some of the teeth, and/or on surfaces of the cutters adjacent said at least some of the teeth; and/or applying the second hardfacing to crests and portions of flanks of said at least some of the teeth. In addition, one embodiment of the method may comprise sequentially applying nickel-based hardfacing (e.g., a high-content nickel alloy with hard component materials) as the second hardfacing, after applying iron-based hardfacing as the first hardfacing.
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. | A drill bit having steel teeth is provided with a combination of hardfacing materials on the teeth. The bases of the teeth are hardfaced with nickel-based materials to significantly reduce any potential cracking therein. Portions of the supporting cones adjacent the teeth also may be fabricated with the nickel-based hardfacing. All other portions of the teeth are hardfaced with iron-based materials. |
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/015,866 entitled INTEGRATED LOCK AND TILT-LATCH MECHANISM FOR A SLIDING WINDOW, filed Jan. 17, 2008, which is a continuation of U.S. application Ser. No. 11/340,428, entitled INTEGRATED LOCK AND TILT-LATCH MECHANISM FOR A SLIDING WINDOW, filed Jan. 26, 2006, now U.S. Pat. No. 7,322,619, which claims the benefit of U.S. Provisional Application No. 60/647,112, entitled WINDOW LOCK SUITABLE FOR DOUBLE AND SINGLE HUNG WINDOWS, filed Jan. 26, 2005, and U.S. Provisional Application No. 60/716,455, entitled LOCK AND LATCH SYSTEM FOR VINYL WINDOWS, filed Sep. 13, 2005, all the aforesaid applications hereby fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to window locks, and more particularly to window locks for sliding windows.
BACKGROUND OF THE INVENTION
[0003] Double-hung windows include two window sashes typically mounted for vertical movement along adjacent parallel tracks in a window frame. Traditional double-hung window designs provide poor washability, because it is difficult for a person located inside a structure in which the window is installed to wash the outside of the window pane. To fully wash the outer surface of such windows (which outer surface is the one which is most often in need of cleaning), the person cleaning the window must typically go outside the dwelling. This is not only extremely inconvenient, as the person has to walk significant distances merely to wash both sides of a single window, but it can also force a window washer, when trying to wash double and single-hung windows located at significant heights, to face the undesirable choice of either risking injury by climbing to that height or doing a relatively poor job of washing by merely reaching from a distance with a hose or a special long pole apparatus of some type. Such cleaning is still further complicated where there are screens or storm windows that must be removed prior to washing.
[0004] To overcome this problem, windows of this type have developed that enable one of the sashes to be tilted inwardly to gain access to the outside surface of the window pane from within the structure. Various types of latching mechanisms have been developed to enable the sash to secure the sash in place in the frame, but to also enable tilting the sash by operating the latches. A common arrangement has such latches positioned in opposite ends of a top horizontal rail of the upper and/or lower sash, with each latch typically including a tongue or plunger which during normal operation extends out from the side of the sash into the sash track in the window frame to guide the sash for typical vertical movement. The tongue or plunger of each latch is retracted when washing is desired to free the top rail of the sash from the track so that the sash may be suitably pivoted inwardly about pivots guiding the bottom rail of the sash in the track and thereby allow the washer to easily reach the outside surface of the window pane of that sash.
[0005] The tongue or plunger in many of the prior art latches is usually biased outwardly into the track by a spring structure or the like, with the tongue retracted inwardly by the washer manually pulling the tongues in toward the center of the top rail against the force of the spring as, for example, in the mechanism disclosed in U.S. Pat. No. 5,139,291. A drawback of such mechanisms, however, is that both latches must be operated simultaneously, requiring that the operator use both hands. Moreover, simultaneous operation of latch controls spaced at the far edges of the sash can be awkward, especially for wide windows. Another mechanism, disclosed in U.S. Pat. No. 5,992,907, commonly owned by the owners of the present invention and hereby fully incorporated herein by reference, has a lever operably coupled with a check rail lock assembly that simultaneously operates remotely located tilt latch assemblies.
[0006] Other mechanisms linking tilt latches with a single control that also locks the sashes together are well known. For example, U.S. Pat. No. 5,398,447 (the '447 patent) discloses a tilt lock latch mechanism wherein a lever positioned proximate the center of the top rail of a lower sash may be rotated in one direction to engage a keeper positioned on the upper sash proximate the lever or in the opposite direction to operate remotely located tilt latches to enable tilting of the lower sash for cleaning. U.S. Pat. No. 5,791,700 (the '700 patent) discloses a tilt lock latch mechanism wherein a single control lever operates both sash locks and remote tilt latches. To accomplish this, the control lever is selectively rotatably positionable in three discrete positions: (1) a first position wherein the sash locks and the tilt latches are engaged; (2) a second position wherein the sash locks are disengaged to enable sliding of the sashes but the tilt latches are still engaged; and (3) a third position wherein the sash locks and the tilt latches are disengaged to enable sliding of the window. Similarly, U.S. Pat. No. 6,817,142 (the '142 patent) and its continuation U.S. application Ser. No. 10/959,696 also disclose a tilt lock latch mechanism having such a three position control lever.
[0007] Each of the above described mechanisms, however, has certain drawbacks. The '447 patent mechanism, while generally simple, requires rotation of the control lever in opposite directions from a center position for unlocking and tilting. This is inconvenient and may result in unintended tilting operation of the window if an inexperienced user seeking merely to unlock the window rotates the lever in the wrong direction. Also, the '447 patent mechanism requires that a separate control be manipulated by the operator to maintain the control lever in a desired position. The '700 patent mechanism, while enabling same-direction rotation of the control lever, is relatively complex, and may be expensive to manufacture and difficult to install and adjust. The '142 patent mechanism may be difficult to adjust, requiring partial disassembly and manipulation of a screw on the tilt latches for tensioning the strap connecting the control lever with the tilt latches. Moreover, the '142 patent describes a separate button that must be manipulated for engaging or releasing the tilt latches. This may be confusing for a user and result in frustration when attempting to tilt the window for cleaning, or in failure to properly reengage the tilt latches when cleaning is complete.
[0008] Another mechanism, described in U.S. Pat. No. 6,877,784, includes a rotary lever with sash lock that actuates remote tilt latches through an extensible member. A drawback of this mechanism, however, is that it is relatively complex, including a spring-loaded control lever and a pivoting trigger release mechanism in each of the tilt latches, making it relatively more expensive to produce and reducing reliability. Further, there are no simple means provided for attaching the extensible member to the tilt latches, nor is any means for adjusting length and tension of the extensible member provided.
[0009] U.S. patent application Ser. No. 10/289,803 discloses a similar tilt lock latch mechanism including a three-position control lever that actuates a sash lock as well as remotely located tilt latches. One drawback of this mechanism, however, is that a relatively complicated fastener arrangement is used for connecting the actuator spool to the tilt latch connector, affecting cost of manufacture and usability of the mechanism. Also, the tilt latches are not equipped with any mechanism for holding the latches in the retracted position. When the window is tilted into position after cleaning, the protruding latch bolts may mar the window frame if the operator forgets to manually retract them. Moreover, a separate button is described that must be manipulated for engaging or releasing the tilt latches, thus complicating operation.
[0010] What is still needed is a low-cost combination tilt-lock-latch mechanism for a double hung window that is easy to install and adjust, and simple to use.
SUMMARY OF THE INVENTION
[0011] The present invention addresses the need for a low-cost combination tilt-lock-latch mechanism for a sliding window that combines ease of installation and adjustment with simplicity of use. In embodiments of the invention, an integrated lock and tilt-latch mechanism for a sliding window includes at least one tilt-latch mechanism adapted for mounting in the window sash. The tilt-latch mechanism includes a housing presenting a longitudinal axis and having an aperture defined in a first end thereof, a plunger having a latch bolt portion, a plunger latch member, and first and second biasing members. The plunger is disposed in the housing and is selectively slidably shiftable along the longitudinal axis of the housing between an extended position in which the latch bolt portion of the plunger projects through the aperture in the housing to engage the window frame so as to prevent tilting of the sash, and a retracted position in which the latch bolt portion of the plunger is substantially within the housing to enable tilting of the sash. The first biasing member is arranged so as to bias the plunger toward the extended position. The plunger latch member is operably coupled with the tilt-latch housing and is arranged so as to be selectively slidably shiftable in a direction transverse to the longitudinal axis when the plunger is in the retracted position. The plunger latch member is shiftable between a first position in which the plunger latch member engages and prevents shifting of the plunger and a second position in which the plunger latch member enables shifting of the plunger. The second biasing member arranged so as to bias the plunger latch member toward the first position so that when the plunger is retracted, the plunger latch automatically shifts to retain the plunger in the retracted position. The plunger latch may include a trigger portion arranged so that when the sash is tilted into position in the frame, the trigger portion contacts the window frame or second sash, shifting the plunger latch so as to release the plunger. The mechanism further includes an actuator mechanism adapted for mounting on the sash. The actuator mechanism includes a housing, a control on the housing, a lock member, and a tilt-latch actuator member. The lock member and the tilt-latch actuator member are operably coupled with the control. A linking member operably couples the tilt-latch actuator member and the plunger of the tilt-latch mechanism. The control is selectively positionable among at least three positions including a locked position in which the lock member is positioned so that a portion of the lock member extends from the housing of the actuator mechanism, an unlocked position in which the lock member is positioned substantially within the housing of the actuator mechanism, and a tilt position in which the lock member is positioned substantially within the housing of the actuator mechanism and the plunger of the tilt-latch mechanism is positioned in the retracted position.
[0012] In another embodiment of the invention, an integrated lock and tilt-latch mechanism for a sliding window having a frame with at least one sliding sash therein, the sash also tiltably positionable relative to the frame, includes an actuator mechanism and at least one tilt-latch adapted for mounting on the sash, and a flexible linking member. The actuator mechanism includes a housing, a control, a lock member, and a tilt-latch actuator member. The lock member and the tilt-latch actuator member are operably coupled with the control, and the tilt-latch actuator has structure for receiving and applying tension to the flexible linking member. The at least one tilt-latch includes a tilt-latch housing presenting a longitudinal axis and having an aperture defined in a first end thereof. A plunger is disposed in the tilt-latch housing, the plunger having a latch bolt portion and being selectively slidably shiftable along the longitudinal axis between an extended position in which the latch bolt portion of the plunger projects through the aperture and a retracted position in which the latch bolt portion of the plunger is substantially within the tilt-latch housing. The plunger defines a channel for receiving the flexible linking member and has a locking member positioned proximate the channel. The locking member is selectively shiftably adjustable from a location outside the tilt-latch housing between a first position in which the flexible linking member is freely slidable in the channel to enable insertion and removal of the flexible linking member, and a second position in which the locking member is engaged with the flexible linking member to fixedly secure the flexible linking member in the channel, thereby operably coupling the tilt-latch actuator with the plunger of the tilt-latch. The control is selectively positionable between at least three positions including a locked position in which the lock member is positioned so that a portion of the lock member extends from the housing of the actuator mechanism, an unlocked position in which the lock member is positioned substantially within the housing of the actuator mechanism, and a tilt position in which the lock member is positioned substantially within the housing of the actuator mechanism and the plunger of the tilt-latch mechanism is positioned in the retracted position. In a further embodiment of the invention, a window includes a frame, a first sash and a second sash, each slidable in the frame. The first sash is also tiltably positionable relative to the frame. An integrated lock and tilt-latch mechanism is positioned on the first sash, including an actuator mechanism and at least one tilt-latch adapted for mounting on the sash, and a flexible linking member. The actuator mechanism includes a housing, a control, a lock member, and a tilt-latch actuator member. The lock member and the tilt-latch actuator member are operably coupled with the control and the tilt-latch actuator has structure for receiving and applying tension to the flexible linking member. The at least one tilt-latch includes a tilt-latch housing presenting a longitudinal axis and having an aperture defined in a first end thereof, and a plunger disposed in the tilt-latch housing. The plunger has a latch bolt portion and is selectively slidably shiftable along the longitudinal axis between an extended position in which the latch bolt portion of the plunger projects through the aperture and a retracted position in which the latch bolt portion of the plunger is substantially within the tilt-latch housing. The plunger defines a channel for receiving the flexible linking member and has a locking member positioned proximate the channel. The locking member is selectively shiftably adjustable, from a location outside the tilt-latch housing, between a first position in which the flexible linking member is freely slidable in the channel to enable insertion and removal of the flexible linking member, and a second position in which the locking member is engaged with the flexible linking member to fixedly secure the flexible linking member in the channel, thereby operably coupling the tilt-latch actuator with the plunger of the tilt-latch. The control is selectively positionable between at least three positions including a locked position in which the lock member is positioned so that a portion of the lock member extends from the housing of the actuator mechanism, an unlocked position in which the lock member is positioned substantially within the housing of the actuator mechanism, and a tilt position in which the lock member is positioned substantially within the housing of the actuator mechanism and the plunger of the tilt-latch mechanism is positioned in the retracted position.
[0013] In yet another embodiment of the invention, a window includes a frame, a first sash and a second sash, each slidable in the frame, wherein the first sash is also tiltably positionable relative to the frame. An integrated lock and tilt-latch mechanism is positioned on the first sash, the mechanism including at least one tilt-latch mechanism having a housing presenting a longitudinal axis, a plunger having a latch bolt portion, a plunger latch member, and first and second biasing members. The plunger is disposed in the housing and is selectively slidably shiftable along the longitudinal axis between an extended position in which the latch bolt portion of the plunger engages the frame of the window to prevent tilting of the first sash and a retracted position in which the latch bolt portion of the plunger is substantially within the housing to enable tilting of the first sash. The first biasing member is arranged so as to bias the plunger toward the extended position. The plunger latch member is operably coupled with the housing and arranged so as to be selectively slidably shiftable in a direction transverse to the longitudinal axis when the plunger is in the retracted position. The plunger latch member is shiftable between a first position in which the plunger latch member engages and prevents shifting of the plunger and a second position in which the plunger latch member enables shifting of the plunger. The second biasing member is arranged so as to bias the plunger latch member toward the first position. The mechanism further includes an actuator mechanism including a housing, a control on the housing, a lock member, and a tilt-latch actuator member. The lock member and the tilt-latch actuator member are operably coupled with the control with a linking member operably coupling the tilt-latch actuator member and the plunger of the at least one tilt-latch mechanism. The control is selectively positionable among at least three positions including a locked position in which the lock member is engaged with the second sash to prevent relative sliding movement of the first and second sashes, an unlocked position in which the lock member is free from contact with the second sash, and a tilt position in which the lock member is free from contact with the second sash and the plunger of the tilt-latch mechanism is positioned in the retracted position to enable tilting of the first sash.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a double-hung window with integrated lock and tilt-latch assembly according to an embodiment of the present invention;
[0015] FIG. 2 is a fragmentary perspective view of an inner and outer sash of a double-hung window with integrated lock and tilt-latch assembly according to an embodiment of the present invention;
[0016] FIG. 3 is a fragmentary perspective view of the top sash rail of a window with integrated lock and tilt-latch assembly according to an embodiment of the present invention;
[0017] FIG. 4 is an exploded view of the assembly depicted in FIG. 3 ;
[0018] FIG. 5 is an exploded view of a tilt-latch assembly according to an embodiment of the invention;
[0019] FIG. 6 is an exploded view of a tilt-latch assembly according to another embodiment of the invention;
[0020] FIG. 7 is a cross-sectional view of the plunger portion of the tilt-latch assembly of FIG. 6 taken at Section 7 - 7 of FIG. 6 ;
[0021] FIG. 8 is a perspective view of a first portion of the housing of the tilt latch assembly of FIG. 6 ;
[0022] FIG. 9 is a side elevation view of the housing portion depicted in FIG. 8 ;
[0023] FIG. 10 is a perspective view of a second portion of the housing of the tilt latch assembly of FIG. 6 ;
[0024] FIG. 11 is a side elevation view of the housing portion depicted in FIG. 10 ;
[0025] FIG. 12 is a bottom perspective view of a housing cover and control lever according to an embodiment of the present invention;
[0026] FIG. 13 is an exploded view of a tilt-latch assembly according to yet another embodiment of the invention;
[0027] FIG. 14 is an exploded view of the base portion of an actuator assembly according to an embodiment of the invention;
[0028] FIG. 15 an assembled view of the base portion of an actuator assembly depicted in FIG. 14 ;
[0029] FIG. 16 is an exploded view of an actuator assembly according to an embodiment of the invention;
[0030] FIG. 17 is an assembled view of the actuator assembly depicted in FIG. 16 ;
[0031] FIG. 18 is an exploded view of the housing cover and control lever of an actuator assembly according to an embodiment of the present invention;
[0032] FIG. 19 is an assembled view of the housing cover and control lever depicted in FIG. 18 ;
[0033] FIG. 20 is a perspective view of the spool of an actuator assembly according to an embodiment of the invention;
[0034] FIG. 21 is a cross-sectional view of the spool depicted in FIG. 20 taken at Section 21 - 21 of FIG. 22 ;
[0035] FIG. 22 is a bottom plan view of the spool depicted in FIG. 20 ;
[0036] FIG. 23 is a side view of the spool depicted in FIG. 20 ;
[0037] FIG. 24 is a top plan view of the spool depicted in FIG. 20 ;
[0038] FIG. 25 is a top perspective view of the sweep cam of an actuator assembly according to an embodiment of the invention;
[0039] FIG. 26 is a bottom plan view of the sweep cam depicted in FIG. 25 ;
[0040] FIG. 27 is a cross-sectional view of sweep cam depicted in FIG. 20 taken at Section 27 - 27 of FIG. 28 ;
[0041] FIG. 28 is a top plan view of the sweep cam depicted in FIG. 25 ;
[0042] FIG. 29 is a top plan view of the pick plate of an actuator assembly according to an embodiment of the invention;
[0043] FIG. 30 is a bottom plan view of the pick plate depicted in FIG. 29 ;
[0044] FIG. 31 is a fragmentary perspective view of the top sash rail of a window with integrated lock and tilt-latch assembly according to an alternative embodiment of the present invention;
[0045] FIG. 32 is an exploded view of the top sash rail of a window with integrated lock and tilt-latch assembly depicted in FIG. 31 ;
[0046] FIG. 33 is an exploded view of the tilt-latch portion of the integrated lock and tilt-latch assembly depicted in FIGS. 31 and 32 ;
[0047] FIG. 34 is a perspective view of a tilt-latch assembly according to an embodiment of the invention with the housing depicted in phantom to reveal structures enabling locking of a linking member from outside the housing with an Allen wrench;
[0048] FIG. 35 depicts the tilt-latch assembly of FIG. 34 with the Allen wrench engaged with the locking cam member;
[0049] FIG. 36 is a perspective view of an integrated lock and tilt-latch assembly according to the present invention in a “locked” position;
[0050] FIG. 37 is a perspective view of an integrated lock and tilt-latch assembly according to the present invention in an “unlocked” position;
[0051] FIG. 38 is a perspective view of an integrated lock and tilt-latch assembly according to the present invention in a “tilt” position;
[0052] FIG. 39 is a bottom perspective view of the actuator assembly of an integrated lock and tilt-latch assembly according to the present invention in a “locked” position;
[0053] FIG. 40 is a bottom perspective view of the actuator assembly of an integrated lock and tilt-latch assembly according to the present invention in an “unlocked” position;
[0054] FIG. 41 is a bottom perspective view of the actuator assembly of an integrated lock and tilt-latch assembly according to the present invention in a “tilt” position;
[0055] FIG. 42 is a perspective view of a tilt-latch assembly according to an embodiment of the invention with the housing depicted in phantom revealing the linking member passage and locking member prior to locking of the linking member;
[0056] FIG. 43 depicts the tilt-latch assembly of FIG. 42 with the locking cam member positioned to lock the linking member to the plunger;
[0057] FIG. 44 is a top perspective view of the body of the base assembly of an actuator assembly according to an embodiment of the present invention;
[0058] FIG. 45 is a bottom plan view of the body depicted in FIG. 44 ;
[0059] FIG. 46 is a top plan view of the body depicted in FIG. 44 ;
[0060] FIG. 47 is a perspective view of a keeper according to an embodiment of the present invention;
[0061] FIG. 48 is a rear elevation view of the keeper depicted in FIG. 47 ; and
[0062] FIG. 49 is a front elevator view the keeper depicted in FIG. 47 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] As depicted in FIG. 4 , tilt lock latch assembly 30 generally includes actuator assembly 32 , tilt latch assemblies 34 , and linking member 36 . Actuator assembly 32 generally includes a housing 38 defined by base assembly 40 and housing cover 42 . Control lever 44 is coupled with housing cover 42 through aperture 46 , which receives shank 48 of lever 44 therethrough. Shank 48 has upper portion 50 which is generally cylindrical in shape and lower portion 52 which defines flats 54 , 54 A. Full height protuberance 55 extends outwardly from flat 54 A, while half height protuberance 55 A extends outwardly from flat 54 . Retainer 56 is received on upper portion 50 of shank 48 and retains lever 44 on housing cover 42 so that lever 44 is rotatable about axis A-A relative to housing cover 42 as annotated in FIG. 12 .
[0064] As depicted in FIGS. 14-17 and 44 - 46 , base assembly 40 generally includes body 58 , sweep cam 60 , spool 62 , detent spring 64 , housing retainer 66 , and pick plate 68 . Underside 70 of body 58 defines semicircular recess 72 which receives sweep cam 60 , and shallow recess 74 which receives pick plate 68 . Aperture 76 extends through from recess 72 to top surface 78 of body 58 . Boss 80 surrounds aperture 76 in recess 72 , and defines inner recess 81 around aperture 76 . Spring receiver 82 intersects with inner recess 81 at inner edge 84 of aperture 76 . Detent spring 64 is received in spring receiver 82 with point 86 of bend 88 facing away from aperture 76 . Stop 89 projects from boss 80 adjacent back edge 89 A of body 58 . Spool housing 90 projects downwardly from underside 70 and generally includes inner wall 92 , outer wall 94 and spool detent 96 . Inner wall 92 and outer wall 94 define slots 98 , 100 , which are aligned in the longitudinal direction of body 58 . Chamfers 101 may be provided at the edges of slots 98 , 100 . Aperture 102 extending through body 58 to top surface 78 is defined in top wall 104 of spool housing 90 . Spool detent 96 is positioned adjacent inner wall 92 and has projection 106 at bottom end 108 extending inwardly toward spool housing 90 .
[0065] Shallow recess 74 is shaped conformingly with and receives pick plate 68 . Pivot post 109 is positioned at end 109 A of recess 74 and has a pair of branches 109 B, 109 C, each with an outwardly extending projection 109 D at the bottom end thereof. Tab 109 E extends inwardly toward 72 from opposite edge 109 F of recess 74 .
[0066] Sweep cam 60 has shaft portion 110 defining opening 112 and cam portion 114 extending radially from shaft portion 110 , as depicted in FIGS. 25-28 . Opening 112 has generally flat sides 116 , 118 , but with full height notch 120 formed in side 118 , and half-height notch 121 formed in side 116 and extending half the length of opening 112 from end 121 A of shaft portion 110 . Cam portion 114 has outer wall 122 spaced apart and connected with shaft portion 110 by web 124 . Circumferential recess 125 is defined in web 124 . Leading edge 126 of outer wall 122 is tapered upwardly from tip 128 to shoulder 130 , at which point the full height of outer wall 122 is reached. Gear segment 132 is formed in outer wall 122 at bottom edge 134 opposite leading edge 126 and shoulder 130 , and is positioned slightly radially outward from the remainder of outer wall 122 . Projections 136 , 137 , extend outwardly from outer surface 138 of shaft portion 110 proximate web 124 . Post 140 projects downwardly from bottom surface 142 of sweep cam 60 proximate opening 112 .
[0067] Sweep cam 60 is rotatably received in recess 72 of body 58 with bottom surface 142 facing downward and shaft portion 110 extending through aperture 76 . Projections 136 , 137 , travel within inner recess 81 , but engage in bend 88 of detent spring 64 to provide detents at two positions in the rotational travel of sweep cam 60 . Stop 89 slides within circumferential recess 125 . Pick plate 68 defines aperture 144 at narrow end 146 , and curved slot 148 . Pick plate 68 is received in shallow recess 74 covering sweep cam 60 and retaining it in recess 72 . Pivot post 109 is received through aperture 144 so that pick plate 68 is pivotable about pivot post 109 in a narrow path of travel corresponding with shallow recess 74 . Curved edge 150 is received under tab 109 E while projections 109 D extend outwardly on either side of aperture 144 to retain pick plate 68 in position. Post 140 extends through curved slot 148 to enable actuation of pick plate 68 with rotation of sweep cam 60 as described further hereinbelow.
[0068] Spool 62 generally includes barrel portion 152 and shaft portion 154 as depicted in FIGS. 20-24 . Barrel portion 152 defines slot 156 extending upwardly from bottom edge 158 . Mouth 160 of slot 156 may have chamfered edges 162 . Gear sector 164 is formed in a portion of top edge 166 of barrel portion 152 . Notch 168 is defined in barrel portion 152 near bottom edge 158 . Shaft portion 154 extends from barrel portion 152 and includes a pair of branches 170 , 172 , each with an outward projection 174 proximate end 176 .
[0069] Spool 62 is rotatably received in spool housing 90 with shaft portion 154 extending through aperture 102 . On top surface 78 of body 58 , projections 174 extend on either side of aperture 102 to retain spool 62 in spool housing 90 . Projection 106 of spool detent 96 engages in notch 168 to form a detent in the rotational travel of spool 62 . With projection 106 engaged in notch 168 , slot 156 is aligned with slots 98 , 100 , in spool housing 90 .
[0070] Top surface 78 of body 58 defines raised portion 178 corresponding with recess 72 . Projections 180 , 182 , extend from raised portion 178 on either side of aperture 76 . Posts 184 , 186 , extend from top surface 78 on either side of raised portion 178 . Posts 184 , 186 , define semicylindrical recesses 188 , 190 , facing toward raised portion 178 . Apertures 192 , 194 , 196 , extend through body 58 .
[0071] As depicted in FIGS. 14 and 15 , housing retainer 66 has planar central portion 198 defining aperture 200 , and square apertures 202 , 204 . Each square aperture 202 , 204 , has a pair of upwardly bent tabs 206 on opposing sides thereof. Ears 208 , 210 , extend outwardly and angle downwardly from the plane defined by central portion 198 . Housing retainer 66 is received on raised portion 178 with projections 180 , 182 , extending through square apertures 202 , 204 . Tabs 206 engage on the sides of projections 180 , 182 to retain housing retainer 66 is place. Outer edges 212 of ears 208 , 210 , are positioned at the inner side of semicylindrical recesses 188 , 190 .
[0072] Housing cover 42 is received on top surface 78 of body 58 with posts 214 , 216 , received in semicylindrical recesses 188 , 190 , respectively as depicted in FIGS. 16-17 . Outer edges 212 of ears 208 , 210 , frictionally engage posts 214 , 216 to securely retain housing cover 42 on base assembly 40 . Guide post 218 is received in aperture 196 to assist with accurate alignment of housing assembly 38 with base assembly 40 . Shank 48 extends into opening 112 of sweep cam 60 so that full height protuberance 55 mates with notch 120 and half-height protuberance mates with half-height notch 121 , thereby coding lever 44 with sweep cam 60 .
[0073] Body 58 and spool 62 are desirably made from easily moldable, durable polymer material such as acetal or nylon. Lever 44 , housing cover 42 , and sweep cam 60 , are preferably cast from suitable metallic material such as zinc alloy. Pick plate 68 and housing retainer 66 are preferably die cut from metallic sheet material. Any of the above components, however, may be made from any other suitable material such as polymer or metal. In the depicted embodiments, actuator assembly 32 is easily assembled by mating sweep cam 60 and spool 62 with body 58 . Pick plate 68 may then be positioned under tab 109 E and aperture 144 pressed down on pivot post 109 to retain sweep cam 60 in place. Lever 44 may likewise be assembled on housing cover 42 by pressing retainer 56 on shank 48 with an arbor press. Housing retainer 66 may be pressed or pushed onto projections 180 , 182 , and the assembly completed by mating housing cover 42 on body 58 as described above.
[0074] As depicted in FIGS. 5-11 , each tilt latch assembly 34 generally includes housing 220 , plunger 222 , primary spring 224 , plunger latch 226 , latch spring 228 , and locking cam 230 . Housing 220 , generally includes barrel portion 232 and face plate 234 . In embodiments of the invention as depicted, for example, in FIGS. 5 , 6 , 8 - 11 , and 13 , housing 220 may be formed in two sections 236 , 238 , which mate along the longitudinal axis of housing 220 . In these embodiments first housing section 236 has projecting hooks 240 , which engage shoulder structures 242 of second housing section 238 to secure the two sections 236 , 238 , together. Second housing section 238 may also have locating pins 244 , which are received in recesses 246 to inhibit relative movement between the sections 236 , 238 .
[0075] Plunger 222 generally includes latch bolt portion 248 , central body portion 250 , and tail portion 252 . End 253 of latch bolt portion 248 is tapered from leading edge 253 A to shoulder 253 B. Channel 254 extends axially from end 256 through tail portion 252 . Central body portion 250 defines lock cavity 258 which includes a first portion 260 extending longitudinally within plunger 222 , and a second portion 262 extending transversely to first portion 260 . Channel 254 continues axially from tail portion 252 through second portion 262 of lock cavity 258 , and emerges at outer surface 264 of central body portion 250 proximate shoulder 253 B of latch bolt portion 248 .
[0076] Plunger 222 is received in barrel portion 232 of housing 220 with latch bolt portion 248 extending through conformingly shaped aperture 266 defined by face plate 234 . Primary spring 224 is received over tail portion 252 and bears against back wall 268 of housing 220 and central body portion 250 to bias plunger 222 toward face plate 234 .
[0077] Locking cam 230 generally includes axle portion 270 and radial protrusion 272 . End 274 of axle portion 270 has hex socket 276 adapted to receive an Allen wrench of standard dimension. Locking cam 230 is received in lock cavity 258 with axle portion 270 extending axially and rotatable within first portion 260 and radial protrusion 272 within second portion 262 . Bore 278 is axially aligned with axle portion 270 and extends from first portion 260 of lock cavity 258 through to front end 280 of central body portion 250 proximate face 282 of latch bolt portion 248 . Adjustment latch arm 284 extends rearwardly from front wall 286 of central body portion 250 , and includes angled portion 288 which intersects bore 278 and laterally projecting tab 290 at end 292 .
[0078] Plunger latch 226 has plate portion 294 defining aperture 296 which is conformingly shaped with the cross-section of latch bolt portion 248 . Trigger portion 298 extends from plate portion 294 and has bent end portion 300 . Plate portion 294 is slidingly received in transverse slot 302 in face plate 234 . Latch spring 228 is received in recess 304 and bears against edge 306 of plate portion 294 to bias plunger latch 226 in the direction of trigger portion 298 .
[0079] In embodiments of the invention housing 220 and plunger 222 of tilt latch assembly 34 are made from low-cost, easily formable acetal polymer material. These components, however, may also be made from any material having sufficient strength and suitable durability characteristics. Primary spring 224 , plunger latch 226 , latch spring 228 , and locking cam 230 are desirably made from metallic material, but may also be made from any other suitable material. In the depicted embodiments, tilt-latch assembly 34 may be easily assembled by first assembling plunger latch 226 and latch spring 228 with separate housing sections 236 , 238 , and locking cam 230 and primary spring 224 with plunger 222 . Plunger 222 may then be placed in one of housing sections 236 , 238 , and the housing sections snapped together by mating projecting hooks 240 with shoulder structures 242 and locating pins 244 with recesses 246 .
[0080] Tilt lock latch assembly 30 is received in top rail 308 of inside sash 310 of a double hung sash window 312 . Top rail 308 has cavity 314 defined in top surface 316 for receiving base assembly 40 with spool 62 disposed in lower cavity portion 318 . Lateral bore 320 extends between side faces 322 , 324 , of top rail 308 and intersects lower cavity portion 318 .
[0081] Tilt lock latch assembly 30 may be assembled by linking each of two tilt latch assemblies 34 disposed in lateral bore 320 of the window 312 with linking member 36 , and placing actuator assembly 32 in cavity 314 to engage linking member 36 with spool 62 . Linking member 36 is preferably formed from a suitable stretch-resistant flexible polymer material. Linking member 36 is engaged with the first tilt latch assembly by inserting an Allen wrench through bore 278 and engaging hex socket 276 of locking cam 230 as depicted in FIGS. 34-35 . As the Allen wrench is inserted, it forces adjustment latch arm 284 outwardly toward barrel portion 232 of housing 220 , engaging tab 290 in aperture 326 to lock plunger 222 axially within housing 220 as the adjustment is made. Once engaged in hex socket 276 , the Allen wrench is rotated to rotate locking cam 230 so that radial protrusion 272 is clear of channel 254 . An end 328 of linking member 36 is then inserted in channel 254 at end 256 and threaded through channel 254 until it extends from housing 220 proximate latch bolt portion 248 as depicted in FIG. 42 . The Allen wrench is then rotated in the opposite direction as depicted in FIG. 43 to rotate locking cam 230 so that radial protrusion 272 forces linking member 36 into second portion 262 of lock cavity 258 . In this position, linking member 36 is frictionally locked within and secured to plunger 222 . The Allen wrench is then withdrawn from bore 278 , enabling tab 290 to recede from aperture 326 . Excess linking member 36 may then be trimmed off flush with face plate 234 .
[0082] With the first tilt latch assembly 34 disposed in, and linking member 36 extending through, lateral bore 320 and trigger portion 298 facing outer sash 327 , linking member 36 may be engaged with the second tilt latch assembly 34 by the same process as described above. With the second tilt latch assembly 34 disposed in lateral bore 320 with trigger portion 298 facing outer sash 327 , and with the Allen wrench inserted in bore 278 of the first tilt latch assembly 34 to prevent its plunger 222 from being retracted, linking member 36 is drawn relatively taut before being locked in place and trimmed. Once linking member 36 is in place and taut, base assembly 40 of actuator assembly 32 may be dropped into cavity 314 so that spool 62 is received in lower cavity portion 318 . As spool 62 enters lower cavity portion 318 , chamfers 101 and 162 guide linking member 36 into slots 98 , 100 , in spool housing 90 and slot 156 of spool 62 respectively. Fasteners 328 may then be driven through apertures 192 , 194 , to secure actuator assembly 32 to top rail 308 and housing assembly 38 engaged with base assembly 40 to complete assembly.
[0083] In operation, with inside sash 310 and outer sash 327 in a closed position as depicted in FIG. 1 , lever 44 may be positioned in a first position as depicted in FIG. 39 , wherein outer wall 122 of sweep cam 60 is received in optional keeper 330 or other structure on outer sash 327 , thereby locking inside sash 310 and outer sash 327 together. Projection 136 of sweep cam 60 is engaged in bend 88 of detent spring 64 to provide a detent at this “locked” position of lever 44 . In this first position, projection 106 of spool detent 96 is engaged in notch 168 of spool 62 and spool 62 remains aligned so that connecting member 36 is not under tension and latch bolt portions 248 of latch bolts 34 project outwardly into grooves 332 in window frame 334 , thereby preventing tilting of inside sash 310 . Pick plate 68 is positioned with leading edge 335 extending under sweep cam 60 to prevent tampering from outside the window.
[0084] Window 312 may be unlocked by rotating lever 44 to a second position as depicted in FIG. 40 . In this second position, sweep cam 60 is substantially within actuator assembly 32 and does not engage keeper structure 330 so that inside sash 310 and outer sash 327 are free to slide vertically in window frame 334 . Projection 137 of sweep cam 60 is engaged in bend 88 of detent spring 64 to provide a detent at this “unlocked” position of lever 44 . Once again, latch bolt 34 are not retracted and project outwardly into grooves 332 to prevent tilting of inside sash 310 . Projection 106 of spool detent 96 is still engaged in notch 168 of spool 62 . As sweep cam 60 rotates from the “locked” to the “unlocked” position, post 140 travels in curved slot 148 of pick plate 68 , rotating pick plate 68 inwardly about pivot post 109 so that leading edge 335 clears outer sash 327 .
[0085] With window 312 unlocked, inside sash 310 may be tilted inward by rotating lever 44 to a third position as depicted in FIG. 41 . As lever 44 rotates sweep cam 60 , gear segment 132 engages gear sector 164 of spool 62 causing spool 62 to rotate, thereby applying tension to connecting member 36 . The tension on connecting member 36 draws plunger 222 of each tilt latch assembly 34 inwardly toward actuator assembly 32 , sliding plunger 222 within housing 220 against the bias of primary spring 224 and drawing latch bolt portion 248 within housing 220 . As leading edge 253 A of latch bolt portion 248 clears plate portion 294 of plunger latch 226 , latch spring 228 urges plunger latch 226 in the direction of outer sash 327 so that plate portion 294 partially blocks aperture 266 . Leading edge 253 A of latch bolt portion 248 engages plate portion 294 , holding plunger 222 retracted within housing 220 . Trigger portion 298 projects slightly from the outer face 336 of top rail 308 . With lever 44 and tilt latches 34 in this “retracted” position, inside sash 310 may be tilted inwardly to gain access to the outside of the window. No detent or spring biasing of lever 44 is provided in the “retracted” position, and lever 44 may be freely rotated back to the “unlocked” position detent, or may remain at any angular position between the “unlocked” position detent and the “stop” position where sweep cam 60 contacts stop 89 .
[0086] Once the window cleaning or other operation is completed and it is desired to return inside sash 310 to its operable position, inside sash 310 may be simply tilted back into position. Trigger portion 298 contacts outer sash 327 , urging plunger latch 226 against the bias of latch spring 228 . When plunger latch 226 clears leading edge 253 A of latch bolt portion 248 , primary spring 224 urges plunger 222 in the direction away from actuator assembly 32 , so that latch bolt portion 248 extends outwardly through aperture 266 and engages in grooves 332 .
[0087] In an alternative embodiment of the invention depicted in FIGS. 31-33 , top rail 308 is substantially hollow as is typically the case in vinyl window construction. Reinforcing insert 338 fits inside hollow top rail 308 to provide support for the tilt-latch assemblies 34 . Housing 220 of each tilt-latch assembly 34 has spring securing tabs 340 projecting on opposite sides proximate outer end 342 . Each tab 340 is resiliently attached to housing 220 at hinge line 344 . Outer end 346 is normally spaced apart from housing 220 , but is capable of being pressed inwardly into opening 348 in barrel portion 232 Lip 349 extends outwardly around perimeter 349 A of end wall 349 B. Housing 220 further has opposing flats 350 , 352 . Flat 350 has longitudinal ridge 354 defined thereon.
[0088] Tilt-latch assembly 34 is received through apertures 356 in top rail 308 and inside reinforcing insert 338 . Insert 338 is preferably made from metal, but may also be made from any other suitably rigid and durable material. Flats 350 , 352 , mate with inside walls 358 , 360 , of reinforcing insert 338 respectively to inhibit undesired rotation of tilt-latch assembly 34 about its longitudinal axis. Longitudinal ridge 354 mates with corresponding groove 362 in inside wall 358 so that tilt-latch assembly 34 is coded for proper orientation. As each tilt-latch assembly 34 is advanced into aperture 356 , tab 340 contacts edge 364 , forcing outer end 346 inwardly. Once outer end 346 clears edge 364 and lip 349 contacts outer surface 366 of top rail 308 , outer end 346 springs outwardly to engage inner surface (not depicted) of top rail 308 to retain tilt-latch assembly 34 in place.
[0089] As depicted in FIGS. 47-49 , optional keeper 330 generally includes flange portion 368 defining a finished outer surface 369 and skirt portion 370 . Skirt portion 370 defines recess 372 for receiving outer wall 122 of sweep cam 60 . Projection 374 engages in circumferential recess 125 of sweep cam 60 when sweep cam 60 is rotated to the “locked” position. Openings 376 may be defined in skirt portion 370 for receiving fasteners (not depicted) to secure keeper 330 to bottom rail 378 of outer sash 327 at a location adjacent actuator assembly 32 when bottom rail 378 is adjacent top rail 308 of inside sash 310 . | A low-cost combination tilt-lock-latch mechanism for a sliding window that combines ease of installation and adjustment with simplicity of use. The mechanism includes at least one tilt-latch mechanism adapted for mounting in the window sash. The tilt-latch mechanism includes a housing and a plunger having a latch bolt portion retractable within the housing. A plunger latch member automatically latches the plunger in a retracted position to enable tilting of the sash. Further, the mechanism may include an actuator mechanism and a flexible linking member. The tilt-latch may include a locking member adjustable from outside the housing of the tilt latch, to lock the flexible linking member to the plunger, thereby operably coupling the actuator mechanism with the tilt-latch. |
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[0001] The invention pertains to the area of warehousing of goods with certain dimensions, such as, for example, containers or open platforms loaded with goods, the storage being done in multi-level sections following each other in a line or in several parallel lines, with the take-in of the platforms at one end of each line (the entrance point) and the take-out of the goods either at the opposite end of each line (the exit point), or at both the entrance and the exit points, simultaneously.
[0002] The major advantages of the invention are listed below:
A A much better utilization of storage space, due to multi-level storage of goods, i.e., a more efficient utilization of a building height or of a ground storage space, due to multi-level structures arrangement into parallel lines, which would not require lift-trucks between these lines for loading and unloading of the goods. B Take-in and take-out of goods loaded on platforms both at the entrance point and at some other point along the line, allows full mechanization and automatic performance of the take-in and the take-out processes.
Further on we are going to illustrate practical implementation of the invention, by describing a method of relocating platforms from one level to another vertically within a section, up and down, by way of gripping the platforms with special lug supports pin-hinged to pillars opposing each other in pairs, with at least one of the pairs being able to move up and down according to a preset sequence. (See FIG. 1 cx.a and 1 cxb ). FIG. 1 cxa presents a schedule of vertical upward relocation of platforms within a section:
Step 0. The initial position: Platform 5 is installed on Lug Supports 4 of Stationary Pillars 3 at the lowest (first) level of the Section Lifter 1 Lug Supports 2 are pin-hinged to Pillar 1 , at h distance below the upper surface of Lug Supports 4 of their stationary pillars. Step 1. Pillar 1 is to be moved upward, Lug Supports 2 lift Platforms 5 off Lug Supports 4 of the stationary pillars, to h height, which is enough to turn Lug Supports 4 into the non-operational (vertical) position. Step 2. Lug Supports 4 of the stationary pillars are turned into a non-operational (vertical) position. Step 3. Lifting pillars 1 use their Lug Supports 2 to raise Platforms 5 into the upper position. Step 4. Lug Supports 4 of Stationary Pillars 3 are moved back into their operational (horizontal) position. Step 5. Lifting Pillar 1 is lowered into the initial lower position, while Platforms 5 are being installed one level up on Lug Supports 4 of the stationary pillars, with the help of Lug Supports 2 of the Lifter. ( FIG. 4 presents it as lifting from Level 1 (the lower one) to Level 2 , etc.)
[0012] FIG. 1 cxb represents the steps and the inter-working of units while platforms are being relocated to the next lower level within the Section.
Step 0. The initial position: Platform 5 is installed at Level 2 of Lug Supports 3 of Stationary Pillars 4 , and Lug Supports 2 of the lifting pillars are pin-hinged below Lug Supports 3 of the stationary pillars at height h, which is enough to turn Lug Supports 2 into a non-operational (vertical) position. Step 1. Lug Supports 2 of Lifting Pillars 1 are turned into the non-operational (vertical) position. Step 2. Lifting Pillar 1 is raised to h height above Lug Supports 3 of Stationary Pillars 4 . Step 3. Lug Supports 2 of Lifting Pillars 1 are returned into the initial (horizontal) position. Step 4. Lifting Pillars 1 are raised into the upper position, where Lug Supports 2 take the platforms off Lug Supports 3 of Stationary Pillar 4 and raise them. Step 5. Lug Supports 3 of Stationary Pillars 4 are turned into a non-operational (vertical) position. Step 6. Lug Supports 2 of Lifting Pillars 1 are lowered to an h distance which allows Lug Supports 3 to be returned into their operational (horizontal) position. Step 7. Lug Supports 3 of the stationary pillars are returned into their operational (horizontal) position. Step 8. Lifting Pillars 1 are lowered into the initial lower position, with Platforms 5 being lowered from Lug Supports 2 of the Lifter to Lug Supports 3 of Stationary Pillars 4 , one level lower than the preceding one.
[0022] This method is offered as the basis for a car storage structure making use of platforms.
[0023] At present, there are several types of structures for multi-level car storage. Mainly, storage is done on platforms attached to sections, with platforms being lifted and lowered with the help of hydraulic cylinders which assist in lowering a platform to Zero level, for car entrance, after which the platform loaded with the car is to be raised to a higher level. The next car is to be loaded in the same manner, the platform is to be raised to the level under the previous one, and so on, until a car is loaded at a platform at the Zero level. The major drawbacks of this structure are the necessity to use additional space for entrance and exit, and the necessity to free the lowest level platforms of the stored cars at the moment when cars stored above these levels are to be taken out.
[0024] The invention we offer, because of its ability to relocate individual platforms up and down within each section, and their relocation from one section into an adjacent section, allows any platform loaded with a car to be relocated to Zero level by way of relocating platforms from one section into another along one line, leaving other stored cars intact, and excludes the storage drawbacks described above.
DESCRIPTION
[0025] A description of the invention—the storage method and a storage structure implementing the method—is presented below.
[0026] FIGS. 1 , 2 , and 3 , respectively, represent the longitudinal section, a cross-section and an overhead view of the device. They show Guide Rollers 1 , Ramp 2 , Platform, 3 , Framework 4 , Platform Storage Section 5 , Car Storage Section 6 , Floor-level Transporter 7 , and Top Carriage 8 .
[0027] FIG. 4 : A ramp consisting of Frame 4 . 2 , Frame Rotation Cylinder 4 . 1 in Pivot Joint 4 . 4 . Rollers 4 . 3 are fixed on the frame.
[0028] FIG. 4 . a represents a ramp with a platform loaded with a car installed on the ramp. The ramp is shown in the tilted position, for the car entrance onto, and exit from the platform, and in the horizontal position where it can facilitate connecting Platform 5 . 1 with Finger 8 . 5 of the transporter with the help of Ratchet Stops 5 . 9 of the platform.
[0029] FIG. 5 : A platform consists of Base Frame 5 . 1 and Support Feet 5 . 2 which guarantee the required clearance between platforms when they are stacked for storage in the storage section. The front part of the base frame has a netlike recess, Recess 5 . 4 , necessary for holding either the left front wheel, or both front wheels of a car. In order to raise the wheel before the car is going to exit the platform, Cylinder 5 . 3 is used. When a car enters the platform, its front left wheel is guided by Rollers 5 . 6 of Movable Carriage 5 . 8 , and the movable carriage is returned into its initial position with the help of Frame 5 . 5 contacting with the wheel while the car is exiting the platform. The platform is gripped with Finger 8 . 5 with the help of Ratchet Stops 5 . 9 fixed on Axis Pins 5 . 10 .
[0030] FIG. 6 illustrates a platform storage section consisting of Stationary Pillars 6 . 5 . rigidly attached to Frame 4 of movable Frames 6 . 4 driven by Cylinder, 6 . 2 . Lug Supports 6 . 7 are gimbal-mounted to the lower level stationary pillars, and are to be driven up and down with Actuator 6 . 6 which could be a cylinder. Movable Frames 6 . 4 have Lug Supports 6 . 3 which are rigidly attached to them below the level of Rollers 8 . 1 of the Zero level transporter. Chains 6 . 8 serve for synchronizing the movement of movable frames. They form Sprockets 6 . 9 ., each pair of which is rigidly attached to Frame 4 , with Shafts 6 . 11 . Sprockets 6 . 10 are rigidly attached to Frame 4 . As the lifting frames at the opposite ends are connected via Chains 6 . 8 ., when a lifting frame at one end is moving, the lifting frame at the other side is moving simultaneously with the first one.
[0031] FIG. 7 illustrates a car storage section. This section is designed similarly to a platform storage section. The first one, though, differs from the second one in having a greater number of Lug Supports 7 . 15 of Stationary Pillars 7 . 8 , as well as of Lug Supports 7 . 4 of Lifting Frames 7 . 13 . Their number corresponds to the number of levels within a section, and as they are vertically installed at a certain distance from each other, these vertical steps form levels. Both the stationary pillar lug supports and the lifting frame lug supports are attached on pin hinges. Lug Supports 7 . 4 of the lifting frames are attached at a certain distance from the level at which Lug Supports 7 . 15 of stationary pillars are attached, and the lower Lug Supports 7 . 4 are located below Rollers 8 . 1 , which form a lower, Zero level.
[0032] Cross-bar 7 . 6 connects Lug Supports 7 . 15 of Stationary Pillars 7 . 8 to a drive mechanism, for example, Cylinder 7 . 7 . Cross-bar 7 . 6 helps to turn Lug Supports 7 . 15 into a non-operational (vertical) position and back. Lifting Frames 7 . 13 have Hydro-cylinder 7 . 16 for a driving mechanism. Simultaneous movement of the lifting frames at the opposite ends is provided by connecting them to Chains 7 . 2 that go around Sprockets 7 . 9 attached to the shaft, and Sprockets 7 . 10 at Frame 4 . Lug Supports 7 , 4 have a shaft, Shaft 7 . 18 , with Driving Mechanism 7 . 17 , to provide for their turning into a non-operational position and back.
[0033] FIG. 8 illustrates the design of the lower, (Zero) level transporter which serves for relocating car loaded and empty platforms between sections at the lower level and onto the ramp, and has the following units: Rollers 8 . 1 attached to Base 8 . 2 , Pulling Fingers 8 . 5 supported by Bearings 8 . 3 . The motion is performed with Roller Chain 8 . 4 (the drive sprocket and the tension sprocket are not shown). Bearings 8 . 3 are supported by Plates 8 . 7 and 8 . 6 . FIG. 8 shows how Platform 5 . 1 and its Ratchet Dogs 5 . 9 are to be driven by Finger 8 . 5 of the transporter.
[0034] FIG. 9 illustrates the design of the top carriage which consists of U-type Frame 9 . 2 with Rollers 9 . 1 attached to it and supported by double-T iron 9 . 6 . Pillars 9 . 8 are attached to Frame 9 . 2 base, and have Lug Supports 9 . 5 in their bottom area, which are pin-hinged to the pillars. The lug supports are to be rotated with the two Shafts 9 , 9 . They turn simultaneously with the lug supports of Stationary Pillars 7 , 6 of the car storage section, which is to be provided by means of a special interlock (“dovetail” joint).
[0035] Motion of the top carriage is provided for by means of a roller chain transporter not exhibited in FIG. 9 . The top carriage is to be used for relocation of platforms between sections at the upper level.
OPERATION
[0036] The offered car storage method and the storage structure can operate in the following way:
[0037] A Cars Take-In For Storage
[0038] In order to accept a car for storage, it is necessary to take a platform from a platform storage section and to place it on a ramp, after which a car would enter the platform. While approaching the ramp, the car is to come to a halt in front of the “Stop” sign. Next comes a command for the ramp to be lifted into the horizontal position ( FIG. 4 ). With this purpose Cylinder 4 . 1 is to be switched on, and Frame 4 . 2 with its Rollers 4 . 3 turns on its Hinge 4 . 4 into its horizontal position. At the same time a command is issued to switch on Hydraulic Cylinder 6 . 2 of the lifting drive in the car storage section.
See FIG. 6.
[0039] Movable Frames 6 . 4 are raised in their upper, final [position. At the same time Lug Supports 6 . 3 of Lifting Frames 6 . 4 raise the platform from Lug Supports 6 . 7 of Stationary Pills 6 . 5 to a height allowing Lug Supports s 6 . 7 of their stationary pillars enough space to move into a non-operational (vertical) position. Then comes the command to switch on Cylinder 6 . 6 and to bring Lug Supports 6 . 7 into the non-operational (vertical) position. Then the next command comes, to move the lifting device down, to the level allowing clearance between the platform resting on the Lug Supports of the lifting device and the platform resting on its support feet. The clearance is necessary for Lug Supports 6 . 7 to be returned into their initial (horizontal) position, which is achieved either with the help of the driving mechanism (the cylinder), or just happens because of the weight of the platform.
[0040] The lifting frame structure of each section consists of two Frames 6 . 4 . They face each other at the opposite ends of the section. Each of the frames has its own driving mechanisms, Cylinders 6 . 2 . To synchronize their movement, the frames on both sides are attached to Chains 6 . 8 which go around Chain Sprockets 6 . 9 sitting on Shafts 6 . 11 joint for each couple of the frames.
[0041] After Lug Supports 6 . 7 of the stationary pillars are returned into their horizontal position, there is a command to go on with moving the lifter downwards, until it reaches its initial lower position. The platforms earlier raised by the lifter lug supports go down, but the platform package or one platform is lowered on Lug Supports 6 . 7 of the stationary pillars, and the lowest platform resting upon Lug Supports 6 . 3 of the lifter is lowered upon Transporter Rollers 8 . 1 . (See FIGS. 6 and 6 a )
[0042] FIG. 6 a shows the steps and the interaction of Lug Supports 6 . 3 of the lifter and of Lug Supports 6 . 7 of the stationary pillars, which is necessary in order to separate the lowest platform from the platform package installed at the lug supports of the stationary pillars.
Step 0. Initial position: Lug Supports 6 . 3 of the lifter are rigidly attached to Frame 6 . 4 of the lifter, at “h” distance below the surface where Transporter Rollers 8 . 1 operate. Platform Package 5 . 1 or just one platform is sitting upon Lug Supports 6 . 7 of the stationary pillars. Step 1. Lug Supports 6 . 3 of Lifter 6 . 4 , as a result of Cylinder 6 . 2 being activated, raise the platform package or one Platform 5 . 1 at “h” height above Stationary Lug Supports 6 . 7 , enough for their turning into a non-operational position, for example, into the vertical position. Step 2. Lug Supports 6 . 7 are turned into a non-operational position when Cylinder 6 . 6 . is turned into its non-operational position. Step 3. Lug Supports 6 . 3 , without the help of the lifter, raise the platform package into the top end position. Step 4. Lug Supports 6 . 7 of the stationary pillars are brought back into their operational (horizontal) position. Step 5. A command is given to turn on Cylinder 6 . 2 for downward movement of Lifter 6 . 4 , with Lug Supports 6 . 3 placing the platform package or one platform upon Lug Supports 6 . 7 of stationary pillars. The lowest platform separated from the package is placed upon Transporter Rollers 8 . 1 . With the lifter continuing moving downwards, Lug Supports 6 . 3 are lowered into their initial position below Rollers 8 . 1 .
[0049] After the frame of the lifter I moved into its lower initial position, a command arrives to switch the transporter drag-out device in the ramp direction, see FIG. 4 a . Pulling Finger 8 . 5 of the transporter pulls Platform Ratch 5 . 10 , and the platform is relocated into a preset position on the ramp. Then comes a command to tilt the ramp with the platform into a preset position allowing for a car to mount the platform. “Stop” signal is substituted by the signal allowing the car to move. The driver approaches the ramp ( FIG. 4 ) and the car front left wheel enters a space between two Rollers 1 angularly related to each other. Continuing to move, the wheel enters the angle between Rolls 5 . 6 of Carriage 5 . 8 installed on the platform.
[0050] Carriage 5 . 8 helps to keep the wheel in the platform track, and while the car continues to move, the wheel gets into Recess 5 . 4 of the platform.
[0051] After the car is installed upon the platform and is fixed in the “PARKING” position, there is a command to place the platform with the car for storage. The ramp goes upward into the horizontal position, the transportation driving device is switched on, and while its pulling finger comes into contact with Ratchet 5 . 9 of the platform, it is relocated to a free layer of the nearest storage section along its way.
[0052] Considering the fact that for the device to function normally at least two sections are required, Section “n” and section “n+1”, FIG. 7 illustrates the longitudinal and the cross-sectional overviews of these two section structures. FIG. 7 illustrates post-operational steps in accepting a platform, with a car or empty, for storage.
[0053] The transporter stops at the pre-appointed area of the section, after which Lifting Frames 7 . 13 of the section use their Lug Supports 7 . 4 to raise the platform from the roller transporter, as well as all the other platforms resting on Lug Supports 7 . 15 of Stationary Pillars 7 . 8 to a certain height above these lug supports, enough for their mandatory turn over into a non-operational (vertical) position. After Lifter 7 . 13 raises into its upper position, Lug Supports 7 . 15 of their stationary pillars are forced back into their operating (horizontal) position. This is done with Shafts 7 . 6 driven from Cylinder 7 . 7 . Then the next command sends the lifter down, and all the platforms resting upon Lug Supports 7 . 4 of the lifter are installed upon Lug Supports 7 . 15 of the stationary pillars at their level, which is one level up. The platform raised from the transporter rollers is installed upon Lug Supports 7 . 15 of the lower level of the section.
[0054] This ends the cycle of car acceptance for storage.
[0000] (see FIG. 7 and FIG. 7 a )
[0055] FIG. 7 a demonstrates post-operational steps of platform acceptance for storage, with or without a car:
Step 0. Platform 5 . 1 to be stored is installed upon Rollers 8 . 1 of the lower transporter. Step 1. The transporter's Lug Supports 7 . 4 lift the platform off the transporter rollers, and all the other platforms off Lug Supports 7 . 15 of the stationary pillars. All of them are risen to “h” height which offers enough room for Lug Supports 7 . 15 of the stationary pillars to be turned into a non-operational (vertical) position. Step 2. When Cylinder 7 . 7 is switched on, shafts 7 . 6 turn Lug Supports 7 . 15 into the non-operational (vertical) position. Step 3. Lug Supports 7 . 4 of the lifter and Platform 5 . 1 are lifted into their upper position. Step 4. Lug Supports 7 . 15 of the stationary pillars are brought back into their operational (horizontal) position by switching Cylinder 7 . 7 on. Step 5. The lifter Lug Supports 7 . 4 are brought into their lower initial position, with the platforms being installed upon Lug Supports 7 . 15 of the stationary pillars, but one level upward, and the platform raised off Rollers 8 . 1 with the help of Lug Supports 7 . 4 is placed upon Lug Supports 7 . 15 of the lower level. This brings the process of accepting the platform for storage to an end.
[0063] A Take-Out of a Platform Loaded with a Car or Without it from the Car Storage Section.
[0064] A user who received the information about the storage code during the car intake, feeds this information into the system of its automated take-out. The following operations are to follow, depending on the layer where the platform with the stored car is located.
[0065] As an illustration, several versions of sequential operations and interaction of mechanism are offered below, which differ because of different layers where the car loaded platform is located.
[0066] 1 The Car Loaded Platform is Located at the Lower Layer (See FIGS. 7 and 7 b )
[0067] All Lug Supports 7 . 4 of the section lifter are driven into the non-operational (vertical) position, after which the lifter starts moving upward. After it passes higher than Stationary Lug Supports 7 . 15 are, Lug Supports 7 . 4 go back into their operational (horizontal) position. If the lifter continues rising, the lifter Lug Supports raise all the platforms resting upon stationary pillars Lug Supports to height “h” which is enough to turn Lug Supports 7 . 15 into the non-operational (vertical) position. The platform resting on the lower Lug Supports rises above the lug supports of the stationary pillars of the first layer. Then a command comes to turn Lug Supports 7 . 15 into their non-operational (vertical) position. After the lug supports have been turned, another command comes, to continue the movement of the lifter downward. After the lifter lug supports are lowered to a certain distance and brought below the level of Lug Supports 7 . 15 of the stationary pillars, they are returned into their operational (horizontal) position. After this one more command follows, to continue the movement of the lifter downwards. This brings all the platforms from the lifter lug supports to the lug supports of the stationary pillars, but one level lower than before. The platform resting upon the lug supports of the lifter Zero level lug supports is installed upon the transporter rollers, moves in the direction of the take-out point and is installed upon the ramp.
[0068] In the same way the platforms located at the first level of any car storage section are given out.
[0069] FIG. 7 b illustrates the operational steps required for a platform take-out.
Step 0. The initial position: the platform is located at the first level (marked with * sign). The platform located in the second level is marked with ** sign. In this position Supports 7 . 4 of the lifting Frame are in their operational (horizontal) position, below Lug Supports 7 . 15 of the stationary pillars and of the Roller 8 . 1 of the lower transporter movement plane. Step 1. Supports 7 . 4 are brought into the non-operational (vertical) position. Step 2. Lifting Frame 7 . 13 raises Lug Supports to a certain height above the platforms installed upon Lug Supports 7 . 15 . Step 3. Lug Supports 7 . 4 of the lifting frame are brought back into their operational (horizontal) position. Step 4. Lifting Frame 7 . 13 raises the platforms from Lug Supports 7 . 15 with the help of Lug Supports 7 . 4 , to a height enough for turning these supports into a non-operational position. Step 5. Lug Supports 7 . 15 of the stationary pillars are turned into the non-operational (vertical) position. Step 6. Lifting Frame 7 . 13 uses its Lug Supports to lower Platforms 5 . 1 below Lug Supports 7 . 15 , to a distance allowing enough space for returning Lug Supports 7 , 5 into their operational horizontal) position. Step 7. Lug Supports 7 . 15 of the stationary pillars are brought back into the initial (horizontal) position. Step 8. Lifting frame 7 . 13 and Lug Supports 7 . 4 are lowered into the initial lower position. All the platforms are removed from hese Lug Supports to Lug Supports 7 . 15 , but one level below. The lowest platform is taken off Lug Supports 7 . 4 of the lifting frame and place them down, upon Rollers 8 . 1 of the lower transporter. With the frame continuing its downward movement, Lug Supports are lowered below the rolling plane of Rollers 8 . 1 ., into their initial position. Then the platform is relocated in the direction of the take-out point and is installed upon the ramp.
[0080] B. The Platform to be Relocated for the Car Take-Out is Not Located at a Lower Level, but at Some Other Level, for Example, at the Second Level, While There is Another Platform at the First Level.
[0081] See FIG. 7 and FIG. 7 b (steps 0-8)
[0082] 7 c * (n+1) (Steps 8-13)
[0083] *n* Steps 14-18
*n* Steps 19-23
[0085] First, Platform (*) is lowered from Level 1 to the transporter rollers by way of performing the step sequence indicated in FIG. 7 b . But as the platform is to be kept in storage, it is to be transported to any other section (n+1), where it is to be installed at the first level of the section, but on the condition that the upper level is not occupied by another platform. If the higher level is occupied, the occupying platform is to be relocated, with the top carriage, to the section from which Platform (*) was taken.
[0086] Below you will find a description of the interaction of the units and parts during the take-out process, this time from the second level.
[0087] After the lifter is brought into the lower initial position, a command is given to switch on the lower transporter in order to relocate a platform from Section “n”. But if this platform, while being delivered for the take-in from this level, moves in the direction of the take-out, a platform required for the take-out from the second level**, after Platform * is installed upon the transporter, it is switched on to move not in the direction of the ramp, but in the direction of the adjacent section (n+1). At the same time, the transporter relocating the top carriage is switched on, for moving the top carriage into the same section.
[0088] As the design of the section is similar to that of the section from which the platform was taken out, all the details are marked with (*) sign.
[0089] After the platform and the top carriage stop in this section, a command arrives to raise Lifting Frame 7 *. 13 and Lug Supports 7 .* 4 , then comes a command for Cylinder 7 *. 16 of the lifting frame, to raise the platform to a “h” height above Lug Supports 7 /* 15 of the syationry pillars, the space being enough to allow these lug supports to be turned into the non-operational (vertical) position. Then there comes a command to Shaft 7 *. 6 and Lug Supports 7 .* 15 of the section, and Lug Supports 9 . 5 of the top carriage, which through Shaft 9 . 7 contacting with Shaft 7 * 6 are turned into the non-operational position.
[0090] The lifter continues to move upward until it arrives to its final top position, When this happens, all the platforms are relocated in the upward direction, to a certain height above the stationary supports 7 * 15 of the section and Supports 9 . 5 of the top carriage. Then the stationary supports both of the section and of the top carriage are brought back into the operational (horizontal) position. There is a command to move the lifter down, and while it moves, all the platforms are installed upon the Lug Supports of the stationary pillars, but one level up compared to their previous positioning, and the platform from the top layer has now been installed upon the Lug Supports of the top carriage.
[0091] The lifter continues its downward movement until it reaches its lower position. When this happens, a command arrives to bring back the top carriage and the platform installed upon its lug supports into Section “n”, from which the previous platform was taken out. Starting from this moment, all the operations aimed at platform relocation described above are to be repeated. Lug Supports 7 . 4 of the lifter are turned into the non-operational (vertical) position and are raised to some height above the platforms installed at the Lug Supports of the stationary pillars. Lug Supports 7 . 4 of the lifter are brought back into the operational (horizontal) position. Then lifting Cylinders 7 . 16 raise Lifter Supports 7 . 13 and Lug Supports 7 . 4 into the final upper position. At the same time Lug Supports 7 . 4 raise all the platforms from Lug Supports 7 . 15 and raise the platform from Lug Supports 9 . 5 of the top carriage. Then Shafts 7 . 6 of the section come into interaction with Shafts 9 . 9 of the top carriage, bringing Lug Supports 7 . 15 and Lug Supports 9 . 5 of the top carriage into the non-operational (vertical) position. Then comes one more command, to move the lifter down to some distance below Lug Supports 7 . 15 and Lug Supports 9 . 5 , allowing enough space for them to be turned into the operational (horizontal) position. While the lifter is moving downward,
[0092] Lug Supports 7 . 4 of the lifter place the platforms upon Lug Supports 7 . 15 , but one lever below, and the platform from the top carriage is now installed at the top level of the section. Platform ** from the section lower level is placed upon Rollers 8 . 1 of the lower transporter. After Lifter 7 . 13 arrives into the initial lower position, there is one more command, to switch on the lower transporter moving in the direction of the take-out point, i.e. in the direction of the ramp.
[0093] This is how a platform take-out is performed from the second level.
[0094] FIG. 7 c (n+1) shows post-operational steps required for the relocation of Platform * from Section “n+1” to Section “n”.
[0095] Step 8, where Platform * is placed upon Rollers 8 . 1 , with the lifting frame in the lower initial position serves as the starting, initial position for further steps.
Step 9. Lifting Frame 7 * 13 uses its Lug Supports 7 * 4 to raise all the platforms from Lug Supports 7 .* 15 to a certain “h” allowing enough space for turning Lug Supports 7 * 15 into the non-operational (vertical) position. Step 10. Lug Supports 7 * 15 of the section and Lug Supports 9 . 5 are turned into the non-operational position. Step 11. Lifting frames 7 /* 13 use Lug Supports 7 /* 4 to raise the platforms to some height above Stationary Supports 7 .* 15 of the section and above Supports 9 . 5 of the top carriage. Step 12. Lug Supports 7 .* 15 and Lug Supports 9 . 5 of the top carriage are turned into the operational (horizontal) position. Step 13. Lifting Frames 7 .* 13 are lowered into the lower initial position, meanwhile Lug Supports 7 .* 4 lower all the platforms of the section upon Lug Supports 7 .* 15 , but one level up, and the top level platform is installed upon Lug Supports 9 . 5 of the top carriage, and after Lifting Frames 7 .* 13 arrive into the bottom level position, the top carriage drive is switched on, and the top carriage, together with the platform it is loaded with, is relocated to Section “n”. After Platform (*) arrives into Section “n”, the take-out of Platform (**) begins, starting from the initial position described below: (See FIG. 14-18 ) Step 14. The initial position, with Platform (**) positioned at the lower level of Section “n”. Step 15. Lug Supports 7 . 4 of Lifting Pillars 7 . 13 are turned into the non-operational (vertical) position, Step 16. Lug Supports 7 . 4 are raised above Stationary Lug Supports 7 . 15 to a distance allowing for turning Lug Supports 7 . 4 into the operational (horizontal) position. Step 17. Lug Supports 7 . 4 are brought back into their operational (horizontal) position. Step 18. Pillars 7 . 13 use their Lug Supports 7 . 4 to raise the platforms to a height allowing enough space for turning Lug Supports 7 . 15 into their non-operational (vertical) position. (see FIG. 19-23 ) Step 19. Lug Supports 7 . 1 ′ 5 abd 9 . 5 are turned into their non-operational (vertical) position. Step 20. Pillars 7 . 13 use their Lug Supports to raise the platforms into their upper position. Step 21. Lug Supports 7 . 4 lower the platforms below Lug Supports 7 . 15 and 9 . 5 , to a distance allowing enough space for bringing them back into their operational (horizontal) position. Step 22. Lug Supports 7 . 15 and 9 . 5 are brought back into their operational (horizontal) position. Step 23. Pillars 7 . 13 are lowered into their lower initial position, with the lug supports of these Pillars 7 . 4 lowering the platform from Lug supports 9 . 5 of the top carriage to the upper level of the section, and lowering the other platforms to Lug Supports 7 . 15 , but one level below. Platform (**) from the lower level of Lug Support 7 . 4 of Stationary Pillar 7 . 13 is installed upon Rollers 8 . 1 of the transporter, and then the platform is sent to the take-out point.
[0114] If a platform from a higher level is demanded for take-out, all the operations relocating the platform from one section to another are repeated, until the platform demanded for the take-out is installed upon the lower transporter.
[0115] After the transporter is switched on to move in the direction of the take-out point, a command arrives to raise the ramp by bringing Cylinder 4 . 1 into a horizontal position, and the platform is installed upon the ramp. The next command sends the ramp into its tilted position designed for car exit from the platform. At the same time a command is sent to Cylinder 5 . 3 , for rising the wheel from the recess in the platform to the platform surface level. This makes the exit much easier, and requires less engine rotations, which, in its turn, lowers air pollution. This ends the cycle of a car take-out, and after the car exit the ramp lowers the platform into its horizontal position. When the transporter is switched on, Ratches 5 . 9 of the platform hook Finger 6 . 1 of the transporter, and the platform is relocated into the platform storage section. See FIG. 6 . When the platform arrives into the storage section, a command is given to Cylinder 6 . 2 , and Lifting Frame 6 . 4 uses its Lug Supports 6 . 3 to raise it until Feet 5 . 2 of the platform free Lug Supports 6 . 7 of the stationary pillars and raise the stored platforms to a height allowing enough space to turn Lug Supports 6 . 7 into the non-operational (vertical) position with he help of Cylinder 6 . 1 . Then the lifting frame is raised into its upper position, a command follows to turn Lug Supports 6 . 7 into their operational position. After they are brought into the operational position there comes a command to move the lifting frame down, to its lower, initial position. While this is happening, the whole platform package is installed upon Lug Supports 6 . 7 of Stationary Pillars 6 . 5 . | The invention pertains to the area of warehousing of goods with certain dimensions, such as, for example, containerss or open platforms loaded with goods, the storage being done in multi-level sections following each other in a line or in several parallel lines, with the take-in of the platforms at one end of each line (the entrance point) and take-out of the goods either at the opposite end of each line (the exit point), or at both the entrance and the exit points, simultaneously. |
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates generally to coverings for stair steps and, more particularly, to a removable mat for step treads of a stair.
[0003] 2. Background Information
[0004] Stairs consist of steps retained by side supports. A step typically consists of a horizontal member or tread and a vertical member or riser. In some instances stairs are constructed without risers. Therefore, the steps consist of only treads supported on each side by a support. The stair treads may be made from a variety of materials including wood, stone, plastic or other natural and man-made material. In all cases, it has been found advantageous to provide a tread covering. A tread covering can provide a safety aspect associated with the use of the stairs. This is especially true of stairs that are exposed to the elements such as stairs for recreational vehicles (RVs), trailers, campers, boats, docks, and the like.
[0005] In response to the above-identified problem, various solutions have been developed. Typical tread coverings include carpet, rubber, or the like that is placed on the stair tread. One such step cover is illustrated in U.S. Pat. No. 115,717 issued to Dieterich et al. on Jun. 6, 1871 (hereinafter “the '717 patent”). The '717 patent provides a step cover consisting of a sheet or slab of vulcanized rubber or gutta-percha beveled on all four edges and contained within a frame. The frame is composed of overlapping and beveled strips that are secured together by screws. The step cover of the '717 patent, however, is disadvantageous for various reasons including the fact that it covers only the top side of the step and is secured to the step by screws.
[0006] In U.S. Pat. No. 161,305 issued to Walter on Mar. 23, 1875 (hereinafter “the '305 patent”) there is disclosed a stair pad having a strip of carpet in a frame. The frame has a curved front edge that wraps over the curved edge of a step. Again, the stair pad of the '305 patent is disadvantageous for various reasons including those described above with respect to the '717 patent. In a similar manner, U.S. Pat. No. 815,391 issued to Weinstock on Mar. 20, 1906 (hereinafter “the '391 patent”), discloses a stair carpet holder having a frame with a biased hook on the front thereof for engaging the front stair edge. The stair carpet holder of the '391 patent, however, suffers from at least the same disadvantages as the others.
[0007] U.S. Pat. No. 6,088,976 issued to Roy on Jul. 18, 2000 (hereinafter “the '976 patent”) discloses a removable non-skid step pad. The step pad includes a pad that is fastened around the stair tread. The pad portion of the '976 patent, however, does not extend about the entire tread and is designed to be placed on the tread in a specific manner that cannot be reversed.
[0008] In view of the above, it would be advantageous to provide a stair mat that has a textured stepping surface that extends entirely around the tread.
[0009] It would be further advantageous to provide a stair mat as indicated above that has a non-skid bearing surface that extends entirely about the tread, particularly in conjunction with the stepping surface.
SUMMARY
[0010] In accordance with the invention, there is provided a mat for a tread of a stair step wherein the step does not have a corresponding riser. The mat has a textured stepping surface that extends entirely around the tread. The mat is secured to itself once wrapped around the tread. Hook and loop fasteners are preferably used to secure one end of the mat with another.
[0011] The mat preferably consists of a textured (e.g. corrugated) indoor-outdoor type carpet as the stepping surface such as a polypropylene carpet. The carpet includes a backing that consists of at least one layer of a rubber or similar elastomeric that provides a non-slip surface. The backing naturally also extends entirely around the tread and is adapted to be in contact with the tread surface.
[0012] In one form, the subject invention is a mat for a stair tread. The mat includes a length of textured material having a first end and a second end, a backing material on one side of the textured material, and a closure formed as a first part disposed on a first end of the textured material and a second part disposed on the backing material on a second end opposite said first end. The closure securing the length of textured material onto a stair tread wherein the textured material extends 3600 about the stair tread.
[0013] In another form, the subject invention is a mat for a tread of a riser-less stair. The mat includes a length of corrugated carpet defining a top surface, a bottom surface, a longitudinal length having first and second ends, and a short length having third and fourth ends. The longitudinal length of corrugated carpet is sufficient to extend entirely around a short length of the stair tread when installed on the stair tread. A non-skid material is disposed on the bottom surface of the corrugated carpet. A fastener is associated with the corrugated carpet and the non-skid material and is adapted to releasably hold the corrugated carpet around the stair tread.
[0014] In another form, the subject invention is a mat for a riser-less step tread. The mat includes a length of polypropylene carpet having an underside surface and first and second longitudinal ends, a rubber backing disposed on the underside surface, and a releasable fastener having a first strip of first fastening material disposed on the polypropylene carpet at the first longitudinal end, and a second strip of second fastening material complementary to the first fastening material disposed on the backing at the second longitudinal end. The fastener allowing the polypropylene carpet to wrap around the tread and be secured thereon, wherein the polypropylene carpet creates a 360° surface around the tread.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings:
[0016] [0016]FIG. 1 is a perspective view of a flight of exemplary stairs on which the subject invention may be utilized;
[0017] [0017]FIG. 2 is an enlarged side view of an exemplary embodiment of a mat made in accordance with the principles of the subject invention;
[0018] [0018]FIG. 3 is a top plan view of the exemplary mat of FIG. 2 with one corner folded down to better illustrate the various features of the subject invention;
[0019] [0019]FIG. 4 is a side view of the exemplary mat of FIG. 2 illustrating the manner in which the mat is installed on a stair tread;
[0020] [0020]FIG. 5 is a perspective view of the stairs of FIG. 1, with each tread having the subject mat installed thereon; and
[0021] [0021]FIG. 6 is a sectional view of one of the treads of the stairs of FIG. 4 taken along line 6 - 6 thereof showing a mat installed thereon.
[0022] Corresponding reference characters indicate corresponding parts throughout the several views.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1, there is depicted an illustration of an exemplary flight of stairs generally designated 10 in which the subject invention may be used. It should be appreciated that the stairs 10 is only exemplary of the many types of stairs that can utilize the subject invention as described herein. While the stairs 10 is shown by itself, it should be appreciated that the stairs 10 may be part of or attached to a structure such as an RV, mobile home, camper, dock or the like.
[0024] The stairs 10 includes a first side support, stringer or the like 12 and a second side support, stringer or the like 14 . Situated between the first and second side supports 12 and 14 is a plurality of treads 16 forming steps. The stairs 10 , and particularly the treads 16 do not have risers associated therewith. Thus the stairs 10 may be considered an open-tread stair or a riser-less stair. It should be appreciated that the subject invention is thus applicable to any type of open-tread or riser-less stair. Moreover, it should be appreciated that the number of steps or treads 16 in the flight of stairs 10 is irrelevant. The subject invention is applicable equally to a single step and a stair having a plurality of steps.
[0025] Referring to FIGS. 2 and 3, an exemplary embodiment of a mat, generally designated 20 , in accordance with the principles of the subject invention is shown. The mat 20 has an outer surface 22 and an inner surface 24 . The outer surface 22 provides a stepping surface while the inner surface 24 provides a backing, contact or bearing surface. When installed on a tread as shown in FIGS. 4 and 5 and described below, the stepping surface 22 faces outward relative to the tread 16 while the contact surface 24 faces inward relative to the tread 16 .
[0026] The stepping surface 22 is preferably formed of a textured material 26 that is preferably at least somewhat weatherproof or impervious to weather (e.g. rain, sleet, snow, sunshine, etc.). The textured material 26 is also preferably relatively easy to clean and is durable. One such material may be an indoor/outdoor type carpet such as a polypropylene carpet. In one form, the stepping surface 22 is formed of a corrugated polypropylene carpet. Of course, other carpets and/or materials may be used.
[0027] The contact surface 24 is preferably formed of a non-skid material 28 . The non-skid material 28 forms a backing for the textured material 26 . The non-skid material 28 may be a rubber, elastomeric or other type of non-skid material that provides a positive traction (non-slip) surface. In one form as shown, the non-skid material 28 may consist of multiple plies 36 , 38 of material (having two or more layers). One ply 36 may be an underlayment such as roping, cording, or the like that provides a good foundational material. A second ply 38 may be an elastomeric or other non-skid material. Of course, the backing 28 may be formed of a single material, a single layer of a composite material, or the like.
[0028] The mat 20 further includes a first retention portion 32 and a second retention portion 34 . The first and second retention portions 32 and 34 together form a releasable fastener 30 (see FIG. 4) that allows the mat 20 to join ends to thus be securely installed on a stair tread, and to easily release the two ends to uninstall (remove) the mat from the stair tread. In a preferred form, the fastener 30 comprises a loop portion and a hook portion. It should be appreciated that while the first portion 32 is depicted as the loop portion and the second portion 34 is depicted as the hook portion, the two are interchangeable.
[0029] The loop portion 32 may constitute a strip of loop material that is applied to the textured material 26 . The hook portion 34 may constitute a strip of hook material that is applied to the backing 28 . Preferably, and as best seen in FIG. 3, the first (loop) portion 32 preferably extends at least, but not necessarily, substantially from one short side of the mat 20 to another short side of the mat 20 . The second portion 34 also preferably extends at least, but not necessarily, substantially from one short side of the mat 20 to another short side of the mat 20 . It should be appreciated that the mat 20 in FIG. 3 has one corner folded over in order to clearly illustrate the position and configuration of the second (hook) portion 34 .
[0030] Referring to FIG. 4, the mat 20 is depicted being folded together as is done when the mat 20 is installed on a stair tread 16 . As the mat 20 is bent or folded around the tread 16 , the first and second portions 32 and 34 join. The mat 20 is thus formed into a continuous loop. Moreover, as the first and second portions 32 and 34 are releasably joined, the textured material 26 extends 360° about the mat 20 . As well, the backing material 28 extends 3600 about the mat 20 .
[0031] In FIG. 5, there is depicted the exemplary flight of stairs 10 as first depicted in FIG. 1. In FIG. 5, each tread 16 has a mat 20 disposed thereon. As indicated above, the textured material 26 extends entirely around the short length of the tread 16 but not necessarily its length. The length may be variable both due to different size steps and desired amount of tread coverage. In this manner, if the mat 20 rotates on the tread 16 either intentionally or not, the textured material 26 always presents itself on the top of the tread 16 .
[0032] The mat 20 may be manufactured in various sizes, colors, stepping materials, and the like. Various designs may be incorporated into the stepping material. Each mat may cover a given amount of stair tread to accommodate various step sizes.
[0033] [0033]FIG. 6 shows a sectional view of the mat 20 installed on the tread 16 . It can be clearly seen that the textured material 26 extends 3600 around the short length of the tread 16 while the amount of the long length of the tread 16 that may or may not be covered depends on the size of the mat 20 . As well, the backing material 28 also extends 360° around the short length of the tread 16 .
[0034] While this invention has been described as having a preferred design, the subject invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the subject invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and that fall within the limits of the appended claims. | A stair mat for a tread of a step includes a textured material such as corrugated, polypropylene carpet having a non-skid backing material such as rubber The stair mat is flexible and is adapted to surround the tread 16 such that the textured material extends 360° about the tread. The stair mat includes a closure such as Velcro® that is formed as a hook strip disposed on one side of the mat adjacent a first longitudinal end, and a loop strip disposed on another side of the mat adjacent a second longitudinal end. |
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This is a division of application Ser. No. 272,030, filed July 14, 1972, now U.S. Pat. No. 3,830,659.
The method of the invention relates generally to a long term trickle feed of root killing chemicals into a drain line.
BACKGROUND OF THE INVENTION
Various drain lines such as drain lines to sewers and septic tanks, or leaching beds, have required periodic maintenance due to the growth of tree roots in areas where there is water seepage from joints in the drain lines. In many instances roots grow through joints in drain lines and fill the drain lines such as to cause them to plug and become inoperative.
Many methods have been used to clear the roots from the drain lines, including mechanical rotary cutters as well as various chemical treatments.
It has been a common practice to introduce various chemicals such as copper sulphate crystals into the plumbing via a conventional toilet bowl or other fixture in a dwelling or the like, and in accordance with such treatment short term chemical action is attained relative to roots in drain lines and at the joints thereof.
It has become well known that the introduction of a batch of chemicals such as copper sulphate crystals into a toilet bowl provides short term and almost momentary treatment of roots in drain lines due to the fact that the flushing of the toilet bowl carries the crystals downwardly into the drain line and in many instances the chemicals flow past the critical root invasion area before fully dissolving and consequently batch treatment only provides short term exposure of the invading roots to the chemical such as copper sulphate or the like.
When the roots are subjected to such short term treatment they may be slightly damaged but are not caused to completely recede from the seepage openings in the drain line and tend to grow back quite rapidly thus necessitating constant maintenance attention and frequent intermittent treatments by flushing batches of chemicals down the toilet or by introducing such chemicals through other fixtures in connection with the drain line plumbing.
The principal difficulty in such prior art treatment methods is that drain lines become plugged and are only free for short periods of time when the bath treatment method is resorted to.
SUMMARY OF THE INVENTION
The present invention relates to a means and method for treating roots about drain lines; the invention comprising a very simple male fitting and container structure adapted to be placed in conventional female plumbing cleanout structures and wherein chemicals are contained so as to promote a method of continuous long term trickle feeding of chemicals into drain lines so that roots which have grown into the drain lines are subjected to the action of chemicals over a long period of time which results in not only killing and shrinking the roots inside the drain line but also causing the roots to be killed completely in the seepage areas through which the roots have grown and which therefore also causes regression of the roots and seepage of the chemicals outwardly into surrounding areas near the drain line, and to thus prevent further growth of the roots thereinto.
The invention includes a very simple chemicals container supported on a male structure carried in a female cleanout plumbing fixture, and the chemicals container includes a water inlet tube having an outlet considerably below an overflow outlet in the container so that water may be introduced in a slight trickle through the chemicals and wherein the chemicals which are dissolved are carried by the trickle of water through the overflow of the container and into the cleanout fitting and downwardly into the drain line. The constant trickle of dissolved chemicals over a period of several days or weeks causes killing of the roots and also the roots outside the drain line and in the surrounding area, and thus preventing regrowth of roots into the drain line.
In accordance with the invention, copper sulphate crystals are utilized in the container of the invention and the chemistry thereof, as it is dissolved, appears as follows: Cu SO 4 + 2H 2 O -- H 2 So 4 + CuO 2 . From the foregoing it will be seen that sulphuric acid is produced when the crystals are dissolved and that roots of trees entering at 60 as shown in FIG. 3 of the drawings will be killed and dissolved and shrunk away by the sulphuric acid during a long term trickle flow of the acid around the roots. The sulphuric acid will then migrate outwardly through the crack into which the roots 60 have grown and the sulphuric acid concentrate will percolate through the soil for a short distance so as to cause the roots to withdraw from the area; however, as the sulphuric acid is dissipated, the free copper oxide will be available to roots of trees at the perimeter of the percolation area where the concentration of acid has been reduced by reaction with the soil.
Accordingly, the ecology of the method according to the invention is beneficial to the trees after the roots have withdrawn from the percolation area around the drain line.
The slow trickle feed of dissolved copper sulphate crystals is very effective over a substantial period of time, as for example, this trickle feed should continue for a period of at least four to twelve hours and the flushing of large amounts of water down the drain line should be avoided, as for example the flushing of toilets should be avoided as much as possible so as to minimize the dilution of acid at the area where it trickles into the proximity of the roots where they enter the drain line.
The means of the invention is a very simple structure which may readily be adapted to screw into or fit into any conventional female cleanout plumbing fitting communicating with a respective drain line.
Additionally, the invention includes novel atmospheric vent means disposed above the water inlet structure which allows water to trickle into the chemicals container of the invention so that backflow into the water supply cannot happen due to siphoning or other action.
Additionally, a water trap is provided in the chemicals container of the invention due to the fact that the water inlet tube is provided with an outlet considerably below the overflow outlet of the container which holds the chemicals such as copper sulphate crystals or the like.
The means of the invention affords a very effective operational method for the killing of roots in drain lines and for causing the recession of such roots from cracks or leaks or openings in the drain line, and for treating the soil around the areas of such openings or cracks to prevent the regrowth of the roots into the drain lines.
The method of operation comprises a long term trickle of chemicals into the drain line so that constant application of the chemicals is maintained over a long period of time and therefore providing very effective treatment of the roots to prevent growth and to prevent plugging of the drain lines thereby.
Accordingly, it is an object of the invention to provide a means for treating roots about drain lines which may be very readily and easily installed in conventional drain line cleanouts and which provides a very effective method for treating roots in drain lines, and for killing the roots and preventing further regrowth thereof.
Another object of the invention is to provide a very economical means for treating roots about drain lines and thereby obviating expensive plumbing service normally attendant to drain lines in areas where tree roots grow.
Another object of the invention is to provide a very safe and simple means for treating roots about drain lines wherein an atmospheric vent is provided to prevent siphoning of water from the drain line or the means of the invention back into the water supply used for trickle feeding of the means of the invention, and further, the invention employs a suitable liquid trap to prevent gases from passing from the drain line outwardly through the atmospheric vent of the invention.
Another object of the invention is to provide a novel and simple means for treating roots about drain lines which may be installed very readily and which may use a trickle flow of water from a conventional garden hose which may readily be attached to said means.
Another object of the invention is to provide means for dissolving copper sulphate crystals in water so as to produce sulphuric acid and free copper so that the acid may kill the roots and percolate up into the surrounding area where the roots have entered the drain line, and further, the free copper from the copper sulphate at the perimeter of the percolation area may be available to the roots of trees so that the ecology of the method is actually nutritious to trees as their roots withdraw from the immediate area of the drain line.
Further objects and advantages of the invention may be apparent from the following specification, appended claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a means for treating roots about drain lines in accordance with the present invention;
FIG. 2 is a horizontal sectional view taken from the line 2--2 of FIG. 1, showing the structure on a large scale;
FIG. 3 is a fragmentary vertical sectional view of a drain line cleanout structure, showing the invention installed therein and showing portions thereof in section and in elevation to amplify the illustration, and further showing the flow of water therethrough to dissolve crystal chemicals and to provide a trickle feed of chemicals into the drain line;
FIG. 4 is a transverse sectional view taken from the line 4--4 of FIG. 3;
FIG. 5 is a fragmentary view of a modification of the water inlet means used in connection with the invention;
FIG. 6 is a modification of the invention showing a plurality of diametrically stepped groups of screw threads adapted each individually to fit a certain size cleanout so that the unit is universally adaptable to the various sizes of cleanouts in existence;
FIG. 7 is an enlarged plan sectional view taken from the line 7--7 of FIG. 6; and
FIG. 8 is an enlarged plan sectional view taken from the line 8--8 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 of the drawings, the invention comprises a male fitting 10 suspendingly supporting a generally hollow tubular chemicals container 12 and screw threadably attached to a side 14 of a projection 16 at the upper end of the fitting 10 is a connection means 18 adapted for the connection of a conventional garden hose thereto.
As shown in FIG. 3, on reduced scale, the male fitting 10 is provided with peripheral screw threads 20 which are screw threadably engaged in internal screw threads 22 of a conventional hollow tubular female cleanout structure 24 which is coupled to a conventional drain line 26, and which forms an intermediate part thereof.
The cleanout structure 24 is provided with a hollow tubular generally vertical portion having a bore 28 in which the chemicals container 12 is suspendingly supported by the male fitting 10. The male fitting 10 is provided with external screw threads 30 engaging internal screw threads 32 at an upper open end of a generally hollow cup-shaped chemicals container 12.
Supported by the male fitting 10 is a water supply tube 34 which extends downwardly into the chemicals container 12 and this tube 34 is provided with an open water outlet end 36 which is at a position substantially below overflow outlet openings 38 in the sidewall of the chemicals container 12 so as to provide a water trap therein and also to provide for the overflow of chemicals containing water, as will be hereinafter described.
The male fitting 10 is provided with an upwardly directed projection 40 having an upper end 42 provided with an atmospheric vent opening 44 which communicates with the interior of the hollow tube 36, which extends upwardly into the projection 40.
The side of the projection 40 is provided with an internally screw threaded bore 46 in which an externally screw threaded portion 48 of a fitting 50 is secured. This fitting 50 is adapted to provide screw threaded connection of a conventional garden hose 52, or any other tubular water conduit as desired.
It will be seen that the male fitting 10 is provided with an internal bore portion 54 communicating with the fitting 46 and with the vent opening 44 and this bore portion 54 is continued by means of the water inlet tube 34, and the bore continues on through to the lower opening end 36, all as shown best in FIG. 3 of the drawings.
In operation, the male fitting 10 may be removed from the cleanout structure 24 and the chemicals container 12 may be screw threadably removed from the male fitting 10 so as to place copper sulphate or other chemical material 56 therein. This material 56 is preferably water soluble material, and when disposed in the container 12 and installed on the male fitting 10, as shown in FIGS. 1 and 3 of the drawings, water may be introduced in a slow trickle through the tube 52 and downwardly through the bore 54 and outwardly through the open end 36. This slow trickle gradually fills the chemicals container 12 to the overflow outlet openings 38 at which time chemicals dissolved by the water is carried in the water downwardly and is fed into the drain line 26 as indicated by the disclosure of droplets 58 in FIG. 3 of the drawings. These droplets of water contain the chemicals dissolved from the crystals or other dissolvable material 56 and a slow trickle of the dissolved chemicals in the water passes into the drain line and moves generally in the direction of the arrow A in FIG. 3 of the drawings, at a slow rate, and consequently may be continued for weeks at a time so that the material slowly trickled in and that which gravitates to the bottom will pass into a joint area 60 through which roots 62 normally tend to grow. With a continued application and trickle of the liquid chemicals into the joint area 60, the roots which have grown thereinto are killed and are shrunk away and dissipated such that the liquid chemicals over a period of time will gradually seep through the joint area 60 and into the soil 64 below the joint area 60, and with a concentration of the liquid chemicals in the soil 64 the roots tend to withdraw from this area and are thus prevented from regrowing into the drain line 26.
As shown in FIG. 3, the hose 52, at its inlet end comprises a conventional screw threaded coupling 53 adapted to be coupled to a faucet. An orifice plate 55 is disposed in the coupling 53, and has an orifice 57 therethrough which may be, for example, 0.0015 inch to 0.025 inch in diameter, so as to allow a slow trickle of water to pass through the hose 52.
It will be understood that the method of the invention comprises a low rate trickle of chemicals for a substantial length of time in contrast to the usual and conventional method of flushing a substantial batch of chemicals through the drain line which only causes momentary contact of the chemicals with the roots 62 and which depends upon chance that some crystals of the chemicals will be trapped in the roots.
In operation, the water passes through the orifice 57 and hose or tube 52 and downwardly through the bore 54 and percolates up through the crystals 56, thereby dissolving them and carrying some of the chemicals through the overflow outlet openings 38 and downwardly into the drain line 26. At this time a liquid trap is maintained in the chemicals container between the open end 36 of the water inlet tube and the overflow openings 38.
Additionally, the atmospheric vent 44 provides a vent to prevent any siphoning from the container 12 into the water inlet tube 52, and also provides for an indication of overcharging of the chemicals container 12 with water in the event too much flow is introduced through the hose or tube 52.
The modification as shown in FIG. 5 comprises a top portion 68 of a male fitting similar to the fitting 10. A standpipe 72 extends upward thereabove to a position above ground water 71 which may occur with lawn irrigation for example. A siphon breaking orifice 74 is similar to the orifice 44. The orifice 74 is thus held above the water level 71 to prevent siphoning action. It will be understood that a conventional siphon breaker may be installed in connection with the tube 52 and amy be used in place of either of the orifices 44 or 74. A fitting 76 of the standpipe 72 is adapted for connection of a hose or tube fitting such as the fitting 48.
Accordingly, operation of the device over a long term, as hereinbefore described, requires that water entering the tube 52 and the bore 54 may be a low rate trickle so that a batch of copper sulphate or other crystals may last for weeks and provide for leaching of the chemicals from the crystals into the water and into the droplets 58 which enter the drain line 26.
As shown in FIG. 6 of the drawings, a container 80 is similar to the container 12. The container 80 is provided with external screw threads 82 screw threaded into internal screw threads 84 of an adapter fitting 86.
The container 80 is provided with outlet openings 88 similar to the openings 38 of the container 12.
The adapter 86 is similar to the male fitting 10 and constitutes a male fitting having three groups of threads of different diameters. A group of threads designated 90 is of the largest diameter; another group of threads 92 is of a substantially reduced diameter; and a third group of threads 94 is of the smallest diameter, such that the groups are diametrically stepped to accommodate various internal screw threads such as the internal screw threads 22 of the female cleanout structure 24 shown in FIG. 3. Inasmuch as these cleanout structures vary in diameter, the various groups 90, 92 and 94 of the threads as shown in FIG. 6 of the drawings are so arranged that one of them will fit the particular internal screw threads of the various female cleanout fittings.
Extending through the male adapter is a tube 96 similar to the tube 34 hereinbefore described, and in the upper end of the male adapter 86 are internal screw threads 98 holding a fitting 100 which carries a conventional hose fitting 102 and screwed into this hose fitting 102 is an orifice supporting fitting 104 having internal threads 106 adapted to receive the end of a hose or the like so as to supply water to an orifice plate 108 having a small central orifice 110 extending therethrough. This orifice 110 is so designed and sized that it will allow a small trickle of water to pass downwardly into the container 80 and gradually to dissolve a load of crystals such as copper sulphate crystals so that dissolved chemicals will continue to flow into the drain line 26 for a substantial period of time, as for example 12 hours or more, in order to provide an effective treatment for roots, as hereinbefore described, and as will be hereinafter described in accordance with the detailed description of the method.
A broken line in FIG. 6 indicates a tubular conduit 112 which may be a garden hose or the like, connectable to a screw threaded portion 114 of a conventional siphon breaker 116 which may be secured to the usual water outlet faucet coupled to domestic water supply.
In accordance with the method of the invention, chemical crystals of a water soluble type are preferably used in the container 80, and copper sulphate has been well known to be effective in killing roots in drain lines, and also has been ecologically satisfactory for such purposes. The chemistry is as follows:
Cu SO.sub.4 + 2H.sub.2 O -- H.sub.2 So.sub.4 + CuO.sub.2
the foregoing indicates that copper sulphate crystals in the container 80, when dissolved by water entering the orifice 110 will react to produce hydrochloric acid and copper oxide, which will pass downwardly into the drain line 26 and around roots 62, and downwardly through the opening 60, causing the roots to shrink and die away and retract from the opening. The sulphuric acid as well as the copper oxide will migrate and percolate out into the soil surrounding the drain line, and the roots will withdraw to a perimeter area of the percolated soil where the concentration of the sulphuric acid has reached a tolerable level due to its reaction with the soil, and the copper oxide in the perimeter of the percolated area may be available to the roots of the trees, and moisture, as it passes from the drain line and as the sulphuric acid reacts with the soil, will reach an area where it is available to the roots without causing them damage.
It is recommended in accordance with the present method that a trickle feed of the dissolved chemicals may continue to flow into the drain line, as hereinbefore described, for a period of at least four hours, but preferably 12 hours or more, and further it is recommended that the flow of other liquids in the drain line should be minimized, as for example excessive flushing of toilets and other large flows of water should be avoided, and thus the flow of other liquids in the drain line should be minimized so as to permit the concentrated acid to be effective during the trickle flow period thereof into the drain line so that a concentrate of the acid is continually gravitating into and around the area 60 where the roots 62 emerge into the drain line.
It will be obvious to those skilled in the art that the present invention, as well as the method for using it, provides long term treatment of roots which kills the roots internally of the drain line, and which kills the roots in the joint openings through which the roots have grown, and further treats the soil in the surrounding areas at the lower sides of the drain line so that the roots will recede from the area of the drain line in the soil surrounding the lower side thereof.
Accordingly, roots are initially killed in the line and subsequently prevented from growing therein due to the fact that long term flow of the liquid chemicals causes sufficient seepage of these chemicals through the joint opening so as to impregnate the soil in the surrounding areas of the joint openings to cause recession of root growth in such areas.
It will be obvious to those skilled in the art that various modifications may be resorted to without departing from the spirit of the invention. | The disclosure relates to a means and method for treating roots about drain lines so that such roots do not plug or impede the flow of fluid through such drain lines, the means comprising a male fitting adpated for disposition in a female drain line cleanout structure and a chemicals container is suspended from the male fitting and adapted to hold crystalline or other suitable dissolvable chemicals such as copper sulphate or the like, and water inlet means is adapted to introduce water through the male fitting and into the chemicals container so that the water will flow through the crystals and overflow from an elevated outlet in the side of the container above an area into which water is introduced into the chemicals container; a vent means provides communication of the atmosphere with the interior of the water inlet tube and a connection means is provided for introducing water into the inlet tube at a level below the atmospheric vent. |
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CROSS REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of prior application Ser. No. 09/798,210, filed Mar. 2, 2001, now U.S. Pat. No. 6,651,401 entitled RETAINING WALL AND METHOD OF WALL CONSTRUCTION.
FIELD OF THE INVENTION
This invention relates generally to the construction of retaining walls used in landscaping applications where such walls are used to provide lateral support between differing ground levels. More particularly, the present invention relates to a retaining wall that uses a series of differently sized, pre-formed horizontal and vertical blocks that operatively connect with each other along adjacent courses to resist pressure exerted against the wall by retained back-fill material and ground water.
BACKGROUND OF THE INVENTION
Retaining walls are widely used in a variety of landscaping applications. Typically, they are used to maximize or create level areas and also to reduce erosion and slumping. They may also be used in a purely decorative manner. In the past, retaining wall construction was labor intensive and often required the skills of trained tradespeople such as masons and carpenters. More recently, retaining wall construction has become significantly simplified with the introduction of self-aligning, modular, molded blocks of concrete that may be stacked in courses without the use of mortar or extensive training. With these types of blocks, it is possible to erect a retaining wall quickly and economically, and the finished product creates the impression and appearance of a conventional block and mortar retaining wall. The feature that allows such blocks to be so easily and precisely assembled is the interconnection between adjacent courses of blocks. Typically, each block will include a projection and a recess located at oppositely facing surfaces, such as a top surface and a bottom surface, for example. The projection and recess are complimentarily shaped, with the projection protruding beyond the bottom surface of the block and with the recess extending inwardly from the top surface of the block. In use, a projection of a first block is received within the recess of a second block to interconnect and position the blocks adjacent each other in a predetermined relation. With a plurality of blocks, such interconnections make it possible to lay courses of blocks in an accurate and expedient manner. Moreover, such an assembled retaining wall is able to resist lateral forces exerted by the material being retained and reduce bowing. Blocks having these interconnections are usually the same size and may be assembled in a coplanar arrangement in only a simple, running bond pattern. In a variation of the aforementioned blocks, the projection and recess may be arranged so that adjacent courses are offset a predetermined amount. With this type of block, each successive course may be offset from the preceding course by the same amount so that the assembled wall is skewed at a predetermined angle from the vertical. These blocks also have the same dimensions to enable them to set in only a simple, running bond pattern.
A recent development in mortarless retaining walls has been the advent of blended pattern retaining walls. These walls differ from the aforementioned walls in that the preformed blocks used to construct a retaining wall are differently sized. This feature allows retaining walls to be assembled in a variety of patterns and bonds. Usually, these types of preformed blocks are horizontally and vertically oriented and have dimensions that are based upon an incremental unit such as the thickness of a horizontal, preformed block. For example, the thickness of a horizontal block is one increment and the height of a vertical block is two increments. With these types of preformed blocks, it is possible to construct a retaining wall with no discernable courses. A drawback with such a retaining wall is that setbacks are not possible and the assembled retaining wall must be substantially vertical. Alternatively, a retaining wall may be arranged in thick courses, and the blocks within these thick courses may be randomly arranged. For example, a course may be two incremental units high within which the differently dimensioned preformed blocks are arranged. Or, the course may be three incremental units high within which the differently dimensioned preformed blocks are arranged. There are several drawbacks with this type of wall. One drawback is that the vertical blocks dictate the height of the course. Thus, if vertical blocks are used, each entire course must be coplanar and all of the blocks must lie in the same plane. Otherwise, the projections of blocks in one course would not be able to be received within the recesses in blocks of another course, and the interconnection would be defeated. Another drawback with such this type of wall is that the number of arrangements available within each course is limited, and a truly random arrangement is not possible.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a plurality of horizontally elongated and vertically elongated, preformed blocks that may be assembled to form a retaining wall. Each horizontal preformed block includes a front member and a rear member connected to each other by a web, opposing sides, a top portion and a bottom portion. The horizontal blocks may be formed in a series of predetermined incremental thicknesses whose additive thickness is equal to the height of the vertical block. For example, the horizontal blocks may have incremental thicknesses of one, two and three units, while the vertical preformed block is three units tall. Thus, the horizontal blocks may be stacked in whatever units which, when added together, would be three units tall.
The front member of each horizontal block includes a rearwardly facing portion having stop surfaces that are aligned with each other and are used to operatively connect adjacent courses of blocks. Each horizontal block also includes a recess and a projection located at oppositely facing support surfaces, respectively. Preferably, the recess is located at the top of each block and extends downwardly with respect to the top support surface of each block forming a through slot with open ends in spaced relation to the front member of each block. An important feature of the recess in these blocks is that the recess includes a stop surface that is in alignment with stop surfaces of the rearwardly facing portion of the front member of each block. Together, these stop surfaces form a single stop surface that extends substantially along the length of each horizontal block. This greatly increases the utility of each block because it allows the blocks of an adjacent upper course of blocks to be slidingly positioned with respect to a lower course of blocks as the retaining wall is being constructed. This adds to the number of possible arrangements of blocks and helps one construct a stronger retaining wall because aligned vertical joints between adjacent courses may be easily avoided.
The projection on the horizontal block extends downwardly with respect to the bottom surface of each block. Preferably, the width of the projection is substantially equal to the width of web that connects the front and rear members together. Each projection includes an indexing surface that is configured to operatively contact a stop surface of an adjacent course of blocks.
Each vertical preformed block includes a front member and a rear member connected to each other by upper and lower webs, opposing sides, a top portion and a bottom portion. The front member of each vertical block includes a rearwardly facing portion having a stop surface. Each vertical block also includes a recess and a projection located at oppositely facing support surfaces, respectively. Preferably, the recess is located at the top of each block and extends downwardly with respect to the top support surface of each vertical block forming a through slot with open ends in spaced relation to the front member of each block. The recess in these blocks includes a stop surface that is coincident with the stop surface of the front member, and, as with the horizontal blocks, the stop surface extends substantially along the width of each vertical block.
As with the horizontal block, the projection on the vertical block extends downwardly with respect to the bottom surface of each block, and preferably its width is coincident with the width of the vertical block. Each projection of the vertical block also includes an indexing surface that is configured to operatively contact the stop surface of an adjacent course of blocks.
Another important feature of the aforementioned blocks relates to the operative connections that occur between the projections and recesses of adjacent courses of blocks. This is achieved by using blocks that have a stop surface which is fixed relative to a common feature of the blocks, such as the viewable surface, and blocks which have indexing surfaces located at a series of predetermined distances from a common feature of the blocks, also such as the viewable surface. For example, to construct a coplanar wall, one would select those blocks where the indexing surfaces are at a first predetermined position. Alternatively, to construct a wall that tilts at a slight angle with respect to the vertical, a different set of blocks with indexing surfaces located at a second predetermined position would be used. And, to construct a wall which tilts at a greater angle with respect to the vertical, yet another set of blocks with indexing surfaces located at a third predetermined position would be used, and-so-on. This feature may be combined with the other features discussed above to produce a myriad of retaining wall configurations that may include combinations with different setbacks and/or no setbacks.
An object of the present invention is to provide a retaining wall that may be assembled without the use of mortar.
Another object of the present invention is to increase the number of arrangements possible between adjacent blocks in a retaining wall.
Yet another object of the present invention is to reduce undesired lateral movement between adjacent courses in a retaining wall.
A feature of the present invention is that vertical, preformed blocks have a height that is equivalent to two or more stacked horizontal preformed blocks.
Another feature of the present invention is that the horizontal, preformed blocks may have the same thickness or may have complimentary thickness whose additive thickness is equal to the height of vertical, preformed blocks.
Another feature of the present invention is that the courses of blocks may be assembled in a coplanar or one of several predetermined offset relations.
An advantage of the present invention is that the use of differently sized and oriented preformed blocks permits a retaining wall to be configured into a myriad of configurations.
Another advantage of the present invention is that each course presents a substantially contiguous, aligned stop surface against which indexing surfaces of projections of an adjacent course of blocks are positioned.
Additional objects, advantages and features of the invention will be 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 invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combination particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front, perspective, partial view of one embodiment of a completed, coplanar retaining wall of the present invention;
FIG. 2 is a perspective view of an embodiment of the preformed blocks of the present invention taken from a position in front of and above the block;
FIG. 3 is another perspective view of the block of FIG. 2 taken from the same position, with the block in an inverted and outwardly facing orientation;
FIG. 3 is another perspective view of the block of FIG. 2 taken from the same position, with the block in an inverted and outwardly facing orientation;
FIG. 4 is a perspective view of another embodiment of the preformed blocks of the present invention taken from a position in front of and above the block;
FIG. 5 is an inverted perspective view of the block of FIG. 4 taken from a position in front of and above the block;
FIG. 6 a partial side view illustrating a first setback and the interface between adjacent courses of blocks;
FIG. 7 is a partial side view illustrating a second setback and the interface between adjacent courses of blocks;
FIG. 8 is a partial side view illustrating coplanar alignment and the interface between adjacent courses of blocks;
FIG. 9 is a side elevational view of an embodiment illustrating various setbacks which are possible with the blocks of the present invention;
FIG. 10 is a front, perspective, partial view of an embodiment of a completed, variable setback retaining wall of the present invention;
FIG. 11 is a front perspective view of an embodiment of a retaining wall with horizontal blocks stacked one above the other in a columnar fashion in accordance with the present invention; and
FIG. 12 is a front perspective view of an embodiment of a retaining wall with horizontal blocks stacked one above the other in a running bond fashion in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, FIG. 1 shows one embodiment of a retaining wall 10 comprising a plurality of horizontally and vertically oriented preformed blocks 30 A, 30 B, 30 C, and 90 of the present invention. As will be discussed later in greater detail, the horizontal, preformed blocks 30 A, 30 B, and 30 C may be formed in different incremental thickness, and are combinable so that their total thickness is equal to the height of the vertical, preformed blocks 90 . As shown in FIG. 1 , the horizontal, preformed blocks 30 A, 30 B, 30 C may be selected and stacked in combinations of twos and threes. That is, block 30 A and block 30 C, two blocks of 30 B, and three blocks of 30 C. It will be understood, that each course of blocks may be defined by the height of the vertical blocks 90 . Thus, beginning with the lower left segment of the wall 10 , the first course 12 comprises two stacked 30 A blocks, a vertical block 90 , two stacked 30 A and 30 C blocks, two stacked 30 C and 30 A blocks, a vertical block 90 etc. The second course 14 is similarly constructed, beginning from the upper left segment of the wall 10 with a vertical block 90 , three stacked 30 C blocks, a vertical block 90 , and so on. Note that the first and second courses 12 , 14 are shifted linearly with respect to each other along their top and bottom surfaces, respectively, by a distance of about one-half the width of a vertical block 90 . This configuration assures that vertical joints do not span adjacent courses. This not only strengthens the retaining wall but also allows the blocks to be arranged in a more random fashion. Note that even though the first and second courses 12 , 14 are arranged to present a more or less planar viewable surface, an extremely large number of combinations of blocks are possible, limited only by the imagination of a designer or an assembler. As a further note, while the viewable surfaces 34 , 94 of the front members 32 , 92 of the horizontal and vertical blocks 30 , 90 , respectively, are depicted as being roughened, it is understood that blocks having other surface finishes and textures may be used.
Referring now to FIGS. 2 and 3 , each horizontal, preformed block 30 includes a front member 32 , a rear member 42 , opposing sides 44 a , 46 a , a top 50 and a bottom 60 . The front member 32 includes a viewable surface 34 having a predetermined texture and finish. As mentioned above, it is understood that the viewable surface 34 may be provided with other textures and finishes, as desired. The front member 32 also includes a rearwardly facing back surface 36 in spaced relation from the viewable surface 34 , with the back surface 36 including stop surfaces 38 , 40 . As will be discussed later, the stop surfaces 38 , 40 enable adjacent courses of blocks to be operatively connected to each other.
For purposes of this application, the term operatively connect is understood mean that movement between adjacent courses of blocks in response to pressure exerted by retained material and water is resisted by complimentary confronting surfaces in adjacent courses of blocks.
Referring again to FIGS. 2 and 3 , each horizontal block includes a rear member 42 having opposing sides 44 b , 46 b , interior surfaces 48 a , an exterior surface 48 b , a top 50 , and a bottom 60 . Rear member 42 is held in spaced relation from the front member 32 by a web 74 . The web 74 includes opposing sides 76 , 78 , an upper surface 80 and a lower surface 82 . With regard to FIG. 2 , the top 50 of the block includes top support surfaces 52 , 54 that are configured to operatively contact bottom support surfaces 62 , 64 of overlying courses of blocks (See, FIGS. 6–9 ). The top 50 of the block 30 also includes a recess 56 that extends downwardly from the upper surface 80 of the web 74 , and downwardly relative to the top support surfaces 52 , 54 . The recess 56 includes a stop surface 58 that is in alignment with the stop surfaces 38 , 40 of the back surface 36 of the block 30 . Together, these stop surfaces 38 , 40 and 56 , extend substantially along the entire width of the block 30 and greatly expand the operative connection range available to a practitioner. Preferably, the stop surfaces 38 , 40 , and 58 will be located a certain, fixed distance measured from a feature common to all of the blocks, such as the viewable surface 34 . The bottom 60 of the block 30 includes corresponding bottom support surfaces 62 , 64 that are configured to operatively contact top support surfaces of underlying courses of blocks (See, FIGS. 6–9 ). The bottom 60 of the block 30 includes a projection 66 that constitutes the other part of the operative connection between adjacent courses of blocks. The projection 66 extends downwardly from the lower surface 82 of the web 74 and downwardly relative to the bottom support surfaces 62 , 64 . The projection 66 includes an indexing surface 68 that is configured to operatively contact the stop surface(s) of an adjacent course of blocks. As will be described later in greater detail, the indexing surface 68 differs from the stop surfaces in that there are a plurality of fixed distances measured from a feature common to all of the blocks, such as the viewable surface 34 , at which an indexing surface 68 may be located.
As described previously, and as shown in the FIG. 1 , the thickness of block 30 may be formed incrementally. That is, the horizontal blocks may be formed in such a manner to allow stacked blocks 30 to be equal in height to a vertical block 90 . And, while the incremental units chosen may be quite small, the preferred incremental thicknesses are approximately one-third, one-half, and two-thirds of the height of a vertical block 90 . For example, the horizontal blocks may have incremental thicknesses of one, two and three units, while the vertical preformed block is three units tall. Thus, the horizontal blocks may be stacked in whatever units which, when added together, would be three units tall.
Referring now to FIGS. 4 and 5 , each vertical, preformed block 90 includes a front member 92 , a rear member 100 , opposing sides 102 , 104 , a top 110 and a bottom 120 . The front member 92 includes a viewable surface 94 having a predetermined texture and finish. However, it is understood that the viewable surface 94 may be provided with other textures and finishes, as desired. The front member 92 also includes a rearwardly facing portion 96 in spaced relation from the viewable surface 94 , with the rearwardly facing portion 96 including a stop surface 98 . As will be discussed later, the stop surface 98 enables adjacent courses of blocks to be operatively connected to each other.
For purposes of this application, the term operatively connect is understood mean that movement between adjacent courses of blocks in response to pressure exerted by retained material and water is resisted by complimentary confronting surfaces in adjacent courses of blocks.
Referring again to FIGS. 4 and 5 , each vertical block 90 includes a rear member 100 that is held in spaced relation from the front member 92 by upper and lower webs 106 , 108 , respectively, and opposing sides 102 , 104 . With regard to FIG. 4 , the top 110 of the block 90 includes top support surfaces 112 , 114 that are configured to operatively contact bottom support surfaces of overlying courses of blocks (See, FIGS. 6–9 ). The top 110 of the block 90 also includes a recess 116 that extends downwardly relative to the top support surfaces 112 , 114 and which includes a stop surface 118 that is coincident with the stop surface 98 of the rearwardly facing portion 96 . As can be seen in FIGS. 4 and 5 , the stop surface 98 (or alternatively 118 in this particular instance) extends along the entire width of the block 90 . Preferably, the stop surface 98 will be located a certain, fixed distance measured from a feature common to all of the blocks, such as the viewable surface 94 . The bottom 120 of the block 90 includes corresponding bottom support surfaces 122 , 124 that are configured to operatively contact top support surfaces of underlying courses of blocks (See, FIGS. 6–9 ). The bottom 120 of the block 90 includes a projection 126 that constitutes the other part of the operative connection between adjacent courses of blocks. The projection 126 also extends downwardly relative to the bottom support surfaces 122 , 124 and includes an indexing surface 128 that is configured to operatively contact the stop surface(s) of an adjacent course of blocks. As will be described later in greater detail, the indexing surface 128 differs from the stop surface in that there are a plurality of fixed distances measured from a feature common to all of the blocks, such as the viewable surface 94 , at which an indexing surface 128 may be located.
As described previously, and as shown in the FIG. 1 , the height of the vertical block 90 is based upon an incremental unit, such as the thickness of the thinnest horizontal block.
Before describing FIGS. 6 , 7 and 8 in detail, it should be understood that the operative connection between vertical and horizontal blocks is essentially the same and the blocks depicted in FIGS. 6 , 7 , and 8 could be any combination of horizontal and vertical blocks. For purposes of simplification, however, the blocks shown in FIGS. 6–9 will be identified and described with the convention that each upper course block is a vertical block 90 and each lower course block is a horizontal block 30 . Using the aforementioned convention, the operative connections between adjacent courses of vertical blocks as depicted in FIGS. 6 , 7 and 8 , will now be discussed.
FIG. 6 illustrates an operative connection in which a viewable surface 94 of vertical block 90 is offset from a viewable surface 34 of a horizontal block 30 by a first predetermined distance 16 . As can be seen, the bottom support surfaces 122 , 124 of the vertical block 90 are in substantial contact with the top support surfaces 52 , 54 of the horizontal block 30 , and the indexing surface 128 of the projection 126 of vertical block 90 is in substantial contact with the stop surface ( 38 , 40 , 58 ) of the back surface 36 and/or recess 56 of the horizontal block 30 .
FIG. 7 illustrates an operative connection in which a viewable surface 94 of vertical block 90 is offset from a viewable surface 34 of a horizontal block 30 by a second predetermined distance 18 . And, FIG. 8 illustrates an operative connection in which a viewable surface 94 of vertical block 90 is coplanar with a viewable surface 34 of a horizontal block 30 . It should be noted that the recesses depicted in the aforementioned FIG. 6 , 7 , and 8 are configured to be sufficiently large enough to accommodate projections of varying sizes, and the only surfaces at which a contacting relation must be established in order to operatively connect or restrain adjacent courses of blocks so that they are able to resist forces exerted by retained material are the stop and indexing surfaces of the recesses and projections, respectively.
FIG. 9 illustrates an embodiment in which a plurality of horizontal blocks having different incremental thicknesses are operatively connected to each other in a plurality of stacked relations, or groups. As described previously, and as shown in the FIGS. 1 and 9 , the thickness of horizontal block 30 may be formed incrementally to allow stacked horizontal blocks 30 to be equal in height to a vertical block 90 . For example, a preferred horizontal block 30 incremental thickness of one, two and three units with approximately one-third, one-half, and two-thirds of the height of a vertical block 90 is shown in FIG. 9 by horizontal blocks 30 C, 30 B and 30 C respectively.
Further shown in FIG. 9 are the viewable surfaces of the two lowermost horizontal blocks 30 A, 30 C that are offset from each other by a first predetermined distance 16 . The viewable surfaces of the second and third horizontal blocks 30 C, 30 B are offset from each other by a second predetermined distance 18 , and the viewable surfaces of the two uppermost horizontal blocks 30 B, 30 B are coplanar.
FIG. 10 illustrates an embodiment in which a retaining wall includes a plurality of blocks, some of which have been setback. Beginning with left side, there are two horizontal blocks 30 B, 30 B that are stacked one above the other in a group, with the upper block 30 B set back from the lower block 30 B a predetermined distance. Next, there are two horizontal blocks 30 A, 30 C that are stacked one above the other in another group, with the upper block 30 A set back from the lower block 30 A a predetermined distance. Next, there is a vertical block 90 that is set back a predetermined distance. And finally, there is a horizontal block 30 A. Thus, the lowermost horizontal blocks of this embodiment are in alignment with each other, while the uppermost horizontal blocks and the vertical blocks are in alignment with each other. Note that the course as depicted is equal to the height of the vertical block. More importantly, with this invention it is possible to have setbacks between adjacent stacked and/or vertical blocks within each course. Thus the possible arrangement of blocks is greatly increased to provide a nearly limitless variety of configurations available to a practitioner.
Shown in FIG. 11 is a retaining wall embodiment where a plurality of horizontal preformed blocks 30 are stacked one above the other in a columnar fashion 130 . One block 30 in one course is positioned directly over another block 30 in an underlying course. Blocks 30 stacked in a columnar fashion 130 may also be positioned in one course in a predetermined relation with blocks 30 in an adjacent course as the indexing 68 and stop surfaces 62 , 64 of adjacent courses of blocks 30 are brought into registry with each other. Another predetermined relation for positioning the blocks 30 is a setback wall in which one block is offset a first predetermined distance from another such that the wall has a constant upwardly receding slope or batter. A third type of predetermined relation for positioning the blocks contemplated by the invention is a setback with a variable upwardly receding slope in which a plurality of predetermined distances is used to offset one block from another.
Blocks 30 stacked in a columnar fashion 130 of the present invention provide the advantage of allowing the viewable surface 34 of a horizontal block 30 to be positioned in a variety of predetermined relations to another viewable surface 34 of another block 30 . Blocks 30 stacked in a columnar fashion 130 may be positioned in a coplanar relation to another viewable surface 34 . A coplanar relationship between the viewable surfaces 34 of horizontal blocks 30 can be understood by modifying FIG. 8 such that the vertical block 90 is replaced by another horizontal block 30 . Similarly, by replacing the vertical block 90 with another horizontal block 30 in FIGS. 6 and 7 , one can appreciate two other types of viewable surface relations made possible by blocks 30 stacked in a columnar fashion 130 . The distance between the viewable surface 34 of lower block 30 from the viewable surface 34 of the upper block 30 is shown by a first predetermined distance 16 . Thirdly, in a setback retaining wall with columnar stacks 130 , horizontal blocks 30 of the present invention may be offset from each other by a plurality of predetermined distances. A modification of FIG. 7 would show the difference between the two viewable surfaces 34 of the two horizontal blocks 30 as a predetermined distance 18 .
FIG. 12 illustrates an embodiment of a running bond 140 type of stacked retaining wall of the present invention. The same advantages provided by the invention to a columnar stacked retaining wall 10 are also provided for a running bond 140 stack of horizontal blocks 30 . The indexing 68 and stop surfaces 62 , 64 may be used to position blocks 30 in one course into a predetermined relation with blocks 30 of an adjacent course. In a running bond 140 stack of blocks 30 , the viewable surfaces 34 of the blocks 30 in one course may be positioned into a predetermined relation with blocks 30 of an adjacent course as the indexing 68 and stop surfaces 62 , 64 of the adjacent course of blocks 30 are brought into registry with each other. Both the blocks 30 , and the viewable surfaces 34 of the blocks 30 , respectively, may be positioned in a predetermined relation with each other in a running bond 140 retaining wall 10 . In a running bond 140 retaining wall 10 , blocks with a plurality of predetermined distances may be positioned in a coplanar relation, a constant batter relation, or a variable batter relation.
A significant advantage to the present invention can be seen in FIG. 12 with a running bond 140 stacked retaining wall. A recess in preexisting blocks offered limited width, which consequently limited the placement options of the horizontal blocks 30 laterally along the course of the wall. The present invention recess 56 extends continuously and completely through the block 30 . Now a block in a running bond pattern may be moved laterally as much as desired in either direction, providing more options and patterns.
The present invention having thus been described, other modifications, alterations or substitutions may present themselves to those skilled in the art, all of which are within the spirit and scope of the present invention. It is therefore intended that the present invention be limited in scope only by the claims attached below: | A retaining wall with a series of differently sized, pre-formed blocks. Each block includes a projection and a recess, with the projection and recess arranged and configured so that each projection effectively engages a recess in an adjacent course to connect and align adjacent courses in registry. Retaining walls made of horizontal blocks may be stacked in columnar fashion or running bond fashion. The location of the indexing surface on a projection relative to the viewable surface of the block may be varied to enable adjacent courses to be coplanar or tiered in a variety of predetermined offset distances. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional Application 61/207,686 filed on Feb. 14, 2009.
BACKGROUND OF THE INVENTION
[0002] This invention relates to sink drain strainers or sink drainage baskets, specifically to a sink drain strainer that reduces the clogging of plumbing systems with food debris.
[0003] Sink drain strainers or sink drainage baskets primary purpose is to catch any large debris that may clog the drainage pipes leading from the sink. The other purpose is to provide a plug or stop that can be lowered from the strainer so the user can fill the sink with water when desired. The problem with present sink drain strainers is they quickly clog with debris from a typical dishwashing. A piece of lettuce, a noodle, or soggy cereal is often enough to stop the flow of water through the strainer requiring the user to pull the messy, greasy, dripping basket out of the sink, walk to the trashcan and bang it on the side of the trashcan to clear it or even worse use their fingers to dredge the food debris from the sink drainage basket and carry it to the trashcan. This invention solves this frequent and messy problem.
[0004] A more complex and expensive solution to this problem is an electric garbage disposal. Electric garbage disposals solve the messy food debris problem but they are expensive to buy, require installation, require electricity, and are often not allowed in apartment buildings.
[0005] In conclusion, what is needed is a sink drain strainer that does not require electricity or installation, allowing the user to manually cut, grind, or push clogging food debris through the drainage holes so that it will be small enough to safely pass through the plumbing system without causing clogs.
BRIEF SUMMARY OF THE INVENTION
[0006] Disclosed are sink drain strainers and sink straining methods that do not require electricity or installation permitting a user to manually cut, grind, push, or punch clogging food debris through the drainage holes so that it will be small enough to safely pass through the plumbing system without causing clogs. A sink strainer for processing a solid organic debris object, includes a sink strainer basket, sized for overlying and covering a drain, the sink strainer basket including a plurality of drainage holes retaining the solid organic debris object and inhibiting the solid organic debris object from entering into the drain; and a manually-actuable debris processor, coupled to the basket, for interacting with the drainage holes to resize the solid organic debris object into smaller debris objects sized to enter into the drain from the basket.
[0007] A solid organic debris object processing method, the method includes the steps of: (a) retaining the solid debris object in a sink strainer basket overlying a drain, the basket including a plurality of draining holes retaining the solid organic debris object and inhibiting the solid organic object from entering into the drain; and thereafter (b) actuating manually a debris process coupled to the basket to resize the solid organic debris object into smaller debris objects sized to enter into the drain from the basket.
[0008] Embodiments of the present invention include an improved sink drain strainer, having a manually rotating paddle that scrapes clogging debris against the drainage holes of the strainer basket. These drainage holes are designed to interact with the paddle (e.g., punching, rotating, or otherwise resizing) to cut or grind clogging debris into smaller pieces allowing them to pass through the drainage holes easily and thus safely through the attached plumbing system. This invention allows the user to simply actuate the paddle, manually, a few times to clear the clogging debris without having to remove the sink strainer to empty it or to dredge the debris out of the basket with their fingers. Embodiments also include a punch-and-cut strainer.
[0009] Accordingly, several objects and advantage of the present invention are: to provide a sink strainer with a simple and manual way to clear clogging food debris; to provide a way to remove clogging debris without having to remove the sink strainer for cleaning; to provide a sink strainer that reduces the mess to surrounding areas by not requiring the user to carry the sink strainer and dripping food debris to a trashcan; to provide a sink strainer that drains properly and won't succumb to constant clogging; to provide a sink strainer that won't be cast aside because of constant clogging thereby risking clogging pipes further down the pluming line with larger debris; to provide a vastly cheaper option to an electric garbage disposal; to provide a simpler solution, as far as installation is concerned, compared to an electric garbage disposal; to provide a drainage solution for already existing installed sink drains; to provide a grinding sink strainer that can be easily disassembled for cleaning; to provide a grinding sink strainer that snugly references the sink drain with either a reference ring or reference pads; and to provide a grinding sink strainer that has the option for a drain plug.
[0010] Further objects and advantages of the invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective top view of the grinding sink strainer showing the strainer basket with cutting drainage holes and a manually rotating grinding paddle;
[0012] FIG. 2 is a perspective angle view of the grinding sink strainer;
[0013] FIG. 3 is a perspective side view of the grinding sink strainer;
[0014] FIG. 4 is a lateral cross-sectional view of the grinding sink strainer positioned above a lateral cross-sectional view of a standard recessed sink drain collar;
[0015] FIG. 5 is a lateral cross-sectional view of the grinding sink strainer positioned inside a lateral cross-sectional view of a standard recessed sink drain collar showing how the two fit together;
[0016] FIG. 6 is a perspective top view of the grinding sink strainer with phantom dotted lines and arrows showing how the grinding paddle would spin;
[0017] FIG. 7 is a perspective side view of the grinding sink strainer showing how the grinding paddle could be removed for cleaning;
[0018] FIG. 8 is a lateral cross-sectional view of how the raised grinding/cutting edges would interact with the grinding paddle to cut large clogging debris into smaller non-clogging pieces;
[0019] FIG. 9 is a top view of corresponding parts from FIG. 8 ;
[0020] FIG. 10 is a lateral cross-sectional view of how the recessed grinding/cutting edges would interact with the grinding paddle to cut large clogging debris into smaller non-clogging pieces;
[0021] FIG. 11 is a top view of corresponding parts from FIG. 10 ;
[0022] FIG. 12 is a lateral cross-sectional view of how a flat grinding/cutting edge would interact with the grinding paddle to cut larger clogging debris into smaller non-clogging pieces;
[0023] FIG. 13 is a top view of corresponding parts from FIG. 12 ;
[0024] FIG. 14 is a perspective top view of a punch-and-cut sink strainer showing the strainer basket with cutting drainage holes and a manual punch paddle;
[0025] FIG. 15 is a perspective angle view of the punch-and-cut sink strainer of FIG. 14 ;
[0026] FIG. 16 is a perspective side view of the punch-and-cut sink strainer of FIG. 14 ;
[0027] FIG. 17 is a lateral cross-sectional view of the punch-and-cut sink strainer of FIG. 14 positioned above a lateral cross-sectional view of a standard recessed sink drain collar; and
[0028] FIG. 18 is a lateral cross-sectional view of the punch-and-cut sink strainer of FIG. 14 positioned inside a lateral cross-sectional view of a standard recessed sink drain collar showing how the two fit together.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention relates to a method, system and apparatus for a sink drain strainer that does not require electricity or installation, allowing the user to manually cut, grind, push or punch clogging food debris through the drainage holes so that it will be small enough to safely pass through the plumbing system without causing clogs. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
[0030] FIG. 1 is a top view of the grinding sink strainer 11 constructed in accordance with the invention. The round strainer basket 12 has a flared rim 13 and series of bottom drainage holes 14 and side-wall drainage holes 15 . Each bottom drainage hole 14 has a raised grinding edge 16 . Each side drainage hole 15 also has a raised grinding edge 17 . Inside the strainer basket 12 is a rotating grinding paddle 18 with bottom recesses 19 and side recesses 20 to match the raised grinding edges 16 and 17 . The plug handle 22 goes through the plug handle collar 21 and attaches to the drain plug 23 .
[0031] FIG. 2 is a perspective view of the grinding sink strainer 11 showing the drainage basket 12 with flared rim 13 , side drainage holes 15 with grinding edges 17 and bottom drainage holes 14 with grinding edges 16 . A rubber (or other material) reference ring 24 is located under the flared rim 13 to secure the grinding sink strainer 11 properly in a standard recessed sink drain. The reference ring 24 (or possibly, reference pads) keeps the strainer basket from slipping in relation to the sink drain so that the grinding paddle 18 can rotate in relation to the strainer basket 12 . Shown inside the drainage basket 12 is the grinding paddle 18 . A collar 21 houses the plug handle 22 and together are the axis that the grinding paddle 18 rotates around. A reference pin 25 at the bottom of the plug handle 22 is used to properly seat the drain plug in the sink drain.
[0032] FIG. 3 is a side view of the grinding sink strainer 11 showing the drainage basket 12 with side drainage holes 15 with grinding edges 17 . Placed under the strainers flared rim 13 is a rubber (or other material) reference ring 24 . This reference ring 24 is for snugly securing the grinding sink strainer 11 in a standard recessed sink drain so that it does not move around while the operator manually rotates the grinding paddle 18 . The plug handle 22 moves the rubber (or other material) drain plug 23 up or down to plug the sink drain. The reference pin 25 below the drain plug 23 , references a standard sink drain to properly seat the drain plug 23 as well as the entire grinding sink strainer assembly 11 in a standard recessed sink drain.
[0033] FIG. 4 is a side cross section view of the grinding sink strainer 11 situated above a side cross section view of a standard recessed sink drain 26 often found in a typical kitchen sink. In this view one can see how the grinding paddle 18 fits into the strainer basket 12 and around the plug handle collar 21 and plug handle 22 . This view also shows how the bottom raised cutting/grinding edges 16 and side cutting/grinding edges 17 interact with the grinding paddle bottom recess 19 and grinding paddle side recess 20 .
[0034] FIG. 5 is a side cross section view of the grinding sink strainer 11 seated properly inside of a side cross section view of a standard recessed sink drain 26 . This view shows how the rubber reference ring 24 contacts the standard recessed sink drain 26 for a snug non-slipping fit. This also shows how the drain plug reference pin 25 fits into the strainer pin reference ring 27 on the standard recessed sink drain 26 .
[0035] FIG. 6 shows how the grinding paddle 18 would manually rotate around the plug handle collar 21 and plug handle 22 .
[0036] FIG. 7 is a side-view of the grinding sink strainer 11 showing how the grinding paddle 18 can be removed for easy cleaning.
[0037] FIGS. 8-13 show various embodiments of the grinding sink strainer 11 with different grinding surfaces 19 , 33 on the grinding paddle 18 and cutting edges 16 , 30 on the drainage holes 14 . The preferred embodiment is shown in FIG. 10 .
[0038] FIG. 8 is a side view of the grinding sink strainer 11 . This cross-section view highlights how the bottom raised cutting/grinding edges 16 interact with the bottom grinding paddle recesses 19 to cut clogging debris 28 into smaller pieces 29 so they can safely and easily pass through the bottom drain holes 14 .
[0039] FIG. 9 is a top view (excluding side walls) of corresponding parts from FIG. 8
[0040] FIG. 10 is a side view of an alternate grinding sink strainer 11 with a flat bottom grinding surface 33 of the grinding paddle 18 and flat grinding/cutting edges 30 of the drainage holes 14 and a recessed leading edge 31 of drainage hole 14 . This cross-section view highlights how the larger clogging debris 28 falls into the recessed edge 31 of drainage holes 14 and are held against the flat grinding/cutting edge 30 of the drainage holes 14 as the flat bottom grinding surface 33 of the grinding paddle 18 passes over to cut larger clogging debris 28 into smaller non-clogging pieces 29 which now pass through the drainage holes 14 .
[0041] FIG. 11 is a top view (excluding side walls) of corresponding parts from FIG. 8
[0042] FIG. 12 is a side view of an alternate grinding sink strainer 11 with a flat bottom grinding surface 33 of the grinding paddle 18 and flat grinding/cutting edges 30 of the drainage holes 14 and without a recessed edge 31 as in FIG. 10 . This cross-section view highlights how the flat cutting/grinding edge 30 interacts with the flat bottom grinding surface 33 of the grinding paddle 18 to cut larger clogging debris 28 into smaller non-clogging pieces 29 so they can pass through drain holes 14 .
[0043] FIG. 13 is a top view (excluding side walls) of corresponding parts from FIG. 8
[0044] Operation
[0045] In operation one uses the grinding sink strainer 11 in standard recessed sink drain 26 similar to a standard sink strainer. The user can, when necessary, unclog the strainer basket 12 simply by rotating the grinding paddle 18 to cut, grind, or push clogging debris 28 through the drain holes 14 so that the water in the sink can drain properly without having to remove the sink strainer. Water pressure from the clogged debris or running water from the sink in combination with the rotating grinding paddle 18 and cutting edges 16 , 30 of the draining holes flush the small debris 29 through the drainage holes 14 .
[0046] Reasons the grinding sink strainer is an improvement over a standard sink strainer include the following: The grinding sink strainer seldom has to be removed from sink; The user seldom has to carry a dripping, dirty strainer to a place of disposal thus reducing the need for having to wipe-up the floor or surrounding area; The user does not have to remove greasy, wet debris with their fingers every time the strainer gets clogged; By easily keeping the drain free of clogging debris, the objects in the sink will not soak in the backed up, often dirty, greasy, water thus requiring less cleaning; Often regular strainers are cast aside because of their frequent clogging problems thus allowing larger debris to go down the drain possibly causing the pluming to clog further down the line.
[0047] Punch-and-Cut Embodiment: FIG. 14-FIG . 18
[0048] FIG. 14 is a perspective top view of a punch-and-cut sink strainer showing the strainer basket with cutting drainage holes and a manual punch paddle; FIG. 15 is a perspective angle view of the punch-and-cut sink strainer of FIG. 14 ; FIG. 16 is a perspective side view of the punch-and-cut sink strainer of FIG. 14 ; FIG. 17 is a lateral cross-sectional view of the punch-and-cut sink strainer of FIG. 14 positioned above a lateral cross-sectional view of a standard recessed sink drain collar; and FIG. 18 is a lateral cross-sectional view of the punch-and-cut sink strainer of FIG. 14 positioned inside a lateral cross-sectional view of a standard recessed sink drain collar showing how the two fit together. Alternate preferred embodiments of the present invention include an improved embodiment of the sink strainer, has a punch pad body 36 with a series of protruding punch cutters 37 that correspond with the bottom drainage holes 38 of the strainer basket. A spring 39 is inside of the punch pad body 36 .
[0049] To operate, the user pushes down on the punch pad body 36 , compressing the spring 39 and punching the protruding punch cutters 37 through the drainage holes 38 . The drainage holes are designed to interact with the protruding nubs 37 to cut and dice larger clogging debris 28 into smaller pieces 29 allowing them to flush safely and easily through the attached pluming system. This invention allows the user to simply push down on the plunger punch pad body 36 to clear the clogging debris 28 without having to remove the sink strainer. When the user releases the punch pad body 36 the spring 39 decompresses and returns the punch pad body 36 to its resting position, allowing the water to flow through the drain holes 38 again.
REFERENCE NUMERALS
[0050] 11 grinding sink strainer
12 sink strainer basket 13 flared rim of basket 14 bottom drain holes 15 side drain holes 16 bottom raised grinding edge 17 side raised grinding edge 18 grinding paddle 19 bottom grinding paddle recess 20 side grinding paddle recess
[0060] 021 plug handle collar
22 plug handle 23 drain plug 24 sink drain reference ring 25 drain plug reference pin 26 standard recessed sink drain 27 strainer pin reference ring 28 clogging debris 29 small non-clogging debris 30 bottom flat grinding edge of drainage hole 31 bottom recessed edge of drainage hole 32 side recessed edge of drainage hole 33 flat bottom surface of grinding paddle 34 flat side surface of grinding paddle 35 punch and cut sink strainer 36 punch pad body 37 protruding punch cutters 38 corresponding drain holes; and 39 spring
[0079] In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.
[0080] Reference throughout this specification to “one embodiment”, “an embodiment”, or “a specific embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases “in one embodiment”, “in an embodiment”, or “in a specific embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention.
[0081] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. It is also within the spirit and scope of the present invention to implement a program or code that can be stored in a machine-readable medium to permit a computer to perform any of the methods described above.
[0082] Additionally, any signal arrows in the drawings/Figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Furthermore, the term “or” as used herein is generally intended to mean “and/or” unless otherwise indicated. Combinations of components or steps will also be considered as being noted, where terminology is foreseen as rendering the ability to separate or combine is unclear.
[0083] As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0084] The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention.
[0085] Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention is to be determined solely by the appended claims | A sink drain strainer and sink straining method that does not require electricity or installation permitting a user to manually cut, grind, push, or punch clogging food debris through the drainage holes so that it will be small enough to safely pass through the plumbing system without causing clogs. A sink strainer for processing a solid organic debris object, includes a sink strainer basket, sized for overlying and covering a drain, the sink strainer basket including a plurality of drainage holes retaining the solid organic debris object and inhibiting the solid organic debris object from entering into the drain; and a manually-actuable debris processor, coupled to the basket, for interacting with the drainage holes to resize the solid organic debris object into smaller debris objects sized to enter into the drain from the basket. |
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BACKGROUND
This invention relates to a system and method of developing a drilling fluid in an efficient and environmentally-friendly manner. This invention further relates to recycling a drilling fluid.
Drilling fluids are used downhole in well-drilling operations in treating subterranean wells. In offshore drilling operations, these drilling fluids are usually mixed onshore in large full scale production volumes and are delivered to the offshore platform by trucks and barges and stored for later use. However, this can be time-consuming, and the equipment needed to transport and store the drilling fluids is costly. Therefore what is needed is a system and method of developing drilling fluids which eliminates these problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view depicting an embodiment of the invention.
FIG. 2 is a schematic view depicting an alternative embodiment of the invention.
DETAILED DESCRIPTION
An embodiment of the system and method of the present invention will be described in connection with the drilling of a subterranean well in an offshore location with a water-based fluid in FIG. 1 .
Water, such as seawater, is recovered in any conventional manner and passes, via a conduit 10 , to a vessel 12 in which chemicals are added to the water to discourage bacteria growth. The treated water then passes through a conduit 14 under the action of a pump 16 and into a blender 20 .
Specialty drilling additives from a container 22 are added to the water in the blender 20 to mix with the water to develop an initial water-based drilling fluid (hereinafter referred to as “drilling fluid”). The specialty drilling additives may include fluid controlling additives such as starches, encapsulating polymers, or other dry material such as caustic soda, sodium chloride, and silicic acid, and/or concentrated liqueurs.
The drilling fluid then passes from the blender 20 through a conduit 24 under the action of a high shear pump 26 , which pumps the drilling fluid into a blender 30 and maximizes the efficiency of materials introduction. Various bulk materials, such as bentonite and barite, from a container 32 , mix with the drilling fluid in the blender 30 to further develop the drilling fluid. It will be understood that drilling additives and materials are drilling fluid components.
The drilling fluid then passes from the blender 30 through a conduit 34 into an analyzer 36 which includes one or more of a number of specialty instruments such as a volume meter, a three-phase meter, a PH meter, and a mud analyzer for measuring rheology and other fluid properties. The analyzer 36 , including the above instruments, analyzes the drilling fluid and provides information as to the suitability of the drilling fluid for use downhole.
If the analyzer 36 determines that the drilling fluid is suitable for use downhole, the drilling fluid from the analyzer is directed into a conduit 38 for passage to a downhole pump system 40 . If the analyzer 36 determines that the drilling fluid is unsuitable for use downhole, the drilling fluid is directed into a conduit 42 which is connected to the conduit 14 for recycling and therefore reconditioning the unsuitable drilling fluid.
After entering and passing through the downhole pump system 40 , the drilling fluid passes through a conduit 44 to and through a hose system 50 and a kelly 51 to a downhole location for assisting in the further drilling of the well.
After use, the drilling fluid is returned from the downhole location, via a conduit 52 , to a shale shaker 54 with vibrating screens to separate out larger drill cuttings (solids) for disposal. The drilling fluid then passes through a conduit 56 and into a degasser 58 to remove unwanted gas from the drilling fluid. For further cleaning, the drilling fluid then passes through a conduit 60 to a mud cleaner 62 that includes hydrocyclones positioned over small mesh screens to remove smaller drill cuttings for disposal.
From the mud cleaner 62 , the majority of the drilling fluid is recycled through a conduit 64 . A smaller amount of drilling fluid passes through a conduit 66 to a centrifuge 68 wherein barite is separated out and recycled through a conduit 70 . The drilling fluid from the centrifuge 68 passes through a conduit 72 to another centrifuge 74 that separates out the smallest drill cuttings for disposal. The drilling fluid from the centrifuge 74 is then recycled through a conduit 76 . During the passage of the drilling fluid through the conduit 76 , the recycled barite from the conduit 70 and the drilling fluid from the conduit 64 are added and mixed with the drilling fluid in the conduit 76 to prepare the drilling fluid for entry into the analyzer 36 . The analyzer 36 again determines the suitability of the drilling fluid for reuse downhole. Alternatively, the recycled water-based drilling fluid may be passed, via the conduit 76 , to the sea or ocean in a safe manner adhering to environmental regulations or used to develop a new drilling fluid system for a new hole section.
The separated drill cuttings from the shale shaker 54 , the mud cleaner 62 , and the second centrifuge 74 are extracted via conduits 80 , 82 , and 84 , respectively, and sent back to shore for an environmentally safe disposal or disposed of on location if regulations allow.
ALTERNATES AND EQUIVALENTS
FIG. 2 depicts an alternative embodiment of the system and method of the present invention that will be described in connection with the drilling of a subterranean well in an offshore location with a hydrocarbon-based fluid. The embodiment of FIG. 2 is similar to that of FIG. 1 , and includes substantially similar components which are given the same reference numerals.
A hydrocarbon-base fluid is delivered in any conventional manner to the conduit 10 for introduction into the vessel 12 . The hydrocarbon-base fluid is developed into a hydrocarbon-based drilling fluid (hereinafter referred to as “drilling fluid”) for use downhole in substantially the same manner as the water-based fluid in the previous embodiment. Thus, it passes through the system in the manner described above before it passes through the hose system 50 and the kelly 51 to a downhole location. The drilling fluid returns from the downhole location in a conventional manner and is passed through the shale shaker 54 , the mud cleaner 62 and the additional centrifuge 74 in the manner described above in connection with the embodiment of FIG. 1 . Drill cuttings (solids) are removed from the shaker 54 , the mud cleaner 62 and the additional centrifuge 74 via conduits 80 , 82 , and 84 , respectively and pass into a solvent extraction unit 86 to recover the hydrocarbon-base fluid.
The solvent extraction unit 86 contains a lower pressure liquid recovery section, wherein the hydrocarbon-base fluid is recovered from the hydrocarbon-based drilling fluid still on the drill cuttings. In particular, the solvent extraction unit 86 contains lower boiling point hydrocarbon-based solvent fluids, or alternatively carbon dioxide, to extract the higher boiling point hydrocarbon-base fluid from the drill cuttings. The drill cuttings may then be disposed of in a safe manner adhering to environmental regulations through conduit 88 .
After recovery of the hydrocarbon-base fluid, the solvent fluids undergo a recompression cycle so that they may be recycled for later use. The hydrocarbon-base fluid is then recycled to a storage container 92 via a conduit 94 . The storage container 92 stores the hydrocarbon-base fluid for reuse and is connected to the conduit 10 via a conduit 96 for recycling the hydrocarbon-base fluid back to the vessel 12 for reintroduction into the drilling fluid system.
The benefits of this system are twofold. First, well construction costs can be reduced by minimizing the volume of drilling fluids used, maximizing the recycling of well-drilling fluids and cuttings, and reducing transportation costs associated with drilling fluids. Secondly, the drilling fluids and components of this system are environmentally friendly in that they are dramatically reduced in volume and can be reused for other well-drilling operations.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to cover the structures described herein as performing the recited function. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | A system and method for developing and recycling drilling fluids at the site of a subterranean well is described, thus eliminating the need for transporting the fluids to the site. |
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FIELD OF THE INVENTION
This invention relates to oil and gas well drilling as well as to completion and production of the same, and more particularly to pressure containment for using cools in under balanced drilling and snubbing operations.
BACKGROUND OF THE INVENTION
In the drilling, completion, and production of oil and gas wells, it is common practice to work with formation pressure. There are various stages and conditions of an oil or gas well during which access to the inside of the well is required. In underbalanced drilling, drilling occurs without restricting pressure from the well bore. Completion is a stage during which the well is perforated by shooting holes in the casing, while well servicing occurs during workover operations. In all of these cases, when drilling, completion or workover operations are performed, it is necessary in order to prevent hydrocarbons from leaking to atmosphere, to provide a containment device to contain gas within the well bore. This containment is important at all times but more particularly during snubbing operations when tool strings or tubing is jacked into and out of the well while the well is live. During snubbing, a stripping device is required for containment of the hydrocarbons, and the well bore pressure. Some standard containment approaches include a Blow Out Preventer (BOP) or an annular preventer, which comprise a piston which squeezes rubber to seal mechanically and may sit above a BOP. These systems may also be rotating pressure control systems. The standard approaches have limits with respect to the size or diameter of tool string or tubing that can be stripped in and out of the containment device for access to the well bore. Often if tool strings or tubing are of widely differing diameters, multiple annular containment spools are required, increasing costs incurred by the purchase and maintenance of multiple devices, and delays and lost production time due to the need to fit a new spool or containment device which fits the new tool string or tubing. This is particularly the case when switching between different tool strings and tubing used in drilling and work over operations. Due to the limits of the ranges of tool string and tubing shaft sizes compatible with standard devices, safety also becomes an issue when the size of a tool string or tubing is not within the safe range of shaft sizes compatible with the containment device. Size of the containment device itself is also an issue as it is more desirable to have a closely configured hydraulic jacking system.
It would be desirable in drilling and snubbing operations for there to a be a single stripping and containment device which has a wide range of tool string or tubing size compatibility. This is desirable for safety reasons and for cost efficiency. It is also desirable to find a single device which can be used for well bore pressure containment during underbalanced drilling, completion and work over operations. It is also more desirable to implement a smaller device than standard existing ones.
SUMMARY OF THE INVENTION
The present invention provides a single stripping and containment device which has a wide range of tool string and tubing shaft size compatibility, can be used for well bore pressure containment during underbalanced drilling, completion and work over operations, and can be integrated into rotating pressure control systems, and moreover is in general smaller in size than existing pressure control systems.
According to a first broad aspect the invention provides an apparatus for use in containing well bore pressure, comprising: a spool having a wall defining a passage therethrough for receiving a shaft; a seal disposed within said passage and having a flexible wall having first and second opposed surfaces, the first surface defining an aperture for receiving the shaft, the flexible wall being capable of flexing away from the spool wall to sealably engage the shaft in response to a force applied thereto, the second surface of the seal wall being accessible for receiving a controllable force directed away from the spool wall and towards said aperture for urging the seal wall inwardly of said passage.
According to a second broad aspect the invention provides an apparatus further comprising: a rigid annular piston sealably receivable within said spool; an outer spool having an outer spool will extending outside and about the spool; a plurality of cylindrical guiding fingers; an outer rigid annular piston sealably receivable inside of the outer spool and extending sealably about the spool and capable of translating in a direction along the axis of the spool; wherein an outer surface of the wall of the bladder, an inner surface of the outer spool wall, and a first end surface of the rigid annular piston define a chamber adapted for a fluid for use in exerting the controllable force, wherein the bladder is sealably fixed at one end to an inner surface of the spool, and is sealably secured to the first end surface of the rigid annular piston at the other end of the bladder, wherein the rigid annular piston is capable of translating in a direction along an axis of the spool in response to variations in a pressure of a fluid in the chamber, wherein the spool comprises an upper portion a lower portion with a gap therebetween, wherein an axis of each cylindrical guiding finger lien in a plane passing through an axis of the spool, and wherein the plurality of cylindrical guiding fingers are fixed at respective first ends to the inner surface of the outer spool wall, and are secured to the outer annular piston at respective second ends, and wherein the plurality of cylindrical guiding finger are adapted to be controllably deformed to forceably engage the outer surface of the wall of the bladder at portions thereof located at the gap in the spool using pressure exerted on the outer annular piston in a direction toward the first ends of the plurality of cylindrical fingers, thereby providing centering forces to the outer surface of the wail of the bladder.
According to a third broad aspect the invention provides a method of operating a seal for sealing to a shaft in a well bore, comprising the steps of providing: a seal having a flexible wall, said seal wall having first and second opposed surfaces, the first surface defining an aperture for receiving said shaft, and applying a force to said second surface to urge said seal wall against said shaft.
Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to the accompanying diagrams, in which:
FIG. 1A is a side view of a well bore pressure containment device according to the invention;
FIG. 1B is a side view of a well bore pressure containment device according to the invention rotated 90 degrees around the vertical axis relative to the view shown in FIG. 1A ;
FIG. 1C is a top view of a well bore pressure containment device according to the invention;
FIG. 2 is an isometric view of the well bore pressure containment device of FIGS. 1A , 1 B, and 1 C in use, with the containment device shown sectioned along its length to expose its interior;
FIG. 3 is an isometric view of the well bore pressure containment device of FIGS. 1A , 1 B, and 1 C in an unpressurized state, with the containment device shown sectioned along its length to expose its interior;
FIG. 4A is a side view of an alternate well bore pressure containment device incorporating bladder guiding polyurethane fingers;
FIG. 4B is a side view of the alternate well bore pressure containment device according to the invention rotated 90 degrees around the vertical axis relative to the view shown in FIG. 4A ; and
FIG. 4C is a top view of the alternate well bore pressure containment device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1A , 1 B, 1 C, and 3 , a well bore pressure containment device constructed according to the invention is described in terms of its structure. The well bore pressure containment device, generally indicated by 10 , comprises an annular pressure spool 100 and a bladder 106 . The spool 100 is an annular metal spool which consists of an annular flange 102 at one end of a hollow cylinder comprising an annular spool wall 104 . Inside the annular spool 100 and extending concentric therewith is located the bladder 106 which is constructed as a hollow cylinder and may be made of rubber, polyurethane, or other appropriate flexible material. The bladder 106 has an outer radius smaller than that of the annular spool wall 104 . An end of the bladder 106 is bonded to the flange end of the annular spool 100 and the opposite end of the bladder 106 is free floating. The floating end is secured to an annular sliding piston 108 which floats freely within the annular spool 100 . The piston has an annular seal 110 which serves to seal the piston against the inner surface of the annular spool wall 104 . Two holes are located in the annular spool wall 104 at positions along its height which overlap with the bladder, one hole serving as an inlet valve 112 and the other serving as an outlet valve 114 . The annular flange 102 has an aperture 117 for passage of a tool string or tubing therethrough. In the preferred embodiment, the annular flange 102 has holes located exterior to the annular spool wall 104 for mounting the annular spool 100 to other equipment which in the preferred embodiment of the invention is the rig BOP which serves as a backup system for pressure containment.
Referring now to FIG. 2 the operation of the pressure containment device 10 shown in FIGS. 1A , 1 B, 1 C, and 3 , is described. The device may be pre-set to withstand different pressure demands for different jobs, and may accommodate tool strings and tubing of differing diameters. FIG. 2 depicts the pressure containment device 10 with a tool string 118 present. In order to maintain pressure and contain the hydrocarbons a seal must be made between the inner surface of the bladder and the outer surface of the tool string. By pumping and releasing pressure respectively through the inlet valve 112 and the outlet valve 114 respectively into and out of the space interstitial of the bladder and the annular spool wall using a special hydraulic or pneumatic valving system, the bladder 104 may be made to expand or contract to varying degrees between a cylindrical tube-like shape and a roughly hyperbolic shape. The bladder 104 is able to freely deform in this manner due to one of its ends being a floating end secured to the floating piston 108 which is free to move along the axis of the annular spool. In this way pumping and releasing fluid pressure through the valves enables the diameter of the inner surface of the bladder to constrict at the bladder's apex (halfway along its length) to the diameter of the tool string 118 passing through the device. The pressure and may be pre-set to the required pressure to maintain a sufficient seal for the particular operation. In some embodiments, additional guiding elements are provided to ensure the bladder concentrically engages the tool string in a symmetric manner.
Referring to FIGS. 4A , 4 B, and 4 C an alternative embodiment of the pressure containment device 10 utilizing polyurethane fingers to help guide the bladder 106 and ensure that it concentrically engages the tool string passing therethrough, is described. To house the system by which the guide fingers are provided, the alternate embodiment has an outer spool 200 which is an annular metal spool concentric with the annular spool 100 having a diameter larger than that of the annular spool 100 . One end of the outer spool 200 is fixed to the flange 102 , the other end is fixed to the annular spool 100 via an annular member 220 . The flange 102 is modified in this embodiment in that it is of a larger diameter. The annular spool 100 is modified in this embodiment to consist of two portions with a gap between them. An upper portion 100 a of the annular spool 100 is fixed to the outer spool 200 via the annular member 220 , and engages the annular sliding piston 108 as described in association with FIGS. 1A , 1 B, 1 C, 2 , and 3 . A lower portion of the annular spool 100 b is fixed to the flange 102 . An outer fixed piston 202 is fixed to the outer surface of the annular spool wall 104 of the lower portion 100 b of the annular spool 100 and the inner surface of an outer spool wall 204 of the outer spool 200 . An outer sliding piston 208 , floats freely between the outer surface of the annular spool wall 104 of the upper portion 100 a of the annular spool 100 , and the inner surface of the outer spool wall 204 . The outer sliding piston 208 has an inner annular seal 210 a which serves to seal the outer sliding piston 208 against the outer surface of the annular spool wall 104 , and an outer seal 210 b which serves to seal the outer sliding piston 208 against the inner surface of the outer spool wall 204 . Twelve cylindrical polyurethane fingers 206 have respective first ends bonded to the outer fixed piston 202 at evenly spaced angular positions. The second ends of the polyurethane fingers 206 are secured to the outer sliding piston 208 also at evenly spaced angular positions. The gap between the upper and lower portions 100 a , 100 b of the annular spool 100 exposes the bladder 106 to a first hydraulic chamber 118 in which the polyurethane fingers 206 are situated. Two holes are formed in the outer spool wall 204 , one serving as the outlet valve 214 and the other serving as the inlet valve 212 to the first hydraulic chamber 118 . The outer sliding piston 208 , the upper portion 100 a of the annular spool 100 , the annular member 220 , and the outer spool 200 define a second hydraulic chamber 216 . Two apertures 218 and 220 are situated in the outer spool wall 204 , one serving as a second hydraulic chamber outlet valve 220 and the other serving as a second hydraulic chamber inlet valve 218 to the second hydraulic chamber 216 . In some embodiments a stop is located at a lower edge of the upper portion 100 b of the annular spool 100 to prevent either or both of the annular sliding piston 108 and the outer sliding piston 208 from disengaging from the upper portion 100 b of the annular spool 100 .
The pressure containment device 10 functions in a similar manner to that described in association with FIGS. 1A , 1 B, 1 C, 2 , and 3 . By pumping and releasing pressure respectively through the inlet valve 212 and the outlet valve 214 respectively into and out of the first hydraulic chamber, the bladder 106 may be made to expand or contract to varying degrees between a cylindrical tube-like shape and a roughly hyperbolic shape. The bladder 106 is able to freely deform in this manner due to one of its ends being a floating end secured to the floating piston 108 which is free to move along the axis of the annular spool within the upper portion 100 a of the annular spool. To assist in guiding the annular spool into symmetric and concentric engagement with a tool string or tube passing therethrough, polyurethane fingers 206 are made to forceably engage the outer surface of the bladder 106 by pumping and releasing pressure respectively through the second hydraulic chamber inlet valve 218 and the second hydraulic chamber outlet valve 220 respectively into and out of the second hydraulic chamber 216 , to move the outer sliding piston 208 towards or away from the outer fixed piston 202 . The movement of the outer sliding piston 208 in relation to the position of the outer fixed piston 202 causes the polyurethane fingers to bend or straighten to varying degrees between a bow-shaped cylindrical shape and a roughly straight cylindrical shape. The polyurethane fingers 206 are biased towards bending towards the axis of the annular pressure spool 100 by having in their relaxed state a slight bend inwards towards said axis. Each of the axes of the polyurethane fingers during their entire range of movement lies in a plane passing through the axis of the annular spool 100 . By pumping and releasing fluid pressure through the second hydraulic chamber input and output valves, the polyurethane fingers engage and apply a force to the outer surface of the bladder 106 , thereby keeping it engaged to the tool or tubing in a symmetric and concentric manner. The pressure may be pre-set to that required to maintain a sufficient force against the bladder 106 . In a preferred embodiment the control of the hydraulic pressures in the first and second hydraulic chambers 118 and 216 is coordinated so that the proper pressure is applied to the bladder 106 while at the same time the outer piston 208 is movable in the desired direction.
In a preferred embodiment, the pressure containment device 10 sits above a BOP, and is mounted thereon using bolts passing through holes 116 of the flange 102 of the annular spool 100 , and can be integrated into a rotating pressure control system. The pressure containment device 10 is flexible with respect to the size or diameter of tool string or tubing that can be stripped in and out of the pressure containment device 10 for access to the well bore. Tool strings and tubing of widely differing diameters may be accommodated by the pressure containment device 10 avoiding the increased costs incurred by the purchase and maintenance of multiple standard containment devices, and delays and lost production time due to the need to fit new standard spools or containment devices which fit each new tool string or tubing. This pressure containment device 10 , due to its flexibility may be used in drilling and work over operations. Due to the flexibility of the pressure containment device, safety is increased since a wider range of sizes of tubing and tool strings are within the safe range of sizes compatible with the pressure containment device 10 . Due to its design, the pressure containment device 10 is also smaller than standard devices and therefor lends itself to closely configured hydraulic jacking systems.
Although the preferred embodiments have been described as using a fluid to flex the bladder against the tool string or tubing passing therethrough, it should be understood that other mechanisms for applying a controllable force against the bladder, directed away from the spool wall and towards a tool passing therethrough, are possible. In fact, mechanical pressure exerted by rigid or semi-rigid fingers similar those described in association with the alternate embodiment could be used, or other mechanical members.
What has been described is merely illustrative of the application of the principles of the invention. Other arrangements and methods can be implemented by those skilled in the art without departing from the spirit and scope of the present invention. | A well bore pressure containment device is provided. Operating as a single stripping and containment device compatible with a wide range of tool string and tubing sizes, the containment device may be integrated with rotating pressure control systems, and be used during completion and work over operations. The containment device has a spool, and a flexible bladder extending about the interior of the spool. The bladder may be controllably deformed to seal against a tool string passing through the device using an inwardly directed pressure, which preferably is exerted by a fluid in the interstitial space between the spool and the bladder. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to a guide for a regulator assembly and more particularly, to an extruded guide for an automotive regulator assembly.
BACKGROUND OF THE INVENTION
Automotive vehicles have windows that are opened and closed via regulator assemblies that are either manually operated or power controlled. Regulator assemblies can be tape driven or cable driven, each having many similar components between the two systems.
A typical tape drive regulator assembly comprises a plastic tape having perforations spaced along its length and has a generally rectangular shaped cross-sectional profile. The tape is attached to the base of the window, and the tape is slidably mounted in a channel track that is fixed to the inner doorframe. The tape is routed around various guides, e.g., metal pulleys, fixed molded sliders, or molded rollers, which are located in spaced relationship within the automotive door and attached to the inner doorframe. The tape is additionally coupled to a tape drive, which comprises a manually operated handle or electrically operated motor. The tape drive has teeth engaging the perforations of the tape, which push or pull the tape to slide the attached window up or down respectively.
A typical cable drive regulator assembly comprises a cylindrical shaped flexible cable passed around a winding device, e.g., a take-up drum or a cylindrical roller. The cable is attached to the base of the window, and slidably mounted in a conduit that is fixed to the inner doorframe. Similar to a tape drive assembly, the cable is routed around guides of the type discussed above, and coupled to a cable drive comprising a manually operated handle or electrically operated motor. The cable drive reversibly rotates the winding device to shorten or increase a free length of the flexible cable to raise or lower the window respectively.
Guides of either the tape or cable regulator assemblies are typically constructed of metal, e.g., pulleys, or are molded plastic components, e.g., fixed molded sliders. These types of metal or molded guides can not be adjusted once they are manufactured, and are designed to fit only one required radius per regulator assembly. Additionally molded guides require separate molds for each radius they are designed to fit. This inhibits the ability to consolidate parts, consequently increasing the number of parts that must be stocked for repair or assembly purposes.
The aforementioned guides have tracks or channels, which guide the cable or tape during operation of the regulator assembly. However, the guides do not retain the cable or tape securely within the channel until fully assembled to the doorframe. Therefore, the guides cannot be preassembled to their associated cable or tape. Consequently guides must be shipped separately when delivered to an original equipment manufacturer (OEM), and additional time is required for assembly of the guides to the cable or tape at the production line.
SUMMARY OF THE INVENTION
This invention offers advantages and alternatives over the prior art by providing an extruded guide for an automotive regulator assembly. Advantageously, the extruded guide is flexible and can be adjusted to fit a plurality of required radii of the regulator assemblies. This enhances the ability to consolidate parts, consequently decreasing the number of parts that must be stored for repair or assembly purposes. Additionally, the present invention securely retains the cable or tape within a channel of the guide before and after assembly. Therefore, the guides can be preassembled to their associated cable or tape before shipping to an OEM. This advantageously reduces assembly time of the entire regulator assembly at the production line.
These and other advantages are accomplished in a preferred form of the invention by providing a guide for receiving a flexible line of a regulator assembly having a longitudinal channel disposed therein. The guide is adjustable radially. Preferably the guide is formed of an extruded material. The extruded guide is considerably lighter and less bulky than the prior art molded or metal guides, and can be advantageously adjusted to fit radii within a variety of automotive regulator assemblies.
In an exemplary embodiment, the guide is tubular wherein the channel comprises an inside surface of the guide sized to receive the flexible line. In an alternative embodiment, the guide includes a base portion and a pair of resilient arms that extend upwardly from the base portion. The base and resilient arms define a generally rectangular or arcuate channel for receiving the flexible line. Preferably each arm includes an extension extending inwardly from upper distal ends of the arms for retaining the flexible line within the channel. The base portion may also have a planar outer surface for mounting to an inner doorframe.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatical view of an automotive regulator assembly of the present invention retaining a flexible line member;
FIG. 2 is a perspective view of the top portion of the automotive regulator assembly of the present invention in partial section, showing an extruded guide retaining a cable embodiment of the flexible line member;
FIG. 3 is a cross-sectional view of the extruded guide of the resent invention retaining the cable;
FIG. 4 is a cross-sectional view of an alternative embodiment of the extruded guide of the present invention retaining the cable; and
FIG. 5 is a cross-sectional view of another alternative embodiment of the extruded guide of the present invention, retaining a tape embodiment of the flexible line member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, an automotive regulator assembly of the present invention is shown generally at 10. Regulator assembly 10 is mounted to an inner doorframe (not shown) of an automotive vehicle, and comprises a drive assembly 12, a flexible line member 14, a pair of extruded guides 16, arcuate mounting supports 18, and a plurality of mounting tabs 24 and 30. Flexible line member 14 is routed within the pair of extruded guides 16, which are located at opposing ends of regulator assembly 10. Extruded guides 16 radially adjust to fit the required radius R formed by supports 18.
Mounting supports 18 form generally an arch upon which extruded guides 16 rest. Supports 18 have an L-shaped cross section; whereby a vertical leg 20 of the support mounts to the inner door frame, and a horizontal leg 22 of the support extends outwardly from the door frame to provide a support for guide 16. Each guide 16 is supported at each end by a pair of L-shaped tabs 24. Tabs 24 are mounted edgewise against the inner door frame. Tab 24 has a horizontal leg 26 which provides support for each distal end of each guide 16, and a vertical leg 28 which restrains the ends of guide 16 against support 18 in its assembled position. Each guide 16 is further supported at its apex by L-shape tab 30. Tab 30 has a vertical leg 32 mounted to the inner door frame, and a horizontal leg 34 extending outwardly from the inner door frame that restrains the guide 16 against support 18 in its assembled position.
Extruded guides 16 are comprised of materials, e.g., acetal copolymer, formulated nylon, polymer material, and metallic material that are wear resistant and have a low coefficient of friction to allow for slideable movement of line member 14 during operation of regulator assembly 10. Extruded guides 16 can be manufactured substantially straight or with a preformed radius 16A (shown in phantom form) to facilitate radial adjustment to radius R of mounting support 18 during assembly.
Flexible line member 14 can be embodied as a cable 35 having a circular cross-sectional profile as shown in FIG. 2. Alternatively, flexible line member 14 can be embodied as a tape 60 having a rectangular cross-sectional profile as shown in FIG. 5.
Referring to FIG. 3, a cross-sectional view of an exemplary embodiment of the present invention is shown taken along the line 3, 4, 5 in FIG. 1, wherein flexible line member 14 comprises a cable 35 having a circular cross-sectional profile. In this embodiment, drive assembly 12 comprises a cable drive assembly having a winding device, e.g., a take-up drum or a cylindrical roller, which is attached to the cable 35, i.e., the cable embodiment of flexible line member 14. The cable drive assembly reversibly rotates the winding device to shorten or increase a free length of the flexible cable to raise or lower the window respectively.
In this exemplary embodiment of the present invention, extruded guides 16 have a tubular shape with a circular channel centrally disposed within. Channel 38 has a sufficient diameter to slidably capture cable 35, i.e., cable 35 is retained within channel 38 regardless of the orientation of the guide 16 and is permitted to freely slide through the channel 38 during operation of regulator assembly 10.
Guide 16 is shown in FIG. 3 mounted between arcuate support 18 and tab 30, wherein support 18 and tab 30 provide support for guide 16 during operation as discussed previously.
Referring to FIG. 4, a cross-sectional view of another exemplary embodiment of the present invention is shown taken along the line 3, 4, 5 in FIG. 1. In this embodiment, extruded guide 40, having a generally "U" shaped cross-sectional profile, comprises a base 42, and a pair of resilient arms 44 extending upwardly therefrom. Base 42 has a flat outer surface 48 and an arcuate inner surface 50. Outer surface 48 rests against horizontal leg 22 of support 18 to prevent guide 40 from rotating during operation and possibly dislodging cable 35. Resilient arms 44 extend upwardly and substantially perpendicular from opposing distal ends of base 42. Inner surfaces 54 of arms 44 and inner surface 50 of base 42 define a generally "U" shaped channel 56. Channel 56 has a sufficient radius to retain cable 35 and permit the cable to freely slide through the guide 40 during operation. Resilient arms 44 have extensions 46, which extend inwardly from upper distal ends of arms 44 to form a gap 58 therebetween. The gap 58 has a width that is less than the diameter of cable 35. Cable 35 initially engages tapered outer surfaces of extensions 46 as it is inserted into channel 56 or is snapped into channel 56. Resilient arms 44 are urged outwardly by cable 35 until cable 35 passes through gap 58 with resilient arms 44 snapping back to their original position to slidably capture cable 35 within channel 56. That is, cable 35 is retained within channel 56 regardless of the orientation of the guide 40 and is permitted to freely slide through the channel 56 during operation of regulator assembly 10.
Guide 40 is shown in FIG. 4 mounted between arcuate support 18 and tab 30, wherein support 18 and tab 30 provide support for guide 40 during operation as discussed previously. Additionally, horizontal leg 34 of tab 30 covers gap 58 to provide a barrier to further prevent cable 35 from dislodging during operation.
Referring to FIG. 5, a cross-sectional view of an alternate exemplary embodiment of the present invention is shown taken along the line 3, 4, 5 in FIG. 1, wherein flexible line member 14 comprises a plastic tape 60 having a generally rectangular cross-sectional profile. In this embodiment drive assembly 12 comprises a tape drive assembly having teeth for engaging perforations of the plastic tape 60, i.e., the tape embodiment of flexible line member 14. The tape drive pushes or pulls the tape to slide an attached window (not shown) up or down respectively.
In accordance with this embodiment, cable guides 62, having a generally U shaped cross-sectional profile, comprises a rectangular shaped base 64, and a pair of resilient arms 66 extending upwardly therefrom. Base 64 has a flat outer surface 70 and a flat inner surface 72. Outer surface 70 rests against horizontal leg 22 of support 18 to prevent guide 62 from rotating during operation and possibly dislodging tape 60. Resilient arms 66 extend upwardly and substantially perpendicular from opposing distal ends of rectangular base 64. Inner surfaces 76 of arms 66 and inner surface 72 of base 64 define a generally rectangular channel 78 therein. Channel 78 has a sufficient width to retain tape 60 and permit the tape to freely slide through the guide 62 during operation. Resilient arms 66 have extensions 68, which extend inwardly from upper distal ends of arms 66 to form a gap 80 therebetween. Gap 80 has a width that is less than the width of tape 60. Tape 60 initially engages tapered outer surfaces of extensions 68 as it is inserted into channel 78 or is snapped into channel 78. Resilient arms 66 are urged outwardly by tape 60 to pass until tape 60 passes through gap 80 with resilient arms 66 snapping back to their original position to slidably capture tape 60 within channel 78. That is, tape 60 is retained within channel 78 regardless of the orientation of the guide 62 and is permitted to freely slide through the channel 78 during operation of regulator assembly 10.
Guide 62 is shown in FIG. 5 mounted between arcuate support 18 and tab 30, wherein support 18 and tab 30 provide support for guide 62 during operation as discussed previously. Additionally horizontal leg 34 of tab 30 covers gap 80 to provide a barrier to further prevent tape 60 from dislodging during operation.
The extruded guide 16 of the present invention has a shape, which slidably captures the cable 35 or tape 60 within its associated channel 38, 56 or 78 before and after assembly. This feature advantageously allows guide 16 to be pre-assembled to cable 35 or tape 60 to form a subassembly of regulator assembly 10. Additionally the extruded guide 16 is flexible whereby it can be adjusted to fit a plurality of radii, e.g., formed from different embodiments of support 18, of regulator assembly 10. While exemplary embodiments apply to window regulator assemblies, one skilled in the art would recognize that the invention can apply to other applications as well, e.g., sliding doors, sun roofs, lift gates and garage door openers.
It will be understood that a person skilled in the art may make modifications to the preferred embodiment shown herein within the scope and intent of the claims. While the present invention has been described as carried out in a specific embodiment thereof, it is not intended to be limited thereby, but is intended to cover the invention broadly within the scope and spirit of the claims. | A radially adjustable guide for a flexible line, a cable or tape, of an automotive regulator assembly is presented. The guide has a longitudinal channel disposed therein for receiving and guiding the flexible line, wherein the guide slidably captures the flexible line within the channel. The guide may be tubular. Alternatively, the guide may include a base portion; a pair of resilient arms extending upwardly from the base portion, defining the channel; and extensions extending inwardly from upper ends of the resilient arms for slidably capturing the flexible line in the channel. Additionally, the base portion of the guide may include a planar outer surface. |
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FIELD OF THE INVENTION
The present invention relates to the field of air treatment devices, and particularly to devices for eradicating objectionable odors from toilet bowls and the like.
BACKGROUND OF THE INVENTION
Until the early 1800's, Europeans and Americans alike relieved themselves in chamber pots, outhouses and alleyways. Eventually, however, indoor plumbing became the standard. In America, the first city with modern waterworks was Philadelphia in 1820; the first city with a modem sewage system was Boston in 1823; and, the first toilet installed in the White House was in 1825 for John Quincy Adams.
A major contributor to the advancement of indoor toilet technology was an Englishman named Thomas Crapper. Through his plumbing fixture company, T. Crapper & Co, Chelsea, London, founded 1861, Mr. Crapper produced many improvements in the fixtures he manufactured. Crapper's name was stenciled on all the cisterns--and later, toilets--that he manufactured. It is likely because of his contributions that he is often accredited with the invention of the toilet. However, it was another Englishman named Alexander Cumming who in 1775 made perhaps the most significant improvement to the indoor toilet. While toilets to that day had emptied directly into a pipe which carried the waste to a cesspool, Cumming improved the device by adding a "stink trap" that kept water in the pipe, thus blocking the backflow of sewage gases. Absent the constant foul-smelling stench of sewer gases wafting through pipes and up into the house, the indoor toilet became an acceptable, and welcomed improvement.
While Cumming's invention addressed foul smelling gases downstream of the stink trap, treating objectionable odors developed in the toilet bowl itself has proven to be a formidable challenge. Many methods have been employed for treating and/or eliminating such odors, such as opening a window, lighting a match, spraying an aerosol deodorizer, and using a range of powered devices. The most common of such devices, the ceiling fan, is often difficult to install, requires ducting to the outside or attic, and has a flow rate that is generally too low to evacuate the odors as fast as most users would like.
One line of development for bathroom odor treatment devices encompasses devices mounted proximal to the toilet bowl and activated to draw the objectionable gases into a chamber, treat them and then exhaust them back to the bathroom area. A number of these and similar devices are disclosed in the following U.S. Patents:
______________________________________U.S. Pat. No. Inventor______________________________________5,727,262 Littlejohn5,555,572 Hunnicutt, Jr.5,519,897 DeSimone5,488,741 Hunnicutt, Jr.%,416,930 Waldner, et al.5,403,548 Aibe, et al.5,240,653 Ramkissoon5,161,262 Quaintance, Sr.4,876,748 Chun4,748,698 Kao4,472,841 Faulkner4,317,242 Stamper4,099,047 Kirkland, Jr.3,857,119 Hunnicutt, Jr.2,846,696 J.R. Herriott______________________________________
While devices disclosed in these patents exhibit a variety of beneficial features for treating and/or evacuating foul odors from a bathroom facility, they also suffer from a variety of drawbacks. For example, the devices disclosed in U.S. Pat. Nos. 4,876,748 and 5,727,262 are quite large and unsightly. Other of these patents describe devices that appear to draw the malodorous gases through some type of filter (U.S. Pat. Nos. 4,317,242, 5,488,741 and 5,555,572) or that draw the gases over a heating device before expelling them back into the air (U.S. Pat. Nos. 4,099,047 and 5,519,897). Further, many of such devices are fairly complex and therefore costly. It is believed that none of these devices achieves an acceptable balance among low consumer cost, ease of use, ease of maintenance, and most importantly, speed and effectiveness of use.
SUMMARY OF THE INVENTION
Generally speaking, there is provided an apparatus for treating and eradicating objectionable odors from toilet bowls and the like. The device is small, easy to use and maintain, and operates in a fast and efficient manner. Moreover, it may be used with a variety of commercially available products to treat and replace the objectionable odors with a wide range of pleasant aromas.
An apparatus for treating objectionable odors from a toilet bowl, where the toilet bowl includes a seat positioned above the toilet bowl, comprising a main body having an inlet opening, an outlet opening and a scent delivery chamber; means for mounting the main body proximal to the toilet bowl with the inlet opening positioned substantially between the bowl and the seat; a drawer removably securable to the main body; fan means for drawing gas in the inlet opening, through the scent delivery chamber and out the outlet opening; a power source; switch means wired with the fan means and the power means and engagable with the toilet seat to electrically connect the power source to the fan means upon downward pressure being applied to the toilet seat relative to the toilet bowl; scent delivery means positioned within the scent delivery chamber for releasing a scent at least when the fan means is drawing gas through the scent delivery chamber; and, wherein the drawer includes a closed condition securing the scent delivery means within the scent delivery chamber, and an open condition exposing and enabling removal of the scent delivery means.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus 10 for treating objectionable odors in toilet bowls and the like in accordance with the preferred embodiment of the present invention, apparatus 10 shown mounted to a standard toilet 11.
FIG. 2 is a front and side, perspective view of the apparatus 10 of FIG. 1.
FIG. 3 is a rear and side, perspective view of the apparatus 10 of FIG. 1.
FIG. 4 is a side view of the apparatus 10 of FIG. 1.
FIG. 5 is a top view of the apparatus 10 of FIG. 1.
FIG. 6 is a side view of the apparatus 10 of FIG. 1
FIG. 7 is a rear view of the apparatus 10 of FIG. 1.
FIG. 8 is a front view of the apparatus 10 of FIG. 1.
FIG. 9 is a bottom view of the apparatus 10 of FIG. 1.
FIG. 10 is a side, cross-sectional view of the apparatus 10 of FIG. 5 taken along the lines 10--10 and viewed in the direction of the arrows, and with drawer 16 in the removed condition.
FIG. 11 is a side, elevational view of a sponge tree 17 of FIG. 10 and of a sponge 97 partially applied to sponge tree 17.
FIG. 12 is a side, cross sectional view of drawer 16 of FIG. 10 and of sponge tree 17 and sponge 97 partially mounted to drawer 16.
FIG. 13 is a perspective view of drawer 16 of FIG. 10.
FIG. 14 is a perspective view of sponge tree 17 of FIG. 11.
FIG. 15 is a cross-sectional view of the sponge tree 17 and sponge 97 of FIG. 11 taken along the lines 15--15 and viewed in the direction of the arrows.
FIG. 16 is a top plan view of apparatus 10 of FIG. 1 and of mounting bracket 14.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments 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 any alterations or modifications in the illustrated device, and any further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring to FIG. 1, there is shown an apparatus 10 for treating and eradicating objectionable odors from toilet bowls and the like in accordance with the preferred embodiment of the present invention. Apparatus 10 is shown in use mounted to a standard toilet 11 by a mounting arm 14 to draw gases from within the toilet bowl 12, between the toilet bowl 12 and its seat 13, and to treat such gases, as described herein.
Referring to FIGS. 2-10, and with particular reference to FIG. 10, apparatus 10 is shown from a variety of angles and generally includes a main body 15, a drawer 16, a sponge tree 17 and a fan 18. Drawer 16 is configured to slide laterally from a closed condition (FIGS. 2-9) out and away from body 15 to an open or removed condition (FIG. 10). Body 15 is integrally molded into two mating body halves 19 and 20 that are mirror images of each other. Each half 19 includes structures 21 which defines holes that align with corresponding holes in the mating other half 20 when the two halves 19 and 20 are brought together. Pins 22 extend from within the holes of one half 19 and into the corresponding, aligned holes of the other half 20 to fix halves 19 and 20 in the desired mutual alignment to form main body 15, substantially as shown in FIGS. 2-9. Similarly, mutually aligned structures 23 in both halves 19 and 20 receive an appropriate securing member such as a nut and bolt combination 24 to fix the halves 19 and 20 together. Although the present embodiment describes main body 15 comprising two mirrored halves, the present invention contemplates manufacturing main body in a variety of different ways including, but not limited to, a unibody construction or two or more parts connected with each other in any appropriate manner, so long as the resulting structure includes the primary elements described herein. As halves 19 and 20 of the present embodiment are mirror images of each other, the following description may be made with reference to only body half 19, it being understood to apply equally to body half 20, unless otherwise stated.
Main body 15 includes an upper inlet spout 26, a battery shelf 27, a filter shelf 28, a drawer compartment shelf 29, opposing front and back fan support ledges 30 and 31, respectively, bottom wall 32, front wall 33, opposing side walls 34 and 35, and rear wall 36. Upper inlet spout 26 extends forwardly from front wall 33, and itself has top and bottom walls 39 and 40 that define a generally low profile inlet spout that diverges as it extends forwardly from front wall 33 to its wide and low-profile opening 42. Apparatus 10 is to be positioned at toilet bowl 12 with the widening, low profile spout structure positioned at or between the top 41 of bowl 12 and the corresponding toilet seat 13. The widened inlet opening 42 facilitates an unrestricted draw of gases from bowl 12.
An electrical switch 44 is mounted by appropriate means such as screws (not shown) to body 15. A spring metal activation arm 45 extends from switch 44, through spout 26, out opening 42, and forwardly of spout 26. With apparatus 10 in its inactivated and rest condition (as shown in FIG. 10), a hump 46 defined at the forward end of activation arm 45 extends a predetermined amount above top wall 39, as shown. As discussed herein, when weight is applied to seat 13, seat 13 will move downwardly slightly, toward toilet bowl 12, just enough to depress activation arm 45 at hump 46, which action will pivot arm 45 at switch 44 to activate switch 44. Battery shelf 27 is sized to receive a battery 48 thereon. Extending rearwardly of battery shelf 27 and at the lateral center thereof is a shaped, vertically extending flange 50 which defines a hole 51 therein.
Filter shelf 28 is juxtaposed a sufficient distance below battery shelf 27, flange 50 and switch 44 to receive a filter 54 thereon. Filter 54 has a wafer shape and is made of any appropriate material that removes odiferous particulates from a gas that flows through such material. In one embodiment, filter 54 is made of a charcoal-based, fibrous material. Filter 54 may be positioned, and thus changed from time to time, simply by sliding it in and onto shelf 28 from the rear of main body 15 when drawer 16 is removed from main body 15 (FIG. 10). Filter shelf 28 is not a solid sheet, but rather defines one or more openings 55 therein to minimize any restriction to fluid flow therethrough. The number and size of such openings 55 may vary as desired, but it is desired to minimize obstruction to fluid flow from one side of filter shelf 28 to the other, and it is therefore desired to maximize the total lateral area of openings 55 while simultaneously providing a stable platform for supporting filter 54. Likewise, drawer compartment shelf 29 defines one or more openings 56 therein to permit unrestricted fluid flow from one side of shelf 29 to the other, and its is similarly desired to minimize obstruction to such fluid flow, and therefore desired to maximize the total lateral area of openings 56. Drawer compartment shelf 29 contributes to the support of drawer 16 and, together with filter shelf 28, front wall 33, side walls 34 and 35, and drawer 16, defines sponge chamber 59.
Extending inwardly from front and rear walls 33 and 36 are fan support ledges 30 and 31, respectively. A fan 18 is supported upon ledges 30 and 31 within fan chamber 62, fan chamber 62 being defined by drawer compartment shelf 29, bottom wall 32, and front, side and rear walls 33-36. A series of vent slots 61 are defined in bottom wall 32 and extend slightly upward along side walls 34 and 35. Fan 18 is any appropriate fan unit which preferably provides a high fluid flow rate is efficiently powered by battery 48, and is relatively quiet. Fan 18 has an upwardly disposed flow inlet to communicate with the openings 56 in drawer compartment shelf 29 and has a downwardly disposed flow exhaust to communicate with vent slots 61. In the present embodiment, fan 18 is positioned upon ledges 30 and 31 of one body half 19 and is secured within fan chamber 62 upon securing body halves 19 and 20 together. In the assembled condition, with body halves 19 and 20 secured together, battery shelf 27, filter shelf 28, drawer compartment shelf 29 and ledges 30 and 31 extend all the way across main body 15, side wall 34 to side wall 35. An arcuate projection 64 juts inwardly from side wall 34 a similar projection (not shown) juts inwardly from mating side wall 35. Projection 64 is sized to register with a complementary shaped recess in drawer 16.
A thumb switch 65 slides within a slot 66 defined in spout 26 between a forward "on" position (shown in phantom at 69) and a rearward "off" position 70. A downwardly projecting lug 71, extending downwardly from switch 65, moves in and out of engagement with activation arm 45 when thumb switch 65 is moved between the on and off positions. That is, when switch 65 is slid forward to the on position 69, projection 71 engages and pushes arm 45 downwardly at a point close to the connection of arm 45 to switch 44. Further pivoting of arm 45, as by weight being applied to seat 13, will apply sufficient additional torque to arm 45 to close switch 44. Conversely, sliding switch 65 to the off position releases the downward bias to arm 45 at switch 44 which disengages switch 44. That is, because activation arm 45 is made of spring metal or a similar material which allows it to bend somewhat over its length, pivoting of activation arm 45 by applying downward pressure to hump 46 will not transmit sufficient torque through arm 45 to switch 44 to close switch 44 and turn on fan 18 when thumb switch 65 is in the off position. The present invention contemplates the use of any appropriate switch arrangement where a switch may be closed by the slight movement of a member like activation arm 45, but where closure of the switch may be overridden by another switch such as thumb switch 65. Wires 65 extend among switch 44, battery 48 and fan 18 to complete the circuit and power fan 18 when switch 44 is closed.
An alternative embodiment is contemplated wherein thumb switch 65 acts to turn on fan 18 even where there is no input from activation arm 45. That is, when switch 65 is in the "off" position, activation arm 45 may operate as described to engage switch 44 and activate fan 18. However, where a child or very lightweight person is too light, perhaps, to activate arm 45, in view of the composition of seat 13 when sitting on seat 13, thumb switch 65 may be slid to the "on" position to activate switch 44 and turn on fan 18. Another embodiment is contemplated wherein thumb switch 65 may be connected with switch 44 and/or arm 45 to move from an "off" position, completely disabling fan 18, an "on" position, turning on fan 18 and overriding activation arm 45, and an intermediate or "seat" position whereby activation arm 45 is operable through switch 44, to activate fan 18 between on and off positions.
Referring now to FIGS. 2-15, and particularly to FIGS. 2, 3 and 10-15, drawer 16 includes rear wall 75, opposing side walls 76 and 77 and sponge shelf 78. The forwardly facing edge 80 of drawer 16 has a contour that is complementary with the rearwardly facing edge 81 of main body 15, and the lower edge 82 of rear wall 75 has a contour that is complementary with upper edge 83 of rear wall 36 of main body 15. Drawer 16 may therefore be slidingly received by main body 15 from the open or removed condition (FIG. 10) to the closed condition (FIGS. 2-9), whereby edges 80 and 81 and edges 82 and 83 come into complete abutting alignment and sponge shelf 78 slides along and atop drawer compartment shelf 29.
Sponge tree 17 has the configuration as generally shown in FIG. 14 with an upper retaining wall 86 and a central post 87 depending downwardly from the center thereof. Retaining wall 86 comprises a central spine 88 and a series of spaced apart legs 89 extending outwardly therefrom. Spine 88 and legs 89 together define both an upper retaining wall for a sponge and a compression platform that may be used to assist in rinsing out such sponge, as will be described herein. Spine 88 and legs 89 have a generally circular cross section in plan view which is approximately equal to or slightly smaller than the dimensions of filter shelf 28 so that retaining wall 86 will fit within sponge chamber 59 just below filter shelf 28. Spine 88 and outwardly extending legs 89 define a series of gaps 90 therebetween which permits fluid flow therethrough. As with filter shelf 28 and drawer compartment shelf 29, spine 88 and legs 89 are configured to maximize the fluid flow rate through gaps 90 while still providing sufficient strength to withstand a downwardly applied compression force for assembling apparatus 10 and changing or cleaning the corresponding sponge.
Central post 87 has a generally flat, rectangular configuration in cross-section with arcuate longitudinal humps 91 and 92 extending outwardly from opposing sides of post 87 and all along the length of post 87, from upper retaining wall 86 and down to the base 93 of post 87, except for a small gap 95 where humps 91 and 92 are absent. That is the absence of a section of each hump 91 and 92 on opposing sides of post 87 defines one gap of 95 at the lower section of each hump 91 and 92. The gaps 95 are located the same distance up from base 93. Base 93 has a generally circular cross section with a diameter that is approximately equal to the width of central post 87. Arcuate, longitudinal humps 91 and 92 are together generally circular in cross-section. They may have other cross-sectional shapes, whereby the shape of the corresponding combined enlarged opening (at 109 and 110 in slot 106 as described herein) will be complementary.
A sponge 97 (FIGS. 11, 12 and 15) has a generally circular cross section in plan view with a diameter that is approximately equal to the diametrical dimensions of upper retaining wall 86. Sponge 97 has a height which is approximately equal to or slightly less than the height of central post 87. Sponge 97 defines a central hole 98, the diameter of which is preferably slightly less than the width of central post 87. Sponges are available in a wide variety of configurations, construction and degrees of porosity. Typically, the more porous the sponge, the lower its capacity to retain fluids. Although because of its inherent porosity, sponges will typically permit fluid flow, and specifically gas flow therethrough, sponge 97 is provided with a plurality of additional recesses 99 and holes 100 along its height to enhance fluid flow from its top surface 101 to its bottom surface 102. These recesses 99 and holes 100 may be defined in sponge 97 in a variety of ways including, but not limited to mechanical and chemical means. Likewise, sponge 97 may be selected from a class of sponges that inherently have a high number of both large and small openings which will facilitate a high rate of fluid flow and a sufficiently high degree of material surface area. A high degree of surface area is desirable to enable sponge 97 to be impregnated with substances having particular aromas.
Referring to FIGS. 12 and 13, sponge shelf 78 includes a raised central, and laterally extending platform. Platform 105 defines a slot 106 which originates somewhat rearwardly of the center of sponge shelf 78 and extends therefrom along a longitudinal axis 107 to the forward edge 108 of shelf 78. At the center of sponge shelf 78, slot 106 has a shape that is substantially identical to the cross sectional shape of central post 87 as is viewed in FIG. 15. That is, slot 106, at the center of shelf 78, bulges outwardly, in opposing directions, at 109 and 110, to define a central, enlarged opening 104. From enlarged opening 104, slot 106 extends a short distance rearwardly at and diverges as it extends toward forward edge 108. Also, platform 105 is raised slightly above the level of the rest of sponge shelf 78, thereby creating a generally rectangular shaped, lateral slot at 112 the width 113 of such slot 112 is approximately equal to or slightly greater thanthe diameter of base 93 of sponge tree 17. As with filter shelf 28, drawer compartment 29 and upper retaining wall 86, sponge shelf 78 is provided with openings 114 to permit fluid flow therethrough, the total area defined by such openings being maximized to minimizing any restriction to such fluid flow.
Sponge shelf 78 further defines a pair of inwardly extending recesses 115 on opposing sides thereof and slightly rearwardly of forward edge 108. Recesses 115 are sized and positioned to register with the mating projections 64 in main body 15. Thus, when drawer 16 is moved into its closed condition (FIGS. 2-9), sponge shelf 78 snaps into registry with projections 64 at recesses 115. Such registration between recesses 115 and projections 64 firmly holds drawer 16 in the closed position relative to main body 15.
If desired, drawer 16 may be more firmly secured to main body 16, and even locked thereto to prevent unauthorized opening of drawer 16. This is accomplished by registration between flange 50 and a complementary shaped and positioned slot 116 (FIG. 13) defined in the upper portion of rear wall 75 of drawer 16. Further, drawer 16 defines a pair of curved and generally laterally extending recesses 118 and 119 and defines a bridge 120 that follows the overall contour of rear wall 75, separates recesses 118 and 119 and is in substantial planar alignment with slot 116. When drawer 16 is moved to its closed condition, flange 50 extends through slot 116, between recesses 118 and 119 and up against the forwardly facing, underside of bridge 120. Hole 51 is exposed by virtue of recesses 118 and 119, and an appropriate locking member such as a padlock may be positioned through hole 51 and around bridge 120, thus preventing the removal of drawer 16 from main body 15.
Indentations 123 are provided on opposing sides of drawer 16 to facilitate the movement of drawer 16 relative to main body 15.
In use, sponge 97, is provided either pre-scented at purchase or may be conditioned by applying a desired scent with a commercial product such as an aerosol or pump-spray, auto or room air freshener. Sponge 97 is then applied to sponge tree 17 (FIG. 11) by inserting central post 87 through central hole 98 until the top surface 101 of the sponge 97 rests against the underside of upper retaining wall 86. Sponge 97 is then manually compressed (shown at 123 in FIG. 12) up against upper retaining wall 86, as shown in FIG. 12, so that gaps 95 in humps 91 and 92 are exposed. Sponge and sponge tree combination 97/17 is then mounted to drawer 16 by sliding central post 87 through slot 106 whereby the opposing edges 121 of slot 106 are aligned within gaps 95. When sponge and sponge tree combination 97/17 reaches the center of sponge shelf 78, and arcuate humps 91 and 92 are vertically aligned with enlarged opening 104, sponge 97 may be released from its compressed position 123, which action causes the bottom surface 102 of sponge 97 to press against sponge shelf 78. Because humps 91 and 92 are aligned with complementary shaped, enlarged opening 104, sponge tree 17 may rise relative to platform 105 until base 93 engages the underside of platform 105 and within lateral slot 112. In this configuration, the lowermost portions of are nested within complementary shaped enlarged opening 104, and sponge tree 17 may be slid vertically through opening 104 and relative to platform 105. However, because the combined lateral dimension of humps 91 and 92 is greater than the width of slot 106 adjacent to enlarged opening, sponge tree 17 is constrained from moving laterally. To remove sponge tree 17, it must be moved vertically until gaps 95 align with the edges 121 of slot 106, and then sponge tree 17 may be slid forwardly out of slot 106. With this configuration, sponge tree 17 and sponge 97 are firmly mounted within drawer 16. With an appropriate filter 54 positioned atop filter shelf 28, the drawer can now be joined with main body 15, as described herein, until edges 80 and 81 and edges 92 and 93 mate, and whereby sponge 97 will be securely positioned within sponge chamber 59, below filter shelf 28 and above drawer compartment shelf 29. Apparatus 10 is now ready for operation. Upon activation of fan 18, gases are drawn in through opening 42, through filter 54, through scented sponge 79, through fan 18, and out through vent slots 61, the ejected gases now devoid of some or much of the original objectionable odors and having a desired aroma picked up from the treated sponge 97.
The sponge tree and sponge combination 17/97 also cooperates with drawer 16 to facilitate rinsing or cleaning of the sponge and related components. Upon removal of drawer 16, and without removing sponge tree 17 from drawer 16, the drawer, sponge tree, and sponge combination 16/17/97 may be positioned appropriately under a stream of water or in a container with cleaning solution or water and appropriately cleaned or rinsed. Upon removal from such water or cleaning solution, the user may compress upper retaining wall 86 toward sponge shelf 78, whereby post 87 slides through complementary shaped slot 106 and enlarged opening 104, and sponge 97 is compressed therebetween, which action squeezes the majority of fluid from sponge 97. This procedure may be repeated as many times as necessary to clean and/or rinse sponge 97. This configuration thereby generally permits the user to clean and/or rinse sponge 97 without requiring sponge 97 to be removed from sponge tree 17 and drawer 16, and further minimizing the amount of direct contact between the users hands and sponge 97. This procedure further permits the sponge to be cleaned and/or rinsed and then for a different fragrance to be applied to sponge 97. If desired, sponge 97 may be replaced with a new sponge simply by reversing the steps for installing the sponge.
Referring not to FIGS. 1 and 16, there is shown a support arm 14 suitable for mounting apparatus 10 to a standard toilet bowl 12. Apparatus 14 includes at one end an inboard mounting section 130 and extends through a pair of bends to an outboard mounting section 131 at the opposite end. Inboard mounting section 130 is provided with an elongate slot 133 that is sized to receive a standard toilet seat mounting bolt 134. An L-shaped bracket 135 depends down from the bottom of upper inlet spout 26 (FIGS. 8-10) and over to front wall 33 to create, in conjunction with the underside of spout 26, an opening 137 sized to receive outboard mounting section 131 of support arm 14 therethrough. Support arm 14 is connected to toilet bowl 12 simply by removing one of the toilet seat mounting bolts 134 (and its corresponding wing nut or similar structure (not shown)) from its connection to toilet bowl 12, positioning support arm 14 atop toilet bowl 12, between toilet seat 13 and tank 136 substantially as shown in FIG. 1, and with slot 133 in alignment over the toilet seat mounting hole (not shown) of toilet bowl 12, and then extending toilet seat mounting bolt 134 through slot 133 and back through the toilet seat mounting hole. Bolt 134 is secured thereto with the corresponding wing nut (not shown). Apparatus 10 is then moved into position whereby outboard mounting section 131 extends through the opening 137 of L-shaped bracket 135. A set screw 140 extends up through bracket 135 to tighten against outboard mounting section 131, thereby firmly securing apparatus 10 to support arm 14.
Because toilets come in a variety of sizes and shapes, the slot 133 in support arm 14 allows support arm 14 to be adjusted to a variety of positions, and apparatus 10 may be slid along outboard mounting section 131, until apparatus 10 is in the desired position relative to bowl 12. Such desired position is substantially shown in FIG. 10 where inlet opening 42 is just above and to the outside of the top surface 41 of bowl 12. Because support arm 14 has a thickness and will raise one side of toilet seat 13 relative to bowl 12 when apparatus 10 is applied thereto, a washer (not shown) made of the same material as support arm 14 and having the same relative thickness as support arm 14 is contemplated for insertion between toilet bowl 12 and the other toilet seat mounting bolt (not shown) to raise that side to level. While standard toilet seats generally have cushion members (not shown) that are mounted to the underside of seat 13 to cushion the contact between seat 13 and bowl 12 when seat 13 is lowered, application of apparatus 10 to bowl 12 will still raise the rear of seat 13 from an otherwise level conditioned, and seat 13 will tilt forward. The present invention contemplates inclusion of replacement cushion members (not shown) to replace the standard cushion members, the replacement cushion members having a thickness that is sufficiently greater than the original cushion members to level out seat 13.
Support arm 14 and its companion washer, along with main body 15, drawer 16, sponge tree 17 and other components herein are made of any appropriate material such as plastic which can be easily cleaned by the user.
Alternative embodiments are contemplated wherein sponge 97 comprises other materials in other configurations, such other materials and configurations being capable of holding a scented material, or comprising a scented material, which can be released into a surrounding gaseous atmosphere. For example, such other materials and configurations include, but are not limited to, the wide variety of solid air fresheners currently available or to be available in the future. Thus, while the present embodiment describes the scent delivering apparatus as a sponge 97, such scent delivering apparatus is intending to include any material that releases a desired scent into the fan-induced air flow. Where sponge 97 is to be replaced by a solid air freshener, sponge tree 17 is removed from drawer 16 and the solid air freshener is placed directly atop sponge shelf 78. Alternative embodiments are contemplated wherein a solid air freshener is provided with a central tree similar to sponge tree 17 with an appropriate lower shape and configuration that mates with a complementary configuration in sponge shelf 78 to facilitate the insertion of such solid air freshener into drawer 16 without the user having to physically touch the air freshener material.
The present invention contemplates alternative means for mounting apparatus 10 proximal to toilet bowl 12. Support arm 14 is believed to be preferable since it is simple, cost-efficient, easy to use, and incorporates the structure of the standard toilet bowl. However, alternative structures are contemplated so long as inlet opening 42 is positioned as close to the gap between bowl 12 and seat 13 as possible to maximize the draw of gases from within bowl 12. That is, apparatus 10 will naturally draw gases from both inside bowl 12 and from the atmosphere outside of bowl 12 (unless the gap between bowl 12 and seat 13 is completely sealed off except for apparatus 10). The farther that apparatus 10 is positioned from bowl 12 and seat 13, the lower the percentage of toilet bowl gases that will be drawn through apparatus 10 and the less effective apparatus 10 will be. Support arm 14 permits a varied adjustment of the position of apparatus 10 relative to the bowl/seat gap, thereby enabling maximum effectiveness of apparatus 10.
Alternative embodiments are also contemplated wherein apparatus 10, having a generally flat bottom wall 32, may be used at locations other than the bathroom toilet merely by sitting apparatus 10 upon an appropriate surface.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrated 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. | An apparatus for treating objectionable odors from a toilet bowl, where the toilet bowl includes a seat positioned above the toilet bowl, comprises a main body having an inlet opening, an outlet opening and a scent delivery chamber; an apparatus for mounting the main body proximal to the toilet bowl with the inlet opening positioned substantially between the bowl and the seat; a drawer removabley securable to the main body; a fan for drawing gas in the inlet opening, through the scent delivery chamber and out the outlet opening; a power source; a switch for electrically connecting the power source to the fan; a scent delivery device positioned within the scent delivery chamber for releasing a scent at least when the fan is drawing gas through the scent delivery chamber; a tree sized and shaped to hold the scent delivery device within the scent delivery chamber; and, wherein the drawer includes a closed condition securing the scent delivery device within the scent delivery chamber, and an open condition exposing and enabling removal of the scent delivery device. |
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Cross-Reference to Related Applications
This application is a continuation-in-part of U.S. Ser. No. 769,223, filed on Aug. 26, 1985, now U.S. Pat. No. 4,664,191, and U.S. Ser. No. 917,324, filed on Oct. 9, 1986.
FIELD OF THE INVENTION
This invention relates to a method for gravel packing formations using a solidifiable blocking agent in combination with a gravel pack operation to minimize formation damage.
BACKGROUND OF THE INVENTION
Sand consolidation and gravel packing are two near wellbore techniques widely used for controlling the production of sand from producing wells such as oil wells, gas wells and similar boreholes. In many instances, highly porous and fragmentable sand formations surround a wellbore. Under production conditions, the sand is often displaced from its aggregated structure and carried along by the fluid flood operations to a producing well. If the sand flow is allowed to proceed unchecked, the producing wellbore soon becomes full of sand, thereby clogging the wellbore and impeding oil production. Furthermore, sand arriving at the surface site of the well erodes the production hardware.
As more and more sand is displaced from its original formation, a region of wash-out cavities surrounding the wellbore region results. As the wash-out zones become more extensive, the integrity of the wellbore is threatened and a danger of the wellbore collapsing exists.
It has therefore been the subject of extensive and intense research by the petroleum industry to develop techniques to minimize or obviate displacement of sand particles into producing well areas and prevent the formation of wash-out cavities surrounding the wellbore. One such general approach suggested by the art is to consolidate the coarse sand structures prior to fluid production. Sand consolidation techniques are aimed at cementing loose sand structures adjacent a wellbore. Such consolidation is effective to prevent breakdown of sand formation and subsequent clogging of producing wells.
In many loosely consolidated or unconsolidated formations, it is not economically or practically feasible to consider sand consolidation techniques. Also, there are many instances where substantial wash-out cavities are either initially present naturally near the wellbore or washed-out cavities form around the wellbore after prolonged use despite previous attempts at sand consolidation.
For these conditions, gravel packing techniques are often used to prevent formation sand production or further erosion and to reestablish the integrity of the wellbore periphery. Gravel packing is a secondary sand consolidation technique involving the introduction of a fluid suspension of exogenous particulate matter downhole, to fill the wash-out cavities or to "squeeze" to pack into the formation in the vicinity of the well. The term gravel is somewhat loosely applied in the art to encompass hard, rigid particulate matter ranging in size from a coarse sand to pebble size material.
Once the placement of sand and gravel has been accomplished, a slotted liner or "screen" placed as part of the production string helps hold the loose filling material and retard the upstream sand flow through the filler material during production conditions.
Present gravel pack procedures often require a filling of the casing with weighted completion fluid or drilling mud prior to perforating. Thereafter, the production casing is perforated via a casing gun with shots placed in a helical arrangement. Substantial amounts of wellbore fluid are often lost as in most instances the wellbore is in an overbalanced condition. If the well is not completely dead following the perforation operation, it is generally "killed" so the perforating tool can be pulled from the borehole. After pulling the perforating tool from the borehole, the production tubing along with a slotted liner is directed into the borehole. As a result of these operations, substantial amounts of expensive workover fluid can be lost during these operations. Because of the density, viscosity and chemical makeup of these workover fluids, damage often occurs to the permeability of a formation. Afterwards, in order to stabilize the sand in the formation, an in-casing gravel pack is generally placed within the wellbore along with additional fluids and chemicals. This results often in additional damage to the permeability of the formation. Preventing damage is made more difficult when the formation contains substantially high temperatures and salinities.
Therefore, what is needed is a gravel pack method which will minimize the permeability damage to the formation caused by workover fluids and chemicals under substantially high temperature and high salinity conditions.
SUMMARY OF THE INVENTION
This invention is directed to a method for minimizing formation damage during gravel pack operations in loosely consolidated formations penetrated by at least one well where substantially high temperatures and high salinity conditions are encountered. In the practice of this invention, the casing of said well is filled with an underbalanced completion fluid. Afterwards, a removable packer capable of isolating the space between said casing and which also separates the formation from the downhole well pressure is placed within said well. A first tubing suitable for perforating and stabilizing the flow of fluids into said well is set through said packer. To obtain fluid communication with the formation, said first tubing along with the casing is perforated.
In order to isolate the formation, a blocking agent is placed into said formation via said perforations. The blocking agent is then allowed to solidify while forming a solidified plug within the wellbore.
Subsequently, the first tubing and retrievable packer is removed from said well. After removing said first tubing from the well, a second tubing having a slotted portion therein which is sufficient to contact said perforation is placed within said well.
The solid plug formed by said blocking agent is removed from the wellbore by circulating fluid while running tubing into the well. Thereafter, a gravel pack is placed within said well around said slotted portion of said tubing and within said formation adjacent to said slotted portion of the pipe. Said blocking agent is caused to liquefy in a manner to flow from said formation into said well. The blocking agent comprises an aminoplast resin containing a methyol group and its alkylated varieties which are reactive with a polymer having at least one functional group selected from a member of the group consisting of an amine, an amide, a hydroxyl, or a thiol. Said methyol group and its alkylated varieties contained on said resin can condense to form a cured resin.
It is therefore an object of this invention to minimize formation damage using a temporary gel plug to isolate a formation wherein a gravel pack is utilized which plug is formed form economical aminoplast resins which co-gel and crosslink with substantially all polymers.
It is another object of this invention to provide a blocking agent which has a gelation reaction which can proceed under all pH conditions encountered in a hydrocarbonaceous reservoir when performing a gravel pack operation.
It is a yet further object of this invention to provide for a blocking agent which forms a substantially stable gel when high temperatures are encountered in a reservoir when performing a gravel pack operation.
It is a still yet further object of this invention to provide for a blocking agent formed by a gelation reaction which will proceed in a saline hydrocarbonaceous reservoir environment while performing a gravel pack operation.
It is a still further object of this invention to protect the integrity of a formation which is sensitive to fluid intrusion from chemicals and workover fluids.
It is a yet further object of the present invention to use a temporary gel plug in conjunction with a gravel pack operation in order to prevent sand fines from plugging the pores of a formation and pores near the wellbore where said gel plug is formed from a novel gel composition.
It is a still yet further object of this invention to increase the production of hydrocarbonaceous fluids from a hydrocarbonaceous fluid producing formation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the formation showing an invaded zone where workover and chemical fluids have entered the formation.
FIG. 2 is a schematic view of the formation showing an in-casing gravel pack and a gravel pack within the washed out portion of the formation or reservoir.
DESCRIPTION OF PREFERRED EMBODIMENTS
It is a purpose of this invention to provide a method for minimizing formation damage caused by the introduction of fluids into an unconsolidated formation or reservoir, particularly hydrocarbonaceous bearing ones. Formation damage is minimized by avoiding the introduction of fluids having high densities, high viscosities and fluid which contain high concentrations of solids. In some formations, these fluids may destroy the salinity balance and cause a dislodgement of fines which can lead to a plugging of the pores within the formation.
In the practice of this invention, as shown in FIG. 2, a well 4 has penetrated the subterranean formation 2. A cement sheath 8 surrounds casing 6. A packer 16 is run in on tubing and set in the well 4 to isolate that portion of the well penetrating the formation 2 from the portion of the well there above. Said tubing is filled with an underbalanced completion fluid. Afterwards, a "through tubing" perforating gun is used to perforate the casing. A reliable gun such as Schlumberger's 25/8 inch Enerjet can be used. A high pressure lubricator can also be used to allow perforating under pressure. Other methods of perforating the casing are discussed in U.S. Pat. No. 3,983,941 issued to Fitch on Oct. 5, 1976, and which is hereby incorporated by reference. The perforating gun is then removed from the tubing. If a lubricator has been used, the perforating gun can be removed through the lubricator. Afterwards, approximately 50 barrels of a fluid compatible with the formation such as KCl or NaCl brine, which is obtainable from various service companies is placed through the tubing. The purpose of this fluid is to condition the formation so as to be receptive to a chemical blocking agent.
Thereafter, a chemical blocking agent is introduced into the formation by said first tubing. The volume of said chemical blocking agent is determined based upon the extent of the perforated interval and the capacity of the formation area desired to be blocked. A chemical blocking agent which can be used is a novel gel. These gels are formed from polymers having functional groups such as NH 2 , --CONH 2 , --OH, and --SH. Said polymers can be gelled with methylated, MF resins. A melamine formaldehyde ("MF") resin which can be used is formed as a reaction product of melamine and formaldehyde. Said resin is known as an aminoplast or amino resin which comprises a class of thermo-setting resins made by the reaction of an amine with an aldehyde. The resultant resin is reacted with a crosslinkable polymer in an aqueous medium under all pH conditions and needs no catalyst. Said polymer has at least one functional group selected from a member of the group consisting of an amine, an amide, a hydroxyl, or a thiol group. This reaction can be carried out at ambient conditions, and also under conditions occurring in a subterranean hydrocarbonaceous formation.
These gels are novel in that they are unaffected by high saline concentrations often encountered in oil reservoirs. High temperatures encountered in said reservoirs do not adversely affect said gels. Carbonate, bicarbonate, and sulfate anions encountered in oil reservoirs which are known to affect certain metal crosslinked gels, but do not affect these novel gels. These novel gels can be formed under all pH conditions and are particularly useful in pH conditions of 10 or less. A method for making a kindred gel is discussed in U.S. Pat. No. 4,157,322 which issued to Colegrove on June 5, 1979. Unlike Colegrove, the instant gelation reaction is not catalyzed by a salt which is acid generating upon the application of heat. This patent is hereby incorporated by reference.
Gels utilized as chemical blocking agents herein can be made from various related materials. These materials will be discussed later.
If the formation is over-pressured, which means the reservoir pressure is greater than the hydrostatic pressure of water (0.433 psi/ft) standing in the wellbore, the volume of chemical blocking agent should be prepared from the high density brine. As is anticipated, a relatively small amount, usually less than about 50 barrels, of the liquefied chemical blocking agent is required to isolate the perforated interval and the washed out portion of the formation surrounding well 4 as shown in FIG. 2. After about 2 to about 4 hours, the chemical blocking agent sets up and solidifies. Subsequently, a high density brine of about 10 weight percent sodium chloride to about 28 weight percent sodium chloride is injected into said first tubing on top of the solidified chemical blocking agent. Placement of the high density brine solution on top of the solidified chemical blocking agent allows the first tubing or "work string" to be removed from the well 4. Upon solidification, the chemical blocking agent also protects the formation 2, as shown in FIG. 2, and the washed out area surrounding the wellbore 4, while forming a solidified plug within well 4.
Once said first tubing or "work string" has been removed from well 4, a production string having a slotted liner assembly 12 is placed into well 4 and penetrates the solidified chemical blocking agent. The slotted liner portion of production string 12 allows contact to be made through the perforations and into the washed out areas surrounding the wellbore for placement of a gravel pack. Thereafter, depending upon the composition of the solidified chemical blocking agent, said solidified blocking agent can be removed by either chemical or physical means.
In order to establish a gravel pack 10 as shown in FIG. 2, it is necessary to remove the solified chemical blocking agent as discussed above, either by chemical or mechanical means. Upon removal of the solidified chemical blocking agent from the well 4, a gravel pack placement operation can begin. Gravel packing methods are known to those skilled in the art. A preferred consolidatable gravel pack method is disclosed by Friedman in U.S. Pat. No. 4,428,427 which issued on Jan. 31, 1984 and which is hereby incorporated by reference. This gravel packing operation immediately follows the removal of the solidified chemical blocking agent from said washed out portion of the formation surrounding the well and also removal of said chemical blocking agent from the core of well 4. A preferred method for the removal of the solidified chemical blocking agent from the formation, the washed out area surrounding the well 4, and within the well is to have a gel composition which liquefies within a specified period of time. In this manner, the chemical blocking agent is allowed to flow from the formation 2 into wellbore 4. Gel compositions which are suitable for use in this preferred embodiment will be discussed later.
After removing the solidified blocking agent from the washed out portion of said formation and the wellbore, a gravel pack 10 is placed within the well 4 and the washed out portion of the formation surrounding the well 4. The gravel pack which is placed into the washed out area and in the well around the slotted portion of tubing 12 is sufficient to prevent fines migration from the formation into the well. Placement of said gravel pack consolidates the sand within the formation and allows fluid communication between the formation and said wellbore for the production of hydrocarbonaceous fluids.
FIG. 1 shows damage resultant from placement of a gravel pack without benefit of this invention. As shown in FIG. 1, the "invaded" zone 18 has resulted because of the placement or injection of consolidation fluids, workover fluids and chemicals ("intrusive fluids") which have penetrated the formation zone in a manner to cause a blocking of the pores within the formation. In the practice of the method disclosed above, and as is shown in FIG. 2, said "invaded" zone is reduced thereby minimizing damage to the formation by said fluids.
Chemical blocking agents which are preferred for utilization in the practice of the invention include solidifiable gel mixtures. Solidifiable gel mixtures which can work in the present invention are selected to withstand conditions encountered in the formation. As will be understood by those skilled in the art, the composition of the mixture can be varied to obtain the desired rigidity in the gel composition. The stability and rigidity of the selected gel will depend upon the physical and chemical characteristics of the gel which are dictated by conditions in the formation. As is known to those skilled in the art, the solidified gel should be generally of a stability and rigidity which will absorb the heat and pressures encountered in a formation. Generally, the pressures encountered in a formation will vary from about 1,000 psig to about 20,000 psig. Heat encountered in a formation will generally vary from about 60° to about 450° F.
Often, it will be necessary to increase the density of the pumpable solidifiable gel to obtain the desired stability and rigidity. To accomplish this, a solid non-reactant material can be added to the pumpable gel mixture. Calcium carbonate is a preferred non-reacting solid material.
A pumpable solidifiable gel which can be utilized herein is made from polymers having functional groups such as NH 2 , --CONH 2 , --OH, --SH can be gelled with methylated, MF resins. Some acceptable polymers include polyacrylamide, Kelco's S-130 biopolymer, acrylamide modified polyvinyl alcohol ("AMPVA"), Xanthan biopolymers, poly (acrylamide-co-acryl-amide-2-methyl-propanesulfonate) "AM-AMPS", "Phillips HE" polymers (a family of acrylamide containing copolymers), and polyvinyl alcohol. Polymers mentioned in U.S. Pat. No. 4,157,322, supra, may be utilized as long as those polymers contain the functional groups above mentioned. Polymer concentration in said gels range from about 0.1 to about 5.0 wt. percent. These polymer concentrations vary depending upon the molecular weight of polymer used. Lower molecular weight polymers require a higher polymer concentration to gel. A polymer concentration of about 0.2-5.0 wt. Percent is preferred. This crosslinking/co-gelation method produces high integrity polymer gels able to withstand high temperatures and high salinity conditions often found in subterranean hydrocarbonaceous formations.
Methylated MF derived as a reaction product of melamine and formaldehyde has a molar ratio of between 1-6. A ratio of 3-6 is commonly found in commercial resins. The methyol group, --CH 2 OH and its methylated varieties are reactive to various functional groups such as NH 2 , --CONH 2 , --OH, --SH and can also self-condense to form cured resins. Its preparation is convenient and well documented in preparative polymer manuals.
The melamine resin that is utilized in this invention can be a commercial product such as Cyanamid's Parez resins. Included among these melamine-formaldehyde (melamine) resins which are useful is this invention are the partially methylated resins and the hexamethoxymethyl resins (i.e. American Cyanamid's Parez, Cymel™373, Cymel 370, Cymel 303, and Cymel 380). The resin, however, has to be one that is soluble or dispersible in an aqueous medium. Other amino resins can also be used. Non-limiting examples are urea-formaldehyde, ethylene and propylene urea formaldehyde, triazone, uran, and glyoxal resins. The amount of MF resins required for adequate gel formation is in the ratio of 10:1-1:10 polymer to amino resins. Preferred polymer concentrations are from about 0.2 to about 5.0 wt. percent. Amino resins are preferred crosslinkers because they (1) are economical to use; (2) can be applied to a wide variety of polymers; (3) form thermally stable, brine tolerant gels; and (4) do not need an acid or base catalyst.
The gelation rate of the composition depends on the amount of each of the components and the temperature at which the reaction is conducted. Thus, one can tailor the gel rate and gel strength of the composition by adjusting the amount of the polymer, the resin amount and the temperature. The higher the temperature at given concentrations of resin and polymer will result in a faster gelation time. If a thicker gelled composition is desired, the polymer and resin concentrations may be increased for a given temperature.
Gels resultant from the gelation reaction were formed in about a 15 to 30 wt. % brine solution containing at least about 1500 ppm Ca(II) and at least about 500 ppm Mg(II). Said formed gels were stable as determined by sustained gel integrity and low gel shrinkage at least about 195° F. for at least three months. Examples of preferred gel compositions are set forth below.
______________________________________Gelation of Melamine- Formaldehyde Crosslinker 30% Deionized ParezExample Polymer Brine.sup.8 Water 613.sup.1______________________________________ 10% AMPVA.sup.2 #1 5 g 5 g 0 .sup. 0.4 g #2 2.5 g 5 g 2.5 g 0.4 g AMPS-AMPVA.sup.3 10% #3 2.5 g 5 g 2.5 g 0.4 g #4 5 g 5 g 0 .sup. 0.4 g PVA.sup.4 5% #5 5 g 2.5 g 2.5 g 0.4 g AMPS-PVA.sup.5 10% #6 5 g 2.5 g 2.5 g 0.4 g Magnifloc.sup.6 1% #7 5 g 5 g 0 .sup. 0.4 g #8 5 g 2.5 g 2.5 g 0.4 g AM-AMPS.sup.7 1% #9 5 g 5 g 0 .sup. 0.4 g#10 2.5 g 5 g 2.5 g 0.4 g______________________________________Gelation with Trimethylolmelamine (TM) 30% DeionizedExample Polymer Brine.sup.8 Water TM______________________________________ S-130 1%.sup.9#11 5 g 5 g -- 0.4 g#12 5 g 5 g 0.2 g HE B 2%.sup.10#13 2.5 g 5 g 2.5 g 0.4 g#14 2.5 g 5 g 2.5 g 0.4 g He E 2%#15 2.5 g 5 g 2.5 g 0.4 g#16 2.5 g 5 g 2.5 g 0.2 g Xanthan.sup.11 2%#17 2.5 g 5 g 2.5 g 0.4 g#18 2.5 g 5 g 2.5 g 0.2 g______________________________________ .sup.1 A commercial 80% active amino resin obtainable from American Cyanamid .sup.2 Acrylamide modified polyvinyl alcohol .sup.3 Acrylamido-2-methyl-propanesulfonate/acrylamide modified polyvinyl alcohol .sup.4 Polyvinyl alcohol .sup.5 Acrylamido-2-methyl-propanesulfonate/polyvinyl alcohol .sup.6 Polyacrylamide obtained from American Cyanamid .sup.7 Poly (acrylamideco-acrylamido-2-methyl-propanesulfonate) .sup.8 30% NaCl, 2000 ppm Ca, 1000 ppm Mg .sup.9 Kelco "S130" biopolymer .sup.10 Phillips HE .sup.11 Pfizer Flocon biopolymer
It is often desirable to have a solidified gel which will withstand a formation temperature range from about 300° F. to about 450° F. for from about 0.5 of a day to about 4 days. These solidified gels will be self destructive after about 0.5 of a day to about 4 days. While the gel is solidifying, preparation can be taken for the gravel packing step. A thermally stable gel can be obtained by mixing into the pumpable gel mixture a chemical known as an oxygen scavenger (such as sodium thiosulfate or short chain alcohols such as methanol, ethanol, and isopropanol), preferably sodium thiosulfate. The concentration of the oxygen scavenger utilized, of course, will depend upon the thermal stability desired to be obtained for the solidified gel in the formation. However, as preferred, it is anticipated that the concentration of the oxygen scavenger in the pumpable gel mixture will be from about 0.10 percent by weight to about 0.75 percent by weight, preferably 0.50 percent by weight.
In formations where temperatures are lower, a gel breaker can be placed in the solidifiable gel prior to injecting the gel into the formation. This gel breaker, included in the gel mixture, is selected from a group of chemicals which can break down the solid gel at temperatures of less than from about 60° F. to about 250° F. Generally this breakdown will occur within from about 2 hours to about 24 hours depending upon type and concentration of breaker added. Chemicals satisfactory for use as gel breakers, and which are incorporated into the gel mixture, include enzymes and oxidizing agents, suitable for breaking down the solid gel (such as sodium persulfate). Other gel breakers sufficient for this purpose are discussed in U.S. Pat. No. 4,265,311 issued to Ely on May 5, 1981, which is hereby incorporated by reference. These chemicals are readily available from chemical suppliers and with the exception of enzyme breakers are sold under their chemical names. Enzyme breakers can be obtained from oil field service companies. The concentration of the gel breaker incorporated into the gel mixture will vary from about 0.01 weight percent to about 0.10 weight percent, preferably about 0.05 weight percent of the gel mixture. Upon cooling to a temperature of from about 60° F. to about 150° F., the gel breaker will breakdown the solid gel causing it to liquefy and flow from the formation. This gel mixture is pumped into the casing of well 4 as shown in FIG. 2 and also into the washed out portion of the formation. After solidification of the mixture, any undesired solidified gel in the wellbore 12 can be removed by contacting it with 15 volume percent of hydrochloric acid in the amount sufficient to solubilize said gel.
As is understood by those skilled in the art, the composition of a selected gel will depend upon many variables including formation conditions. The above example is mentioned as one possible variation among many others.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims. | A method for minimizing formation damage during gravel packing operations in a loosely consolidated hydrocarbonaceous fluid producing formation penetrated by at least one well. Solidifiable chemical blocking agents are used to keep intrusive fluids, e.g. kill fluids, from the hydrocarbonaceous fluid producing interval of said formation during said gravel packing operation. Said blocking agents comprise gels wherein amino resins such as melamine formaldehyde ("MF") resins co-gel and crosslink with polymers useful for profile control where said polymers have amine, amide, hydroxyl and thiol functionalities. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This a continuation-in part, of prior application Ser. No. 09/832,384, filed Apr. 11, 2000 abandoned, which is hereby incorporated herein by reference in it's entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to vehicle barriers and in particular to vehicle barrier posts.
2. Description of the Related Art
Over the years, various devices have been used to guide vehicles along a stretch of road, particularly in areas where a vehicle operator may mix—interpret the course of the roadway due, for example to an abrupt change of direction or a temporary construction work site. Devices used in the past include guard grails, barricades of various sizes to be placed on or near the roadway surface and barrels or the like devices acting as pylons. As pointed out in recent studies culminating in NCHRP 350 guidelines, attention has been focused on roadway or roadside devices which may be inadvertently struck by vehicles traversing the roadway. Such studies are especially concerned with injuries that may result when roadside devices are inadvertently struck by moving vehicles. In general, it has been found desirable to reduce the mass of roadside devices and to alter their construction where possible to reduce or eliminate immovable fixing of the roadside devices. In response to these and other similar concerns, a number of different post constructions have been proposed, which readily deflect when impacted by a moving vehicle. In general, these posts are made to have a much smaller mass than other roadside path-guiding devices, such as barrels and barricade. A number of posts are made flexible by reason of the materials (such as resilient plastic) from which the posts are made (see, for example, U.S. Pat. Nos. 4,343,567; 4,092,081; 4,084,914 and 4,123,183). In other post constructions, deflectability is provided, in general, by segmenting the post and joining the post members using spring forces, which are readily overcome upon impact. Examples of these latter constructions may be found in U.S. Pat. Nos. 4,106,878; 4,092,081; 5,199,814; and 4,806,046. Although these spring-loaded constructions are made to deflect upon impact and often provide automatic restoration when the impact force is removed (sometimes described as self-upriding) various improvements are being sought. For example, due to the construction of the spring-loaded devices, their response to an impact force may depend upon the direction at which the impact is made to the post. Accordingly, posts with directional response must be oriented with respect to the direction of oncoming traffic and some measure of uncertainty as to the response of the device when struck from a different direction, must be taken into account. Further improvements are sought in simplifying the construction of such devices, which usually leads to cost reduction.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a vehicle barrier post fur use in roadside applications as well as applications on a roadway surface.
Another object of the present invention is to provide a vehicle barrier post of the above type which presents little or no practical resistance when impacted by a moving vehicle.
A further object of the present invention is to provide a post of the above-described type which is self-restoring after the impact-force is removed.
A further object of the present invention is to provide a vehicle barrier post of the above-described type which can be economically formed from a minimum number of inexpensive parts.
These and other objects of the present invention are provided in a deflectable sign mounting, comprising:
a tubular body, having upper and lower ends, for supporting the sign;
an extension spring secured within the tubular body;
a rocking base at the lower end of the tubular body;
said tubular body, said extension spring and said rocking base together comprising an upper assembly;
a stand-off member defining a hollow cavity and having upper and lower ends, the upper end of the standoff adapted for rocking engagement with the rocking base;
an elongated tether member having a second end secured to said deflectable sign mounting and a first end engaging said extension spring so as to hold said extension spring in tension;
a device base supporting said extension spring in an extended position, the device base defining an interior opening receiving the second end of the said elongated tether member;
a retainer member engaging the second end of said tether member so as to support the second end of the device base to maintain a predetermined tension in said extension spring; and
the rocking base and the upper end of the stand-off cooperating such that the upper assembly rocks about the stand-off upon application of a lateral force to the tubular body at a rest position, causing a bias energy to be stored within said extension spring, biasing the rocking base toward its rest position upon removal of the dislodging force.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a vehicular barrier post according to principles of the present invention;
FIG. 2 is a rear cross-sectional view taken along the line 2 — 2 of FIG. 1;
FIG. 3 is a top plan view thereof;
FIG. 4 is elevational view similar to that of FIG. 1 but showing internal components in phantom; and
FIG. 5 is an exploded cross-sectional view of the vehicular barrier post with an alternative mounting arrangement.
FIG. 6 is a cross-sectional view of an alternative mounting arrangement according to principles of the present invention;
FIG. 7 shows a fragment of FIG. 6 taken on an enlarged scale;
FIG. 8 is a cross-sectional pattern; and
FIG. 9 is a fragmentary view of another mounting arrangement according to principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and initially to FIGS. 1-4, a mounting arrangement or vehicular barrier post constructed according to principles of the present invention is general indicated at 10 . Included are an upper body portion in the form of a hollow cylindrical tube 12 and a bottom body portion or tubular stand-off 14 . As indicated in FIG. 4, the bottom end 16 of stand-off 14 rests against an external support 20 having an upper surface 22 , and an opposed lower surface 24 and a hole or passageway 26 . Disposed between upper body portion 12 and stand-off 14 is a rocking base 30 , shown in cross-section in FIG. 2 . The rocking base preferably comprises a first cylindrical portion 32 joined at its upper end to a circular disk 34 having an upper surface 36 and an opposed lower surface 38 . As indicated in FIGS. 1 and 4, the base portion 32 is dimensioned for telescopic insertion within the inner bore of stand-off 14 . The circular disk portion 34 of rocking base 30 has cross-sectional size greater than that of upper body portion 12 and stand-off 14 . When assembled in the manner shown in the figures, the disk portion 34 of rocking base 30 protrudes laterally beyond the sides of upper body portion 12 , disposed there above and stand-off 14 disposed there below. A coiled extension spring 46 is disposed within the inner bore of upper body portion 12 and is secured at its upper end 47 by a pin 48 which extends through upper body portion 12 (see FIG. 2 ). The lower end of spring 46 is secured to a flexible tension member 54 , preferably in the form of a chain. With reference to FIG. 4, the tension member 54 extends through rocking base 30 and stand-off 14 as well as passageway 26 formed in the external support 20 . The flexible tension member 54 is then pulled to store energy in spring 46 , with retraction of the spring being perverted by a locking pin 58 bearing against the underneath surface 24 of external support 20 . As a result, the body portions 12 , 14 and 30 of post 10 are joined together to assume the upright position shown, for example, in FIGS. 1 and 4. If desired, the flexible tension member 54 could take the form of a wire cable or a spring rod. Non-metallic tension members, such as a fiberglass rod, may also be used, if desired.
When impacted by a force in the direction of arrow 64 , shown in FIG. 1, upper body portion 12 is inclined, or rotated in the direction of arrow 66 , with the upper end of body portion 12 moving to the left. This applies a downward force to the left end of disk portion 34 which, initially, is free to follow movement of upper body portion 12 . Eventually, with sufficient inclination, tube portion 32 of the rocking base 30 contacts the inner wall of stand-off 14 thereby limiting further inclination of disk portion 30 depending upon the relative clearance between tube portion 32 and the inner bore of stand-off 14 . In the preferred embodiment, stand-off 14 is not affixed to the external support 20 and is free to move under the applied displacement force. However, it is generally preferred that the spring of 46 be constructed so as to yield before stand-off 14 is made to undergo substantial deflection. In its preferred operation, further bending of post 10 occurs between upper body portion 12 and rocking base 30 . In the preferred embodiment, spring 46 and the construction of tension member 54 cooperates so as to allow upper body portion 12 to undergo substantial deflection, to the point where upper body portion 12 is allowed to bend in a generally horizontal direction. Spring 46 is constructed so as to readily extend a length sufficient to allow upper body portion 12 to assume a horizontal direction. The tension member 54 is constructed so as to slide over any portions it may contact as the upper body portion 12 is allowed to “pull away” from its rest position, shown in the figures. When the distorting force indicated by arrow 64 is removed, spring 46 is allowed to resume to a position minimizing stored energy, causing tension member 54 to pull against locking pin 58 , as the upper body portion assumes an upright position.
In the preferred embodiment, the upper body portion is affixed to rocking base 30 to form an integral assembly therewith. The tubular portion 32 of rocking base 30 is dimensioned so as to be freely movable within the inner bore of stand-off 14 allowing freedom of movement, throughout the full range of motion of upper body portion 12 , i.e., between the upright position as shown in the figures and an horizontally directed position, generally assumed to be full deflection. It is possible that the upper body portion 12 could undergo a further displacement, forming an acute angle with the vertical line of stand-off 14 .
As mentioned above, the bottom end 16 of stand-off 14 is held against the upper surface of external support 20 . Due to the flexible mounting of upper body portion 12 , stand-off 14 could be affixed to prevent motion relative to external support. However, it is also possible to assembly post 10 with affixing the stand-off to external support 20 , especially if the spring 46 is constructed so as to allow ready expansion so as to allow most of the deflection of post 10 to occur at rocking base 30 , without substantial deflection of stand-off 14 relative to external support 20 .
During deflection of upper body portion 12 , the corner 70 formed by the tubular portion 32 and disk portion 34 of rocking base 30 rides or pivots over the upper end 72 of stand-off 14 . Preferably, upper end 72 is rounded for smooth operation. If desired, the corner 70 of rocking base 30 can be filled in or rounded to assume a convex shape to more smoothly travel over the upper end 72 . As will be appreciated, the rocking movement of upper body portion 12 is made directionally independent. Further, pieces interfitting with a close tolerance fit are eliminated by the design of the present invention, thereby avoiding the negative effects associated with roadside operation, such as elevated corrosion rates associated with ocean environments and ice melting products. As will now be appreciated, the major body components of post 10 , namely the upper portion 12 , rocking base 30 and stand-off 14 can be made of plastic materials, further enhancing corrosion resistance. Of course, if desired, one or more of these components could be made from metal, or metal alloys.
As mentioned, it is generally preferred that upper body portion 12 be joined to rocking base 30 to form an integral assembly, with the tubular portion 32 of the rocking base being permitted freedom of full travel within the inner bore of stand-off 14 . Although conventional limit stops could be added to either the rocking base 30 , or the stand-off 14 , or both, this would hinder the ready deflection of post 10 , when employed as a vehicular barrier device. In a different application, the upper body portion 12 can be extended so as to receive an upright sign support, and rotation limiting of a rocking base 30 may become desirable so as to limit the amount of inclination of the sign panel supported by post 10 . It is generally preferred that such sign supporting uses of post 10 be employed at locations where vehicle impact is unlikely.
Reference has been made above to external support 20 . As contemplated by the present invention, external support can comprise any number of conventional arrangements, such a planking installed on a roadway surface, or a base, such as that shown in U.S. Pat. No. 5,199,814 or U.S. Design Pat. No. 334,314. Alternatively, external support 20 could comprise a short section of construction material, dimensioned larger than the cross-section of stand-off 14 . After adjusting the tension of spring 46 , the external support 20 and possible the lower portion of stand-off 14 could be cast in roadway material filling a roadway depression. It should be noted in this regard, that the present invention would still allow ready replacement of internal components within post 10 . For example, a tripod or other device could be assembled above post 10 to support the upper end of spring 47 , allowing the extraction pin 48 , thereby allowing replacement of spring 46 or the replacement of upper body portion 12 with a body portion of different length.
Turning now to FIG. 5, an alternative embodiment generally indicated at 100 is shown. As can be seen with comparison to the preceding figures, post 100 generally resembles the construction described above for post 10 . In the arrangement of post 100 illustrated in FIG. 5, the stand-off described above is replaced with a second body portion 104 having an upper end 106 functioning in a manner similar to the upper end 72 of stand-off 14 , described above. A ground penetrating tip 110 is provided at the lower end of body portion 104 and, as indicated in FIG. 5, is located below grade. If desired, body portion 14 could be pounded or turned into the ground, with the remaining components thereafter being assembled in the manner illustrated. Alternatively, a hole similar to that required for a fence post could be provided for ready installation of body portion 104 . The hole could be filled with concrete, asphalt or other fixing medium. Alternatively, a ground socket having an inner bore dimensioned to receive the lower end of body portion 104 could also be provided. If desired, the post 100 could be fully assembled before insertion of body portion 105 into the roadway surface or ground. Alternatively, the flexible tension member 54 could be pinned at 58 to body portion 104 with the spring 46 being pulled from above to allow insertion of pin 48 holding the spring 46 captive against downward displacement. The upper end of spring 46 could, for example, be provided with a pull ring for this purpose.
Turning now to FIGS. 6-9, further embodiments according to principles of the present invention are shown. FIG. 6 shows a mounting arrangement 200 which contains several features of the mounting arrangement or post 10 described above. Included is a unitary upper body portion 210 and a unitary lower body portion 250 coupled together in a rocking engagement. In FIGS. 6 and 7, a small gap is shown between the upper and lower body portions 210 , 250 for illustrative purposes only. When fully assembled, the upper and lower body portions are pressed into engagement with one another.
Unitary upper body portion 210 includes a cylindrical tube portion 212 and a lower base portion 214 . Unlike the mounting arrangement of post 10 , cylindrical portion 212 and lower base portion 214 together comprise a unitary construction. A spring 217 and a chain 54 are enclosed within cylindrical tube portion 212 , with the upper end of spring 217 being secured by pin 48 .
Lower base portion 214 includes a cylindrical part 216 integrally formed with a circular disc part 218 . Together, the cylindrical part 216 and circular disc part 218 formed a stepped outer surface which nests within the stepped inner surface of unitary lower body portion 250 . Included in unitary lower body portion 250 is a stepped upper end 252 and a stand off body part 256 defining an inner bore 260 through which chain 54 passes. Unitary lower body portion 250 is secured to an external support such as support 20 . An optional flange 264 is provided at the bottom end of unitary lower body portion 250 for joinder to support 20 . If desired, unitary lower body portion 250 and support 20 can be formed as a monolithic part.
As shown in FIGS. 6 and 7, cylindrical part 216 and stand off body part 256 define internal passageways 262 , 260 , respectively which together form a continuous passageway through the lower end of a mounting arrangement. Alignment members 270 have a shape corresponding to the pattern of FIG. 8 and define a cross-shaped internal opening 274 which receives chain 54 controlling the rotation orientation of chain 54 as it passes through the alignment members 270 .
Referring to FIG. 9, an alternative mounting arrangement 300 generally resembles mounting arrangement 200 as can be seen by comparison to the fragmentary cross-sectional view of FIG. 7 . However, unlike mounting arrangement 200 , the center of stand off body part 356 and the center of cylindrical part 316 include solid portions 317 , 357 which have a cross-sectional shape corresponding to the pattern of FIG. 8, forming a continuous cross-shaped central passage way 274 which preserves a desired rotational alignment of the chain passing through that part of the mounting arrangement 300 shown in FIG. 9 . Central portions can be formed separately, or can be integral with the body part and the cylindrical, if desired.
The gap shown in FIG. 9, between the upper and lower body portions is introduced for graphical clarity. When the mounting arrangement 300 is fully assembled, the upper and lower body portions are pressed into engagement with one another.
Thus, it can be seen that vehicular barrier posts according to principles of the present invention can be provided for a variety of installations, both permanent and temporary. With the present invention, the vehicular barrier post can be modified for replacement of internal components or to alter the height or style of the upper portion of the post. As a further advantage, the present invention allows substantial reduction in mass of the vehicular barrier post. As can be seen from the above, major body portions of vehicular barrier posts according to principles of the present invention are hollow and can be formed from lightweight construction materials, such as plastic pipe or tubing. Further, with the present invention stability during deflection is improved. As mentioned above, the corner of the rocking base pivots around the upper end of tubular stand-off. The corner of the rocking base provides substantial capture of the upper end of the stand-off 14 , representing an enhancement over previous constructions which required an end-to-end engagement of similarly dimensioned components.
If desired, spring tensions can be adjusted in small increments in a number of ways. For example, with reference to FIG. 4, when a chain is employed as the tension member, the number of lengths of chain protruding from bottom surface 24 can be counted to provide a ready indication of corresponding energy stored in spring 46 . Alternatively, if the length of the tension member is to remain constant, a series of holes can be formed in upper body portion 12 extending along its length. With the pin 48 received in a lower hole, for example, spring 46 , held captive by pin 48 , will store less tension than when the spring is held captive at a higher position hole. Such arrangements may be particularly advantageous when extension members other than chains are employed.
The drawings and the foregoing descriptions are not intended to represent the only forms of the invention in regard to the details of its construction and manner of operation. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purposes of limitation, the scope of the invention being delineated by the following claims. | A vehicular barrier post includes an upper tubular portion and a lower tubular stand-off. The upper portion is joined to a rocking base having a tubular bottom portion telescopically received in the stand-off. The upper end of a tension spring is secured to the upper body portion by a pin. The lower end of the spring is attached to a tension member, such as a chain, which passes through the stand-off so as to be received in a hole in a suitable external support. The chain is pulled past the external support and when the spring is appropriately tensioned, a locking pin is passed through the chain, preventing its reverse travel through the external support. The upper body portion is allowed to freely rock about the stand-off. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This invention claims priority to U.S. Provisional Patent Application Serial No. 60/354,605, filed Feb. 5, 2002.
BACKGROUND
[0002] The prior art locking cam, as shown in FIG. 7 of the drawings, includes a locking cam ( 20 ), a torsion spring ( 27 ), and a ring plate ( 28 ). The locking cam has crescent shaped cutouts ( 30 ) for mating engagement with a set of ball bearings, a spring retention slot ( 29 ), bearing surfaces ( 26 ) with a reduced diameter section ( 22 ), and driver surface ( 31 ). When assembled, a first end ( 32 ) of the torsion spring ( 27 ) is retained in the slot ( 29 ), the locating ring ( 28 ) is placed on the reduced diameter section ( 22 ) of the cam, and the second end ( 33 ) of the torsion spring ( 27 ) is wound to allow attachment to a projection ( 34 ) on the locator ring ( 28 ). When the locking cam ( 20 ) is inserted into a cavity in a lock body, the projection ( 34 ) on the locator ring ( 28 ) positions the locking cam ( 20 ) into the correct orientation in the lock body cavity by insertion into a retention cavity. A key cylinder then contacts the locking cam at the driver surface ( 31 ) such that when the key cylinder is rotated from locked to unlocked positions, the locking cam is rotated such as to align the cutouts ( 30 ) with the ball bearings. When the cutouts ( 30 ) and ball bearings are aligned, the ball bearings can move into the cutouts ( 30 ) thereby allowing the toe side of the_shackle to be removed from the lock body.
[0003] In the prior art structure, the torsion spring is located on the outside of the cam and the ring plate is used to orient one end of the spring in the lock. In use, the prior art locking assembly has a tendency to tip off-axis since the outer diameter of the assembly is not constant and therefore does not match to the constant diameter bore in the lock body. In addition, as the cam of the lock rotates the spring will cock. The rotation of the spring causes the spring coil to elongate. The torsional force and elongation cause the spring to get off axis creating instability in the assembly.
SUMMARY OF THE INVENTION
[0004] One embodiment of the invention is a locking device for padlocks with multi-functioning cams. The locking device contains a cam and a driver partially housed within the cam. The locking device also contains a torsion spring housed within the driver.
[0005] A method of locking and unlocking the locking device by rotating a key cylinder in a clockwise direction in which an assembled driver, spring, and cam are connected to the key cylinder. The key cylinder causes the driver to rotate in a clockwise direction, in which the direction of rotation is defined by viewing towards the key insertion point of the key cylinder. The driver drives the cam by applying a torque to a drive surface of the cam. The torque rotates the cam in a clockwise direction. A spring end stops the rotation of the cam by butting against a stop surface of the cam.
[0006] An option desired by customers is to be able to insert and have operate a variety of key cylinders and the invention accommodates this desire by implementing three different styles of drivers that can be used in the assembly. The type of cylinder used in a lock is also dependent upon the geometry of the lock body. The customers also have a requirement for two different modes of operation commonly known as Non Key Retaining (NKR) and Non Removable Key (NRK). In order to provide the NKR function, the invention must be capable of allowing the driver component to turn independently without affecting the orientation of the cam component. This motion without interaction is commonly called ‘lost motion.’
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 shows a perspective view of one embodiment of the internal components of the locking device assembled.
[0008] [0008]FIGS. 2A, 2B, and 2 C show perspective views of different embodiments of a driver of the present invention.
[0009] [0009]FIGS. 3A and 3B show a perspective view of different embodiments of a spring of the present invention.
[0010] [0010]FIGS. 4A and 4B show perspective views of different embodiments of a cam of the present invention.
[0011] [0011]FIG. 5 shows a perspective view of one embodiment of a cam of the present invention.
[0012] [0012]FIG. 6 shows an exploded view of one embodiment of the present invention.
[0013] [0013]FIG. 7 shows an exploded view of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention will be described in reference to the drawings. FIG. 1 shows the internal mechanisms of a padlock body 100 a driver 3 , a torsion spring 6 , and a cam 1 . The driver 3 is housed partially in the cam 1 . Located within the driver 3 and in contact with the cam 1 is the torsion spring 6 .
[0015] As shown in FIG. 5, the cam 1 is generally cylindrical with two crescent shaped recesses 11 cut from an external wall 80 of the cam 1 . In addition, the cam 1 has a cavity 36 formed by the internal wall of the cam and extending approximately half-way down cam 1 . The external wall of cam 1 extends to a variety of heights, thereby forming two stop surfaces 7 and 9 . Two ledges 8 and 10 connect the two stop surfaces 7 and 9 and are at two different heights. Ledges 8 and 10 meet at rest surface 40 . Thus, aperture 10 a is formed by stop surface 9 , rest surface 40 and ledge 10 .
[0016] The crescent shaped recesses 11 and the first cavity 36 of the cam 1 intersect and form two windows 22 . In addition to the first cavity 36 , there is a second cavity 37 within the first cavity 36 that extends deeper inside the cam 1 . Bearing surfaces 75 and 76 are formed by the internal walls inside the two cavities 36 and 37 .
[0017] The driver may be a number of different embodiments, as shown in FIGS. 2A, 2B, and 2 C, each having a pivot rod 21 , a trepanned collar 41 with an aperture 13 a formed by wall surfaces 13 and 14 , and two drive surfaces 15 and 16 .
[0018] Shown in FIG. 3A, the torsion spring 6 is a coiled spring with two radially protruding ends identified as a long end 19 and a short end 20 .
[0019] When assembled, the torsion spring 6 fits inside the trepanned collar 41 of the driver 3 so that the long spring end 19 projects through the aperture 13 a of the driver and the short spring end 20 extends beyond the trepanned collar 41 and engages cam 1 or 2 at one of the two windows 22 , but does not extend beyond the external wall 80 of cam 1 or 2 . The aperture 13 a prevents relative motion between the long spring end 19 and the locking mechanisms in at least one direction. The driver pivot rod 21 fits in the second cavity 37 of the cam 1 and the short spring end 20 is engaged through the window 22 of the cam 1 directly under the additional ledge 10 . The driver rests on and is supported by ledge 8 . The bearing surfaces 75 and 76 within the first and second cavities 36 and 37 stabilize the driver 3 within the cam 1 to eliminate tilt. During assembly, a preload is applied to the torsion spring 6 via the driver 3 to cause the long spring end 19 to project through the cam aperture 10 a.
[0020] The driver is engaged with the end of a key cylinder 44 called a cylinder plug 45 . Three different embodiments of the driver 3 , 4 and 5 are shown in FIGS. 2A, 2B, and 2 C illustrating a different engaging structure with the key cylinder 44 . FIG. 2A shows a first embodiment for the driver 3 which is designed to engage a tenon on the end of a key cylinder with the drive surface 15 on the end of the driver 3 . FIG. 2B shows a second embodiment for the driver 4 which is designed to engage the cylinder plug 45 of various door hardware type key cylinders via a tenon 17 . FIG. 2C shows a third embodiment for the driver 5 which is designed to engage a small format interchangeable core via throw member studs 18 .
[0021] The key cylinder 44 applies clockwise torque to the drive surface 15 of the driver 3 , the tenon 17 of the driver 4 , or the throw member studs 18 of the driver 5 , depending upon which driver is used in the assembly. The torque is transferred to drive surface 16 of the driver which in turn transfers the torque to stop surface 7 of the cam 1 or 2 . The long spring end 19 has been at rest against rest surface 39 or 40 of the cam 1 or 2 and held captive within a cavity in cam 1 or 2 . Cam 1 or 2 turns clockwise as a result of the torque and can continue to rotate until the stop surface 9 of cam 1 or 2 makes contact with the long spring end 19 and the rotation of cam 1 or 2 is stopped. At some point in the rotation, the recesses 11 in cam 1 or 2 become aligned to allow the ball bearings 43 to move toward the center of cam 1 or 2 to a point where the ball bearings 43 no longer engage the crescent shaped cutouts 42 in the shackle 50 . Shackle 50 may be pulled outward from the padlock body 100 until the toe end 46 is clear and in the unlocked position while the heel end 47 of shackle 50 is retained in the padlock body 100 .
[0022] When shackle 50 is in the unlocked position the heel end ball bearing 43 is trapped between shackle 50 and cam 1 or 2 to prevent withdrawal of the heel end 47 from the padlock body 100 . Cam 1 or 2 is under spring pressure from the winding of the torsion spring 6 . After the toe end 46 of shackle 50 is returned to the closed position this spring pressure rotates the cam counter-clockwise and the cam pushes outward on the ball bearings 43 and forces the ball bearings 43 out of recesses 11 in the cam into the crescent shaped cutouts 42 in shackle 50 locking the padlock body 100 .
[0023] In operation of the NKR (Non Key Retaining) version of the invention shown in FIGS. 4A and 5, stop surface 12 is eliminated thereby allowing counter-clockwise rotation of the driver 4 even though the cam 1 is held in position via the relationship of the ball bearings 43 and the unlocked shackle 50 . Torque may be applied to the key in the counter-clockwise direction to allow the key cylinder to be rotated to the key pull position, thus allowing withdrawal of the key from the key cylinder 44 . The torsion spring 6 is now under full load and applying torque to the cam 1 in a counter-clockwise direction. When the shackle 50 is pushed back into the locked position within the padlock body 100 the torque on the cam 1 forces the ball bearings 43 away from the center of the cam 1 and out of the recesses 11 and into the crescent shaped cutouts 42 in the shackle 50 , locking the shackle 50 into place. When the ball bearings 43 are no longer engaging the recesses 11 , the cam 1 is rotated in a counter-clockwise direction until surface 39 makes contact with the long spring end 19 .
[0024] In operation of the NRK (Non Removable Key) version of the invention shown in FIG. 4B, the added surface 12 on the NRK cam 2 is in direct contact with surface 15 of the driver 5 and the driver 5 cannot turn in a counter-clockwise direction unless the cam 2 does. The torsion spring 6 is now under full load and applying torque to the cam 2 in a counter-clockwise direction. When the shackle 50 is pushed back into the locked position within the padlock body 100 the torque on the cam 2 forces the ball bearings 43 away from the center of the cam 2 and out of the recesses 11 and into the crescent shaped cutouts 42 in the shackle 50 , locking the shackle 50 in place. When the ball bearings 43 are no longer engaging the recesses 11 , the cam 2 is rotated in a counter-clockwise direction until surface 40 makes contact with the long spring end 19 .
[0025] [0025]FIG. 3B illustrates the same component relationships using a different torsion spring 24 . The spring end 25 corresponds to the short spring end 20 on torsion spring 6 for location and function and a longitudinal spring end 23 is designed to enter a third cavity 38 in the cam. This third cavity 38 prevents rotation of the longitudinal spring end 23 relative to the cam. With longitudinal spring end 23 in a third cavity 38 , shown in FIG. 5, and spring end 25 against driver surface 13 , the driver is rotated until surface 16 of the driver rests against surface 7 of the cam. In this orientation spring end 25 continues to rest against surface 13 of the driver which is coplanar with surface 39 of the cam. This rotation of the driver provides the preload needed for correct operation of the invention.
[0026] Although the present invention has been described in detail with reference to certain preferred embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiment contained herein. | A locking device for locking systems that use different key cylinder types. The locking device is capable of allowing a key to be removed when a lock is in an unlocked position or retaining the key within the padlock body in an unlocked position. The device prevents fatigue of an internal torsion spring and creates more stability for all the internal mechanisms inside the padlock body. |
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BACKGROUND OF THE INVENTION
This invention relates generally to padlock shields and more specifically to shields for protecting padlocks from adverse weather conditions.
SUMMARY OF THE PRIOR ART
A number of shields have been previously proposed for protecting padlocks from damage through exposure to rain and snow. Examples of such protective devices are shown in U.S. Pat. No. 676,001, granted to Jarvis on June 11, 1901; U.S. Pat. No. 1,244,404, granted to Ankovitz on Oct. 23, 1917; and U.S. Pat. No. 4,033,156 granted to Cottingham on July 5, 1977.
While all these protective devices are capable of protecting padlocks from exposure to rain and snow, many of them have a disadvantage in that they are designed to only accept staples which are oriented either in a vertical direction or in a horizontal direction. In the case of the Jarvis or Ankovitz devices, for example, the padlock shields may only be effectively used with staples which are vertically oriented. If the staple is oriented horizontally, rain or snow may enter the open side of the shield and damage the padlock. None of the devices previously disclosed are able to be used in conjunction with staples which have different orientations from that for which the device was manufactured.
SUMMARY OF THE INVENTION
The padlock shield of the present invention comprises a cover having a plurality of walls, one of which is provided with a means for receiving a staple oriented at any one of a plurality of angles.
In a first embodiment of this invention, the means for receiving the staple comprises a cruciform-shaped opening in the wall. As the cover is made from a pliable material, the areas of the wall delimited by the arms of the cross are able to deflect to a certain degree. The staple may be oriented in a vertical position, horizontal position, at 45 degrees to the vertical or 135 degrees to the vertical.
In a second embodiment of the invention, the means for receiving the staple comprises a rotatable wheel mounted in the wall of the cover, said wheel having a staple-receiving slot therein. When the staple is received into the slot, the wheel may be rotated to a degree sufficient to ensure that the shield is disposed to adequately protect the padlock from the elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of this invention will now be more fully described with the aid of the following drawings, in which:
FIG. 1 is a perspective view of a first embodiment of the invention showing a padlock secured to a staple;
FIG. 2 is a bottom view of the first embodiment of the invention;
FIG. 3 is a perspective view of the rear wall of the the embodiment of the invention shown in FIG. 1 without the padlock and staple;
FIG. 4 is a perspective view of a second embodiment of the invention;
FIG. 5 is an exploded side view through line A--A of FIG. 4;
FIG. 6 is a partially cut-away perspective view of a third embodiment of the invention.
FIG. 7 is a partially cut-away perspective view of the embodiment of the invention shown in FIG. 6, where the cover is rotated to allow the base to open in a direction which will substantially prevent the entrance of snow or rain into the cover;
FIG. 8 is a bottom view of the invention through line B--B of FIG. 7.
DESCRIPTION OF THE INVENTION
The shield of the present invention is designed to protect a padlock 10 which is fastened to a staple 11. Referring to FIGS. 1, 2 and 3, there is shown a first embodiment of the invention, used in conjunction with the conventional staple 11/hasp 12 combination which is used to secure doors, gates etc. The cover 13, which may be made from a pliable or resilient material such as plastic, comprises an upper wall 14a; two side walls, 14b, 14c; a front wall 14d, a lower wall 14e and a rear wall 14f. The rear wall 14f is hingedly connected to one of the side walls so that the cover 13 is in the form of a rear wall 14f and a front portion 15 which may be secured to the rear wall 14f by a latch 16. A drainage hole 30 is formed in the lower wall 14e, as shown in FIG. 2, to allow any condensed moisture to drain from the cover 13.
The rear wall 14f has a cruciform-shaped opening 17 for receiving the staple 11 therethrough. The arms 18 of the opening 17 delimit areas 19 therebetween. The areas 19 are sufficiently deformable so that the opening 17 can receive the staple 11 either vertically, horizontally, or at an angle of 45 degrees or 135 degrees to the vertical. This means that a staple 11 fixed to a surface 20 in any one of these aforementioned orientations can be received into the rear wall 14f of the cover 13 and may be there be secured by a padlock 10.
It will be understood by those skilled in the art that it is possible to manufacture the padlock shield with any shape of opening 17 which will allow the shield to receive a staple 11 at any one of a plurality of orientations, or to manufacture the shield with any number of arms 18. The shield is also made of a sufficiently resilient material which will allow a user to either enlarge one of the arms 18 of the opening 17, or to cut a new arm at a different angle to receive a staple which cannot be accommodated by the padlock shield as disclosed above.
The cover 13 is not permanently attached to the surface 20, or to the staple 11 or the hasp 12, but is rather held and locked in position by the padlock 10 being secured to the staple 11. When the padlock 10 is removed, the cover 13 does not remain in position.
The first embodiment of the invention is used in the following manner. The hasp 12 (if present) is positioned over the staple 11. The rear wall 14f of the cover 13 is brought into close proximity with the staple 11, which is then forced through the opening 17. Depending on the orientation of the staple, different areas 19 of the rear wall 14f will be deformed to accommodate the staple 11. The padlock 10 is then secured to the staple 11 and the front portion 15 of the cover 13 is latched to the rear wall 14f by the latch 16. When the user wishes to gain access to the premises secured by the padlock 10, he simply opens the front portion 15 of the cover, unlocks the padlock 10 and removes the same from the staple 11.
A second embodiment of the invention is shown in FIG. 4. In this embodiment, a rotatable wheel 21 is secured into a hole 22 in the rear wall 23 of the cover 24. The rotatable wheel 21 has an upper portion 21a and lower portion 21b. As shown in FIG. 5, the upper portion 21a and lower portion 21b are positioned so that they lie on opposite sides of the rear wall 23. The upper portion 21a and lower portion 21b may then be glued together or joined together by other suitable means. The wheel 21 has a staple-receiving slot 27 through which the staple (not shown) may be passed.
The second embodiment of the invention is used in the following manner. The wheel 21 is rotated to align with the staple. The rear wall 23 of the cover 24 is brought into close proximity to the staple which is then received through the slot 27. The padlock (not shown) is secured to the staple, and the front portion 28 of the cover 24 is secured to the rear wall 23 by a latch 29.
A third embodiment of the invention is shown in FIG. 6. In this embodiment, the cover 31 comprises an upper wall 32a, two side walls 32b, 32c, a front wall 32d and a rear wall 32e. The cover 31 is open at its base 33 to allow any condensed moisture to drain from the cover 31.
A rotatable wheel 34 is secured into a hole 35 in the rear wall 32e of the cover 31 in the same manner as described for the second embodiment of the invention. The wheel 34 has a staple-receiving slot 38 through which a staple may be passed. The rear wall 32e also has a groove 39 which begins at the base 33 of the cover and runs substantially parallel to the longitudinal axis of the wall and terminates in the hole 35. The slot 38 in the wheel 34 may be aligned with the groove 39, as is shown in FIG. 6, so that a staple 41 can be drawn through the groove 39 and into the slot 38.
As is shown in FIG. 8, the rear wall 32e in the vicinity of the groove 39 may be formed into lips 43 which partially project over the groove 39. As the padlock shield is manufactured from a resilient material, the lips 43 are bendable and the staple 41 can therefore be forced through the lips 43 and into the groove 39. The lips 43 then return to their original position. The lips 43 aid in preventing rain and snow from readily entering the groove 39 and gaining access to the padlock 40.
The third embodiment of the present invention is used in the following manner. For the purposes of this illustration only, the staple will be assumed to lie in a horizontal orientation. Referring to FIG. 6, the padlock 40 is secured to the staple 41. The cover 31 is brought into close proximity with the padlock and staple so that the staple 41 is received within the groove 39. The cover is then moved towards the padlock and staple, so that the padlock and staple is effectively moved towards the upper wall 32a of the cover. The staple 41 travels in the groove 39 of the rear wall 32e until it is received in the slot 38. At this point, the base 33 of the cover 31 is vertically aligned, thereby permitting rain and snow to enter the cover. The cover 31 is therefore rotated as shown by the arrow in FIG. 7, to the point that the base 33 faces in a direction that permits any condensed moisture to run out of it and which essentially prevents rain and snow from entering the cover with ease. The rotation of the cover does not have to result in the base being horizontally oriented, but may result with the base being inclined at an angle as is shown in FIG. 7.
When the user requires to gain access to the padlock 40, he simply rotates the cover 31 until the slot 38 and groove 39 align, and then slides the cover off the padlock and staple. If the staple is oriented in the vertical position, the cover 31 may be brought into the proximity of the padlock 40 and staple 41 so that the staple 41 enters the groove 39. The cover 31 is then simply moved downwardly toward the padlock and staple until the staple enters the slot 38. There is no need to rotate the cover 31 in this instance.
In the third embodiment of the invention, the padlock 40 is locked into the cover 31 by the rotation of the same, for all orientations of the staple, except vertical.
In all three embodiments of the invention, the cover is held in position by the padlock being secured to the staple. The cover is not attached to any surface, or to the hasp or staple.
Variations in the above invention will be obvious to those skilled in the art and these variations considered to lie within the scope of the present invention. | A padlock shield for protecting padlocks from exposure to rain and snow is disclosed. The shield is comprised of a cover which is made up of a plurality of walls, one of which includes a mechanism for accepting a staple therethrough at any one of a plurality of orientations. |
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BACKGROUND OF THE INVENTION
The present invention is directed to an oil well swab cup for use on a swabbing mandrel and removing fluids from an oil well. More specifically, the present invention involves a swab cup of the design wherein an elastomeric sealing element is bonded to a metallic reinforcing structure. The prior art devices are directed to the structures for swab cups, wherein the elastomeric material is bonded to the outside and usually on the inside of the reinforcing cage.
The difficulties incurred in the prior art devices include rapid deterioration and wear of the elastomeric material along the outer surfaces of the prior art devices. The present invention overcomes these disadvantageous by utilizing a reinforcing structure which forms a major portion of the outer surface of the swab cup, which reinforcing structure may be formed from a relatively hard metal providing far greater wear resistance for the apparatus. The present invention provides a sturdy long wearing swab cup which is easy to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a lateral cross-sectional side view of one embodiment of the invention;
FIG. 2A is an axial cross-sectional view taken at line 2--2 of FIG. 1 and illustrating one type of reinforcing structure utilized;
FIG. 2B is an axial cross-sectional view illustrating a second embodiment of the reinforcing structure used in FIG. 1;
FIG. 3 is a partial lateral cross-section showing another embodiment of the invention;
FIGS. 4, 5, and 6 illustrate partial cross-sectional side views of three additional embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a swab cup 10 having an outer metallic reinforcing structure 11. Structure 11 comprises a circular base 12 from which extend a plurality of upward extending reinforcement arms 13. An elastomeric sealing material 14 is attached to the inner surface of structure 11 by means such as bonding or cementing.
A bore passage 15 is located through the center of the elastomeric element 14 and element 14 is arranged to sealingly engage the swab mandrel shoulder on the rod string upon which the swab cup is placed. The arms 13 are located a spaced distance apart and define a series of longitudinal slots therebetween, which slots are filled by the elastomeric material 14 to provide additional sealing against the tubing or casing wall in which the swab cup is being used.
The reinforcing structure 11 features an inwardly tapered base 12 with outwardly tapered arms 13 extending upward therefrom. At the upper extremity of arms 13 is an inward flexed lead-on area 13a, and an annular sealing lip 13b which provides a full circle seal against the inner wall of the tubing or casing. The lead-on area is provided to prevent hang-up of the swab cup in collars.
Referring to FIGS. 2A and 2B, two different types of construction of arms 13 are illustrated. FIG. 2A, a plurality of segmental-arc support arms 13c are shown having a curvilinear cross-sectional configuration. Each supporting arm 13c is separated from the other arms by a longitudinal gap 16, which is preferably filled with elastomeric material. In FIG. 2B, a different configuration for the support arms is illustrated at 13d. These reinforcement arms are provided with an inner reinforcing rib 17 formed along the inner curved surface of the arm.
This results in a generally T-shaped cross-sectional configuration which provides for extended life of the swab cup by providing a continuous reinforcement even after most of the curved outer portion has worn away. The relatively thinner arms 13c will wear out faster than the T-shaped arms of 13d but offer the advantage of better flexibility, whereas the T-shaped arms will wear longer and sustain heavier loading.
FIG. 3 illustrates another embodiment of the invention utilizing a lower integral base section 20 and upward extending reinforcement arms 18 having axial longitudinal spaces therebetween. An elastomeric sealing element 19 is bonded or cemented to the inside of the reinforcing structure and protrudes radially outward filling the spaces between the reinforcing arms 18.
The reinforcing structure utilizes a narrowed flex section 21 and a thicker wear section from section 21 to the sealing lip 22. Thus, the embodiment of FIG. 3 combines the longer wear life of arms 13d with the greater flexibility of arms 13c into one swab cup structure.
In FIG. 4, a reinforced cup structure 25 is illustrated having two cylindrical exterior surfaces 26 and 31 of different outer diameter. The upper surface 26 is formed by the thicker upper portion of vertical segmented-arc arms 27 having axial spaces therebetween filled with elastomeric material 28.
The metal or rigid-material reinforcing structure 29 consists of a reduced diameter cylindrical base section 30 and the parallel, spaced-apart vertical arms 27. The lower portion 31 of each of arms 27 is relatively thin and of the same outer diameter as base section 30. An inner annular enlargement 32, cut from the inside of arms 27, adds to the flexibility of the arms.
Elastomeric material 28 is injection-molded into the inner bore of reinforcing structure 29 and fills the axial spaces between vertical arms 27. The material extends upward past the upper end of the arms to provide a flexible annular lip 33 at the top of the cup.
The different degrees of loading on a typical swab cup cause different areas of the cup to provide sealing contact with the conduit in which it is located. These different areas are denoted in FIG. 3 by arrows. A light load on the swab cup is carried by area L of the cup engaging the conduit inner wall. A moderate load pushes area M out into engagement with the conduit and effictively removes most of the load from area L. A heavy load moves the contact area down the section H and reduces most or all of the load on areas L and M. Thus, that portion of the cup where the greatest portion of per-unit-area of loading will occur is designed to contain the thickest wear areas.
Another embodiment of the invention is illustrated in FIG. 5 wherein the swab cup 40 is formed as a tapered cylinder with a generally tapered cylindrical reinforcing structure 41. Structure 41 has a tapered cylindrical outer surface and a generally right-cylindrical inner surface with an annular undercut 42 near the lower end thereof. A circular base portion 43 contains a number of upward extending spaced arms 44 with axial slots therebetween. An elastomeric material 45 is bonded to the inside of structure 41 and in the axial slots between arms 44.
The reduced thickness of section 42 provides the requisite flexibility of the cup and the thicker sections 46 provide the long wearing ability of cup. An annular upper lip 47 is formed of the elastomeric material for light loads on the swab as mentioned above with respect to FIG. 3.
Yet another embodiment of the invention is disclosed in FIG. 6 which illustrates a swab cup 50 with a generally cylindrical hard-material reinforcing structure 51. Structure 51 has a closed cylindrical base section 52 with a plurality of arc-segmented, upward extending arms 53 formed thereon.
The structure of cup 50 is generally the same as that of cup 40 except that the flex area 54 formed by an external undercut is in the reinforcing structure. Also, base section 52 has a slightly smaller OD that that of arms 53.
Elastomeric material 55 is injection-molded to the inside of structure 50 and fills the spaces between arms 53 as well as the annular undercup 54. An upper lip 56 is also formed of the elastomeric material to provide light-load sealing.
Thus, several embodiments of improved swab cups have been disclosed which provide greater wearing ability in the conduit. The provision of a thick wear area with a thin flex area provides optimal swab cup characteristics. This feature is extremely important to the operator because it greatly reduces the chances of swab cup failure and loss of metal pieces into the wellbore which could damage other tools therein.
Also, the provision of a curvilinear outer surface on the swab cup reinforcing structure, which surface is substantially of the same arc and diameter as the inside of the swabbed conduit, means that swab cup requires no initial wearing or "seating" in to provide full sealing contact in the conduit. Prior art devices utilize wire reinforcing material or flat reinforcement arms which initially have small surface area contact resulting in high surface loading and resultant fast wear on the structure.
Although certain preferred embodiments of the present invention have been herein described in order to provide an understanding of the general principles of the invention, it will be appreciated that various changes and innovations can be effected in the described swab cup design without departing from these principles. For instance, the present invention has been described as structure for use as a swab cup but it would be possible to utilize identical or similar structure on a larger scale, on a packer mandrel for use as a well packer in a wellbore. Also, whereas the reinforcing structure has been disclosed as made of a metal, it is clear that other materials such as plastics could be used. All modifications and changes are deemed to be embraced by the spirit and scope of the invention except as the same may be necessarily limited by the appended claims or reasonable equivalents thereof. | An oil well swab cup with improved wear characteristics utilizes a single integral reinforcing structure featuring a wear surface forming a substantial portion of the external surface of the cup. |
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BACKGROUND
[0001] In subsurface production efforts, a pump (e.g., Electric Submersible Pump or Progressive Cavity Pump) is generally used to bring a liquid (e.g., oil) to the surface. Specifically, a pump in a production well will pull the liquid (in some cases the pump carries mostly water, but the desired “product” can be minerals or gas, and can be produced with other means) into tubing that carries the liquid to the surface. The pump cannot discriminate between the liquid, and other material (e.g., sand, dirt, rocks) that may also be pulled into the tubing. When gas enters the tubing or when liquid level drops in the annulus from which it is being pumped, the lack of fluid in the tubing creates a cavity or void (e.g., cavitation or gas lock or vapor lock in the pump). This condition caused by gas or low fluid level can cause damage to the pump based on the frequency and duration of its occurrence.
SUMMARY
[0002] According to one embodiment, a system to identify a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing includes a tool configured to create a binary event based on the condition, the binary event representing a change in state of a parameter; a sensor configured to detect the binary event based on the parameter; and a processor configured to process output from the sensor to identify the condition.
[0003] According to another embodiment, a method of identifying a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing includes creating, using a tool in the subsurface environment, a binary event based on the condition, the binary event representing a change in state of a parameter; detecting, using a sensor, the binary event based on the parameter; and processing, using a processor, an output from the sensor to identify the condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0005] FIG. 1 is a block diagram of a system to identify a cavitation condition according to embodiments of the invention;
[0006] FIG. 2 is a cross sectional block diagram of a system to identify cavitation in tubing according to an exemplary embodiment; and
[0007] FIG. 3 is a process flow of a method of identifying cavitation in tubing according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
[0008] As noted above, cavitation in the production tubing can result in damage to the pump. Thus, awareness of the condition can aid in extending the useful life of the pump. Currently, flow rate of liquid (e.g., oil) production at the surface is monitored. This monitoring allows an operator to identify when flow rate has dropped and further investigate whether the drop in flow rate is due to cavitation. However, a change in flow rate or a particular value of the flow rate is not dispositive, and the analysis and investigation needed to make a determination may require the pump to be shut off. Embodiments of the systems and methods described herein relate to a sensor identifying cavitation in the tubing based on a dispositive or binary event.
[0009] As used in the present application, “binary event” refers to an event that indicates an objective and discernable switch or change in state of a parameter. The exemplary binary event detailed below is a change from positive to negative pressure (pressure to no pressure) for fluid flow of liquid being pumped to the surface. That is, the exemplary binary event is a switch in state of the exemplary parameter of pressure. The exemplary embodiment detailed herein relates to a diverter whose operation results in a switch in pressure (from positive to negative) when cavitation occurs in the tubing. This binary event or switch in pressure in the particular embodiment can be detected by a sensor. Alternate embodiments contemplate a different downhole tool than the diverter causing a different dispositive or binary event based on cavitation and a different sensor identifying cavitation based on that binary event.
[0010] FIG. 1 is a block diagram of a system to identify a cavitation condition according to embodiments of the invention. Generally a tool 5 is disposed in a downhole environment 2 . The tool 5 creates a binary condition based on cavitation in tubing 20 . Although the tool 5 is shown in the tubing 20 , embodiments of the system may include the tool 5 being disposed on or outside the tubing 20 , as well. A sensor 6 identifies the binary event created by the tool 5 . A processing system 7 coupled to the sensor 6 processes the sensor 6 output to automatically take action or provide information to an operator.
[0011] FIG. 2 is a cross sectional block diagram of a system to identify cavitation in tubing 20 according to an exemplary embodiment. The exemplary embodiment relates to a pressure switch sensor 110 , which is an embodiment of the sensor 6 , identifying cavitation based on a switch in pressure caused by a diverter 120 , which is an embodiment of the tool 5 , during a cavitation condition. A subsurface environment 2 including a borehole 10 is shown below the earth's surface 1 . The borehole 10 may be cased and has tubing 20 disposed therein that may be production tubing, for example. The tubing 20 is comprised of sections of tubes with interfaces 30 between them. In the embodiment of the cavitation identification system discussed with reference to FIG. 1 , a diverter 120 , discussed further below, is disposed at an interface 30 of the tube sections, and sensor 110 is disposed in the flow of the tubing 20 at the surface 1 . The sensor 110 is coupled to a surface processing system 130 , which is an embodiment of the processing system 7 . The surface processing system 130 includes one or more processors 132 processing data based on instructions stored in one or more memory devices 134 and outputting the results through an output interface 136 . In addition to identifying cavitation based on data received from the sensor 110 , the surface processing system 130 may perform additional functions related to the production effort and may include additional components involved in that effort.
[0012] According to the embodiment shown in FIG. 1 , the diverter 120 is designed to divert debris such as rocks, sand, and dirt that are suspended in the fluid out of the (production) tubing 20 and into the annulus 15 between the (cased) borehole 10 and the tubing 20 when the pump 40 is turned off. However, when gas is in the tubing 20 or, for another reason, fluid levels drop in the tubing 20 , the diverter 120 according to one embodiment of the invention operates while the pump 40 is running. Under these conditions (pump 40 is on and diverter 120 is functional), any gas (and fluid) in the tubing 20 will be diverted out of the tubing 20 . When fluid levels are sufficiently low in the tubing 20 during this procedure, the diverter 120 operation causes pressure drop in the fluid flow and a vacuum is created at the diverter 120 causing fluid to flow in the opposite direction (drop toward the pump). At the pressure switch sensor 110 , this change in flow direction of the fluid is seen as a switch from pressure to no pressure (a binary event). As a result, the pressure switch sensor 110 need not be a sophisticated measurement device that measures flow or any particular parameter. The pressure switch sensor 110 may instead be a check valve that switches between on and off or a pressure valve that switches from positive to negative pressure to indicate that the cavitation condition has occurred in the tubing 20 . The surface processing system 130 coupled to the pressure switch sensor 110 may monitor a length of time that the condition lasts or a frequency of the condition over a period of time to take automatic action (e.g., shutoff of the pump 40 ). In alternate embodiments, the surface processing system 130 may provide the information indicated by the pressure switch sensor 110 to an operator through the output interface 136 so that the operator determines the action to take. According to the embodiment discussed with reference to FIG. 1 , the diverter 120 includes features described in U.S. Pat. No. 6,289,990. In alternate embodiments, the diverter 120 is another diverter that produces the vacuum and subsequent change in fluid flow direction when it operates while the pump is on during a cavitation condition.
[0013] FIG. 3 is a process flow of a method of identifying cavitation in tubing according to an exemplary embodiment of the invention. At block 310 , disposing a tool 5 along the tubing 20 includes disposing the diverter 120 at an interface 30 between tube sections, for example. The diverter 120 , according to the exemplary embodiment described above, diverts gas while the pump is on such that a vacuum is created. At block 320 , positioning a sensor 6 to sense a binary event created by the tool 5 includes positioning the pressure switch sensor 110 at the surface 1 in the flow of the tubing 20 . As noted above, the pressure switch sensor 110 according to the exemplary embodiment described above may be a check valve or pressure valve. Processing the sensor 5 output, at block 330 , includes processing system 7 (e.g., surface processing system 130 ) providing the indication of a cavitation condition to an operator. Alternatively, processing the sensor 5 (pressure switch sensor 110 ) output includes monitoring the frequency or duration or both of the cavitation condition to determine an action such as, for example, shutting down or slowing down the pump 40 .
[0014] 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 system and method to identify a condition of cavitation or gas lock in a pump configured to convey a liquid to a surface from a subsurface environment via tubing are described. The system includes a tool to create a binary event based on the condition, the binary event representing a change in state of a parameter. The system also includes a sensor to detect the binary event based on the parameter, and a processor to process output from the sensor to identify the condition. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application is a continuation-in-part of U.S. patent application Ser. No. 14/517,905 filed on Oct. 19, 2014, and claims priority to U.S. patent application Ser. No. 13/543,554, filed on Jul. 6, 2012, U.S. provisional patent applications Ser. No. 62/076,259 filed on Nov. 6, 2014, and Ser. No. 61/523,253 filed on Aug. 12, 2011, all of the disclosures of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to enhancing navigation capabilities for locating equipment used in horizontal directional drilling, and more specifically it relates to extending the operating range and increasing the operating modes of the current locating tools.
BACKGROUND
[0003] Directional boring, commonly called horizontal directional drilling, is a steerable trenchless method of installing underground pipes, conduits and cables or the like in a shallow arc, along a prescribed subsurface bore path by using a specialized drilling rig. The drilling assembly that creates the boring is surface launched at a shallow angle and is steered along the predetermined path.
[0004] Pipes laid, or well casing installed in this manner can be made of materials such as iron, steel, PVC, polyethylene, polypropylene, or the like.
[0005] Products installed by directional drilling are typically used for utilities transmission or distribution, water supply, or remediation of contaminated soil or groundwater.
[0006] With this type of drilling there is typically minimal impact on the surrounding area compared to trenching or other alternatives. Directional boring can often be used when trenching or excavating is not practical, such as under roadways, or other existing structures. It is suitable for a variety of soil and rock conditions.
[0007] One feature of horizontal directional drilling is the incorporation of electronic locating equipment that enables the driller or another crew member to determine the relative position of the drill head in three dimensions and in real time. This information—typically X and Y coordinates along the ground surface, the depth below ground surface, and the current pitch or angle of the drill bit—is used to determine if the bore is being advanced along the desired path and to enable the driller to make steering corrections as necessary to maintain the path.
[0008] Electronic locating equipment may be supplied in several forms and uses several different technologies. The simplest, easiest to employ, and least expensive locating equipment is battery powered and comprises a combination of an instrument package that is placed in a housing behind the drill bit (the “sonde” and “sonde housing”) and a receiver assembly (the “receiver”) that is carried by a technician at the ground surface along the bore path, over the drill bit, during drilling operations. The sonde contains sensors to monitor various parameters such as temperature, tool pitch and roll, and battery strength, as well as a radio transmitter and antenna that emits an electromagnetic signal that is analyzed by the receiver to calculate the drill head position. This combination of sonde and receiver is known in the industry as a “walkover locating system.”
[0009] The exemplary walkover sonde that is commonly used in the industry comprises a metallic and resin cylinder that contains a circuit board, transmitting antenna, and battery compartment. The circuit board contains various sub-components, including the RF transmitter, antenna, and other sensors described above. The electronics and other components on the circuit board are encapsulated in an epoxy resin to provide a singular electronics package that is water-resistant and durable.
[0010] In another embodiment of a locating sonde for deeper drilling, the sonde contains geomagnetic sensors that detect the earth's magnetic field for determination of tool azimuth. These systems made be used at depths too great to receive a signal at the surface from a subsurface transmitter. Through computer analysis of azimuth, pitch, and drill string length calculations, the sonde position may be fixed in three dimensions. In this embodiment, the sonde does not contain an antenna to transmit a signal directly to the ground surface, but instead sends the signal through a hard-wired wireline connection which is threaded through the drill string to a connection at the drill rig itself. The wireline is used for signal transmission as well as to supply power to the sonde.
[0011] Due to practical engineering constraints in smaller drilling equipment, locating sondes have been limited in size, both in diameter and length, in order to fit into common drill tooling. For bores up to approximately 80 feet in depth, the currently available sondes provide adequate signal strength for locating. However, below this depth, signal strength typically declines to an unusable level. Further, the existing sonde packaging does not permit the use of larger antennae or additional batteries to emit a more powerful signal. To date, there has not been integration between the sonde itself and the housing which encloses it in order to provide this enhanced capability.
[0012] The capabilities of this technology are evolving, and borings of greater depth and length are now feasible that were not possible previously. As a result, there is an increased need for locating equipment that has enhanced capabilities to enable locating at greater depths and longer bore lengths, and that also have longer battery life to allow greater distances to be drilled before battery failure. A locating system that allows increased battery capacity or a larger antenna array would be of benefit to the industry.
[0013] Additional developments in the industry include the use of miniaturized radio repeaters that can be embedded in the individual drill rods comprising a drill string. Such repeaters may be used to transmit a radio signal for great lengths up the interior of the drill string, which serves as a wave guide to focus the transmission. Such a system could be easily adapted to use with locating technologies intended for depths greater than typically used for battery operated sondes. Such a system would eliminate the requirement for a wireline to transmit the sonde signal to the surface, but with current technology would not eliminate the need for the wireline to supply power to the sonde.
SUMMARY
[0014] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
[0015] This presents an invention for improving the capabilities of a directional drilling locating system. The invention provides an integrated system for attaching a locating sonde to the end of a string of drill rods and system. The sonde includes locating electronics that may be securely received within a chamber formed within the sonde.
[0016] In disclosed embodiments, the one or more chambers may be provided and the electronics can include a battery, a sensor, a transmitter, an antenna and connecting wires. One or more secure windows may be provided in the sonde body to allow the locating electronics to wirelessly transmit outside of the sonde body. The electronics may be potted within the chamber with a solidifying potting agent to improve durability of the electronics in a drilling environment.
[0017] Many of the attendant features will be more readily appreciated as the same becomes better understood by reference to the following detailed description considered in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0018] The present description will be better understood from the following detailed description read in light of the accompanying drawings, wherein:
[0019] FIG. 1 shows a horizontal drilling operation.
[0020] FIG. 2 shows a process for horizontal drilling.
[0021] FIG. 3 shows a system for drilling and installing a well casing in a single ended completion.
[0022] FIG. 4 shows a process for single ended completion drilling.
[0023] FIG. 5 shows a specially designed system for drilling and installing well casing in a single-ended completion that tends to improve drilling performance.
[0024] FIG. 6 is a process flow diagram showing a unique, exemplary method of creating a well utilizing the system described herein.
[0025] FIG. 7 shows a conventional centered sonde assembly.
[0026] FIG. 8 shows a specially constructed offset transmitter sonde assembly.
[0027] FIG. 9 shows an end view of the offset sonde housing.
[0028] FIG. 10 shows the assembly of drill string systems components, including the adapter with latch mechanism coupling a sacrificial drill bit assembly to an offset sonde housing forming a flush interior drilling string.
[0029] FIG. 11 is a process flow diagram for a process of detaching or knocking off a drill bit.
[0030] FIG. 12 shows the knock off bit assembly in the drilling configuration.
[0031] FIG. 13 shows the knock odd drill bit assembly prior to being detached, or knocked off.
[0032] FIG. 14 shows the knock off bit assembly knocked off or detached from the drilling string.
[0033] FIG. 15 is an exploded, longitudinal cross-sectional view of a sonde in accordance with an embodiment of the present invention.
[0034] FIG. 16 is a cross-sectional view of the sonde of FIG. 15 taken along line 16 - 16 of FIG. 15 .
[0035] FIG. 17 is a cross-sectional view of an alternative possible sonde assembly showing an alternative possible triple internal chamber option.
[0036] FIG. 18 is a cross-sectional view of a second alternative possible sonde assembly showing a second alternative possible pass-through sonde chamber.
[0037] FIG. 19 is a cross-sectional view of a third alternative possible sonde assembly showing a third alternative possible internal orientation of components within the sonde chamber.
[0038] Like reference numerals are used to designate like parts in the accompanying drawings.
DETAILED DESCRIPTION
[0039] The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or utilized. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.
[0040] The examples below describe a System and Method for Installing Casing in a Blind Horizontal Well. Although the present examples are described and illustrated herein as being implemented in a horizontal system, the system described is provided as an example and not a limitation. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of drilling or boring systems.
[0041] FIG. 1 shows a horizontal drilling operation, or double ended installation, or equivalently double ended completion 100 . The double ended completion drilling is shown at various stages of completion. Horizontal directional drilling may be used to install utilities and pipelines and to construct river crossings and shoreline approaches for submerged pipelines, power and communications lines and the like. Horizontal drilling may also be used to install horizontal wells for environmental projects such as the remediation of contaminated soil and groundwater, for reinjection of treated water from industrial processes, for groundwater development and the like.
[0042] In a type of horizontal directional drilling project called double-ended completion a well casing may be installed, a drill rig 106 may be situated at an entry location 101 . A borehole is extended underground 105 to an exit location 102 some distance away, whereupon the drill bit (not shown) at the end of a drilling string may be detached and a swivel and reaming tool (not shown) may be attached. The product (not shown) to be installed on the bore hole (such as exemplary casing, wiring, or the like) is then attached to the swivel and the material is pulled back 103 into the exit end of the boring until it emerges at the entry end, and the exemplary well casing is installed 104 .
[0043] FIG. 2 shows a process for horizontal drilling, or double ended installation. First a pilot bore may be drilled from entry to an exit point 201 . Next a decision is made at 202 where it is determined if the bore needs to be enlarged so the casing may fit. If the casing will not fit, and the bore needs to be enlarged 209 than at block 203 the bore is reamed to the proper diameter before proceeding to block 204 . If the bore does not need to be enlarged 208 , the drill string is next extended through the bore to the exit 204 . Continuing on at block 205 , materials to be disposed in the well bore are attached to the end of the drilling string. Next the drilling string and attached materials are pulled back towards the drilling rig, while the rods are removed from the drilling string 206 . And finally at 207 the well instillation is complete.
[0044] FIG. 3 shows a system for drilling and installing a well casing in a single ended completion 300 . The single ended completion drilling is shown at various stages of completion. In a type of horizontal directional drilling project called single-ended completion, or “blind” well completion the borehole may not exit the ground 105 . Instead, the drilling rig 106 , may start the pilot bore 301 , with the bore drilled to some length without having exited the ground 105 . After the pilot bore is complete. the bore hole may be reamed if needed 302 . Next, the drilling tools that may include a drilling string or a reamer are removed from the borehole 303 , and the well casing and screen are installed from the entry end 304 . Such an installation procedure is similar to that for a conventional vertical well. This type of drilling may often be used for environmental projects.
[0045] FIG. 4 shows a process for single ended completion drilling 400 . First a pilot hole or bore may be drilled from an entry point to a desired depth 401 . Next, after the bore reaches it desired depth it is determined if the bore needs to be enlarged to fit a casing being installed in the well 401 . If the bore needs enlarging 404 the bore is forward reamed to a desired diameter 405 . The sub process in block 406 is then executed.
[0046] Returning to block 401 , if the bore does not 403 need to be enlarged to fit the casing, then the drilling string is removed from the bore 406 . Well materials to be installed into the bore hole, are pushed in from the entry location. Occasionally during this process the bore hole might have caved in 408 . If so 409 , then the process returns to block 405 , where it is repeated to open the closed bore. If not 410 then the well instillation is finished 411 .
[0047] There can be problems in single-ended completion drilling. In cohesive soil materials, single-ended completion generally provides acceptable results. The borehole may remain open for a sufficient duration to allow the well materials to be inserted. However, in non-cohesive soil materials, the borehole may collapse, preventing the installation of the well materials. This may call for re-drilling the bore to a larger size, using higher viscosity drilling fluid, or other remedies that may degrade the effectiveness of the completed well.
[0048] Also in horizontal directional drilling the bore is not necessarily straight. During the drilling operation, the drilling tools can be steered by orientation of an asymmetric drill bit, guided by information received from a transmitter sonde (not shown) that is disposed in the drill string. A conventionally constructed sonde is typically positioned in-line behind the drill bit. In exemplary implementations, the sonde transmitter may be encased in a sonde housing made of steel or other suitable material, with ports machined into the housing walls to allow the transmitter signal to escape. The conventionally constructed sonde in current implementations is substantially centered along the central axis of the sonde housing.
[0049] FIG. 5 shows a new system for drilling and installing well casing in a single-ended completion that tends to improve drilling performance by utilizing a knock off drill bit 500 . This type of drilling makes use of a specially constructed drill bit assembly, that includes a drilling string with a knock off drill bit and a specially constructed sonde, to implement a new method of horizontal drilling.
[0050] The system and method also uses drill rods with an open interior passage that enables the well casing and screen to be emplaced through the drill string. The system and method also uses unique navigation sonde housing, described herein, that uses an offset sonde cavity to maintain a through passage within the sonde housing. The system and method also uses a special drill bit holder or latching mechanism, also described herein, that permits the drill bit to be detached underground after the drilling has been completed, allowing the drill string to be retracted over the emplaced well materials after they have been pushed into the drill rods.
[0051] To illustrate the specialized system and method in operation a well during various stages of completion is shown 500 . As shown a drilling rig 506 with controls suitable for operation as part of the modified drilling system starts a bore 501 utilizing a knock off drill bit (shown generally at 504 ) coupled to the large diameter drilling string and the unique sonde housing (not shown). This is unlike the usual pilot bore where the drilling string is removed prior to installing the well casing. Here the string remains in the bore until the well casing is in place. As the bore progressed from start 501 , to completion 502 , the drilling rig 506 controls the drilling progress, and guides the drill as the bore is completed 502 .
[0052] When the bore is completed 502 , the large bore drill string remains in the pilot bore, with the hollow drill rod supporting the walls of the bore hole (unlike the conventional process where the drilling string is retracted and the walls of the bore hole may be prone to collapse). In the typical process the drilling string must be removed before casing is inserted into the bore hole because the drill bit is fixed at the end of the string and the string and drill bit must be removed to make way for the casing to be inserted in the bore as the bit cannot be removed while at the end of the blind hole. The well casing material is inserted through a cavity disposed inside of the drilling string remaining in the bore hole with the specially constructed drill bit and sonde housing remaining at the blind hole end of the bore hole. Typically, the inserted casing would block removal of the drill string with the drill bit fixed at its end. However, with the specially constructed knock off drill bit the casing may be inserted while the drill bit remains at the end of the bore 503 .
[0053] Next to allow the drill string to be removed from the bore and leave the casing in place, the drill bit is remotely disconnected from the drill string and left at the blind end of the bore 504 , allowing the drilling string to be removed.
[0054] The drilling string supports the casing and keeps the bore open as the drilling string is extracted 505 . Once the drilling string is extracted, the casing walls are no longer shielded by the interior cavity of the drilling string, and the casing walls are then in close proximity or contact with the walls of the bore hole. Since the casing is already in place when the drilling string is removed, there are no problems with trying to insert a casing down a collapsed bore hole. As the walls of a bore hole collapsing can be a problem in the conventional process, especially in loose soil. Accordingly this system allows for increased productivity in drilling single ended completion wells, as the need for re-drilling collapsed bore holes, or even being unable to drill a bore hole in loose soil tends to be eliminated.
[0055] In exemplary operation, the driller assembles a drill head assembly 1000 including, at the far end, the knock off bit assembly 1003 , coupled either directly or with an adapter 1002 , 1005 to the offset transmitter sonde assembly 800 . In turn, the offset transmitter sonde assembly is connected, directly or by use of an adapter, to the end of a flush interior drill rod 1007 . As the borehole is advanced 501 , with steering and navigation, additional drill rods (not shown) are added to the advancing drill string 507 .
[0056] The drilling process continues as previously described, until the bore reaches the desired depth 502 . In the current example the permanent well materials 508 that are to be left in the bore may include well screen (not shown) and well casing materials that are to be installed in the completed bore are assembled and inserted into the inside annulus of the drill rods 1007 . When the permanent well materials reach the end of the drill string, they are physically manipulated by a combination of pressure and/or rotation in order to unlatch the knockoff bit assembly 1003 and may push the knock off assembly 1003 away from the end of the drill string. In this fashion the permanent well materials 508 are then enabled to exit the end of the drill string and enter the open bore. The drill rods 1007 are then extracted from the bore, leaving the permanent well materials 508 in place.
[0057] A method of creating a well described herein may utilize one or more unique components or sub-assemblies 1003 , 1002 , 1005 , 800 , 1007 which may be combined into a system, as described above, and operated in accordance with a method to produce a well.
[0058] FIG. 6 is a process flow diagram showing a unique exemplary method of creating a well utilizing the system described in FIG. 5 . First at block 601 a bore is drilled from an entry point to a desired depth with the specially constructed drilling string. At block 602 the drilling crew, with the aid of the drilling rig push or otherwise insert, or install the well casing materials through an annulus disposed in the drilling string. The casing materials are disposed in the interior of the drilling string. As the well casing materials reach the end of the bore, they encounter a latch mechanism disposed on the knock off drill bit assembly that when actuated by engagement with the well casing materials causes the drill bit assembly to disengage or otherwise uncouple from the drilling string at block 603 . At block 604 the well casing materials may be used to further push the disengaged drill bit assembly, and the well materials past the end of the bore. This may be done to position an exemplary well screen, or otherwise free the end of the bore from obstruction.
[0059] At block 605 the drilling string is removed from the bore leaving the well casing in contact with the surrounding ground, and the sacrificial knock off drill bit assembly in the ground at the end of the bore hole. At block 606 well installation is completed.
[0060] In the system and method previously described, a specially constructed offset transmitter sonde assembly that contains an open central passage through which well casing can be inserted, and a specially constructed drill bit assembly that can be remotely activated to open a passage, whereby the casing can be installed in a directional drilled bore. In particular the method described above may utilize 1) an offset transmitter sonde assembly, 2), a knock off drill bit assembly and 3) a flush interior drilling string which will be described in the following paragraphs.
[0061] FIG. 7 shows a conventional centered sonde assembly 700 . In this device a sonde 702 is coaxially located in a sonde cavity 707 that may include an indexing mechanism 708 . The cavity 707 may be sealed with a cap 701 to protect it from drilling fluid flowing through passageways 704 , and from other contaminants.
[0062] Location and guidance of the drilling is important since the drill bit is not visible while drilling. If uncontrolled or unguided the well path can deviate from the desired path.
[0063] Various types of locating equipment may be used for locating the droll bit. A sonde, or transmitter, typically disposed behind the drill bit may register angle, rotation, direction, and temperature data. This information may be encoded into an electro-magnetic signal and transmitted through the ground to the surface so that a nearby receiver may pick up the signal. The signal is decoded and steering directions may be relayed to the drilling machine operator to change the course of the drilling.
[0064] The sonde is typically a radio frequency device, and for the radio waves to be received ports 706 are typically provided in the sonde housing 705 . The sonde housing 700 may be coupled in line with the drilling string and accordingly threads 703 , 709 may be provided to couple the sonde to the drilling string.
[0065] In this type of unit the locator sonde 702 is located in the axial center of the drilling string. this type of sonde is unsuitable for use with the present examples since the center location of the sonde 702 , when thread coupled to the drill string 709 , would prevent insertion if the well casing interior, and also interfere with the ability to use the well casing to knock off the drill bit assembly. The sonde assembly could in alternative examples be made sacrificial as well, but to save expense it is advantageous to utilize a specially constructed offset sonde assembly.
[0066] FIG. 8 shows a specially constructed offset transmitter sonde assembly 800 suitable for use in the exemplary system. The example described herein is of a special “offset” sonde which differs from a conventional sonde housing previously described. In the current configuration, the cavity 808 which holds the locator sonde 805 is disposed within the sonde housing 811 in its exterior wall, and not at the center. Advantageously the sonde 805 is in close proximity to one or more radio transmission ports 806 . The cavity is plugged 804 , and an indexing mechanism 809 may be disposed in the cavity 808 . This arrangement clears the center of the housing 807 so that the well casing is not blocked. The centralized sonde of FIG. 7 tends to block the advancement of tooling through the central annulus of any drill rods that are attached to it.
[0067] Various configurations of ports may be machined into the housing to permit the free flow of drilling fluid past the offset sonde 804 , 806 , 808 , 809 , through various adapters or couplers, through the drill bit assembly, and finally exit from the cutting face of the drill bit. The exemplary sonde housing may utilize a two piece housing including a sonde housing end piece 801 that may be thread coupled, or equivalently coupled 802 to a drill string. The opposite end of the end piece may include threads or their equivalent to couple to the main housing 811 .
[0068] The offset transmitter sonde assembly may include a housing 811 which contains an internal passage 807 through which well casing (not shown) can be inserted, a cavity 808 in which a transmitting sonde 806 can be disposed, threaded ends 802 , 810 by which the assembly can be attached to a drill string, and various passages and ports through which conventional drilling fluid, such as an aqueous based bentonite, polymer drilling fluid (not shown) or the like can be circulated and from which electromagnetic signals can be broadcast from a commercially-available transmitting sonde 805 to the exterior of the assembly 806 . The sonde assembly may be constructed from any suitable material.
[0069] The sonde is located to allow the viscous aqueous fluid known as drilling mud to circulate to the drill bit. Allowance in the design is made to pump the drilling mud to the cutting head or drill bit so that it may remove cuttings, and cool the drill bit among other functions.
[0070] FIG. 9 shows a simplified end view of the offset sonde housing 811 . The offset transmitter sonde assembly 800 described enables the operator to use a commercially available locating sonde 805 , disposed in an offset sonde cavity 808 , and transmitting through radio transmission ports 806 , with the knock off bit assembly. The offset sonde assembly 800 may be constructed such that the sonde 805 is located off the longitudinal axis of the drill string and does not block the central annulus thereof, which remains unobstructed 807 . Well casing materials (not shown) can be inserted through the central annulus 807 without being obstructed by the sonde 805 , which would be the case with conventional, centered sonde housing.
[0071] FIG. 10 shows the assembly of drill string components 1000 including an offset sonde knock off drill bit assembly 1002 coupled to a flush interior drilling string 1009 . The primary system components 1000 , may be considered to form two major sub-assemblies; the assembly recovered from the bore hole after detachment, 1004 , and the assembly left in the bore hole after detachment 1003 .
[0072] The assembly recovered from the bore hole after detachment 1004 may include a flush interior drilling string 1009 , includes a retrievable portion, or equivalently the retrievable knock off assembly with latch mechanism 1005 of an adapter 1010 coupled to the transmitter sonde assembly 1006 then to a plurality of individual drill rods 1007 coupled end-to-end in a continuous string going back to a drill rig (not shown). Each drill rod 1007 , and the offset sonde housing contains an interior annulus, which is flush through the entirety of the string with no protrusions into the annulus. The annulus is of sufficient diameter to allow a selected well screen and casing 1008 to pass through. The adapter portion withdrawn 1005 , may include a latch mechanism that is recovered.
[0073] The assembly left in the bore hole after detachment 1003 includes a sacrificial adapter, or sacrificial knock off assembly 1002 , which is part of the adapter 1010 that remains in the bore hole. The sacrificial adapter 1002 couples to a detachable drill bit 1001 . The sacrificial adapter may include a standard female threaded portion, into which a standard drill bit 1001 can be coupled.
[0074] The latch mechanism 1011 may be constructed in any suitable way to allow the sacrificial knock off assembly described herein to be knocked off utilizing the method of actuating knocking off the bit described herein. In the example provided herein, the retrievable knock off assembly with latch mechanism 1005 attaches to the sacrificial knock off assembly 1002 with a cam or latch arrangement 1011 which can be unlatched when desired to insert well casing. Unlatching the cam mechanism 1011 detaches the bit holder or sacrificial knock off assembly 1002 and bit 1001 from the drill string 1005 , 1006 , 1007 , leaving it 1002 , 1001 in the borehole. Unlatching is achieved by the action of inserting the well casing (and typically including a well screen) 1008 through the hollow drill rod 1007 , so that when the casing 1008 reaches the latch mechanism 1011 , contact with the latch mechanism 1011 , disengages the latch 1011 .
[0075] The construction of the latch may be provided in various alternative examples in which configurations of parts which lock in place to retain the drill bit sacrificial knock off assembly 1002 , and subsequently unlock with an unlatching collar or equivalent structure to release the latch 1011 , are all within the scope of this invention. For example although a latching mechanism actuated by a pushing motion has been described, in alternative examples a latching mechanism that may be caused to unlatch by rotational movement, a combination of both, or any other motion or force that may be applied to the adapter 110 may be provided. Further, the sacrificial knock off assembly 1002 may also be used to retain an end plug or other tooling, which is subsequently uncoupled to permit casing installation in a pre-drilled bore.
[0076] The adapter 1010 may be constructed to retain a standard horizontal directional drill bit or tri-cone bit 1001 while drilling, and enables the bit 1001 to be remotely detached from the assembly recovered 1004 from the bore hole when the borehole has been advanced to a target location. The assembly contains a retrievable knock off body 1005 and a sacrificial knock off body 1002 . The drill bit 1001 may be threaded into the sacrificial body 1002 , which is then locked into the retrievable body 1005 and may be held in place with set of splines and a latch mechanism, or its equivalent. The latch mechanism 1011 prevents the sacrificial body from becoming unlatched in normal use. The adapter 1010 can be constructed to fit virtually any drill bit diameter or thread size, or may be assembled to a standard bent sub and used with a conventional tri-cone drill bit. The assembly may be constructed of a variety of materials, including carbon steel, stainless steel, or non-magnetic alloy.
[0077] The latch may be constructed as needed to implement the disengagement process provided below.
[0078] FIG. 11 is a process flow diagram for a process of detaching or knocking off a drill bit. The adapter is constructed to facilitate the disengagement of the drill bit remotely either by engagement with the well casing, an unlatching collar, or other such tool. For example, when it is desired to remove the drill bit from the end of the drill string, at block 1101 an unlatching collar is attached either to the end of the well casing or to a set of smaller drill rods, 1102 extended inside the drill string to put the unlatching collar in close proximity to the adapter for unlatching. The knock off tool may be inserted into the drill string at the distal end of well casing to be installed in the bore, or may be attached to a smaller diameter drill string to detach the drill bit retainer and bit prior to well casing placement. At block 1103 the unlatching collar engages the latch mechanism and unlocks it from the retrievable body. The knock off tool may be operated by a linear extension of the tool (“pushing”) along the axis of the knock off bit assembly, or the retainers may be configured to require a rotational movement to unlock. In the current description, a straight linear motion is described. With additional extension of the knock off assembly and retraction of the primary drill string at block 1104 , at block 1105 the drill bit and sacrificial body are detached from the end of the drill string and left in the bore as the well casing is installed (if not previously done at block 1101 ) at block 1106 through the hollow drill string and offset transmitter sonde assembly. Finally the drill string is removed at block 1107 .
[0079] To implement this process the knock off bit assembly can be assembled in a wide variety of configurations, and with different retention components. Including the examples provided herein, the present invention includes any configuration of parts which, when assembled, enables the drill bit to be remotely removed from the end of the drill string, leaving an open bore through the base housing, through which the well casing can be installed.
[0080] The following figures will further describe the knock off mechanism and process without the offset sonde assembly present. Although in equivalent alternative examples the offset sonde assembly may be included, or excluded from the drilling string depending upon the drilling situation, and operator preferences.
[0081] FIG. 12 shows the knock off bit assembly in the drilling configuration 1200 . A drill bit assembly is provided including a novel coupling system that enables a soil or rock drilling bit and a portion of the drill bit assembly to be remotely disconnected from a drill string at a desired subsurface location. The assembly comprises a retrievable knock off body 1005 and a sacrificial knock off body 1002 to retain a bit 1001 . Additionally, the adapter 1005 , 1002 includes a latch mechanism 1206 that unlocks the sacrificial knock off body 1002 from the retrievable knock off body 1005 , enabling the sacrificial knock off body 1002 with the drill bit 1001 coupled to it to fall free from the retrievable knock off body 1005 .
[0082] The retrievable knock off body 1005 is a cylindrical tube of steel or other suitable material, with an inner diameter somewhat larger than the outside diameter of a well casing or a smaller diameter drill rod (not shown) that may be ultimately installed in the bore. At casing end of the retrievable knock off body 1005 a set of threads 1311 may be machined, and used to connect the retrievable knock off body 1005 to the end of the drill string 1311 , which subsequently extends up hole to the drill rig. At the other end of the retrievable knock off body 1005 a splined coupler 1205 or its equivalent is formed in the removable knock off body 1005 and the sacrificial knock off body 1002 , and include a set of radial serrations. Mating engage to mating serrations to rotatably drive the drill bit 1001 . These mating serrations or teeth comprise a Hirth coupling which transfers torque from the retrievable knock off body 1005 to the sacrificial knock off body 1002 , and drill bit 1001 during drilling. Inside the retrievable knock off body 1005 is a plurality of latching recesses 1204 , which engage a matching set of pivotally disposed locking levers in a latching mechanism 1206 on the sacrificial knock off body 1002 , to lock the Hirth, or splined coupling 1205 together during drilling operations. The serrations of the Hirth coupling which engage with the mating serrations of the retrievable knock off body 1005 are machined into the secondary adapter piece 1211 .
[0083] The sacrificial knock off body 1002 may be a cylindrical tube of steel or other suitable material having a secondary adapter piece 1211 and a neck 1210 extending into the annulus of the retrievable knock off body 1005 . The neck 1210 , may form a guide for an unlatching collar ( 1303 of FIG. 13 ) that may slidably engage the neck to activate the latch mechanism 1206 . Into the neck 1210 may be formed the latch mechanism 1206 , may be pivotally disposed, and with levers coupled to latching recesses 1204 to keep the coupler 1205 engaged. It may be coupled by any suitable method to a secondary adapter piece 1211 which may include a portion of the coupler 1205 , and also couples to the drill bit 1001 . To couple the sacrificial knock off body 1002 to the drill bit 1001 it is threaded with industry-standard female threads. The threads engage with mating threads on a standard drill bit 1001 . Alternatively, the neck 1210 , and the second adapter piece 1211 may be machined or otherwise formed from a common piece of material, eliminating any need to couple two separate pieces.
[0084] The latching mechanism 1206 includes a plurality of locking levers, in which springs, and axles or pins may hold the levers in an engaged position to the recess 1204 . Alternatively, the latching mechanism 1206 may be constructed to couple to the sacrificial knock off body 1002 to the retrievable knock off body 1005 .
[0085] The coupler body 1005 is coupled through a threaded coupling 1311 to a drill string, comprising a plurality of connected drill rods that extend to the drill rig. As the boring is advanced, additional drill rods are attached to the drill string at the drill rig. The coupler body threaded coupling 1311 may be machined with any of several standard thread patterns. The coupling between the coupler body 1301 and the drill string may be made directly to a drill rod end, or to an adapter or sub, which may be used to adjust the length of the drill string or to adapt from one thread pattern to another. The coupler body connection may also be made to an offset sonde housing ( 800 of FIG. 8 ), which contains an electronic package that is used for locating the drill bit while drilling in order to enable steering corrections to be made.
[0086] The borehole is advanced using conventional horizontal directional drilling technology, with walkover navigation. The electronics sonde for the walkover navigation are enclosed in the offset sonde housing (not shown).
[0087] FIG. 13 shows the knock odd drill bit assembly prior to being detached, or knocked off 1300 . In this view a bore hole has been completed and the exemplary well casing, or smaller diameter drill rod 1305 has been inserted through the drill string 1007 . At the end of the drill string may be disposed any suitable structure to uncouple the drill bit 1001 such as the exemplary unlatching collar or bit retainer disengagement tool 1303 .
[0088] In knocking off the drill bit linear motion 1330 transmitted through the well casing by an operator, causes the unlatching collar 1303 to engage the neck of sacrificial knock off body 1002 where the collar 1303 is guided outwardly engaging the ends of locking levers 1323 through force exerted by the collar 1303 . Locking levers 1323 , are generally linearly formed structures, and are pivotally coupled to sacrificial knock off body 1002 . On the side of the pivot 1324 opposite to that being outwardly engaged by the unlatching collar, the lever extension is forced inwards 1331 , to disengage the sacrificial knock off body 1002 , since that end of the locking lever 1323 , had previously been engagedly coupled to a recess 1204 disposed in the retrievable knock off body 1002 . The discussion above has focused on describing the operation of a single latch however it is understood that a plurality of latching mechanisms may be present, and operable at the same time.
[0089] FIG. 14 shows the knock off bit assembly knocked off or detached from the drilling string 1400 . The well casing 1305 , with the unlatching collar 1303 disposed at its end, has disengaged the sacrificial knock off body 1002 , by uncoupling latch mechanism 1206 , through it's being pushed through the interior of the well casing 1305 . Once detached the well case, may be pushed further so that the end of the bore is somewhat cleared. The well casing 1305 may be retracted as needed to distance it from the sacrificial knock off body 1002 remaining in the bore hole. Finally the hollow drill rod covering the well casing may be removed, leaving the well casing disposed in the well bore.
[0090] In the description herein horizontal is generally taken to mean generally having more run than rise (45 degrees or less elevation from I level plane). However, horizontal as used in describing the boring angle capable of being created by a horizontal drilling machine, and may include bores of a constant bore angle, or bores that change their angle, such as those that may be created by first drilling at an acute angle with the ground surface, and are then caused to level off to a substantially horizontal angle.
[0091] Referring to FIGS. 15-19 , a multi-chamber sonde housing 1500 having one or more additional chambers 1502 received therein is disclosed. These chambers 1502 offer an improved way of arranging the components of a locating system, as well as an improved way to contain those components at the end of a set of drill rods down a bore hole.
[0092] In FIG. 15 , a rigid housing 1504 , such as a steel or the like, is attached to the end of the drill string, between the drill bit and the drill rig. The housing has one or more chambers 1502 formed into it, such as by drilling or the like, with end caps 1501 operably secured at each end as shown. The locating transmitter 1510 , within the sonde, is divided up into various component modules—the electronic circuitry 1512 , one or more antennas 1514 , and one or more battery packs 1516 —and the modules are inserted into the chambers 1502 and connected together appropriately with connecting wires 1518 or the like.
[0093] The number of chambers 1502 within the sonde housing 1500 can be as many or as few as required. FIGS. 15 & 16 show two chambers 1502 received therein. FIG. 17 shows three chambers 1502 received therein.
[0094] Referring to FIGS. 18 & 19 , the sonde housing 1500 may be a large hollow cylinder. The interior shaft 1560 that goes through it is designed to be strong enough to handle the stress of drilling. The large, hollow chamber 1502 ′ that surrounds it contains the sonde transmitter. The outer part 1562 of the sonde housing 1500 primarily provides protection for the sonde, has windows 1564 in it that are transparent to radio and magnetic signals such as high-strength plastic or boron glass or carbon fiber or the like. The sonde (the combined electronics, antenna and battery power) are cast or potted into a single module, preferably with a hardening filler 1563 such as epoxy potting resin or the like, shaped like an elongate donut—which slides into this chamber. In this embodiment, the advantage is that all of the electronic parts are already connected and placed into predetermined positions so there is less likelihood if installation error and few electrical connection problems in the field because it is solid state. The only moving parts are the caps on the battery chamber 1570 .
[0095] Those skilled in the art will realize that the process sequences described above may be equivalently performed in any order to achieve a desired result. Also, sub-processes may typically be omitted as desired without taking away from the overall functionality of the processes described above. | A drill assembly with a drill body coupled to a drilling string and a sonde body having a least one chamber defined therein for receiving locating electronics therein. In disclosed embodiment, the one or more chambers may be provided and the electronics can include a battery, a sensor, a transmitter, an antenna and connecting wires. One or more secure windows may be provided in the sonde body to allow the locating electronics to wirelessly transmit outside of the sonde body. The electronics may be potted within the chamber with a solidifying potting agent to improve durability of the electronics in a drilling environment. |
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BACKGROUND OF THE INVENTION
There is a need for environmental control dike installations where the accidental release of stored chemicals poses a threat to the environment and human safety. There are many sites around the world where petroleum-contaminated process water, industrial chemicals, liquid agricultural chemicals or other corrosive chemicals are stored in tanks. When the tank or the connecting pipes fail the liquids are released into the environment with disastrous consequences to the environment and human safety. Business entities which maintain such facilities perform maintenance on the tanks and piping and also construct dikes to prevent the accidental spills from spreading. Most dikes are constructed of earth, concrete or wood in such a way as to be permanent. Expansion for added capacity is impractical and expensive. The permanent systems are costly and leave a permanent scar on the area, even when vacated.
One system of temporary concrete bolt together panels has no effective system of covering the horizontal surface of the ground inside the vertical walls.
Metal containment dike systems are known. These systems can be easily transported to remote locations and are easily assembled. They are useful for containment of many types of materials. Prior metal systems, however, are not useful in the containment of material such as liquid fertilizers, which are highly reactive to metals.
Prior metal systems having wall sections which are directly bolted to support posts are susceptible to frost heave damage. In particular, differential frost heavage between the wall sections and the support posts causes the seal of the containment wall to be compromised and requires costly maintenance.
A metal containment dike system is required which can be used for containment of corrosive liquids. A metal containment dike system is also required which can be used in areas where frost heavage is a concern.
Dike systems are often used in combination with fencing systems. The fencing systems act to prevent entry of animals and unauthorized personnel. Fencing systems are often installed outside of the metal containment system requiring installation of a duplicate set of posts in concrete.
A metal containment dike is required which can be combined with a fencing system.
SUMMARY OF THE INVENTION
A metal containment dike system is provided which is cost-effective and expandable. The system can provide for attachment of a liner rendering it useful for containment of metal-reactive liquids. The system can also accommodate differential frost heaving action between the support post and the wall sections. Alternately or in addition, the system provides for the attachment of a fence above the vertical wall section.
In accordance with a broad aspect of the present invention there is provided a containment dike system comprising: a wall constructed of metal forming an enclosure; and a flexible material lining the enclosure, the material being resistant to the passage of liquid therethrough.
In accordance with another broad aspect of the present invention, there is provided a containment dike system comprising a wall constructed of metal forming an enclosure, the wall including at least one wall section; at least one post for supporting the wall section, the wall section being secured to the post by a fastener engaging the wall section and extending through an aperture formed through the post, the aperture having a length and being sized to permit movement of the fastener along the length of the aperture while being retained therein; a flexible material lining the enclosure, the material being resistant to the passage of liquid therethrough and being secured to an upper edge of the wall.
In accordance with a further broad aspect of the present invention, there is provided a method for constructing a containment dike comprising: installing on a ground surface a wall formed of metal to form an enclosure; lining the enclosure with a flexible material resistant to the passage of liquid therethrough; and applying solid materials on the liner to cover a lower portion of the liner.
DESCRIPTION OF THE INVENTION
The metal dike system of the present invention includes a wall portion and a plurality of support posts. Together, the wall and posts form a continuous wall about a facility, such as a storage tank, to be contained. Preferably, a liner is disposed beneath the storage tank and is sealed to the walls. As such, a system for containment of liquids is provided.
Support posts are required along substantially straight wall sections in oblong, square or rectangular dikes. The support posts are installed securely in the ground, such as by setting in concrete. Preferably, the posts are set below average frost depths. The support posts can have any suitable form and can be manufactured from any suitable materials. Suitable posts are, for example, galvanized steel pipe or beams. In a preferred embodiment, the posts are formed as galvanized sheet steel beams with Z-shaped cross sections.
The wall portion extends substantially vertically upwardly from ground level and can be any desired height. The area within the wall and the height of the wall above ground level is usually selected with reference to the volume of liquid which is to be contained. The wall portion is generally formed in sections having predefined lengths, for ease of handling, and of any suitable metal materials such as, for example, corrugated galvanized steel. The wall sections are connected to each other along the length of the wall such as by the use of fasteners. Preferably, fasteners, such as bolts are inserted through alignable apertures and a sealant material is provided about the bolts and at the interface of the two segments.
The wall is secured to the support posts using any suitable means. In one embodiment, the wall is secured to each post by use of fasteners, such as bolts. The wall can be disposed with its lower edge at or preferably below the surface of the ground.
Where the dike system is installed in an environment where there is a risk of frost, an embodiment of the invention can be employed wherein the wall is secured to the support posts in such a way as to accommodate differential frost heavage between the wall and the posts. In this embodiment, the support posts have apertures for accepting a fastener acting between the wall and the post. The aperture is, as will be appreciated, sized such that the stem of a fastener can be inserted therethrough and retained therein by a nut. The aperture is formed to be elongate in a direction parallel with the long axis of the post so that a fastener, once inserted, can be moved along the length of the aperture. By use of the posts of the present embodiment, a fastener, such as a bolt can be fixed to the wall, such as by insertion through a hole, and can be secured in the elongate apertures. Movement of the wall by frost heavage relative to the post, will be permitted by movement of the bolt along the length of the aperture. It is to be understood that the fastener is inserted through the aperture in the post such that it is free to move along the length of the aperture. To facilitate such installation where a bolt/nut-type fastener system is used, a spacer, such as a bushing, is provided about the bolt stem for preventing overtightening of the nut onto the bolt. The spacer is preferably sized to space the nut from the wall a distance just greater than the thickness of the supporting post at the aperture.
Preferably, a liner is disposed beneath the ground surface within the containment area for preventing seepage of liquids through the ground. The liner is any suitable material for preventing passage of liquids therethrough. Preferably, the liner is a coated scrim such as, for example, at least 0.030 mil polypropylene coated polyester scrim or ELVALOY™ (trademark of DuPont) coated polyester scrim.
In another embodiment useful for the containment of chemicals which are reactive to metal, the surface of the wall facing the contained area is covered with a liner which prevents passage of liquid therethrough. Preferably, the liner covering the wall is an extension of the liner used to extend across the containment area and is secured to the wall in such a way that it is resistant to being torn away from the wall. In one embodiment, the liner is secured to the wall by means of a plurality of fasteners. In a preferred embodiment, the liner is folded over the upper edge of the wall and a U-shaped or V-shaped clamp having a base and a pair of upstanding walls is fixed over the upper edge of the wall and over the liner. Preferably, the clamp is formed of steel.
Fasteners are inserted to secure the clamp, liner and wall together. Preferably, the fasteners are self-drilling screws to avoid the necessity of aligning apertures. To permit the clamp to be tightly fit over the upper edge of the wall and the folded liner, the clamp can be notched, to permit bending along the length thereof. Preferably, also the walls of the clamp diverge as they extend away from the base, and are flexible so that the bracket can be easily fixed over the wall and liner without catching on the liner and then can be pressed together to secure the liner to the wall. Where a liner is used which extends to the upper limits of the wall, the seals between overlapping wall sections can be eliminated, if desired.
A corner bracket can also be provided to secure the liner at any wall corners. To reinforce the liner, a geotextile pad can be used with the liner. The pad is formed of any suitable material such as, for example polypropylene fibres, and is used as a second layer with the liner. In one embodiment, an 8 ounce polypropylene fabric is used. In an embodiment with a pad, both the pad and liner are folded over the upper edge of the wall and secured by means of the clamp.
Where a fence system is required to be installed in combination with the dike system, support posts can be used which can support a fencing structure. In this embodiment, a fence post is secured to the support post by any suitable means, such as for example, by fasteners. The fence post can be formed of any suitable materials capable of supporting fencing materials. In a preferred embodiment, the fence post is formed of a U-beam formed of galvanized sheet steel. A plurality of apertures are provided on the fence post for alignment with similarly spaced apertures formed on the support posts. Fasteners are disposed through the aligned apertures for securing the posts together. Fencing material is then secured to the fence posts. Where building code regulations require, fence posts formed of circular pipe can be used at the corners of the fence adjacent the corner of the wall.
To construct the dike system of the present invention, the supporting posts are securely installed in the ground about the area or facility to be contained. The posts are preferably installed below the average frost depth and preferably in concrete. The wall sections are then secured to the posts. The wall sections are positioned at or, generally, at most about 6 inches below the final ground surface level. The liner, and pad if desired, are extended over the surface within the dike and secured to the wall. Preferably, solid materials such as soil or gravel are placed on the liner at ground surface level to weight the liner from being moved about by wind.
If desired, where there is a risk of frost heavage, support posts can be used having elongate apertures for accepting the fasteners securing the wall sections to the posts. Where a fence is desired to be used in combination with the dike, supporting posts can be employed which are formed to accept fence posts thereon. Where the dike is to be used with liquids which are reactive to metal, the liner can be secured to the upper edge of the wall, preferably by use of a clamp.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, wherein:
FIG. 1 is an exploded view of an embodiment of the environmental containment dike system of the present invention.
FIG. 2 is an exploded view of a post and wall of the invention.
FIG. 3 is a front elevation view of a post useful in the present invention.
FIG. 4 is a side view of a bushing useful in the present invention.
FIG. 5 is a cross sectional view through a wall showing the attachment of the liner to the wall according to the present invention.
FIG. 6 is a perspective view partly in section showing the attachment of the liner to a curved wall according to the present invention.
FIG. 7 is a perspective view showing the attachment of the liner to the wall at a corner.
FIG. 8 is a perspective view of a dike system according to the present invention having a fencing system mounted thereon.
FIG. 9 is a perspective view showing the attachment of a fence post to a support post.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment will now be described with reference to FIGS. 1 through 8. Referring to FIG. 1, an embodiment of an environmental control dike system is shown. The dike system is comprised of a plurality of steel wall sections 10 supported by posts 11. Posts 11 are preferably positioned to equalize the forces of pressure on the wall. The dike further includes a liner 12 and a geotextile pad 13 beneath the liner which covers the entire enclosure's internal floor and vertical wall sections. Liner 12 and pad 13 are securely fastened by a clamping device 14 to the upper edges of wall sections 10. The dike is constructed on a ground surface 15. In a preferred embodiment, the dike system includes a layer of sand 16 beneath liner 12 and pad 13. Preferably also, a piece of geotextile pad 17 and a layer of pea gravel 18 are disposed above the liner. The pea gravel 18 supports, for example, a tank 19 for storing liquid. It has been found that a 2 inch layer of sand and a 6 inch layer of pea gravel are particularly useful.
Referring to FIGS. 2, 3, and 4, it has been found that wall sections 10 of between about 25 to 57 inches in height and 56 to 112.5 inches in length which are formed of 10 or 12 gauge high strength galvanized corrugated sheet steel are particularly useful. Sections 10 can be configured into round, oblong or rectangular shapes to almost any dimension.
Posts 11 are preferably formed from Z-beams of galvanized steel. Suitable lengths are from 6 to 12 feet depending on the height of the wall which is desired. The post spacing is preferably standard and preengineered eliminating the need for expensive engineering services to design containment to meet required capacities and permeability requirements.
The wall sections 10 are attached end to end by bolts 19a to form a continuous wall. A strip 20 of sealant is applied at the interface of the sections to create a seal therebetween. The wall sections 10 are secured to posts 11 by bolts 19b, washer 21 and nuts 22. To accommodate differential frost heave between the wall sections and the posts, elongate apertures 23 are provided on posts 11. Apertures 23 are preferably sized to permit bolts 19b to move within the aperture while being retained therein by means of nut 22 and washer 21. In particular, apertures 23 are preferably elongate in a direction parallel to the long axis of the post, indicated at 24. An aperture having a length of about 2 inches has been found to be particularly useful.
A bushing 25 is provided about bolt 19b to space nut 22 from wall 10 and prevent overtightening of nut 22. Bushing 25 is formed as a cylinder and has a length, indicated as a, which is selected to be greater than the thickness of the post at the aperture. The post 11 is set in concrete 26 below the average frost line and will heave very little due to frost. The steel wall 10 is set no more than 6 inches in the soil and will heave more than the post. The bushing 25 prevents the bolt 19b and nut 22 from locking the post 11 and wall section 10 together and allows them to move separately due to frost heave.
Referring to FIG. 5, in a preferred embodiment, as shown, liner 12 and pad 13 are secured by clamps 27 to the upper edge of wall section 10, which is preferably shaped as a flange 28. The clamps 27 provide a double securing action and tightly retain the liner 12 and protective geotextile 13 around the flanged top 28 of the wall section 10. The clamp 27 is substantially V-shaped having a base portion 27' and a pair of upstanding walls 27". A plurality of drive screws 29 secure the clamp 27 to the flange 28 and compress the liner and pad therebetween. This double clamping action prevents tear out of the liner 12 and geotextile 13 around the drive screw 29. For the liner to tear loose from the drive screw, an entire liner area of approximately one foot wide would have to pull away from the clamp.
Referring to FIG. 6, notches 30 can be formed in the walls of clamp 27 to facilitate bending along the length thereof for fitting over wall sections 10 which have been installed to form a curved wall portion. Referring to FIG. 7, a corner bracket 31 can be used where a pair of wall sections 10,10 come together to secure the liner.
Referring to FIGS. 8 and 9, the dike system of the present invention can be combined with a fencing system to prevent entry by animals and unauthorized personnel. The fencing system includes a plurality of fence posts 35 and fencing material 36 mounted on the posts 11. Preferably, pipes 42 having a circular cross-section shape are placed in the corners of the fencing system. (A requirement of certain building codes). In a preferred embodiment, as shown, posts 11 have a pair of apertures 37 and posts 35 have a similarly spaced pair of apertures 38. Bolts 39 and nuts 40 secure post 11 to post 35 by acting through apertures 37 and 38, when aligned.
In order to construct a preferred dike system of the present invention, the site is first roughly leveled and the post holes dug. Once the site has been prepared sections 10 are deployed end to end around the planned enclosure area. Sections 10 and all other components are hauled to the site by any convenient means. Posts 11 are next bolted into position on the sections 10 by passing a bolt 19b through a hole in section 10, placing bushing 25 on bolt 19b and passing bolt 19b and bushing 25 through aperture 23 on post 11. Nut 22 is then threaded onto bolt 19b and tightened against bushing 25. The post and wall assemblies are set into the post holes one by one. As each successive section is set in place, the sections are bolted together with a tape mastic and a plurality of bolts 19a and nuts and washers. Once all sections are in place, concrete 26 is poured into the post holes and allowed to set up to form an enclosure.
A 2 inch layer of sand 16 is spread inside the enclosure. Next the geotextile 13 is placed on the sand layer 16 and draped over the top of the containment wall sections. The liner 12 is spread on top of geotextile pad 13 and is draped over the top of the containment wall. The liner and pad are pulled over the upper flange 28 of the wall as shown by the large arrows in FIG. 6 and 7. Clamps 27 are then installed, tightly clamping the liner and geotextile to the top of the containment wall. Screws 29 are then driven through clamp, liner, pad and flange. Geotextile layer 17 is placed on the ground level inside the enclosure on top of the liner. To secure the previous layers and protect the liner from the pressure of the filled storage tank 19 a 6 inch layer of pea gravel 18 is placed inside the wall area. Tanks 19 can then be installed inside the containment area.
Fence posts 35 can be mounted on post 11, as desired, and fencing 36 can be secured thereto. To facilitate construction, a section of the wall can be initially left out and the pea gravel layer can be spread with a skid loader. The skid loader operator can prepare his own "roadway" of gravel ahead of the skid loader as he spreads the gravel inside the enclosure. Shop built storage tanks of up to 30,000 gallons can then be backed throughout the open section and set in place with a hydraulic equipped truck bed. This eliminates the need for costly cranes on site to set storage tanks over concrete, dirt or wood walled dikes. Entire environmental dike systems can be installed with as little equipment as a skid loader, with post auger attachment. This equipment is inexpensive and easy to transport.
It will be apparent that many other changes may be made to the illustrative embodiments, while falling within the scope of the invention and it is intended that all such changes be covered by the claims appended hereto. | An environmental control dike system constructed of a plurality of bolted steel sections supported by steel posts set in concrete below average frost depths, the interior area of the steel wall having a synthetic liner cover with mating geotextile pad, joined to the flanged top of the steel wall by a plurality of V-shaped steel clamps sized to securely form the synthetic liner and geotextile pad, compressed gently but firmly, into a 180 degree fold around the flanged top of the steel wall, the V-shaped steel clamp being held securely in place by a plurality of self drilling screws into the top flange of the steel wall. The connection between the steel wall and steel posts is secured with two bolts having a gasketed steel washer under the head of the bolt, the bolt passes through a round hole in the steel wall and through a slotted hole in the post allowing differential movement due to frost heaving between the post and the wall, the post having been set in concrete below average frost depth moves very little due to frost heaving of the soil, the wall sheet placed no more than six inches into the soil will be moved a greater distance due to frost heaving, the bolt passing through the slotted opening in the post having a concentric steel bushing with a dimension greater than the thickness of the steel post when the nut is tightened on the bolt prevents subsequent locking action between the post and the wall. The posts can support a fencing system thereby avoiding the need to install a duplicate system. |
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BACKGROUND OF THE INVENTION
The present invention pertains to an improved drill bit for forming boreholes as in drilling oil and gas wells. Moore particularly, the present invention pertains to drill bits which employ and contain polycrystalline diamond cutting elements, and are usually referred to as "PDC" drill bits.
Many "PDC" drill bits of the prior art experience a destructive whipping action, or radial vibration of the drill bit which randomly occurs during rotary operation due to clearance between the outside of the drill bit and the wall of the borehole. This whipping tendency intensifies in proportion to the hardness or toughness of the formation being drilled and in proportion to the rotational speed of the drill bit, causing impact contact between the cutting elements of the drill bit and the formation material being drilled, which in turn results in fractured, chipped, or displaced cutting elements, thus drastically shortening the operating life of the drill bit and causing the operating life to be inconsistent and unpredictable.
Another problem often found in prior art "PDC" drill bits is erosion which is caused by high velocity drilling fluid acting on the cutting mountings of the cutting elements, on the drill bit face, and on other components of the bit. This shortens the operating life of the drill bit.
Another problem associated with prior art "PDC" drill bits is balling, plugging, or packing of cut material onto the face of the drill bit due to uneven or unbalanced fluid flow over the face of the drill bit which results in reduced penetration rates and inadequate and uneven cooling of the cutting elements and thereby unpredictably diminish the resultant drilling operation.
Because of the above problems, "PDC" drill bits have heretofore been used economically only in drilling a very limited range of different rock and earth formations. U.S. Pat. Nos. 712,887 (Wyczynski); 2,857,141 (Carpenter); and 3,062,303 (Schultz) each contain radially acting stabilizing means. However, as the respective specifications show, each of those are based on considerably different and less effective principles of operation than the present invention.
SUMMARY OF THE INVENTION
A stabilized drill bit having a main body of general cylindrical configuration and a pin end opposed to a lower drill face. The lower drilling face is of a particular novel configuration and includes cutters thereon for penetrating geological formations when the drill bit is rotated and making hole. A throat is formed longitudinally through the main body for passage of drilling fluid from a drilling string, through the bit, and through the drilling face. The drilling fluid exits the bit and flows across the face in a novel manner.
A plurality of circumferentially arranged bores are formed from the outer surface of the bit into communication with the bit throat. Hydraulically actuated stabilizing members are reciprocatingly received within the bores. Each of the stabilizing members have an outer face which is retracted into alignment with the outer surface of the bit, and which can be extended outwardly from the surface of the bit and into engagement with the wall of a borehole.
Hydraulic means are incorporated into the bit by which each of the stabilizing members are forced to move in a direction outwardly of the main body when the hydrostatic pressure within the throat is greater than the hydrostatic pressure measured at the face of the stabilizing members. The hydraulic means maintains the stabilizing members in the extended configuration, and as the face of the stabilizing member is worn, the member is further extended into engagement with the borehole wall.
The hydraulic means further enables retraction of the stabilizing members respective to the borehole wall surface when the pressure drop across the face of the bit has been equalized.
One object of the present invention is to provide a "PDC" drill bit having a substantially increased operating life with equal or greater drilling penetration rate than prior art "PDC" drill bits and having the capability of drilling more predictably and economically through an extremely wide range of different rock and earth formations.
Another object of this invention is to provide a drill bit having reduced tendency to whip, or radially vibrate, during rotary operation.
Another object of the present invention is to provide an improved drill bit having reduced tendency to ball or plug.
Another and further object of this invention is to provide a "PDC" drill bit that is economical to manufacture.
An additional object of the invention is the provision of a rotary drill bit having retractable stabilizer members arranged about the circumference thereof which can be extended into engagement with the borehole wall while making hole.
Other objects and advantages of the present invention will be apparent upon consideration of the following specification, with reference to the accompanying drawings forming part thereof, and in which like numerals correspond to like parts throughout the several views of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal, cross-sectional view of the invention;
FIG. 2 is a bottom view of the invention of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a reduced, cross-sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 1;
FIG. 6 is a diagrammatical, flattened, inverted, partial side view taken along line 6--6 of FIG. 2 for purposes of simplifying the drawing;
FIGS. 7-14, respectively, are inverted, partial cross-sectional views taken along lines 7-14, respectively, of FIG. 2; and,
FIG. 15 is a diagrammatical, part cross-sectional view of a drilling operation with the bit of the present invention being schematically illustrated therewith.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures of the drawings, and in particular FIG. 1, the present invention comprises an improved drilling bit, generally indicated by the numeral 110. The bit has a main body 21 made of a suitable material such as steel. The main body 21 is generally cylindrical in shape and the upper end thereof is threaded in a conventional manner, or is otherwise provided with a known means for attachment to the end of a drill pipe or "drill string". The main body 21 has a central fluid passage or throat 22 extending from the top threaded end, along the central axis towards the lower end or face 23. The lower marginal end of the bit can be an integral part of the bit, as seen in FIG. 1, or it can be a separate member suitably attached to the main body 21.
Near the face 23, the throat 22 branches into the illustrated two flow ports 24 which extend from the throat 22 and through the face 23. Flow restrictors 25 are installed in each of the ports 24 and are retained in place by snap rings 26 or other suitable retaining means. Opposed flow slots 27 are machined into the face 23 and into the sides of the main body 21 as more clearly seen in FIGS. 2 and 5. The slots 27 communicate with the two port 24, and as seen in FIGS. 1 and 2, each slot commences at the respective ports 24 and then spirals outward in a direction opposite to the normal rotational direction of the bit. The slots continue along opposite sides of the face 23, then extend up the opposite sides of the main body 21.
In FIGS. 1-2, the bit has mounted thereon a plurality of commercially available polycrystalline diamond cutters such as the illustrated cutting elements 1 through 18. The cutting elements 1-18 preferably are the STRATAPAX (TM) manufactured by The General Electric Company. The cutters are installed in a conventional manner, such as by mounting the cutters on a stud, and pressing the stud into mounting holes formed in the face 23. The cutting elements 1-18 preferably are arranged in two opposite spiral patterns directly behind the flow slots 27, such as illustrated in FIG. 2.
In FIG. 1, the cutters 1-18 are spuriously drawn side by side to show the cutting profile. In actual practice, the cutters 1-18 are each advantageously positioned to cut distinct but overlapping circular paths during the drilling operation, so that a continuous and complete cutting operation is achieved on the bottom of a borehole.
FIGS. 6 and 14 show extra cutters 52 which are added to the periphery of the bit to enhance the ability of the bit to maintain accuracy of the diameter of the borehole. Any number of peripheral or "gauge" cutters 52 may be added as needed. Each of the cutters 1-18 and the gauge cutters 52 are oriented with respect to the main body 21 to engage the formation at the most optimum cutting angle and thereby provide optimum penetration rate of the bit.
The present invention includes a plurality of novel radial stabilizing pistons 29 installed in complementary radial bores 30 formed through the sides and into the main body 21 of the bit 110 to intersect the throat 22. The bores 30 are symetrically arranged about the longitudinal axis of the bit. The pistons 29 are arranged to be positioned as near the face 23 as possible after allowing sufficient space for the other illustrated components therebetween. The preferred embodiment of FIGS. 1-4 show eight such pistons 29, however any suitable number may be employed. The pistons 29 are reciprocated by differential pressure thereacross, with each piston 29 having a small diameter at the inner end thereof and a large diameter at the outer end thereof. The radial bores 30 have corresponding diameters respective to the small end of the pistons 29 facing radially inward towards the center axis of the main body 21 and with the large ends of the pistons 29 facing radially outward. The pistons 29 may be installed directly in the main body 21 as shown, or alternatively may be installed in a separate body (not shown) which is removably attachable to the main body 21. The pistons 29 are slidably sealed to the sides of the radial bores 30 by o-rings 31, or similar means, so that a sealed variable volume chamber 32 is formed between the smaller and larger ends of each piston 29. The chambers 32 increase in volume as the pistons 29 move radially outward and decrease in volume as the pistons 29 move radially inward. The inward travel of the pistons 29 is limited by the larger diameter portion of the pistons 29 abutting against the shoulder formed at the bottom of the larger diameter portion of the bore 30. The outward travel of the pistons 29 is limited by the illustrated shoulder 33'. The pistons 29 are prevented from rotating in the bore 30 by a detent formed by punch impressions 33, or other suitable means, which slidably engage grooves 28 formed along the side of the pistons 29. The grooves 28 extends from the rim of the outer ends of the pistons 29, inwardly along the side of the pistons 29, to a position just short of the outer o-ring seals 31, thus allowing adequate outward travel of the pistons 29, without disrupting any of the seals 31. Each piston 29 may contain one or more grooves 28 as needed.
The outer face of the pistons 29 are provided with wear resistant tungsten carbide buttons 36 pressed into complementary axial holes formed in the face of the pistons 29, so that the wear resistant button 36 is flush or aligned with the outer face of the piston 29, thereby making the outer ends of the pistons 29 wear resistant. The pistons 29 may alternatively be made entirely of a wear resistant material such as ceramic, or may be made wear resistant by other known expedients.
In the cross-sectional illustration of FIG. 4, a check valve 34 is seen to be provided with a corresponding fluid passage 35 for each chamber 32 to allow an incompressible hydraulic fluid, such as viscous oil, to enter but not leave the variable chamber 32. In the embodiment of FIGS. 1-4, a common cylindrical fluid reservoir 51 is provided to pairs of chambers 32 and to respective pairs of check valves 34, with the fluid inlet ends of the check valves 34 being positioned within the reservoir 51. The reservoir 51 is arranged radially respective to the longitudinal central axis of the main body 21. The reservoir 51 is illustrated as being located between pairs of chambers 32 and check valves 34. A small, concentric radial hole 46 extends radially inward into communication with the throat 22, and into communication with the respective passages 35, and provides a means by which a blocking valve assembly 45 can be actuated.
Each radial hole 46 is fitted with one blocking valve 45, which includes a valve element and a mating valve seat formed at one end of a sleeve 50. The blocking valve assembly 45 is arranged to selectively block or freely allow fluid flow into or out of the reservoir 51. The inner end of each blocking valve 45 is reciprocatingly sealed respective to the corresponding radial bore 46 by an o-ring 49, or similar seal means, and is arranged to function as a piston, with the o-ring 49 positioned inward relative to the corresponding pair of passages 35. The outer end of each blocking valve 45 is reduced in diameter respective to the holes 46, to allow fluid to pass from the passage 35 into the hole 46 and vice versa, and includes an end portion which is shaped to be received in sealed relationship against the illustrated valve seat of the sleeve 50. The inward travel of each valve 45 is limited by the illustrated shoulder; however, a snap ring or similar retainer positioned within the inner extremity of each hole 46 can serve as an alternative. The outward travel of each valve 45 is limited by the outer end thereof seating and sealing against the valve seat of the sleeve 50. Each sleeve 50 is fastened and sealed in the illustrated fixed position within each corresponding hole 46, and is positioned to provide the desired contact with respect to the corresponding valve 45. The length and inner bore of the sleeves 50 are sized to accommodate shanks 44 of isolating caps 43 so that the shanks 44 can reciprocate freely in a guided manner within the bore of the sleeves 50.
The isolating caps 43 are received within the bore of the reservoir 51, and are movably sealed in a reciprocating manner therein by o-rings 48, so that hydraulic fluid contained therewithin is isolated from contaminants from without. The caps 43 have the before mentioned rigidly attached shanks 44 which are radially oriented into the sleeves 50 to stabilize the caps 43. The shanks 44 are grooved or flattened to allow fluid to pass through the sleeve 50 into and out of the reservoir 51. The caps 43, with their shanks 44, are arranged to freely move in a stabilized manner as fluid enters or leaves the reservoir 51 to thereby accommodate any change in volume. The radial travel of the caps 43 is sufficient to provide adequate fluid displacement for the corresponding chambers 32. The outward travel of the caps 43 is limited by punch impressions 47 formed on the rim of the reservoirs 51, or by other suitable stop means.
During assembly of the apparatus of the present invention, the chambers 32, check valves 34, passages 35, holes 46, and the reservoir 51 are all filled with a suitable hydraulic fluid, and all gas bubbles are evacuated therefrom so that an incompressible fluid is contained therein. Hydraulic fluid can be filled through resealable drilled holes located in the caps 43, or in the body 21, or the filling could be completed before the caps 43 are installed, or various other filling methods might be utilized in order to achieve this desired result.
As best seen illustrated in FIGS. 1 and 5, each of a plurality of additional wear resistant buttons 36 are pressed flush into each of a plurality of radial holes arranged symmetrically around the outer periphery of the lower marginal end of the main body 21 at a location immediately above the face 23. Any other suitable means may be employed to protect the periphery of the main body 21 from undue abrasion and wear.
In FIG. 1, the flow restrictors 25 are each arranged to provide optimum fluid flow restriction therethrough while also providing relatively low fluid output velocity therefrom into the flow slots 27 and onto the face 23. In the present embodiment, each of the flow restrictors 25 comprise a plurality of commercially available wear resistant nozzles 37 having an o.d. corresponding to the size of the ports 24 so that each port 24 contains a first or uppermost nozzle, one or more intermediate nozzles, and an outlet or lowermost nozzle. In the present embodiment, the first nozzle in each port 24 is inverted or otherwise shaped to provide diffused fluid flow and has its orifice 41 sized to provide optimum fluid flow restriction. The intermediate nozzles located in each port 24 are also inverted or otherwise shaped to provide diffused fluid flow, but have their orifices sized to provide relatively low fluid flow restriction. The outlet nozzle in each port 24 is non-inverted or otherwise shaped to provide straightened fluid flow, and its orifice 42 is sized to provide relatively low fluid output velocity. All the nozzles 37 are sealed to the walls of the ports 24 by o-rings 38. Different quantities, shapes, and sizes of nozzles 37 may be installed in the ports 24 depending upon the kind and degree of fluid control desired. Also, the restrictors 25 may be of one piece, multistage construction rather than of a plurality of series connected individual nozzles. The restrictors 25 are thus arranged to provide both a means for developing a desired fluid pressure drop and a means for reducing the resultant fluid escape velocity.
In FIGS. 2 and 6-14, a fluid flow isolating ridge 39 extends from one side of the face 23 along the trailing edge of the cutters 1-18 on the first side of the face 23, across the center of the face 23, then along the trailing edge of the cutters 1-18 on the second side to the opposite side of the face 23. The ridge 39 is affixed or made integrally respective to the face 23 and is the minimum thickness for achieving the necessary required strength. The height of the flow isolating ridge 39 beyond the face 23 is equal to the height of the cutters 1-18 so that the ridge 39 contacts the bottom of the borehole during the drilling operation.
In FIGS. 2, 6-8, and 14, a plurality of fluid flow isolating ribs 40 extend concentrically along the face 23 from the trailing side of the ridge 39 along paths concentric with the main body 21 to the leading edges of the corresponding slots 27. The ribs 40 are solidly attached to the ridge 39 and to the face 23 and are the minimum thickness considered necessary for the required strength. The height of the ribs 40 beyond the face 23 is equal to the height of the cutters 1-18 and to the height of the ridge 39 so that the ribs 40 similarly contact the bottom of the borehole during the drilling operation. The ribs 40 are symmetrically located on the face 23 spaced radially from the center of the face 23 the maximum distance that provides adequate fluid flow isolation. The ridge 39 and the ribs 40 are of a material, such a steel, that can be worn away readily by rubbing against the bottom of a borehole while making hole.
As seen in FIGS. 1 and 3, parallel wrench flats 53 are machined onto opposite sides of the neck portion of the main body 21 in the conventional fashion to accommodate conventional tools for attaching or detaching the bit 110 to a drill pipe 62.
In FIG. 15, a borehole 60 has a drill string 62 and drill collar 64 therein with the bit 110 attached to the lower end thereof. A drilling rig 70 manipulates the drill string 62. Drilling fluid flows at 72 into the string and is returned through a rotating blowout preventor 74 in the usual manner.
In operation, the upper threaded end of the main body 21 is attached in the conventional manner to the lower end of a drill pipe, or drill string 62 and is then inserted in a borehole 60 and rotated in the conventional manner. The bit is forced downward against the bottom of the borehole by weight applied to the drill string in the conventional manner. As the invention is continuously rotated with weight applied, the ridge 39, the ribs 40, and the cutters 1-18 are all rubbed against the bottom of the borehole. The ridge 39 and the ribs 40 are reduced in height due to wear against the bottom of the borehole; however, the edges of the cutters 1-18 wear only slightly due to their material of construction. Thus, the cutters 1-18 penetrate the bottom of the borehole and remove material therefrom as the bit is rotated with weight applied. The action of the cutters 1-18, moves the cuttings from in front of the cutters 1-18 into the slots 27. The gauge cutters 52 remove material from the wall of the borehole and there by achieve the desired diameter of the bore hole. Conventional drilling fluid, supplied in the conventional manner from a suitable pump, is continuously pumped downward at 72, through the drill string 62, through the throat 22 of the present invention, through the flow restrictors 25, through the flow slots 27, then back up the bore hole annulus located outside of the drill string. The cut material is carried along by the flowing drilling fluid and is thus removed at 74 from the borehole.
Since the pressure drop across an orifice varies approximately as the square of the change in flow rate of a fluid flowing through the orifice, then the resultant fluid volume flowing through both orifices 41 (i.e. both restrictors 25) of the present invention will remain practically equal or balanced when appropriate total fluid volume and pressure is maintained. The orifices 41 can be sized to provide a predetermined or desired pressure drop for any given fluid flow rate. At any given fluid flow rate, the greater the pressure drop the more firmly equalized or balanced the flow through the restrictors 25 becomes. Also, each corresponding port 24, flow restrictor 25, and flow slot 27 forms and provides an isolated fluid path because the ridge 39 and the ribs 40 all contact the bottom of the borehole and thus prevent drilling fluid flowing in one slot 27 from escaping that slot except at the upper end of that slot. The flow of drilling fluid through either of the slots 27 will not become overbalanced or diverted and will therefore continue to flow adequately through each slot 27 and thereby force out the cut material even if packing or clogging tends to occur. Accordingly, balling or plugging is effectively avoided on the face 23 of the present bit.
Due to the configuration and arrangement of the flow restrictors 25, the velocity of the flowing drilling fluid as it leaves the restrictors 25 and enters the slots 27 is kept low enough so that no appreciable fluid erosion occurs on any part of the present bit even when a relatively high fluid flow rate and resultant pressure drop is maintained.
Drilling fluid flowing through the present bit is at a relatively elevated pressure within the throat 22 because of the pressure drop measured across the restrictors 25. Therefore, an outward force is exerted on the smaller end of the pistons 29, forcing the outer ends of the pistons 29 to move outward to any one of a range of extended positions and into relatively light contact with the wall of the borehole. Also, the blocking valves 45 are forced outward so that the outer ends of the valves 45 are seated in sealed relationship against the valve seat end of the sleeves 50, blocking any fluid flow therethrough. As the pistons 29 move outward, the chambers 32 expand in volume, causing a pressure differential which forces the hydraulic fluid from the reservoir 51, through the check valves 34, through the passages 35 and into the chambers 32. The caps 43 move inward to accommodate the reduced volume within the reservoirs 51. The check valves 34 prevent any reverse flow of hydraulic fluid and thus provides a hydraulic barrier within the chambers 32 so that the pistons 29 cannot move inward from any extended position, even when an extreme opposite force is exerted inwardly on the pistons 29 from the wall of the borehole. In like manner, as the outer ends of the pistons 29 slowly wear due to friction against the wall of the borehole, the pistons 29 continually move slowly outward and more hydraulic fluid is drawn into and retained within the chambers 32. Thus, means are provided by which the pistons 29 are continually compensated for wear and remain in constant contact with the wall of the borehole. Accordingly, the present invention provides means by which a drill bit is prevented from whipping or radially vibrating. During this time, the cutters 1-18 and the gauge cutters 52 are positioned where they are protected from impact damage and from the premature failure which may otherwise result therefrom.
Reduced circulation of drilling fluid reduces the pressure drop across the restrictors 25, and the fluid pressure within the throat 22 is therefore reduced until it becomes equalized with respect to the fluid pressure on the outside of the main body 21. Thus, in this condition, no outward force is exerted against the pistons 29 or the blocking valves 45. Hence, the outer ends of the blocking valves 45 are no longer sealed against the valve seat ends of the sleeves 50 and fluid is therefore allowed to flow therethrough. Thus, in this condition, when an inward force is exerted on the outer ends of the pistons 29, hydraulic fluid flows freely out of the chambers 32, through the passages 35, against the outer ends of the blocking valves 45, forcing the blocking valves inward away from the valve seat of the sleeves 50, so the fluid flows through the sleeves 50 past the shanks 44, and into the reservoirs 51. At this time, the caps 43 can move outward to accommodate the added fluid volume within the reservoirs 51. Therefore, the pistons 29 can be selectively allowed to retract inward by removing fluid pressure within the throat 22.
The main body 21 and the holes and passages therein, the pistons 29, blocking valves 45, sleeves 50, and the caps 43 with shanks 44 all can be readily fabricated by convenional methods, such as machining or molding. The cutters 1-18, o-rings 31, wear resistant buttons 36, nozzles 37, o-rings 38, and the gauge cutters 52 are all readily available commercial products which can be installed in the bit of the present invention. Various different check valves 34 of conventional design may be either built into the present bit or purchased separately and assembled thereinto. Thus, the present invention can be readily and economically manufactured.
Having thus described the invention, it is to be understood that certain modifications in the construction and arrangement of the parts thereof may be made, as deemed necessary, without departing from the scope of the appended claims. | A stabilized drill bit has a cylindrical main body, a formation cutting face at the lower end of the body, and means by which the upper end of the bit can be connected into a drill string. A drilling fluid flow passageway extends axially through the main body and provides flow of drilling fluid to the drilling face. A plurality of hydraulic actuated stabilizing members are arranged circumferentially about the throat and within the main body. Stabilizing members have a borehole wall engaging face thereon which can be retracted flush with the outer surface of the main body, and extended away from the main body face and into contact with the borehole wall, thereby stabilizing the drill bit as the bit is rotated while making hole. Hydraulic means is connected to the stabilizing members by which the members are progressively extended toward the borehole wall as the members become worn, and which normally prevents retraction of the stabilizing members so long as drilling fluid pressure is effected within the passageway. The stabilizing members are retracted when the drilling fluid is reduced to a predetermined value. |
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BACKGROUND OF THE INVENTION
The invention relates to a device for operating a mechanism of a rinsing fixture. It concerns, in particular, a device for operation of a closing and opening mechanism or of a locking mechanism of a rinsing fixture. The device comprises a float and a first hydraulic of pneumatic force means that shows a regulating unit controllable by means of the float as well as a second hydraulic or pneumatic force means that shows a hydraulic or pneumatic regulating unit that is connected with the regulating unit of the first force means, whereby this regulating unit is actively coupled to the mechanism. The float is attached, for example, to a rod. The regulating unit of the first force means is able to be driven by this float rod.
A device for operating the closing and opening mechanism of the type named in the introduction is known from DE 37 18 812 A1. The mechanism serves to operate a float-controlled cut-off valve of a rinsing chamber for rinsing a storage space for a liquid, whereby the float is effective in the region of the low point of the bottom of the storage space. Upon the emptying of the storage space, with the sinking motion of the float the float rod connected to the float operates the mechanism of the cut-off valve, the float rod being fixedly connected with the regulating unit related to the valve, whereby the regulating unit is operated by the lifting as well as by the sinking of the float. Due to this connection of the float rod with the regulating unit of the first hydraulic force means and the hydraulic connection of this regulating unit with the regulating unit of the second force means at the rinsing fixture, a displacement of the one regulating unit causes a displacement of the other regulating unit. In order to achieve a sudden opening of the mechanism in the manner of an instantaneous opening, in the known device the float is attached in a pivoted manner to the float rod and, referring to the raised position of the float rod with weight, the float rod, on the basis of a tipping lever located on it that grasps a stationary support, is prevented from sinking as soon as the storage space runs empty. The pivoted float, on the contrary, can follow the lowering liquid level and by way of a control rod on the tipping lever influences the tipping lever in such a way that it is released from the support upon the emptying of the storage space, whereupon the float rod with the weight swings instantaneously downward and drives the hydraulic force means. Hydraulic fluid passes into the enlarging space of the first hydraulic system that is designed as a bellows, whereby the space of the second hydraulic system that is also designed as a bellows enlarges and its regulating unit opens the mechanism of the cut-off valve.
Disadvantages of this device are the high construction cost in the area of the float and the high cost of the control. In particular, the pivoting of the float must be assured over a long time period, since the device otherwise cannot function. Here one must take into consideration that the device is exposed to mixed liquids or waste water, which contains considerable amounts of contaminants and from this the danger exists that the float mounting can become blocked. With this device the releasing of the rinsing can be only poorly adjusted.
The fundamental problematic nature of the cleaning of the bottom of a storage space by means of liquid accumulated in a rinsing chamber is described in EP 0 211 058 A1.
From EP 0 658 657 A2 is known a device for operating a locking mechanism of a tilt-rinsing fixture for rinsing a length of channel. The liquid level of the channel at any given time is determined by an inductive sensor and is passed on by an evaluation unit, which then, when it ascertains a complete emptying of the channel or channel shaft, sends forward a releasing impulse to the locking mechanism that holds fast the tilt-rinsing equipment that is filled with rinsing liquid.
A further fundamental possibility for rinsing of a storage space is described in DE 195 33 483 A1. This shows a locking mechanism for a rinsing fixture that is fully or partially raisable from the bottom and is designed as a rinsing container.
SUMMARY OF THE INVENTION
The task of the present invention is to advance the design of a device according to the type mentioned in the introduction for operating a mechanism of a rinsing fixture, in particular for operation of a closing and opening mechanism or of a locking mechanism of a rinsing fixture, so that a rapid float-controlled activation of the mechanism of a rinsing fixture for instantaneous rinsing is assured and that this is done in a simple manner as well as with little production expense.
The task is solved in a device of the type named in the introduction in this way, that the float upon rising drives, against a restoring force, the regulating unit of the first force means for operating the mechanism, that the float upon sinking is uncoupled from the regulating unit of the first force means, and that in the connection of the two force means a valve is arranged that is controlled by the float for moving the regulating unit of the first force means or is controlled by another float, in such a manner that the connection is opened by the lifting of the float, that it is closed off by the raised float as well as during the sinking of the float and that it is opened by the sunken float.
It is essential to the present invention that the float is coupled to the regulating unit of the first force only when raised. With the raising of the float the regulating unit of the first force means moves together with the float and, due to the connection with the regulating unit of the second force means, causes the latter regulating unit to likewise be moved and thus, for example, operate the closing mechanism in the sense of a closing movement or transfer the locking mechanism into its locking position. Since with the sinking the float is uncoupled from the regulating unit of the first force means, the float itself cannot transfer the closing mechanism into its open position or the locking mechanism into its released position. To be sure, the restoring force works, now as before, on the regulating unit of the first force means. If the float sinks due to the decoupling of the float and the regulating unit of the first force means, with the maintaining of the position of the regulating unit of the first force means the sunken float operates the valve arranged in the hydraulic connection of both force means, which valve is instantaneously opened. In place of this float the operation of the valve can take place through another float. This auxiliary float has the sole task of operating the fast-opening valve, while the other float serves the driving of the first force means. Preferably it is a question of a single-float control, i.e., only one float is planned and that the task is to drive a first force means or a series of first force means and to operate the valve.
According to the invention, with the valve opened both regulating units under the influence of the restoring force can be effective in the opposite direction, with the result that the regulating unit of the second force means operates the mechanism. for example opens or closes the mechanism and thus releases the rinse or closes it off or moves a locking mechanism out of or into its locking position and thus releases or engages a locking position. With a renewed accumulation of liquid and thus with the raising of the float(s) the regulating unit of the second force means is moved by means of the regulating unit of the first force means and the valve is closed.
Advantageously the float that drives the first force means is connected with a float rod that is mounted so that it can pivot and can be brought into an active connection with the first force means.
A particular configuration of the invention provides for the restoring force to be generated by means of a spring or a bellows, in particular a spring-loaded bellows that drives the regulating unit of a force means, in particular of the first force means. Further, another spring or another bellows, especially another spring-loaded bellows, can drive the regulating unit of the other, in particular a second, force means. The effective directions of the springs or bellows, in particular spring-loaded bellows, are opposed and the spring or bellows of the other, in particular of the second, force means, is weaker than the spring or the bellows of the one force means, in particular the first force means. Here the weaker spring or the weaker bellows serves the purpose of supporting the closing or locking process since with the raising of the float hydraulic fluid is forced out of the second hydraulic force means and in this way supports the closing process of the closing mechanism or the locking process of the locking mechanism. The changing of the effective direction in the system can be achieved simply by exchanging the different strength springs.
From a construction viewpoint the device can be simply designed if the first and also the second force means show a cylinder that includes a regulating unit configured as a bellows or as a spring-loaded bellows The float rod or the closing/opening mechanism or the locking mechanism grasps a rod connected to the piston.
According to a particular implementation form of the invention provision is made for the valve to be configured as a check valve that its basic closing direction can be unblocked by means of the float or the other float, in particular the float rod provided with the float or the other float. The check valve is thus always passable in one direction of liquid flow, whereas it prevents liquid flow in the opposite direction, as long as it is not unblocked by the float rod. One such check valve requires only a minimal construction cost and a simple addition to the hydraulics is possible without distribution pieces. With this a separate bypass required to detour around the check valve becomes unnecessary. The check valve designed according to the invention thus represents a cost-effective configuration. The few pipe connections reduce the danger of leakage. With defective hydraulic function only the replacement of one part is required; this considerably simplifies the search for the defect. Only a slight raising is required to accommodate large changes of cross-section of the valve. Due to this minimal raising this valve can be hermetically sealed and is thus especially well suited for installation in a rough environment, for example in connection with waste water
A design for the check valve that is particularly simple to build provides for a slidable plunger in the valve housing for raising a shut-off element from its valve seat, which element closes off passage through the valve. The plunger is here slidable against the force of a restoring force element. The displacement is accomplished preferably through the float rod. The shut-off element is preferably designed as a ball and the restoring force element is designed as a spring, in particular as a coil pressure spring.
The hermetically sealable design of the check valve can be achieved in an especially simple manner by having the plunger work in combination with an elastic membrane that is connected with the valve housing so that it is sealed. For example, the float rod pushes against the membrane, that is preferably designed as a steel membrane, and displaces this along with the plunger and thus closes off the check valve.
Besides the design of the previously described conceptual check valve, the various designs of a valve for achieving the objectives according to the invention come into question. The valve can, for example, be designed as a check valve, where a bypass is operated by means of a float, so that the hydraulic oil can flow past the check valve against the passage direction of the check valve Further, the valve can, for example, be configured as a ball valve whereby the ball valve, corresponding to the position of the float or of the other float, assumes the desired passage or cut-off position.
The invention is not limited to having a float rod pivotable around one axis that consequently works as a single-armed or a two-armed lever that accepts the float in the region of the far end, it is just as possible to mount the float to be vertically or horizontally displaceable and to provide for such a coupling with the regulating unit of the first force means that the float, when rising, carries the regulating unit along and that the float can sink down without the driving of this regulating unit.
In principle the possibility exists of operating, by means of a float rod or something similar and a first force leans coordinated with this, several second force means and thus mechanisms of several rinsing fixtures, or of locking several rinsing fixtures. For this, between the valve and the mechanisms for opening, closing, locking or releasing, provision is made for a distribution of the connecting pipes into several branching connections corresponding to the number of mechanisms.
On the other hand the possibility exists of providing for several first force means and several second force means that are controlled by separate valves and one common float rod or the like. With this design the possibility exists of a time-delayed opening of the valve for example by means of the float rod, i.e., the float rod opens the one valve earlier than another one in correspondence with the liquid level in the storage space. The adjustment can be accomplished through positioning screws or through the valves being at different levels.
Several rinsing courses can thus be operated in a time-delay fashion, whereby the possibility exists of allowing rinsing processes to run in sequence, being controlled by only one float.
Further characteristics of the invention are represented in the dependent claims, in the description of the figures and in the figures themselves, where it should be noticed that all individual characteristics and all combinations of individual characteristics are essential to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the figures the invention is represented by way of example with the help of several implementation forms, without being limited to these. Shown in greatly simplified representation are:
FIGS. 1A, 1B, and 1C a first implementation form of a device for operating a closing mechanism of a cut-off flap shown in the closed position with the flap locked (FIG. 1A: closing mechanism in the opened position; FIG. 1B: closing mechanism closing; FIG. 1C: closing mechanism in locking position).
FIGS. 2A, 2B, and 2C the implementation form of the device according to FIGS. 1A through 1C with unlocking of the flap (FIG. 2A: closing mechanism in locking position; FIG. 2B: closing mechanism opening; FIG. 2C: closing mechanism opened).
FIG. 3 another implementation form in which the closing mechanisms of two flaps are operated by means of one float rod common to these,
FIG. 4 another implementation form for illustration of a battery-like construction in which the closing mechanisms of a multiplicity of cut-off flaps are operated by one float rod,
FIG. 4a a view of the various valves applicable in the configuration according to FIG. 4,
FIG. 5 a implementation form of a device for operating a locking mechanism of a tilt-rinsing device,
FIG. 6 another implementation form of a device for operating a locking mechanism of two modified tilt-rinsing fixtures by means of float rods common to these,
FIGS. 7A, 7B, 7C, and 7D variations of float, cylinder and valve arrangements with different positions of the float arm pivot points,
FIG. 8 another implementation form where an additional float is provided for operating the valves,
FIG. 9 another implementation form where the rinsing fixture is designed as a raisable and lowerable container that in its lowered position can be held fixed to the floor of the storage space by means of the locking fixture and
FIG. 10 a section through a check valve modified according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows a rectangular cut-off flap 1 that serves the closing off of a corresponding rectangular inlet opening of a rinsing chamber. The cut-off flap 1 is attached to an outer wall of the rinsing chamber so as to be pivotable around an upper horizontal axis 2. A storage space is connected to the rinsing chamber, so that after the emptying of the storage space the latter can be rinsed out by means of the liquid accumulated in the rinsing chamber, if the cut-off flap 1 is opened. In the region of its lower end the cut-off flap 1 is provided with lugs 3 that project beyond it downward, which can be brought into working connection with a closing mechanism 5 that is likewise connected to the outlet wall 4. The closing mechanism 5 can for example show a pivotable shaft 7 with lugs 6, which lugs, when the cut-off flap 1 is in the closed position, i.e., when the flap 1 is in the vertical position, are tilted so that they engage the lugs 3 from behind and thus press the cut-off flap 1 against the wall 4 or against its frame and prevent a swinging away of the cut-off flap 1 from the rinsing chamber opening. The closing mechanism 5 can, for example, also be designed as a pusher construction, as is described, for example, in DE 37 18 812 A1. The closing mechanism 5 is moved, i.e., the shaft 7 is rotated or a bolt is pushed, by means of a bellows 8 that is carried in a cylinder 9. A pipe 11 is connected to the internal space 10 of the cylinder 9, which pipe leads to a check valve 12 and from this another pipe 13 leads to the inner space 14 of another cylinder 15 into which a bellows 16 leads. The basically free passage direction of the check valve 12 is from the pipe 11 arranged with the cylinder 9 into the pipe 13 arranged with cylinder 15. Shown is the valve seat 17 for check valve 12 and the ball 18 that works in conjunction with this. Located in the housing 19 of the check valve 12 is plunger 20 that is mounted in such a way that it can be pushed and that, in the position of having been driven into the housing 19, lifts the ball 18 from the valve seat 17 and thus enables passage in both directions through the valve 12. The ball 18 is spring loaded by means of a spring 21 in the direction of the valve seat 17.
Effective in bellows 16 is a relatively strong pressure spring 22 that spring loads the bellows 16 in the direction of the pipe 13. Corresponding to this, arranged in bellows 8 is a relatively weak pressure spring 23 that spring loads the bellows 8 in the direction of pipe 11.
Leading out of the cylinder 15 and connected with bellows 16 is a rod 24 that leads through an opening, not shown in detail, in a float rod 25 formed as a lever. The rod 24 is provided with a pivotable drive plate 26 on the side that is turned away from the cylinder 15, which plate engages the float rod 25 from behind. Corresponding to this is a rod 27 connected with the bellows 8 of cylinder 9, which rod 27 leads out of the cylinder housing 10 and drives the movable component that effects the closing process, either directly by a translational motion or through conversion of the translational motion to rotary motion.
The float rod 25 in the region of one end carries a ball-shaped or cylinder-shaped float 28 and can be pivoted around an axis 29. In the lowest position of the float the lever arm of the float rod 25 opposite the float 28 contacts the plunger 20 of the check valve 12, so that the ball 18 is raised from the valve seat 17. This condition is illustrated in FIG. 1A and shows clearly the flap 1 with the lugs 6 of the closing mechanism 5 that release the lugs 3.
A mounting plate shown in dashed lines is indicated by the reference numeral 37. The plate provides the stationary mounting for the bearing axis 29, the float rod 25, the cylinder 15 and the check valve 12.
Proceeding from the position according to FIG. 1A, with the complete sinking of the float 28, relatively relaxed pressure spring 22 and relatively stressed pressure spring 23 as well as driven plunger 20 of check valve 12 the float rises upon accumulation of a liquid in the storage space (not illustrated further). In consequence of the pivoting motion of the float rod 25 resulting from this, the latter comes out of contact with the plunger 20 of the check valve 12, whereupon the valve 12 works exclusively as a check valve. Furthermore, the float rod 25, by way of the drive plate 26, pulls the rod 24 along with the bellows 16 downward against the force of the strong pressure spring 22 into the cylinder 15 so that due to the adjusting increased cylinder volume, hydraulic fluid flows out of the cylinder 10 through the pipes 11 and 13 into cylinder 15, The relatively weak pressure spring 23 that is effective on bellows 8 supports its displacement and thus the transfer of hydraulic fluid from cylinder 9 into cylinder 15, whereby the rod 27 shifting along with the bellows 8 operates the closing mechanism 5. FIG. 1B illustrates the process of the closing mechanism. Upon further inflow of liquid into the storage space the float is raised higher and float rod 25 pivots further. The float rod 25 remains out of contact with the plunger 20 of the check valve 12 while the pressure spring 22 located in the cylinder 15 is further stressed through float rod 25 and the pressure spring located in cylinder 8 is further relaxed FIG. 1C shows the condition where the closing mechanism 5 has been transferred into its locking position in which the lugs 6 of the closing mechanism 5 engage the lugs 3 of the cut-off flap 1 in such a way that the cut-off flap 1 is completely pressed against the outlet wall 4 of the rinsing chamber or against its frame.
The FIGS. 2A through 2C show the steps in the opening of closing mechanism 5. The condition of the closing mechanism 5 according to the representation in FIG. 2A corresponds to that of the representation in 1C. If The liquid level in the storage space and thus the float 28 sinks, the float rod 25 pivots back, whereby due to the closed position of the check valve 12 the spring-loaded bellows 8 and 16 of cylinders 9 and 15 remain in their positions, while the float rod 25 moves relative to the rod 24 that passes through it. FIG. 2B shows the partially sunken float 28 and the condition of the cut-off flap 1 shortly before its opening.
If the float 28 sinks lower, to a level that corresponds to the emptied condition or the near-emptied condition of the storage space, the float rod 25 has reached an angle at which it contacts the plunger 20 of the check valve 12 and thus lifts the ball 18 of the check valve 12 from its seat 17. With this, due to the effect of the bellows 16 that is stressed by a strong spring 22, the hydraulic fluid can enter through the pipes 11 and 13 into the inner space 10 of cylinder 9 and it presses the bellows 8 located there against the force of the weaker spring 23 acting on it. In consequence of this motion of bellows 8 and thus of the motion of its rod 27 the closing mechanism is driven so that its lugs 6 release the lugs 3 of the cut-off flap 1, whereby this flap opens instantaneously under the pressure of the liquid located in the rinsing chamber. The opened closing mechanism 5 is illustrated in FIG. 2C.
The implementation form described below is based on the same manner of operation as the implementation forms described above:
FIG. 3 shows the control of two cut-off flaps 1 by means of a common float rod 25 with float 28. Associated with each cutoff flap 1 are a cylinder 9, pipes 11 and 13, a check valve 12 as well as a cylinder 15. The single float rod 25 is penetrated by both rods 24 of cylinder 15, the rods 24 being provided with drive plates 26. Further, the float rod 25 works in conjunction with the plungers 20 of both check valves 12.
FIG. 4 shows a configuration of the invention by which a multiplicity of cutoff flaps 1 can be operated. Here also, associated with each cut-off flap 1 are a cylinder 9 and 15, a check valve 12, and pipes 11 and 13. This implementation form also shows the pressure springs 22 and 23. A wall is indicated by the reference numeral 36 on which the float rod 25 with float 28 is attached so that it can pivot. FIG. 4a is to be seen in the context of the representation of FIG. 4 and illustrates in a cross-beam 30 of the float rod 25 screws 31 screwed in to different depths, which can be brought into active connection with the plungers 20 of the associated check valves 12, whereby the screws 31, due to the different depths to which they are screwed in, release the check valves 12 at different points in time and thus the cut-off flaps 1 are opened and their rinses are released at different points in time.
FIG. 5 shows a tilt-rinsing fixture whereby the actual rinsing container 32 can be pivoted on an axis 33 that is not arranged at the center of gravity of the rinsing container 32 so that after emptying the rinsing container 32 automatically rights itself into the position shown in FIG. 5. The rinsing container 32 is arranged above the floor of the storage space for liquid and is, for example, filled with stored liquid. In order to ensure that it only empties if the area of the liquid storage space or channel that is to be rinsed has emptied, the locking mechanism 35 is provided for; it is constructed in the simplest manner through the slideable piston rod 27 of cylinder 9 and in an end position prevents the rinsing chamber 32 from tipping. In this respect reference can be made to the implementation in FIGS. 1a through 1c and 2a through 2c, with the basic difference that with the implementation form according to FIG. 5 a pressure spring 23 is arranged in the cylinder 9 associated with rinsing container 32, which spring is relatively strong, while the spring 22 arranged in the other cylinder 15 is relatively weak, and further, that by way of a single-armed float rod 25 with the raising of the float 28 the space for hydraulic fluid in cylinder 15 is decreased through the compression of bellows 16 in cylinder 15 and correspondingly the space in cylinder 9 is increased by expansion of the bellows 8, and further that the check valve 12 is passed through in the opposite direction so that it closes off the flow from pipes 11 and 13 when the plunger 20 is not operated.
FIG. 6 shows a variant based on the implementation form according to FIG. 5 in which the pipe 11 separates into two sections 11a and 11b that lead to cylinders 9 and that work in conjunction with two rinsing containers 32. With this implementation form each rinsing container 32 is provided with a counterweight 34 that assures that the rinsing container 32 associated with it, after the emptying, rights itself automatically into the position shown in FIG. 6. With this configuration a large-volume cylinder 15 is used that works together with two cylinders 9 that show a smaller volume.
The FIGS. 7A through 7D show variations of float, cylinder, and valve arrangements with different locations of the float-arm pivot point for application with the different types of rinsing fixtures.
FIG. 8 shows a modified implementation form where provision is made for an additional float 28a, which is taken up by a float rod 25a that can pivot about an axis 29a. This auxiliary float effects the opening of the check valve 12 upon complete or nearly complete emptying of the storage space, since the section of the float rod 25a that overhangs the axis 29a pushes the plunger 20 of the check valve 12 and transfers this into its opened position. The method of operation of this implementation form is identical with the implementation form according to FIGS. 1a through 1c and 2a through 2c with the difference that there the float 28 takes on the function of floats 28 and 28a according to the implementation form of FIG 8.
FIG. 9 illustrates a container-type rinsing fixture. A cylindrical container 40 is mounted on a stand 42 and is displaceable through a strut 41 and a mounting bushing connected to this, not illustrated in detail. The stand 42 is arranged to be oriented vertically in a central region of the liquid storage space and is connected to the basin bottom 43. Inside the container 40 is mounted a float 44 that surrounds the mounting bushing; the float 44 provides buoyancy for the container 40. On the basin bottom 43 two hook-formed clamping elements 35 are mounted so they can pivot. If a particular clamping element 35 is to be pivoted by means of the cylinder 9 described in the previous implementation forms, the piston rod 27 of the cylinder 9 grips a lever extension of the clamping element 35. Not shown in FIG. 9 in the sense of the previous implementation forms are the other components working together with the cylinder 9; in this respect reference is made to the previous illustrations. With the emptying of the liquid storage space the clamping elements 35 are disengaged by the float control and the container 40 filled with liquid rises. The closing off of the container rinsing fixture could take place, for example, at the stand 42, preferably in its upper region.
FIG. 10 shows a detailed representation of the valve 12 as described in relation to the previous implementation forms. This shows a displaceable plunger 20 for lifting from its associated seat 17 the ball 18 that closes off the passage through the valve. At its end that is turned away from ball 18, the plunger 20 is connected with an elastic steel membrane 45 that is held in a sealed fashion in the valve housing 46. By means of float rod 25 or, in the case of the implementation form according to FIG. 8, by means of float rod 25a, the steel membrane 45 and thus the plunger 20 are pushed against the force of the coil pressure spring 21 and release the check valve 12 from its closing-off position. | The invention concerns a device for operating a mechanism (5) of a rinsing fixture, in particular for operating a closing and opening mechanism or a locking mechanism of a rinsing fixture. It shows a float (28) and a first hydraulic or pneumatic force means (15) that shows a regulating unit (16) that is controllable through a float. A second hydraulic or pneumatic force means (9), which has a regulating unit (8) that is connected hydraulically or pneumatically with the regulating unit of the first force means, has an active connection with the mechanism (5).
According to the invention it is planned that upon rising the float, in opposition to a restoring force, drives the regulating unit of the first force means for operating the mechanism, that the float upon sinking is uncoupled from the regulating unit of the first force means, and that a valve (12) is arranged in the connection (11, 13) of the two force means. The valve is controlled by the float for movement of the regulating unit of the first force moans or by an additional float, so that the connection is open upon the rising of the float, is closed off when the float has risen or is sinking and is open when the float has sunk. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 09/190,090, filed Nov. 12, 1998, which is a divisional application of U.S. patent application 08/816,559, which is a continuation application of U.S. patent application Ser. No. 08/448,442, now abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is directed to one-leaf or two-leaf sliding doors, swinging doors or pocket doors with an electric, pneumatic or hydraulic drive, in particular, for vehicles.
[0004] 2. Description of the Related Art
[0005] A swinging/sliding door with an electric drive is known, for example, from DE-C 36 30 229 which discloses a two-leaf door in which each leaf has an upper and a lower guide rail in which at least one roller engages. The vertically extending rotational axis of the rollers is swivelable about a vertically extending door post pipe, this swiveling movement causing the door to open outward.
[0006] Since the electric drive can carry current only when the door is actuated, a dead-center mechanism is required for locking the door so as to ensure that the closed door cannot be opened by manipulation.
[0007] As another consequence of this dead-center mechanism, the door is only locked when it has been moved completely into the final closing position, so that any failure of the drive or any obstacle preventing the door from being closed completely will allow the door to open, e.g., as a result of the vibrations of the moving vehicle. On the other hand, the dead-center mechanism must also be adjusted precisely which, under heavy-duty operating conditions and during large differences in temperature, is difficult and accordingly disadvantageous.
[0008] The use of the door post pipe which is associated with each door leaf and is located at the edge of the door opening in the region of the lateral closing edge is another great disadvantage. When the door is open, this door post pipe can be covered only with difficulty and, even then, not completely. In the process of closing the door, the door post pipe in the region of the lateral closing edge poses the most serious kind of risk, especially for children and older, frail persons seeking a handhold.
[0009] Problems also occur in alignment because the door post pipe must be fitted and aligned in the floor region as well as in the roof region. There is no need to demonstrate in particular such problems which occur in all three axial directions.
[0010] Swinging/sliding doors with a pneumatic or hydraulic drive in which the door leaves are guided in a swivelable manner by means of a slide so as to be longitudinally displaceable at a stationary circular supporting pipe have also been known from Austrian Patent document 188 323. The corresponding guide rails for the opening out movement and for longitudinal guidance are arranged on the vehicle side in the region of the upper edge and lower edge of the door. Suitable guide rollers are provided at the door leaf.
[0011] The drive is effected via a cylinder-piston unit, and various lever mechanisms and scissor mechanisms have been suggested for reducing installation width. In the closed state, these doors are locked in the region of the lateral closing edge by a mechanism arranged in that location so that they remain closed while the vehicle is in motion in the event of a drop in pressure in the drive, but also because the normal operating pressure is not sufficient to prevent the door from opening in a reliable manner. It is not possible to achieve an operating pressure sufficient for this purpose in an economical manner due to the required wall thickness of the pipes and tubes.
[0012] The lock projecting beyond the free profile of the door at the height of the door handle in the region of the lateral closing edge poses a source of risk on a par with the door post pipe in the construction mentioned above.
SUMMARY OF THE INVENTION
[0013] Therefore, it is the primary object of the present invention to provide a one-leaf or two-leaf door of one of the types mentioned above which does not have their disadvantages and which is easy and simple to install and remove and in which, in particular, alignment is also simplified. Moreover, the lateral closing edge should be unencumbered by obstacles and objects or built-in elements posing a risk of pinching.
[0014] In accordance with the present invention, the sliding door arrangement including at least one door leaf mounted in a door frame has a drive for moving the at least one door leaf. The at least one door leaf has a lateral closing edge and a running surface at the lateral closing edge. The door frame has a counter-support surface, wherein, in a closed position of the at least one door leaf, the running surface is located essentially immediately below the counter-support surface.
[0015] In a development of the invention, a door support in the form of a roller arranged at the door frame is provided in the region of the lateral closing edge of the door above the conventional height of a handle and preferably near the upper edge of the door so that it is covered by the covering of the door drive. The axis of this roller extends substantially horizontally and lies normal to the movement direction of the door in the final closing region and cooperates with the supporting surface of the door which comes to rest under the roller.
[0016] Surprisingly, this brings about a substantial improvement in the stability of the door in the closed state, since any attempt to open the door, whether on the part of passengers or as a result of pressure shocks caused by wind resistance, results in a lifting of the door in the region of the lateral closing edge. The support effectively counters this lifting and accordingly prevents the door from being lifted out and opened.
[0017] In accordance with an embodiment of the invention, a spindle is provided at one end with a freewheel and a releasable brake or clutch preventing the rotation of the stationary part of the freewheel.
[0018] As a result of this construction, a self-adjusting, continuous locking of doors is achieved which dispenses with the dead-center mechanism, the locking at the lateral closing edge, and the undesirable door post.
[0019] The actual hanging of the door can be effected in different ways corresponding to the prior art and depends on whether the door has one or two leaves, on whether it is a sliding door, swinging/sliding door or a pocket door as well as on the type of drive provided.
[0020] The release of the brake or clutch during the opening movement is preferably effected electrically also when a pneumatic or hydraulic drive is used, since this allows a simpler control and a smoother opening than pneumatic or hydraulic actuation.
[0021] In two-leaf doors, not only is the door movement synchronized by the spindle drive, but the transmission of movement forces for a door leaf is also effected via the spindle when the actual door drive acts on a door leaf. That is, the movement of this door leaf in this case sets the spindle in rotation via the nut connected with the door leaf, this rotation being transmitted to the other door leaf via its nut in such a way that both leaves open and close synchronously since, as was mentioned above, the spindle is constructed symmetrically with respect to the center of the door so as to be right-handed along half its length and left-handed along the other half.
[0022] Of course, a linear drive can also act on an independent nut arranged on the spindle so that both door leaves are moved by means of the spindle. This is also the case in a drive producing a rotational movement in the spindle, e.g., an electric motor which sets the spindle in rotation via a toothed belt or a toothed wheel gear unit.
[0023] Another advantage which can be achieved with the invention consists in the advantageous arrangement of a pneumatic piston-cylinder unit above the door. The length of the piston corresponds to roughly half the width of the door, that is, it corresponds to a door leaf. Since it acts on the door leaf to which it is adjacent, it can act directly on this leaf or on a projection arranged at this leaf without a rod linkage or scissor mechanism. The door leaf located below the pneumatic piston-cylinder unit is moved via the spindle without taking up substantial space.
[0024] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, specific objects attained by its use, reference should be had to the drawing and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0025] In the drawing:
[0026] [0026]FIG. 1 shows an interior view of a door according to the invention without its covering;
[0027] [0027]FIG. 2 shows a section along line II-II of FIG. 1;
[0028] [0028]FIG. 3 shows an enlarged sectional view of the upper part of FIG. 2;
[0029] [0029]FIG. 4 shows the end remote of the drive of the spindle;
[0030] [0030]FIG. 5 shows a detailed sectional view of the end shown in FIG. 4;
[0031] [0031]FIG. 6 is an enlarged top view showing the support;
[0032] [0032]FIG. 7 shows an interior plan view of the support;
[0033] [0033]FIG. 8 shows another variant of a door according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The door according to the invention which is shown in FIG. 1 has two door leaves 1 , 2 , each of which is fastened at a rail 4 so as to be moveable by means of a slide 3 . The drive itself, including the spindle, is not shown in this drawing.
[0035] [0035]FIG. 2 shows a view of the door along section II-II of FIG. 1. The rail 4 , around which the slide 3 is supported in a swivelable manner, can be seen in section in the upper region of the door. The door 2 is shown in the closed position flush with the vehicle body and also in the opened out or (outward) position as indicated by the thin section shown in the upper region.
[0036] The door itself is guided in the upper region by guide rollers 5 which run in a rail 6 and in the lower region by deflectable rollers 7 and associated guide rails 8 in the door.
[0037] The entire region of the lateral closing edges 9 located between the guide rollers and rails is free of structural elements which could pose a risk of a user being pinched.
[0038] [0038]FIG. 3 shows an enlarged plan view of the drive region according to FIG. 2. The drawing shows the actual drive motor 10 which sets a spindle 12 in rotation via a toothed belt or V-belt 11 . A nut 21 is connected in a stationary manner with each door 1 , 2 and slide 3 associated therewith, this nut 21 being moved axially by the rotation of the spindle 12 resulting in an opening and closing of the door. The synchronizing of the two doors is brought about by a symmetrical construction of the spindle threads with respect to the plane of symmetry of the door.
[0039] [0039]FIG. 4 shows the end of the spindle 12 remote from the drive 10 in a plan view corresponding to FIG. 1, wherein the rail 4 is located in front of this spindle 12 . An emergency actuating device 13 , which can be released by the clutch or brake of the freewheel, is only schematically shown in FIG. 4.
[0040] In order to release the brake for emergency actuation and accordingly enable manual opening, an actuating rod 14 must be displaced to the right, with reference to the drawing, against the force of a spring 29 , which is effected manually by means of a Bowden cable 15 or, in normal operation, by releasing the electromagnetic clutch.
[0041] The support arranged in the upper door region for stabilizing the position of the door in the closed state is also shown in FIG. 4 and in enlarged scale in FIG. 7 with reference to door 2 . A substantially horizontal running surface 17 is arranged at the door 2 at the lateral closing edge. In the closed state of the door, this running surface 17 cooperates with a roller 18 which comes to rest above the running surface 17 and is supported thereon.
[0042] The roller 18 is rotatable about a substantially horizontal axis 19 whose position is shown more clearly particularly in FIG. 6, although FIG. 6 refers to door 2 . Towards the end of the closing process, the door moves substantially in the direction of line 20 . The axis 19 of the roller 18 extends normal to the final closing direction 20 .
[0043] With reference to FIG. 4 again, it will be seen clearly that the door is constructed in a freely supported manner in the region of the lateral closing edge. For this reason, any attempt to open it causes torque to be produced about an axis extending approximately horizontally and normal to the plane of the door resulting in a turning of the door approximately about its suspension at the slide 3 . This turning causes the door to be lifted in the region of the lateral closing edge 9 . This lifting is effectively prevented by the support 17 , 18 , whose vertical position has no influence on its action. Accordingly, it is possible to arrange the support at a height where there is no danger of a passenger being pinched or risk of substantial soiling during operation. This height region is preferably located near the upper edge of the door so that the support is also covered by the covering of the door drive.
[0044] [0044]FIG. 5 shows an embodiment example of a freewheel, including brake, which can be used according to the invention. The plan view shows the end of the spindle 12 remote of the drive 10 , including the nut 21 connected with the door via the slide 3 , in the open position of the door.
[0045] The end of the spindle 12 is supported in a receptacle 22 also having a conventional freewheel 23 . When the receptacle 22 is held so as to be fixed with respect to relative rotation, the freewheel 23 enables a rotating movement of the spindle 12 in the direction corresponding to the closing of the doors 1 , 2 .
[0046] In order to open the doors, i.e., to rotate the spindle in the opposite direction, it is necessary to release the receptacle 22 so that it can rotate along with the spindle 12 . This is effected in the following manner: the receptacle 22 is connected in a stationary manner or integral with a shaft 24 which is supported so as to be rotatable relative to the body of the vehicle and is connected with a clutch disk 25 having clutch linings 26 at either end side.
[0047] Counter-disks 27 , 28 are constructed on both sides of the clutch disk 25 considered axially. These counter-disks 27 , 28 are fixed with respect to rotation relative to the vehicle body and are displaceable axially relative to the shaft 24 . When the rod 14 is displaced toward the right, as indicated by its two positions, the two clutch disks 27 , 28 are released axially by swiveling a cam so that the disk 25 which is located between the two counter disks 27 , 28 and connected with the shaft 24 is likewise released. This allows the receptacle 22 to rotate along with the spindle 12 in the opening direction.
[0048] This releasing is effected automatically by the door drive every time the door is opened or manually in case of emergency by means of the Bowden cable 15 . Depending upon the user's attitude regarding safety precautions, the brake can either be applied again following manual actuation or can be held in the open position by means of a lever mechanism which is not shown in the drawing. In one case, proper closing and continued operation of the doors is enabled. In the other case, it is possible to determine misuse and to take countermeasures.
[0049] The special arrangement of the freewheel and brake results in a final closing position region in which the door is secured against unwanted opening instead of the fixed final closing position determined by the dead center point. This results in a substantial simplification in assembly because, for example, there is no longer any need to allow for rubber seals of varying width.
[0050] The embodiment according to FIG. 8 shows a variant in a plan view similar to FIG. 1, although in this instance the actual door drive acts pneumatically, via a cylinder-piston unit 30 , on a shoulder 31 which is connected in a stationary manner with the door leaf 1 . In the example shown in the drawing, this shoulder is the nut 21 arranged on the spindle 12 .
[0051] When the door leaf 1 is moved, this nut sets the spindle 12 in rotation so that the nut 32 connected with the door leaf 2 causes the door leaf 2 to move synchronously in a mirror-inverted manner with respect to door leaf 1 .
[0052] The left end of the spindle 12 , with reference to FIG. 8, carries a freewheel 23 and a brake or clutch 24 - 28 as is shown in detail in FIG. 5.
[0053] The door according to the invention is not limited to the example shown. For instance, it is possible to construct the drive of the spindle in a different manner, e.g., by means of a toothed wheel gear unit or, space permitting, by means of a motor flanged coaxially to the spindle.
[0054] If the issue is one only of unauthorized opening by the user, the support 17 , 18 can be constructed differently, e.g., by means of two supporting surfaces which are a slight distance apart in the normal state and can be suitably lubricated under certain circumstances in order to reduce wear.
[0055] However, it is also possible to provide two supporting or running surfaces 17 at the door, one of which lies below the support roller, as is shown, while the other comes to rest substantially directly above the support roller, so that the slide 3 and the supporting rail 4 are relieved of loading in the closed state of the door. Of course, it is also possible to provide the roller at the door and to provide the supporting surface(s) at the body of the vehicle.
[0056] Another construction of the invention with respect to the releasable freewheel consists in arranging the latter coaxially to the spindle 12 . Should there be insufficient space adjacent to the door opening, it will be an easy task for the person skilled in the art to arrange the freewheel, including the releasable brake, at an incline at the top within the spindle 12 as seen from the body side similar to the door drive 10 shown in the drawing and to produce a working connection by means of a V-belt or toothed belt, toothed wheel gear unit, chain or the like. Apart from reducing overall length, this also has the advantage that the spindle 12 can be supported in a stationary manner at both sides and that the brake can also be taken into account per se during assembly since the working connection is capable of compensating for assembly errors and oblique axial positions and the like.
[0057] The brake can be constructed so as to produce a frictional engagement (friction clutch) or a positive engagement (toothed clutch).
[0058] If a linear drive is used, it may be constructed pneumatically as was already mentioned, but can, of course, also be constructed hydraulically or electrically. It can act on one of the door leaves or on the spindle via an independent nut.
[0059] In doors which slide exclusively without an opening out movement, e.g., pocket doors which are pushed into a pocket between the outer wall and inner wall of the vehicle when opened, a linear drive can be arranged in a particularly simple manner since it need not participate in a swinging movement.
[0060] The spindle itself can have various profiles, e.g., the conventional trapezoidal profile. However, spline spindles are particularly preferred.
[0061] Any device permitting rotation of the spindle 12 in the direction corresponding to the closing direction of the door even when the stationary part of the freewheel is fixed, but which prevents a rotation in the opposite direction, can be used as freewheel. When the stationary part is fixed against rotation, the spindle can rotate in any direction.
[0062] While specific embodiments of the invention have been described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A sliding door arrangement with at least one door leaf mounted in a door frame includes a drive for moving the at least one door leaf. The at least one door leaf has a lateral closing edge and a running surface at the lateral closing edge. The door frame has a counter-support surface, wherein, in a closed position of the at least one door leaf, the running surface is located essentially immediately below the counter-support surface and the counter-support surface rests on the running surface for preventing lifting of the door leaf. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit and priority to Mexican application No. MX/a/2012/007271 with a filing date of Jun. 21, 2012, the disclosure of which is incorporated herein by reference in its entirely.
FIELD OF THE INVENTION
[0002] The present invention named “Detector of Slickline Irregularities” (“DILA” for its acronym in Spanish) is within the field of the instruments used to measure or determine abnormalities in the slickline used to operate oil wells.
BACKGROUND
[0003] Among the many activities that take place in an oil well, there are those undertaken by Slickline area, which with a Motor Unit in which a spool is installed with a steel line (wire) with special tech specs, performs mechanical works such as installation and removal of tools, bottom inspections, etc.
[0004] Slickline area, belonging to the Operative Base for Servicing Wells, operates mobile units carrying a slickline spool of special features in terms of geometry, strength, hardness and composition. Due to the nature of these operations, the line is at risk of suffering changes, breakdowns, stretching or deformation caused either by rubbing the line with the other mechanical elements such as oilers, blowout preventers, etc., or chemical attack from sulfhydric gas or carbonic acid. This may cause abnormalities in the line and increases the likelihood of breaking it during operation, which entails that the tools being used at that time are trapped within the well, so it is necessary to retrieve the tools lost at the bottom when the slickline breaks.
[0005] The difficulty of a fishing operation will depend on many factors, of which, one that complicates the most tool recovery is when rupture occurs in the moment in which the line has been lowered to a considerable depth, and when rupture occurs and recovery is to be performed, the presence of a large amount of tangled wire in the intermediate zone between the surface unit and the tool complicates the fishing operation. In addition, there is an economic loss, since the line that was left downhole is practically unusable.
SUMMARY OF THE INVENTION
[0006] Therefore, the Systems and Tools for Information Acquisition from Wells (“SHAIP” for its acronym in Spanish) group of the Instituto Mexicano del Petróleo (IMP) [Petroleum Mexican Institute] was given the task of developing a system to detect and assess changes suffered by the slickline used in field operations, such as reduced diameter, nicks, severe scratches and pores, that could put on risk the tools used in well operations.
[0007] This system was named with the initials DILA-IMP (Detector of Slickline Irregularities of the IMP).
[0008] Therefore, one object of the present invention is to provide a device which can adapt to the field units and allows to monitor the status on the line before, during and after an operation, in order to allow timely cutting the damaged line sections.
[0009] Another object of the present invention is to reduce failures in the slickline as a result of rupture, deformations for excessive efforts or collisions in the various elements (centering roles, mechanical counter, anchor pulley, stuffing box, preventer, valve shaft and output tubing) by passing the slickline from the spool to the bottom of the well.
[0010] The features of the invention are provided by a detector system of slickline irregularities to operate in oil wells, comprising: a) an eddy current sensor, wherein the slickline passes through the eddy current sensor; b) an eddy current reader, which detects a change in diameter in such slickline, c) an optical encoder, which conditions the analog signal; d) an electronic module for data acquisition, which acquires and conditions the signals from the sensors and processes the signals to the computer; and e) a computer, which displays the measurement made.
[0011] The eddy current sensor measures slickline abnormalities within diameters of 0.092 to 0.125 inch by changing the diameter of the sensor's adapter.
[0012] The detector of the invention detects flattening and folds on the slickline, lack of nickel coating (darkest zones on slickline), porosity and corrosion from acid attack without interfering with the line or in testing workshop before the specified service during operation.
[0013] The depth gauge has a 1.1997 m pulley perimeter with 500 pulses and CCW direction.
[0014] The detector measures anomalies or irregularities such as pitting, bends or wear areas on the slickline based on the measured changes in an electromagnetic field generated by eddy currents as the slickline passes through the eddy current sensor. The anomalies can be identified, for example, using respective signatures of the anomalies (e.g., selected characteristics of the electromagnetic fields that indicate various types of anomalies) that can be compared with the measured changes in the electromagnetic fields along the length of the slickline. The location of the anomalies on the slickline are recorded in a memory integral or external to the microcontroller.
BRIEF DESCRIPTION OF DRAWINGS
[0015] The characteristical details of Detector of Slickline Irregularities (DILA) systems are clearly shown in the following description and figures presented.
[0016] FIG. 1 is a perspective view of the Detector of Slickline Irregularities (DILA), the parts of the system comprising: eddy current sensor (part No. 1 ), eddy current reader (part No. 2 ), optical encoder (part No. 3 ), electronic module of data acquisition (part No. 4 ), computer (part No. 5 ), slickline spool (part No. 6 ), counter pulley (part No. 7 ).
[0017] FIG. 2 is a block diagram of the internal structure of part No. 4 in FIG. 1 , which is the data acquisition module.
[0018] FIGS. 3 a - 3 b show a first case of the irregularity of line occurred at 164 meters.
[0019] FIGS. 4 a - 4 c illustrate a second case of irregularities of a line at 2382.3 meters and at 2405.6 meters.
[0020] FIGS. 5 a - 5 d show a third case of irregularities of a line at 3094, 3095 and 3104 meters.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Detector of Slickline Irregularities (DILA) is a comprehensive electronic system that allows detecting and proactively assessing irregularities present in slickline due to interventions made in the field (production wells) or to a new slickline. It is governed by the principle of eddy currents or eddies, or Foucault currents.
[0022] This comprehensive electronic system allows to detect and assess irregularities of the slickline used in interventions of oil wells. It is noteworthy to mention that these lines can vary in diameter depending on the operation to be performed on each well.
[0023] In accordance with FIG. 1 , the present invention relates to a system consisting of: an eddy current sensor (part No. 1 ), eddy currents reader (part No. 2 ), optical encoder (part No. 3 ), electronic module for data acquisition (part No. 4 ), a computer (part No. 5 ) with a Windows environment software for interpreting and graphing the results. This system is installed in Slickline Motor Units to operate in oil wells.
[0024] The object of the present invention is to contribute to reduce failures in the slickline as a result of rupture due to deformations for excessive stresses or collisions in the various elements of the slickline that runs from the slickline spool (part No. 6 , FIG. 1 ) up to the bottom of the well, passing through: centering rollers, mechanical counter, anchor pulley, stuffing box, preventer, valve shaft and output tubing.
[0025] In order to meet the above mentioned object, irregularities or deformations of slickline are detected by this invention, and obtained values of deformation and depth shall be graphed to allow decision making for using or discarding a length or the whole slickline depending on the risk this represents for execution of the self activity.
[0026] Principle of operation. In accordance with the present invention, the detection of irregularities and anomalies in the slickline is performed using the eddy current principle or eddy currents. Eddy currents are defined as the alternating current induced in a conductor when subjected to a time-varying magnetic field, eddy current then generates its own secondary electromagnetic field which is used to identify or distinguish between a wide variety of physical, structural, metallurgical, ferromagnetic and non-ferromagnetic conditions and in non-metallic parts that are not electrically conductive. This method does not require direct electrical contact with the inspected part.
[0027] In accordance with FIG. 1 , the operating principle of the detector system of slickline irregularities is based on passing the slickline through the center of eddy current sensor (part No. 1 ), the same upon detecting a change in diameter on the slickline because of deformation, this generates a change in the electrical field becoming a current variation that is transmitted to the eddy current reader (part No. 2 ) for conditioning analog signal sent to the electronic module for data acquisition (part No. 4 ) and this one in turn to a computer (part No. 5 ) which plots and records data with software designed for this purpose.
[0028] Slickline irregularities detector is a comprehensive electronic system to detect and evaluate the irregularities that occur in the slickline due to field operations in oil wells.
[0029] The optical encoder (part No. 3 ) is installed on the side of the counter pulley (part No. 7 ) of the slickline motor unit, which signal is converted into units of length per unit time (speed) and also becomes a longitudinal measure to measure the depth of the line.
[0030] The optical encoder (part No. 3 , FIG. 1 ) is a transducer that obtains the depth or displacement of the slickline and converts the mechanical motion into electrical signals that are sent to the electronic module for data acquisition (part No. 4 ) for processing speed and depth. Being both signals obtained from eddy currents reader (part No. 2 ) and the optical encoder (part No. 3 ), these are sent to the electronic module for data acquisition (part No. 4 ) where they are processed by the general-purpose microcontroller ( FIG. 2 ) that conditions the sensor signals and sends them via a serial communication cable to the computer (part No. 5 ) containing the visualization software for such measurements.
[0031] With reference to the FIG. 1 , Detector System of Slickline Irregularities (DILA) of the present invention also consists of software whose function is to display and plot data acquired from the optical encoder (part No. 3 ) and eddy current sensor (part No. 1 ), as well as an electronic module for data acquisition (part No. 4 ) which is in charge of acquiring input signals from the sensors, process them and send them to computer via an RS232 serial communication cable.
[0032] Part No. 1 in FIG. 1 shows the primary sensor where the slickline crosses and causes an electrical signal that is sent to eddy current reader (part No. 2 ). This sensor varies in dimensions according to the diameter used in the steel line. The sensor interprets this signal and transmits it to the electronic module for data acquisition (part No. 4 ) as ±5 v signals of horizontal and vertical measurement channels.
[0033] The detection of irregularities or anomalies in the slickline is performed using the eddy current principle or eddy currents. Eddy currents allow the detection of surface and subsurface discontinuities in the material structure, as seams, overlaps, cracks, porosity and inclusions.
[0034] The eddy current sensor (part No. 1 ) is placed in front of the counter pulley (part No. 7 ) through which the slickline passes, and the optical encoder (No. 3 ) is placed on the side of the same counter pulley. Signal from eddy current sensor (part No. 1 ) is connected to the eddy current reader (part No. 2 ), which generates two ±5 v electrical signals of horizontal and vertical measurement and together with optical encoder signal (No. 3 ) are connected to the electronic module for data acquisition (part No. 4 ) and these are sent to the computer (part No. 5 ) via a serial communication cable ( FIG. 2 ) RS232. It is noteworthy to mention that the eddy current reader (part No. 2 ), the electronic module for data acquisition (part No. 4 ) and the computer (part No. 5 ) are located inside the cab of the motor unit (Slickline Unit).
[0035] Part No. 5 shows a computer containing the visualization software. This visualization software called DILA-WIN is a program developed with Windows operating system, so that the user graphic panels are easy to use and understand. The computer screen shows the software that displays and plots the speed and depth information of the slickline operation. The software has a recording capacity in the range of 60 to 80 m/min.
[0036] Part No. 3 in FIG. 1 shows an optical encoder, which is a transducer that enables the measurements of depth (displacement of slickline through the well) and speed of operation of the same line. These signals are sent to the electronic module of data acquisition as shown in part No. 4 .
[0037] FIG. 2 shows the parts of the electronic module for data acquisition (part No. 4 , FIG. 1 ), which represents the main part of the detector system of slickline irregularities, as this acquires, conditions the signals from the sensors and processes the signals for subsequent delivery to the computer (part No. 5 , FIG. 1 ), by means of a RS232 serial communication cable. This system basically consists of a general purpose microcontroller that performs the conversion and adaptation of analog to digital signals, processes them, and sends the information by a communication protocol RS232 to the computer.
[0038] This electronic module has a keyboard for entering parameters settings such as: the slickline diameter, pulley diameter and number of optical encoder pulses. These parameters are shown on a LCD dot matrix character display, which displays alphanumeric data of 2×16 (2 lines, 16 characters). Similarly, the electronic module contains a battery as a backup alternative, because if the main power source for any reason is interrupted, this battery would keep operating DILA system.
[0039] During the data acquisition with the DILA, the following information channels are obtained: PROF, VEL ANH AND ANHV ANV, PROF channel refers to the depth in units of meters (m). VEL Channel is the speed of rising or falling in units of meters per minute (m/min). ANH channel refers to the measurement performed by the eddy current sensor in the horizontal orientation. ANV channel refers to the measurement performed by the eddy current sensor in the vertical orientation. ANHV channel measurement refers to both channels ANV and ANH
[0040] DILA-IMP is a system that identifies slickline irregularities in qualitative form from a threshold 160 pre-established value as a fault indicator. The channel ANALOG ANHV uses 0-200 scale without units as an indicator of irregularity in slickline.
[0041] Based on visual inspection and touching the slickline, the data values above the pre-established fault indicator are considered noticeable irregularities of the line and need operator strict review. Table 1 shows the typical configuration parameters of DILA-IMP system for use in the field.
[0000]
TABLE 1
Configuration Parameters of DlLA-IMP system
For depth gauge
Pulley perimeter = 1.1997 meters*.
Pulses = 500*
Direction = CCW
Eddy current reader
Sensor Frequency = 100 kHz
Measurement angle = 0
Horizontal gain = 60.0 dB
Vertical Gain = 60.0 dB
Filter passes low detection = 150 Hz
Filter passes high detection = 30 Hz
Continuous measurement = 1.0 Hz
In DilaWin-IMP Software
Record speed = 60 to 80 meters per minute (m/min).
*Depends on the pulley and encoder to be used.
EXAMPLES
[0042] DILA system has been installed and operated in Slickline Units of Services for oilfield wells. To date the inspection was made with 0.092″ (92 mils) in diameter slickline in routine well operations, achieving also work with other slickline diameters up to 0.125″ if the diameter adapter used in the eddy current sensor is changed (part No. 1 , FIG. 1 ).
[0043] In these evaluations the steel The irregularities were detected at different lengths, being 3 cases shown below:
[0044] First case: FIG. 3 shows the irregularity of the line occurred at 164 meters as can be seen at point A on the graph ( FIG. 3 a ). Also, on the slickline ( FIG. 3 b ), a flattening indicated at point A is detected, which corresponds to point A on the graph in FIG. 3 a.
[0045] Second case: FIG. 4 a , shows irregularities on line at 2382.3 and 2405.6 meters (points A and B, respectively). FIGS. 4 b and 4 c show the lack of nickel coating on the slickline (darkest) corresponding to the irregularities shown in the graph as points A and B of FIG. 4 a , respectively.
[0046] Third Case: FIG. 5 shows irregularities of the line at 3094, 3095 and 3104 meters respectively in sections A, B and C. FIGS. 5 b , 5 c and 5 d show porosity and corrosion due probably to acid attack on the line which correspond to irregularities shown at points A, B and C on the graph in FIG. 5 a. | Detector of Slickline Irregularities (DILA) is a electronic system to detect and assess irregularities in production wells or to a new slickline by measuring eddy currents or eddies or Foucault currents. The system lines can vary in diameter depending on the operation to be performed on each well. The electronic system includes an optical encoder, eddy current sensor, eddy current reader, an electronic module for data acquisition and a computer. The detector monitors the integrity of the slickline in the well, interprets and records the data for graphing and reduces failures in the slickline as a result of rupture caused by excessive stress or collisions within the producing wells, detects flattening and bending, lack of nickel coating, porosity and corrosion. |
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BRIEF SUMMARY OF THE INVENTION
This invention relates to a building wall adapted to be erected with blocks that are pregrooved on the inner and outer faces and ends to form a matrix of grooves to receive a surface overcoat into which a variety of designs can be impressed or indented, and it also relates to a method of developing many designs in a surface coating for one or more surfaces of walls using grooved surfaces in underlying blocks.
The prior art is known to have a concrete or masonry block wall capable of being manufactured with surface designs. However, normally the wall blocks do not come with any pattern of grooves so that the grooving has to occur after the blocks are laid up in a wall. A special situation is known where concrete masonry blocks formed in apparatus of U.S. Pat. No. 3,381,345 of Charles L. Williams offer limited possibilities for surface decoration, as these blocks are sized and shaped only to simulate the appearance of standard brick wall lay ups. It is also known in the art that designers and architects like to call for esthetic characteristics in a lay up of blocks in a wall such that they form designs in or on the wall surface or designs with raised surfaces on two or more blocks which is repeated throughout the wall. Generally it requires several blocks to be matched to complete one design which is repetitive. These prior art examples are expensive and require many different blocks to complete a wall design. Great care is required to properly match blocks which takes time and increases costs and requires large inventories of blocks for each design. Each block design also requires its own mold parts, so an inventory of molds is required.
It is also known that an architect or designer will seldom use a design more than one time, and it is very unlikely that his competitors will use the same design or pattern. Therefore, special designed masonry units are very costly.
The objects of the present invention are to provide a modular matrix of grooves carried as a standard throughout many different sizes of molded concrete blocks so that a wall lay up with any one block size or even several sizes of blocks can have the matrix of grooves match up to form the basis for receiving a coating of suitable material capable of being impressed or indented in a variety of designs drawn out of the underlying matrix of grooves, to provide a coating for the surfaces of a building wall that can receive a design while it is in a workable state and hold a design thereafter, where the design or designs may be composed of lines selected from corresponding underlying grooves in the wall blocks, to provide a method of achieving ornamental designs in a masonry wall or walls with the use of simple well known jointer tools, and to provide architects with a generally common system of grooved blocks to quickly and economically choose different designs and form selected designs in one or all of the walls of a building or vary the designs for each wall of a building after the wall is laid up.
The invention is embodied in a decorative building wall, whether an internal partitioning wall or an exterior wall, which comprises in combination a plurality of blocks laid up in cooperative abutting relation in courses to form a wall surface, a plurality of grooves formed in each block with the grooves providing a matrix in the lay up of the wall, and a layer of a settable material covering the grooved matrix in which is impressed a pattern of grooves, following one or more of the grooves in the matrix whereby the surface of the wall formed by the blocks takes on a decorative appearance.
The invention is further embodied in a method of decorating the surface of an otherwise raw building wall, whether an interior partition or an exterior wall, composed of blocks arranged in abutting relation in courses to form a wall surface, which method consists in grooving the surfaces of the individual blocks, laying the blocks in abutment in the wall with the grooves exposed in cooperative adjacency to form a matrix of grooves and joints, covering the matrix with a coating of settable material, and impressing the coating material prior to setting with a decorative pattern of visible grooves which overlie one or more of the grooves in the covered matrix.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is embodied in certain forms of molded blocks with a selection of grooves forming a matrix in a wall lay up, and is represented in the accompanying drawings, wherein:
FIG. 1 is a perspective view of a typical block having a 4 inch thickness carrying a pattern of side and end grooves, the pattern on the visible end being duplicated in the hidden surfaces when necessary;
FIG. 2 is a perspective view of a typical 6 inch thick block carrying a pattern of grooves in the visible end and side, it being sometimes necessary to form similar grooves in the hidden surfaces;
FIG. 3 is a perspective view of a typical 8 inch thick block formed with a pattern of grooves in the end and sides, and when necessary with grooves in the hidden surfaces;
FIG. 4 is a perspective view of a typical 10 inch block having the pattern of grooves like those in the block of FIG. 2, and when necessary in the hidden surfaces;
FIG. 5 is a perspective view of a 12 inch thick block having the grooves compatible with those of the other blocks, and when necessary in the hidden surfaces;
FIGS. 6, 7 and 8 are perspective views of fragmentary wall lay ups using 8 inch thick blocks of FIG. 3, and showing the varieties of designs that can be impressed or indented in the coating applied to the wall; and
FIG. 9 is a fragmentary sectional view taken along line 9--9 in FIG. 6 to show a typical detail of the coating applied to the surfaces of blocks of FIG. 3.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The molded concrete block 10 in FIG. 1 has a generally rectangular body with opposite vertical ends 11, opposite vertical faces 13 and top and bottom surfaces 14 and 15. The body is formed with cored openings 16 to reduce weight. The visible end 11 and face 13 are formed with aligned grooves 17, 18 and 19 and the face 13 is formed with parallel vertical grooves 20, 21 and 22. It is preferred to form block 10 with certain dimensions that have become standard in the concrete block industry. Therefore, block 10 is formed to be about 4 inches wide, about 8 inches high, and about 16 inches long. These dimension are then used to determine where to place the several horizontal grooves and the vertical grooves.
For example, if the block 10 is to be compatible with the standard brick, which is 21/4 inches, by 35/8 inches, by 75/8 inches, the groove 18 is located to divide the 8 inch height equally. The grooves 17 and 19 are then located in spaced relation from groove 18 to divide the 8 inch height into three equal parts. The vertical set of grooves 20, 2l and 22 (FIG. 1) are located to divide the length of 16 inches into quarters, or divisions of about 4 inches each. Obviously due allowance needs to be made for mortar joints, but for the simplicity of this disclosure the foregoing general arrangement of the horizontal set of grooves 17, 18, 19 in the ends as well as the sides will be followed throughout the other blocks.
If a wall is laid up using only the blocks of FIG. 1, the running bond between the first and second courses (FIG. 9) would be on a one quarter bond in which one space between the vertical groove 22 and the nearest end 11 would lap on the adjacent underlying block. This bond pattern is dictated by the way the blocks in a corner are overlapped. It is clear that the grooves 17, 18 and 19 and the grooves 20, 21 and 22 form a matrix of horizontal and vertical grooves out of which can be selected an infinite variety of designs from a design of a standard brick lay up to wide horizontal bands or vertical column effects.
Having now visualized the possible designs that can be selected, it is the next step of this invention to mask the entire matrix of grooves in a complete wall with a settable coating. The coating can be made up from a cement base with fine sand or crushed limestone, a bonding agent such as ACRYL 60 by Standard Dry Wall of Florida, and suitable waterproofing agents. Coloring can be mixed into the coating, or paint can be applied later. The coating can be laid on in any approved manner and has a thickness which may vary from about one-sixteenth to about three-sixteenth inch so as to completely cover all grooves and joints. It is preferred to rely upon the thinner coating for ease of tooling and following the underlying grooves. Before the coating sets up or hardens, the wall is tooled with a mason's jointer tool in the vertical and horizontal groove locations previously chosen. As the tooling progresses the selected design will emerge and give the wall a pleasing appearance. In this manner, a raw concrete block wall usually having the blocks boldly outlined in rectangles of 8 inches by 16 inches can be transformed into one that is made to look like a brick wall without actually having an underlying brick wall. Examples of generally standard designs for a raw uncoated wall are Coursed Ashlar, Vertical Stacking, Horizontal Stacking, Square Stacking, Basket Weave, and Patterned Ashlar. A coated wall with an underlying groove matrix is unique as patterns can be brought out in which the coating is indented with the pointing tool to build the selected design. It is important to allow the mortar used to hold the blocks in the wall to set up and become rigid so that the impressing of the design will not disturb the lay up. In creating a design, the tooling must progress right along with the application of the coating so the grooves can be followed.
In FIG. 2 there is shown a 6 inch wide block 23 formed with cored out openings 24 to reduce weight. This block is formed with a series of vertical and horizontal grooves on its 16 inch long face 25 which exactly duplicate the grooves in the face 13 of block 10, and these grooves have similar reference numbers. The pattern of grooves in the visible end 26 includes the continuation of the three horizontal grooves 17, 18 and 19 from face 25. The end 26 which is 6 inches wide is formed with a pair of vertical grooves 27 and 28 which are spaced from the corners of the block body so that groove 27 is spaced from the farthest corner 29 a distance equal to about the width of block 10. The other groove 28 is spaced a similar distance from the farthest corner 30 so as to maintain modular compatibility with block 10.
In like manner, the block 31 of FIG. 4 is formed on its face 32 with a pattern of horizontal grooves 17, 18 and 10 described before, and with a pattern of vertical grooves 20, 21 and 22 as before noted. The block 31 is cored out at 33 to reduce weight. Carrying out the modular pattern of the vertical grooves 27 and 28 in the end of block 23, it is now evident to have four such grooves in the end of block 31 and these are designated 27, 28, 27A and 28A.
The block 35 of FIG. 3 is the most widely used size, being about 8 inches wide and high and about 16 inches long. Cores 36 are formed to reduce weight. The pattern of grooves in the side face 37 are the same as for block 10 and are so designated by similar reference numbers. The end 38 is about 8 inches wide and, therefore, lends itself to be divided by a single vertical groove 39 into about 4 inch halves.
The remaining block 40 shown in FIG. 5 is 12 inches wide and is formed with cores 41 to reduce weight. Again, the side face 42 is formed with the now familar pattern of horizontal grooves 17, 18 and 19, and with the equally spaced vertical grooves 20, 21 and 22. The grooves in the end 43 include vertical grooves 44 and 45 which are spaced to divide the end into about 4 inch equal divisions. The spacing of grooves 44 and 45 is about the same as for the spacing of grooves 20, 21 and 22 in the side to maintain the modular dimensions.
Turning now to FIG. 6, it can be seen that the wall lay up is composed of the blocks seen in FIG. 3, and the wall includes a corner and two wall runs leading away from the corner. This perspective view illustrates the steps of the method of transforming the raw surface of a block wall into a wall having a pleasing appearance. The raw wall lay up of blocks 35 can be seen at the left so that the matrix of grooves 17, 18, 19, 20, 21 and 22 match up in a running bond with mortar joints 46 outlining the respective blocks. After the blocks 35 are laid up, a parget or coating 47 is applied over the blocks 35 so the several grooves are covered and the coating penetrates the grooves. FIG. 9 is a fragmentary section to show the coating 47 covering grooves 21, 22 and a mortar joint 46 between adjacent blocks 35. The grooves and joint 46 are raked or rectangular so the coating 47 will penetrate the same and preserve the integrity of the coating layer when tooling in the design. One example is to form the groove about 3/4 inch wide and 3/16 inch deep, and to apply the coating 47 to a depth of from about 1/16 inch to about 3/16 inch. The coating extends to the left from the corner and the area covered is about as large as is desirable for the purpose of allowing the worker to pick up the desired underlying grooves from those exposed ahead (to the left) of the application of the coating. The wall area to the right of the corner has a complete columnar design impressed therein by indentations 48.
The views of FIGS. 7 and 8 provide other examples of designs impressed in the coating 47 applied over a wall composed of blocks 35 having mortar joints 46. In the design of FIG. 7 the vertical indentations 48 are now blended into adjacent horizontal impressions 49 and by broken or discontinuous horizontals 50. The coating 47 is laid on and the design follows up closely behind the progressive laying on the coating. The view of FIG. 8 shows still another wall design which is a variant of the design of FIG. 7 but having smaller areas defined by the indentations. Thus the vertical indentations 48 are further blended into evenly spaced horizontal indentations 51, and by a combination of short vertical indentations 52 and cooperating horizontal indentations 53.
The blocks seen in FIGS. 1 to 5 can be commercially produced in known manner by providing the forming molds with vertical ribs or inserts which form the grooves 20, 21, 22, 27, 28, 27A, 28A, 39, 44 and 45 and allow the blocks to be ejected onto a conveyor. The blocks are then aligned and passed adjacent gang masonry saws or grooving discs and the respective grooves 17, 18 and 19 are formed in two passes, one for the sides and one for the ends.
As can be seen in FIG. 3, the block 35 is formed in the cored passages 36 with notches 55 extending through the heighth of the block, and with a central slot 56 in the body web between cored openings 36. The notches are supplied to make it easy to break off a portion of the block body so the reduced portion will fit a need for less than a complete or whole block. The slot 56 serves the same function when a one-half block is needed. The other blocks seen in FIGS. 1, 2, 4 and 5 may be similarly provided with notches and slots but these are not thought necessary to show as it can be readily appreciated from FIG. 3.
It can now be understood that a building wall laid up with blocks of the character described, having a resulting matrix of cooperating grooves in one or both surfaces, can be coated or pargetted with a settable material and impressed or indented with any of many designs or with a combination of designs overlying and guided as to location by the underlying grooves in the blocks. The resulting wall construction with a decorative surface design different from the regular running bond mortar joint scheme can be created by the unique method of selecting a pattern of guiding grooves from the wall block groove matrix, coating the blocks, and tooling the selected design into the coating. Where the blocks are used to form interior walls between adjacent spaces or areas, the unique method can be used to great advantage to impress a different design on the opposite surface of the common wall. Since it has been pointed out before that the blocks can be grooved on opposite ends or sides, it follows that a common wall, such as a partition separating adjoining spaces, can be made up of blocks having the same matrix of grooves on the opposite exposed faces and the decorative designs of FIGS. 6, 7 or 8 may be impressed in the opposite walls so that the monotony of repetitive designs is easily avoided. | A building wall erected from blocks presenting one or more surfaces formed with a matrix of grooves generally horizontally and vertically related, and an overlay veneer or applied surface coating adapted to be impressed or indented with appropriate tools in a manner to produce a wide variety of designs by selection of different combination of the grooves in the matrix. A method of variously decorating one or more building wall surfaces or sides of walls with the guidance of a matrix of grooves and an overlay coating adapted to be impressed or indented in cooperation with preselected grooves of the matrix. |
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BACKGROUND OF THE INVENTION
The present invention relates to an analyzer device for analyzing at least one gas contained in a liquid, in particular a drilling liquid, flowing in a drilling pipe in an installation for extracting fluid from a subsoil. The device comprises an analyzer for analyzing the gas and a sampling apparatus for sampling at least a fraction of the gas. The sampling apparatus has at least one porous membrane member, the member comprising a support and having a first face in contact with the liquid flowing in the drilling pipe and a second face opening into a pipe connected to the analyzer.
When drilling a well for oil or some other effluent (in particular gas, steam, water), it is known to analyze the gaseous compounds contained in the drilling muds emerging from the well. Such analysis is used to reconstruct the succession of geological formations through which the borehole is being drilled and it contributes to determining the working possibilities of the fluid deposits encountered.
Such analysis is performed continuously and comprises two main stages. The first stage consists in extracting the gas conveyed by the mud (for example hydrocarbon compounds, carbon dioxide, hydrogen sulfide). The second stage consists in qualifying and quantifying the extracted gases.
For this purpose, mechanically-stirred degassers are frequently used. However, because of their size, such degassers must be installed at a distance from the well, generally close to a vibrating screen downstream from the wellhead. Muds are conveyed from the wellhead to the degasser via a flow line that might be open to the atmosphere. Thus, a fraction of the gaseous compounds present in the mud is released into the atmosphere while the mud is traveling along the line. An analysis of the gas present in the mechanically-stirred degasser is therefore not representative of the gaseous content of the mud in the well.
To solve that problem, devices of the above-specified type have been implanted directly in the drilling pipe, upstream from the wellhead, as described in U.S. Pat. No. 5,469,917. Such devices include a capillary tubular membrane supported capillary membrane (SCMS). However, the muds flowing around the membrane are laden with pieces of rock.
In order to avoid degrading the tubular membrane under the effect of impacts against these pieces of rock, the membrane is wound on a threaded rod. The thread of the support then protects the membrane against pieces of rock of a size greater than the distance between two consecutive threads of the threaded rod.
Those devices do not give entire satisfaction. To wind the membrane around the threaded rod, and thus provide it with protection, certain stresses need to be applied to the membrane. Thus, a membrane of tubular shape must be used in order to be capable of winding between the threads of the threaded rod. Furthermore, the membrane must be relatively flexible. Consequently, only a membrane based on organic materials can be used in such a device. Unfortunately, organic membranes present abilities at withstanding high temperatures and chemical compatibilities that are not always satisfactory in certain applications.
SUMMARY OF THE INVENTION
A main object of the invention is thus to provide a device for analyzing gas contained in a liquid that contains debris of varying size, in particular a drilling fluid, the device being installed directly in a pipe of an installation for extracting fluids from the subsoil, without putting large stresses on the membrane, in particular stresses concerning the nature and the shape of the membrane.
To this end, the invention provides a device of the above-specified type, characterized in that the first face presents Vickers hardness greater than 1400 kilograms-force per square millimeter (kgf/mm 2 ), in particular Vickers hardness lying in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 .
The device of the invention may comprise one or more of the following characteristics taken in isolation or in any technically feasible combination:
the porous membrane member includes a coating covering the support over the first face; the coating is based on silicon carbide; the first face is also water- and oil-repellent; the wetting angle of water on the first face is greater than 120°; the first face includes fluorine-containing polymers incorporated by grafting; the first face of the membrane member that is in contact with the liquid is substantially plane; the device further comprises a regulator for regulating the pressure in the pipe in register with the second face of the membrane member; and it includes a plurality of membrane members, and the second faces of the members open out in succession to the pipe connected to the analyzer.
The invention also provides an installation for extracting fluids from the subsoil, the installation being of the type comprising a drilling pipe connecting at least one point of the subsoil to the surface, and a delivery pipe connected to the drilling pipe at the surface. The installation is characterized in that it further comprises at least one device according to the above-described characteristics, and in that the sampling apparatus of the device is mounted on a tubular element constituted by the drilling pipe or by the delivery pipe.
The installation of the invention may comprise one or more of the following characteristics taken in isolation or in any technically feasible combination:
the first face of the membrane member in contact with the liquid is disposed substantially parallel to the long axis of the tubular element; the first face in contact with the liquid is disposed in a wall of the tubular element; the first face is disposed set back in a wall of the tubular element; the tubular element includes a branch connection and the sampling apparatus is placed in the branch connection; and the sampling apparatus of the device is placed in the drilling pipe upstream from the delivery pipe; and the installation further includes a filter downstream from the delivery pipe and it includes two devices as defined above, the respective sampling apparatus of the two devices being placed respectively upstream and downstream of the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described below with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic vertical section view of a drilling installation provided with an analyzer device of the invention;
FIG. 2 is a diagram showing the main elements of the analyzer device of the invention;
FIG. 3 is a diagram showing a detail of a variant of the installation shown in FIG. 1 ;
FIG. 4 is a diagrammatic vertical section view of an installation including two analyzer devices of the invention; and
FIG. 5 is a diagrammatic vertical section view showing a detail of a variant of the device shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A device of the invention is used for example in an installation 11 for drilling an oil production well. As shown in FIG. 1 , the installation 11 comprises a drilling pipe 13 in a cavity pierced by a rotary drilling tool 15 , a surface installation 17 , and an analyzer device 19 of the invention mounted on the drilling pipe 13 .
The drilling pipe 13 is placed in the cavity drilled in the subsoil 21 by the rotary drilling tool 15 . At the surface, the pipe 13 has a wellhead 23 provided with a delivery pipe 25 .
The drilling tool 15 comprises a drilling head 27 , a drill string 29 , and a liquid injector head 31 .
The drilling head 27 has means 33 for drilling rock in the subsoil 21 . It is mounted at the bottom end of the drill string 29 and it is positioned in the bottom of the drilling pipe 13 .
The drill string 29 comprises a set of hollow drilling tubes. These tubes define an inside space 35 enabling a liquid to be taken from the surface 37 to the drilling head 27 . For this purpose, the liquid injector head 31 is screwed onto the top portion of the drill string 29 .
The surface installation 17 includes means 41 for supporting and rotating the drilling tool 15 , means 43 for injecting drilling liquid, and a vibrating screen 45 .
The injector means 43 are hydraulically connected to the injector head 31 to inject and drive a liquid along the inside space 35 of the drill string 29 .
The vibrating screen 45 collects the liquid laden with drilling residue that leaves the delivery pipe 25 and separates the liquid from the drilling residue.
The analyzer device 19 has a sampling head 51 for taking at least a fraction of the or each gas, and analyzer means 53 for analyzing the or each gas.
As shown in FIG. 2 , the sampling head 51 comprises a porous membrane member 55 having a plane first face 57 in contact with the liquid flowing in the pipe 13 and a second face 59 looking into a pipe 61 connected to the analyzer means 53 .
The porous membrane member 55 comprises a membrane support 63 and a coating 65 covering the support 63 beside the liquid on the first face 57 .
This first face 57 is disposed in the pipe 13 parallel to the long axis of the pipe 13 , i.e. parallel to the flow of liquid. This first face 57 is preferably disposed along a wall of the pipe 13 or else is set back a little from said wall. Thus, tools can be inserted or extracted into or from the drilling pipe 13 while minimizing any risk of damaging the membrane member 55 by mechanical contact or impact. Furthermore, having the liquid flow parallel to the first face 57 puts a limit on the abrasive forces that are applied to the coating 65 .
The membrane support 63 is made on the basis of a porous material, e.g. a ceramic. Preferably, the membrane support 63 is in the form of a disk. In the example shown in the drawings, the diameter of the support is substantially equal to 50 millimeters (mm) and its thickness is less than 10 mm.
Examples of materials suitable for use in making the membrane support 63 include sintered stainless steel, metal fibers, or alumina fibers.
The size of the pores in the membrane support 63 lies in the range 0.01 micrometers (μm) to 5 μm, depending on the intended application. Pore diameter is preferably selected to lie in the range 0.02 μm to 3 μm.
The coating 65 which constitutes the first face 57 of the membrane member 55 comprises a thin layer based on silicon carbide deposited on the support 63 . The thickness of this layer lies in the range 0.5 μm to 2 μm. This thin layer covers the surface of the support between the pores.
Thus, the membrane member 55 is permeable to all of the gas present in the mud.
Furthermore, the Vickers hardness of the first face 57 of the membrane member 55 is greater than 1400 kgf/mm 2 . In the example described in the figures, this Vickers hardness lies in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 .
This thin layer thus protects the membrane member 55 against abrasion generated by pieces of rock and drilling debris.
In a variant, the coating 65 is modified by grafting fluid-containing polymer chains that are highly water- and oil-repellent. This grafting is preferably performed on the basis of a perfluoroalkylethoxysilane. This modification of the coating 65 enables the first face 57 of the membrane member 55 to be made water- and oil-repellent. Consequently, the wetting angle of water on the first face 57 of the membrane member 55 is greater than 120°, and is substantially equal to 130°.
The membrane member 55 is thus impermeable to the liquid flowing in the pipe, which contributes to limiting clogging of the pores in the support by solid residue coming from the liquid.
The pipe 61 connecting the porous membrane member 55 to the analyzer means 53 includes a gas-receiver chamber 71 , a pressure controller 73 for controlling pressure in the chamber, means 75 for conveying the extracted gas from the receiver chamber 71 to the analyzer 53 , and filter 77 for filtering the extracted gas.
The receiver chamber 71 covers the second face 59 of the membrane member, in register with the first face 57 . It comprises a bell having an inlet orifice 79 and an outlet orifice 81 connected, respectively to the conveying means 75 and to the pressure controller 73 .
The pressure controller 73 for controlling pressure in the chamber comprises elements 83 for measuring the pressure difference between the liquid in the pipe and the gas in the chamber, associated with a pressure regulator 85 mounted on the delivery pipe downstream from the chamber.
This regulator 85 is controlled in such a manner that when the device of the invention is used for analyzing the gases contained in mud, the pressure difference between the liquid flowing in the drilling pipe 13 and the gas present in the receiver chamber 71 is substantially zero. This substantially zero pressure difference prevents the liquid flowing in the drilling pipe 13 from penetrating into the membrane member 55 .
Nevertheless, if the porous membrane member 55 should become clogged, it is possible to control the pressure regulator 85 so that the pressure in the chamber 71 becomes much greater than the pressure in the drilling pipe 13 for a few seconds. The difference between these two pressures can then lie in the range 1 bar to 3 bar. It is thus possible to unclog the pores in the membrane member 55 .
The means 75 for conveying the extracted gas comprise means 87 for introducing a vector gas into the receiver chamber 71 via the inlet orifice 79 . By way of example, the vector gas is nitrogen or air.
A mass flow regulator 89 sets the rate at which the vector gas enters into the chamber 71 , and consequently the rate at which gas enters into the analyzer 53 . As a result, the rate of dilution of the extracted gas is constant over time. A volume flow meter 91 is mounted in the pipe 61 downstream from the filter means 77 in order to measure the flow of gas that results from the vector gas together with the extracted gases.
The filter 77 is disposed on the pipe downstream from the pressure regulator 85 . The filter 77 serves in particular to eliminate the water vapor present in the extracted gas. By way of example it is constituted by a desiccator based on silica gel filter cartridges, a molecular sieve, or a coalescing filter.
The analyzer 53 comprises instrumentation 93 for detecting and quantifying one or more extracted gases, together with a computer 95 for determining the gas concentration in the liquid flowing in the drilling pipe 13 .
By way of example, the instrumentation comprises infrared detector appliances for quantifying carbon dioxide, flame ionizing detector (FID) chromatographs for detecting hydrocarbons, or indeed a thermal conductivity detector (TCD), depending on the gases to be detected. It is thus possible with the device of the invention to detect and quantify a plurality of gases simultaneously.
This instrumentation 93 is placed in the explosive zone in the vicinity of the well head 23 ( FIG. 1 ) in order to avoid conveying the gases over a long distance, thereby improving measurement accuracy.
The analyzer further comprises a sensor 97 for measuring the temperature of the liquid flowing in the drilling pipe 13 .
The computer 95 has a memory 99 containing calibration charts and a processor 101 for implementing a calculation algorithm.
The calibration charts are established as a function of temperature, of flow rate, and of the characteristics of the mud. They contain data relating to the concentration of one or more gases in the mud to the concentration of the gases extracted from the mud through the membrane member, and as measured using the instrumentation.
The calculation algorithm determines the real quantities of the gases in the mud on the basis of the measurements performed by be instrumentation 93 , the temperature measured in the drilling pipe 13 by the sensor 97 , and the data contained in the memory 99 .
The concentration of gases in the mud is determined either individually or cumulatively.
The operation of the device of the invention while drilling a well is described below by way of example.
While drilling, the drilling tool 15 is rotated by the surface installation 41 . A drilling liquid is introduced into the inside space 35 of the drill string 29 by the injector means 43 . The liquid goes down to the drilling head 27 and passes into the drilling pipe 13 through the drilling head 27 . This liquid cools and lubricates the drill 33 . Thereafter the liquid collects the solid cuttings that result from the drilling, and it rises via the annular space defined between the drill string 29 and the walls of the drilling pipe 13 . This liquid flows substantially parallel to the walls.
The liquid thus flows continuously over the first face 57 of the membrane member 55 . A fraction of the gas present in the liquid is extracted through the membrane member 55 and penetrates into the extractor chamber 71 . The pressure controller 73 controlling the pressure in the chamber 71 is activated so that the pressure difference between the chamber 71 and the drilling pipe 13 is substantially zero. This prevents liquid penetrating into the membrane member 55 .
The extracted gases are then entrained by the vector gas from the extractor chamber 71 through the outlet orifice 81 , the pressure regulator 85 , and the filter 77 to the analyzer 53 . The extracted gases are then analyzed by the instrumentation 63 and the computer 95 determines the real concentration of each analyzed gas in the drilling mud as a function of time.
In the variant shown in FIG. 3 , the sampling head 51 is installed in a branch connection 111 on the drilling pipe 13 . Isolation means, such as an inlet valve 113 and an outlet valve 115 , are provided at the ends of the branch connection 111 on either side of the head 51 to isolate the branch connection and make it easy to remove the sampling head 51 . In this configuration, the risk of the membrane member 55 being damaged by mechanical contact or impact when tools are being inserted into the drilling pipe 13 or are being moved therealong is minimized.
In the variant shown in FIG. 4 , a recirculation pipe 121 is provided for conveying the liquid extracted from the vibrating screen 45 to the means 43 for injecting liquid into the inside space 35 of the drill string 29 .
Unlike the installation shown in FIG. 1 , two devices of the invention 19 and 19 A are used. The measuring head 51 of the first device 19 is disposed on the delivery pipe 25 in the upstream portion of said pipe, i.e. at the wellhead 23 . The measuring head 51 A of the second device 19 A is disposed on the injection pipe 123 between the injector means 43 and the injector head 31 . It is thus possible to quantify the difference between the gaseous content of the liquid leaving the drilling pipe 13 , and the gaseous content of the liquid reinjected after being degassed by the filtering screen 45 .
In the variant shown in FIG. 5 , unlike the device shown in FIG. 1 , the sampling head 51 has two porous membrane members 55 and 55 A. Each porous membrane member 55 , 55 A is associated with a respective receiver chamber 71 , 71 A for receiving extracted gases, and each having an inlet orifice 79 , 79 A and an outlet orifice 81 , 81 A. The inlet orifice of the first chamber is connected to the conveyor means 75 . The outlet orifice 81 of the first chamber is connected to the inlet orifice 79 A of the second chamber 71 A by the pipe 61 .
Thus, the vector gas is brought into the first chamber 71 via the inlet orifice 79 of said first chamber 71 . This gas brings the gases extracted into the first chamber 71 up to the second chamber 71 A via the outlet orifice 81 , the pipe 61 , and the inlet orifice 79 A of the second chamber 71 A. The second chamber 71 A thus receives a mixture containing the gases extracted into the first chamber 71 and the vector gas. This mixture then receives the gases extracted into the second chamber 71 A, thereby enriching it in gas coming from the drilling pipe 13 and making it easier for the analyzer 53 to detect the extracted gases.
In a variant, the support 63 of the porous membrane member has a face that presents Vickers hardness greater than 1400 kgf/mm 2 , in particular lying in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 , without it being necessary to have a coating based on silicon carbide. In an example, the membrane member of this type may be made of α alumina.
In another variant, the membrane support is made on the basis of an organic material such as polytetrafluoro-ethylene, for example, and it has a coating of silicon carbide.
In another variant, a heater means is implanted on the drilling pipe upstream from the device of the invention relative to the flow direction of the drilling fluid in order to make it easier to extract dissolved or free gases. Under such circumstances, the device and the heater are disposed in a branch connection through which the mud flows freely or under assistance.
The invention as described above provides a device for analyzing accurately and continuously the gases contained in an abrasive liquid flowing along an installation for drilling into the subsoil.
Membrane members of a variety of kinds and shapes can be used with the device, depending on the characteristics of the drilling fluid and on the configuration of the well being drilled.
In particular, the device can be made from membranes that are simple in shape and easily available such as membranes in the form of plane disks.
The device is not selective and can be used to analyze individual or accumulated concentrations of a plurality of gases that are dissolved or free in the drilling liquid.
The device also presents the advantage of minimizing any risks of the device being damaged when objects are inserted into the drilling pipe and moved therealong.
The device also makes it possible to limit to a very great extent any clogging of the membranes and to limit the resulting loses of efficiency. | A device includes an analyzer ( 53 ) and a sampling apparatus ( 51 ) for taking a sample of at least one fraction of the gas that has at least one porous membrane element ( 55 ). The porous membrane element ( 55 ) has a support ( 63 ) and a first surface ( 57 ) which is in contact with liquid circulating in duct ( 13 ) and a second surface ( 59 ) which opens out into a duct ( 61 ) which is connected to the analyzer ( 53 ). The hardness of the first surface ( 57 ) is more than 1400 Vickers (kgf/mm 2 ), ranging more particularly between 1400 and 1900 Vickers (kgf/mm 2 ). The device can be used to analyze the gaseous content of oil well boring sludge. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to marine vessels for use in retrieving oil that has been spilled into an aquatic marine environment, and more particularly relates to an improved oil recovery system for use in a marine environment wherein a deep draft vessel provides an oil holding interior that includes one or more oil separators positioned under the water surface of the vessel interiors so that oil separation takes place underwater, enhancing oil/water separation and providing for continuous and/or intermittent discharge of water and continuous and/or intermittent batch-type removal of the separated oil.
2. General Background
In the clean-up of oil spills, it has been- known to use vessels having an intake that skims a combination of oil and water into the vessel interior. Thereafter, the oil is separated by pumping it into separators or by simply filling the vessel completely to its capacity with whatever oil can be skimmed. The problem with such vessels is that they are limited by the capacity of their interior oil containing compartment which can be only a very small fraction of the overall volume of oil contained in the spill. Another problem with oil skimmer vessels is that they must typically be large enough to contain a sufficient volume of oil so that their construction is very expensive as compared to their ability to contain a certain volume of oil.
Other types of skimmers include an elongated endless belt in the form of a brush-type structure which is dispensed to the oil slick and which returns to a mother ship where a squeezing mechanism separates the oil which accumulates in the endless belt.
Other types of oil skimmers include long flexible booms that accumulate the oil in to a central area within the boom so that pumps can simply suction the accumulated oil into a container such as a barge. The problem with booms is that so often the oil spreads quickly and cannot be boomed off before it has spread over an area much larger than the boom itself can encompass.
Another problem with prior art-type oil skimmer devices is that they are usually large, clumsy, and have an inability to quickly be placed in service at the time the spill occurs.
Thus, there is a need for a relatively small, yet efficient oil retrieving vessel which not only accumulates oil but also continuously separates the oil from the collected water so that it can be quickly and continuously dispensed to a remote collection facility such as a barge.
SUMMARY OF THE PRESENT INVENTION
The present invention solves these prior art problems and shortcomings by providing a highly sufficient yet relatively low cost marine vessel for accumulating and separating oil in a marine environment after a spill. The present invention thus provides a vessel having an interior collection chamber for receiving an oil and water mixture from the adjacent sea surface after a spill has occurred. At least a portion of the collection chamber extends to an elevation below the sea surface during use. One or more oil/water separators container within the vessel collection chamber are positioned at least partially below the sea level surface during use so that oil and water can be separated by the separator below the sea level surface by the mechanical action of the oil attempting to rise to the sea level surface. The separator includes a plurality of vertically spaced members with surfaces that allow rising oil to accumulate thereon during separation, and an oil inlet at the lower end portion of the separator for adding oil to the separator. One or more intakes are provided for collecting oil and water from the adjacent sea surface and a flowline is provided for communicating oil from the intake to the separator at the oil inlet portion thereof.
In the preferred embodiment, the intake comprises a catch basin having an outlet with an elevation below the sea level surface during use. In the preferred embodiment, the intake includes a boom extending outwardly from the vessel for channeling oil to the intake as the vessel is moved.
In the preferred embodiment, the vessel is self-propelled.
In the preferred embodiment, the separator includes a closed wall separator structure having multiple vertically spaced plates therein.
In the preferred embodiment, at least some of the plates are angled with respect to horizontal.
In the preferred embodiment, at least some of the plates are parallel to each other.
In the preferred embodiment, the separator is a closed wall structure having a bottom, and a side wall, defining an oil holding interior and the side walls include one or more water outlets, the oil inlet communicates with the bottom and the interior has multiple, transverse and vertically spaced-apart plate members with surfaces for catching and accumulating oil that is rising within the interior. Thus, the oil that is transmitted to the separators via the bottom oil inlet flows upwardly in the separator and is interrupted in its upward vertical movement by the plurality of plates so that oil accumulates thereon while water flows laterally out of the separator.
In the preferred embodiment, there is provided a flowline for indicating when the vessel interior is filled with oil so that discharge of the oil can be initiated to a remoted storage location, such as a barge, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like reference numerals denote like elements, and wherein:
FIG. 1 is an elevational view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a top view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is a partial sectional elevational view of the preferred embodiment of the apparatus of the present invention illustrating the oil separator and inlet flowline portions thereof;
FIG. 4 is a partial elevational view of the preferred embodiment of the apparatus of the present invention illustrating the oil/water intake portions thereof;
FIG. 5 is fragmentary elevational view of the preferred embodiment of the apparatus of the present invention illustrating the oil separator portion thereof;
FIG. 6 is a fragmentary elevational view of the preferred embodiment of the apparatus of the present invention illustrating the oil intake portion thereof;
FIG. 7 is another fragmentary elevational view of the oil intake portion of the preferred embodiment of the apparatus of the present invention;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 best illustrates the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. The marine vessel for collecting and separating spilled oil in a marine environment is designated generally by the numeral 10 in FIG. 1. The apparatus includes a floating vessel 12 having an interior 13 for collecting an oil/water mixture from the adjacent water surface WS such as a sea surface, ocean surface, lake surface, or other such waterway.
At least a portion of the collection chamber 13 extends to an elevation below the water surface WS, the bottom being designated generally by the numeral 14. The bottom 14 includes an outlet 15 in the form of an elongated transferse conduit 16 for discharging water from collection chamber 13 as indicated by the arrow 17 in FIG. 1. Thus, as the apparatus 10 intakes an oil/water mixture from the surrounding waterway, oil is continuously separated and the water which is taken in with the oil can be continuously returned to the adjacent waterway, lake, or the like. In addition, an oil discharge line 20 is provided for continuously discharging collected oil from the vessel 10 for collection in a remote location or in an adjacent floating vessel such as a barge or the like. Thus, the present invention provides an apparatus 10 for continuously separating oil and water and for continuously returning water to the adjacent aquatic environment while simultaneously continuously (or in batch form) discharging collected oil to an adjacent "mother" ship, barge, or like vessel.
In the embodiment of FIG. 1, a pair of oil separators 30, 32 are provided. Separators 30, 32 are preferably disposed below the water surface WS. In the preferred embodiment, the water WS externally of the vessel 10 and internally of the vessel 10 are substantially the same. Thus, the vessel 12 can be an open channel so that the water surface WS is the same both internally and externally of the vessel 12. Separators 30, 32 are preferably positioned entirely below the water surface WS, as can be seen in FIG. 1. Each separator 30, 32 can be generally rectangular in plan view defining a rectangular, closed wall structure, each having a bottom 31, 33 respectively, end walls 35A and side walls 35B. It should be understood that a pair of separators 30, 32 are shown in the embodiment of FIG. 1. However, in the scope of the present invention, multiple arrangements of separators could be provided, such as, for example, an array of separators in a larger vessel 10. The bottoms 31, 33 and the vertical end walls 35A and vertical side walls 35B thus define a closed wall separator structure having an interior 40 that separates oil and water during use.
A plurality of longitudinally extending, generally flat rectangular plates 41-46 are positioned in parallel, paired fashion (FIG. 5) and are each preferably inclined. Plates 41-43 are angled at an angle of, for example, 30°-45°, and are parallel to each other, being maintained in spaced apart generally parallel and inclined position by means of a plurality of vertical supporting post members 47. Similarly, plates 44-46 are inclined, generally parallel inclined flate plate members which are supported by a plurality of structural posts 48. The posts 47, 48 can be, for example, cylindrical pipe joints or other suitable structural members, such as a flanged "I" beam or the like. Plates 41-46 extend longitudinally, and span between opposed end walls 35A.
Oil inlet 50 dispenses oil via inlet opening 52 to separators 30, 32. Oil inlet flowline 50 thus can be connected to the discharge 53 side of pump 54 which includes a suction line 55 that receives flow from catch basin intakes 60, 62 (see FIG. 2 and 6-8). The pump 54 pumps oil and water mixture which is skimmed from the adjacent sea water area using catch basins 60, 62 to the vessel interior 13 via line 50 and inlet 52 so that oil and water are added to the separators 30, 32 at the lowermost portion thereof. The water will tend to settle in the separators 30, 32 while the oil will rise upwardly. The rising oil will hit one or more of the plate 41-46 accumulating on the underside surface thereof and being routed toward the central portion of the separator because of the inclined orientation of the plates, including the left plurality of the plates 41-43 and the corresponding right plurality of plates 44-46. Thus, an interior vertical channel 49 is defined between the first set of plates 41-43 and the second set of plates 44-45 which allows oil to flow upwardly. However, the channel 49 is sufficiently narrow so that oil floating upwardly will be substantially coalesced and collected upon the underside of plates 41-46 at the time of discharge at channel 49 upwardly so that substantially water free oil collects at the top of the separators 30, 32. A plurality of side openings 56 allow water to discharge from each separator 30, 32. The discharged water thus flows downwardly to the lowermost portion 14 of vessel 12 where it can exit, as illustrated by the arrow 57 via outlet valve V and discharge line 16. The outlet valve V can have an upwardly extending valve stem VS for operating the valve between open flow and closed flow positions. Stand pipe 70 allows a worker standing upon the vessel deck 12A to monitor the quality of fluid contained at the lowermost portion of the vessel interior 13. Thus, the stand pipe 70 allows an operator to determine whether or not water or in fact oil has filled the vessel interior 13. If the operator pumps fluid upwardly in stand pipe 70 to outlet 72 and finds that oil is transmitted, this means that the vessel has been substantially filled with oil and it is time to pump that oil to a collection vessel, such as a "mother" ship, barge, or the like, via line 20. However, if the operator receives water at outlet 72, operation can continue until such time that the vessel is filled completely with oil. Thus, for example, a small bilge pump or the like could be connected to the stand pipe 70 for a continuous flow of fluid so that an operator would simply glance occasionally at the stand pipe discharge 72 to determine whether or not oil was being discharge therefrom. Thus, the bilge pump (not shown) could pump, for example, a few gallons per minute continuously to determine whether or not the vessel interior 13 were filled with oil.
Each catch basin 60, 62 is equipped with a pivotal boom 63, 64 that could be rotated inwardly and outwardly using handles H. The boom aids in the collection of oil at catch basin 60, 62 as the vessel moves forward under the power of its engine E and motor M, the collection of oil being designated schematically by the flow arrows 65 in FIG. 2. Each basin 60, 62 can have an intake screen 80, 82 respectively and an intake funnel 85, 87 respectively that is positioned to receive incoming spill water designated by the arrows 89 in FIG. 8. The funnels 85, 87 communicate with suction line 55. Funnels 85, 87 can be adjustably, preferably slideably movable with respect to vessel 12 so that their fluid intake position can be changed and adjusted vertically using telescoping suction pipe section 55A.
In view of the numerous modifications which could be made to the preferred embodiments disclosed herein without departing from the scope or spirit of the present invention, the details herein are to be interpreted as illustrative and not in a limiting sense. | An oil spill retrieval vessel has an interior that contains skimmed oil and separates the oil within the vessel and underwater using a plurality of separator surfaces vertically stacked to catch and accumulate oil as it rises within the vessel interior. |
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent App. Nos. 62/145,455 and 62/145,460, both filed Apr. 9, 2015, which are herein incorporated by reference for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates generally to door latching assemblies, and more particularly, to door latching assemblies that use a motorized lock mechanism to lock a door handle and prevent it from rotating.
BACKGROUND
[0003] There are many factors and constraints that influence designs of lock and trim assemblies, including the number of lock functions supported, the strength of the lock, the ability of the lock to thwart an attack, and the cost of manufacture. Each design constraint compounds the complexity of such a design, because attempting to accommodate a given design constraint may restrict one's ability to accommodate a different design constraint. Because not all designs are equally effective or practical, and because changing circumstances continually give rise to new design constraints, there is always a need for innovation.
[0004] For example, lock and trim assemblies that utilize a door lever commonly engage the spindle directly to the door handle, relying on a stop mechanism to prevent the lever and spindle from rotating. In many such assemblies, it is possible to defeat the stop mechanism by applying a crowbar or long wrench to the lever, shearing off components of the stop mechanism. Therefore, it is advantageous for a lock and trim assembly to be designed in a manner that thwarts such an attack.
[0005] As another example, many lock mechanisms require a door handle to be in a neutral, non-latch-retracting position in order to lock the handle. It is therefore advantageous for the trim assembly to incorporate a return spring to bias the handle back to the neutral position and an escapement spring to engage the lock when the handle returns to the neutral position.
[0006] Moreover, when choosing a replacement trim assembly for a door, it is important to find a trim assembly that is compatible with the spindle and possibly other elements of the interior latching assembly, that matches the door function (e.g., is it an interior door or an exit door), that is compatible with the handedness of the door, that matches the physical dimensions and relative placement of the mortise and/or bore cylinder, and that matches the physical arrangement of trim mounting holes.
[0007] Most trim assemblies, however, are only suitable for a specific type or make of lock. It would be advantageous to have a universal trim assembly that, with minimal substitution or rearrangement of parts, accommodates a wide variety of types and makes of locks, as well as a wide variety of lock functions. However, the design of such an assembly is complicated by the typically tight spacing of trim assembly components. For example, a rearrangement of the trim mounting posts may require a rearrangement of other trim assembly components.
[0008] The present invention described below can be characterized in many different ways, not all of which are limited by its capacity to address the above-mentioned issues, needs or design constraints.
SUMMARY
[0009] The present invention is directed to a lock trim assembly that incorporates an electric motor and an escapement assembly to operate a lock. The door trim assembly comprises a driver assembly operated by the motor, an escapement assembly, comprising a control member and an escapement spring, operated by the driver assembly, and a coupling assembly for coupling a door handle to a latch-retracting spindle. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. The coupling assembly alternates between a default orientation and a blocking orientation, wherein the default orientation allows the escapement assembly to move into the locking position and the blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the default orientation, the motor is operable to move the escapement assembly between the unlocking position and the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation.
[0010] The lock trim assembly also preferably incorporates a handle-to-spindle coupling assembly designed to thwart a torque attack on a door lever. Furthermore, the motor and escapement assembly are preferably arranged in a trim assembly that is adaptable to a variety of different doors, latching assemblies, and trim preparations.
[0011] These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded view diagram of one embodiment of a trim assembly according to the present invention.
[0013] FIG. 2A is a perspective view of the trim assembly of FIG. 1 , in assembled form.
[0014] FIG. 2B is a perspective view of an alternative embodiment of an assembled trim assembly.
[0015] FIG. 2C is a perspective view of another alternative embodiment of an assembled trim assembly.
[0016] FIG. 2D is a perspective view of yet another alternative embodiment of an assembled trim assembly.
[0017] FIG. 3 is an exploded view diagram of the motorized lock and escapement mechanism of FIG. 1 .
[0018] FIG. 4 is a perspective view of the trim assembly of FIG. 2A , with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration.
[0019] FIG. 5 is like FIG. 4 , showing the trim assembly in an unlocked position.
[0020] FIG. 6 is a plan view of the trim assembly showing the trim assembly in a locked position.
[0021] FIG. 7 is a cross-section view of the trim assembly cut along line A-A of FIG. 6 , with the trim assembly in a locked position.
[0022] FIG. 8 is another cross-section view of the trim assembly cut along line A-A of FIG. 6 , with the trim assembly in an unlocked position.
[0023] FIG. 9 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0024] FIG. 10 is a perspective view, from a right side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0025] FIG. 11 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0026] FIG. 12 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0027] FIG. 13 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0028] FIG. 14 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0029] FIG. 15 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0030] FIG. 16 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0031] FIG. 17 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0032] FIG. 18 is a perspective view of the trim assembly when in an escapement condition, with the control member marked in dashed lines to reveal the spread-apart legs of the escapement spring.
[0033] FIG. 19 is a plan view of an alternative embodiment of the trim assembly, with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration.
[0034] FIG. 20 is another plan view of the alternative embodiment of FIG. 19 , showing the trim assembly in an unlocked configuration.
[0035] FIG. 21 is another plan view of the alternative embodiment of FIG. 19 , showing the trim assembly in an escapement condition.
[0036] These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
DETAILED DESCRIPTION
[0037] FIGS. 1-21 illustrate various embodiments of a trim assembly 10 . In describing preferred and alternate embodiments of the technology described herein, as illustrated in FIGS. 1-21 , specific terminology is employed for the sake of clarity. The invention is not intended to be limited to the specific terminology so selected, but rather to be construed liberally in the context of this specification. The invention described herein, moreover, should be understood to incorporate all technical equivalents that operate in a similar manner to accomplish similar functions.
[0038] The trim assembly 10 comprises a coupling assembly 25 —for example, a handle coupler 20 and spindle driver 30 —that transfers load from a door handle 18 to a spindle 36 . The trim assembly 10 also comprises a return spring 19 and a stopper or locking dog 50 operative to selectively lock the coupling assembly 25 , preventing it from rotating to retract the door latch (not shown). The trim assembly 10 also comprises a motor 11 , a transmission or driver assembly 60 , and an escapement assembly 70 that together operate the stopper 50 . The spindle 36 extends into a door cavity that houses a latch assembly (not shown), for example, a cylindrical trim assembly or a mortise trim assembly. Rotation of the spindle 36 is operative to retract the latch (not shown).
[0039] The trim assembly 10 also comprises an escutcheon 14 and a back plate assembly 15 that is mounted to the face of the door. The motor 11 , driver assembly 60 , escapement assembly 70 , handle coupler 20 , and most of the spindle driver 30 are contained between the escutcheon 14 and the back plate assembly 15 . The handle coupler 20 is configured to be coupled to and rotated with a door handle/lever 18 . A return spring 19 biases the handle 18 toward a neutral, non-latch retracting orientation. In one embodiment, the handle 18 can be operated in either direction from the neutral, non-latch retracting orientation to retract the latch. The trim assembly 10 may also provide collars or flanged parts 94 and 95 to adapt the trim assembly 10 to particular door widths.
[0040] As best illustrated in FIG. 3 , the handle coupler 20 comprises a disk or flange 22 mounted for coaxial rotation with the handle 18 , a slot 24 for receiving a stopper 50 , and fins 28 on either side of the slot 24 . The handle coupler 20 further comprises bent-up tabs 26 that fit into corresponding notches 38 of the spindle driver 30 to detachably couple the handle coupler 20 to the spindle driver 30 . The handle coupler 20 also comprises a bridge 23 that fits into the broach 17 of the handle 18 . The spindle 36 does not go into the broach 17 . Therefore, subjecting the handle 18 to an overtorquing attack shears the bridge 23 without turning the spindle 36 .
[0041] The handle coupler 20 also comprises a spring leg bracket 21 for mounting opposite legs of a return spring 19 . Rotation of the handle coupler 20 pulls and/or pushes the legs of the return spring 19 apart, biasing the handle 18 back toward a neutral, non-latch-retracting position.
[0042] Like the handle coupler 20 , the spindle driver 30 also has a slot 34 for receiving a stopper 50 , although in alternative embodiments, only one of the handle coupler 20 and spindle driver 30 have a slot 24 or 34 for receiving a stopper 50 .
[0043] Advantageously, the use of the spindle driver 30 in conjunction with the handle coupler 20 not only thwarts overtorquing attacks, but also enables the trim assembly 10 to be adapted to a variety of different spindles with minimal substitution of parts. The spindle driver 30 's eight-pronged opening 39 accommodates both spindles 36 that are square and spindles 36 that are diagonally oriented (as shown, for example, by the Corbin spindle in FIG. 2C ) when in the neutral, non-latch-retracting position. If the internal latching assembly has a larger or smaller spindle diameter, the trim assembly 10 can be adapted to the spindle 36 simply by swapping out the spindle driver 36 for one with an appropriate-sized spindle aperture.
[0044] The motor 11 is mounted to the escutcheon 14 and includes an upper face or bracket 12 and a shaft 13 . The shaft 13 is oriented perpendicular to the spindle 36 . The driver assembly 60 is mounted on the motor 11 and operative to rotate an eccentrically-positioned offset pin 79 (or, alternatively, a cam) between an engage-lock position and a disengage-lock position.
[0045] The driver assembly 60 comprises a slip clutch 62 mounted on the motor 11 and a carousel 76 mounted on the slip clutch 62 for rotational movement with the shaft 13 . The carousel 76 rotates the eccentrically-located offset pin 79 .
[0046] The escapement assembly 70 comprises a control member 85 and an escapement spring 72 . In FIGS. 1-18 , the control member 85 is a pivot arm mounted to the escutcheon 14 to pivot about an axis 86 parallel to a spindle axis between locking and unlocking positions. In FIGS. 19-21 , the control member 85 is a slider that slides vertically between locking and unlocking positions. (Note that for clarity, structure constraining the slider's movement is not shown in FIGS. 19-21 ).
[0047] The control member 85 either has a pivot member or post 84 ( FIGS. 19-21 ) upon which the coiled core 75 of the escapement spring 72 is mounted, or an aperture 91 ( FIGS. 1-18 ) for receiving a spring pivot (not shown). The coiled core 75 of the escapement spring 72 is mounted to the control member 85 via the post 84 or inserted spring pivot. The control member 85 also has a spring leg anchor or abutment 87 . The legs 73 , 74 of the escapement spring 72 straddle the spring leg anchor 87 . In FIGS. 1-18 , the spring anchor 87 is configured as a wedge 87 that has a lower face 88 and a ramped upper face 89 with a wedge angle that matches the angle between the first and second spring legs 73 , 74 ( FIG. 17 ). In FIGS. 19-21 , the spring anchor 87 is configured as a post. In both embodiments, the first and second spring legs 73 , 74 straddle and grasp a wedge-shaped abutment 87 of the control member 85 . And in FIGS. 1-18 , the spring leg anchor 87 also provides an abutment that acts as a stop to constrain rotation of the offset pin 79 between two rotational limits.
[0048] The escapement spring 72 is a helical torsion spring with a coiled core 75 , an axis 86 parallel to the spindle's axis, and two legs 73 , 74 . Each leg has an elongated radially extending portion 73 a, 74 a and an axially extending portion 73 b, 74 b ( FIG. 3 ). In FIGS. 1-18 , the spring 72 is mounted to the control member 85 by forcing the legs 73 , 74 to intersect each other and straddle the spring leg anchor 87 . In FIGS. 19-21 , the legs of the escapement spring 72 do not intersect.
[0049] The axially extending portions 73 b, 74 b of the first and second spring legs 73 , 74 extend beyond the spring leg anchor 87 into positions above and below the offset pin 79 . If non-alignment of the spindle driver slot 34 and/or handle coupler slot 24 blocks the stopper 50 from engaging the spindle driver slot 34 and/or handle coupler slot 24 , rotation of the offset pin 79 into an engage-lock position forces the lower spring leg 73 downward and away from the lower face or edge 88 of the spring leg anchor 87 , as illustrated in FIGS. 15-18 and 21 . This spreads the spring legs 73 , 74 apart, winding the coiled core of the escapement spring 72 and storing energy. (Note that in the non-intersecting spring leg embodiment of FIGS. 19-21 , the spring is wound oppositely of the embodiment of FIGS. 1-18 ). Assuming that the carousel 76 is maintained in the same position, realignment of the spindle driver 30 and handle coupler 20 allows the spring 72 to release the stored energy by driving the upper spring leg 74 and control member 85 in a downward direction, until the stopper 50 is engaged with the spindle driver slot 34 , as illustrated in FIGS. 9-11 .
[0050] In FIGS. 1-18 , a hanger 86 projects out from the control member 85 . The hanger is configured to fit in a slot 51 of the stopper 50 in order to carry the stopper 50 between locked and unlocked positions. In FIGS. 19-21 , the stopper 50 is rigidly coupled to, or simply an extension of, the control member 85 . In both embodiments, the stopper 50 is operative for radial movement between a locked configuration that blocks the spindle driver 30 and/or handle coupler 20 from rotating and an unlocked configuration in which the spindle driver 30 and handle coupler 20 are free to rotate. In a locked configuration, the stopper 50 engages the spindle driver slot 34 and/or handle coupler slot 24 , blocking the spindle driver 30 from rotating.
[0051] The offset pin 76 , control member 85 , and escapement spring 72 are respectively arranged so that rotation of the offset pin 79 between its rotational limits biases the control member 85 to travel between its locking position ( FIGS. 9-11, 19 ) and its unlocking position ( FIGS. 12-14, 20 ). They are also arranged so that the offset pin 79 is in contact with and operative to push the second leg 73 of the escapement spring 72 away from the first leg 74 of the spring 72 , thereby biasing the control member 85 toward the locking position. If the spindle driver slot 34 and/or handle coupler slot 24 are not aligned with the stopper 50 , then one of the fins 28 of the handle coupler 20 blocks the stopper 50 from descending into a locking position. Rotating the offset pin 79 into the engage-lock position results in a first escapement condition, described further below, in which the offset pin 79 pushes the second leg 73 of the escapement spring 72 away from the first leg 73 , as shown in FIGS. 15-18 and 21 . The stored energy of the spring 72 biases the control member 85 toward the locking position. If the spindle driver 30 rotates from a position in which the slot 24 and/or 34 is/are not aligned with the stopper 50 to a position in which the slot 24 and/or 34 is/are aligned with the stopper 30 , the biasing of the escapement spring 72 pushes the stopper 50 into the slot 24 and/or 34 .
[0052] The escapement assembly 70 is operative under a non-escapement condition and at least a first escapement condition. The first escapement condition is characterized by an attempt to lock the door when the stopper 50 is not aligned with the spindle driver slot 34 and/or handle coupler slot 24 . Until alignment is restored, the stopper 50 is blocked from extending into the slot 24 and/or 34 .
[0053] Movement of the handle 18 and handle coupler 20 into a neutral, non-latch-retracting position lines the stopper 50 up with the handle coupler slot 24 . Once aligned, the stored energy of the escapement spring 72 rotates the control member 85 down, extending the stopper 50 into the slot 24 and/or 34 , thus locking the handle 18 in a non-latch-retracting position.
[0054] A second escapement condition is characterized by an attempt to unlock the door while the locked lever arm 18 is being pushed on. The asymmetry of the load exerted on the stopper 50 may have a binding effect, preventing the stopper 50 from retracting out of the slot 24 and/or 34 . Under this condition, rotation of the offset pin 79 into a disengage-lock position will push the upper leg 74 of the escapement spring 72 upward and away from the ramped upper surface 89 of the spring anchor 87 , again winding up and storing energy in the spring 72 . Once pressure is released from the lever arm 18 , thereby removing the binding effect, the spring 72 forces the control member 85 up, retracting the stopper 50 away from the slot 24 and/or 34 .
[0055] In the non-escapement condition, by contrast, the spring anchor 87 stays in substantial alignment with the offset pin 79 as the offset pin 79 rotates between engage-lock and disengage-lock positions.
[0056] In either escapement condition, the control member 85 is blocked from rotating, thereby impeding movement of one of the legs 73 , 74 of the escapement spring 72 . Operation of the motor 11 in either escapement condition causes the pin 79 to spread the axially extending portions 73 b, 74 b of the legs 73 , 74 apart, winding up and storing energy in the escapement spring 72 . Once the stopper 50 is free to travel between locked and unlocked positions, the stored-up energy of the wound-up escapement spring 72 is released into control member 85 , causing the control member 85 to rotate until the spring legs 73 and 74 reach their minimum-energy condition, in which they are once again grasping the spring anchor 87 .
[0057] The driver assembly 60 optionally comprises a slip clutch 62 mounted to the motor 11 . The slip clutch 62 —which, in one embodiment, comprises an over-torque clutch—comprises a keyhole for receiving the motor shaft 13 , a stationary portion mounted to the motor bracket 12 , and a carousel 65 driven within torque limits by the motor shaft 13 . Carousel couplers 66 couple the carousel 65 to the pin carrier 76 for synchronized rotation therewith. In another embodiment, the motor 11 is directly connected to the pin carrier 76 .
[0058] Advantageously, the back plate assembly 15 allows trim mounting posts 99 to be mounted to the trim assembly 10 in a variety of arrangements, to accommodate a variety of existing borehole and trim mounting hole arrangements, without interfering with the motor 11 , driver assembly 60 , and escapement assembly 70 . In the embodiment shown, the back plate assembly 15 comprises an upper plate or deadbolt plate 96 , a mid plate 93 positioned over the motor 11 , driver assembly 60 , and escapement assembly 70 , and a bottom plate or spindle plate 97 . Posts 99 can be mounted to the plates 93 , 96 , and 97 wherever necessary to adapt the trim assembly to any of a variety of configurations of trim mounting holes on an existing door. In FIG. 2A , for example, two posts 99 are positioned at relative 4:30 and 10:30 o'clock positions on the spindle plate 97 . In FIG. 2B , two posts 99 are positioned at relative 1:30 and 7:30 o'clock positions on the spindle plate 97 . And in FIG. 2D , which depicts a trim assembly 10 for an exit door, a single post 99 is positioned at the 6:00 o'clock position on the spindle plate 97 . Also, the deadbolt plate 96 provides an elongated aperture 69 for receiving a deadbolt assembly. This accommodates variable spacing that may exist in existing doors between the deadbolt borehole and the spindle 36 .
[0059] Also advantageously, the trim assembly 10 is configured and arranged in a manner that shares much in common with the trim assembly described and depicted in my co-pending U.S. Patent Application No. ______, filed the same day as the instant application, and entitled “Door Trim Assembly with Clutch Mechanism,” which application is herein incorporated by reference for all purposes. Many of the components are the same or substantially the same. The back plate assembly 15 and spindle driver 30 , for example, are the same. The same handle 14 may be used. The escutcheon 14 , for example, is the same except for a few stamped parts. The commonalities between the locks reduce the cost of manufacture and allow for a more uniform set of instructions in assembling either trim assembly to a door.
[0060] Several different types of motors 11 are suitable for use with the present invention. In one embodiment, a stepper motor is used. In another embodiment, gear motor is used in conjunction with an over torque clutch 62 .
[0061] It should be noted that the embodiments illustrated and described in detail herein are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims. | A lock trim assembly incorporates an escapement assembly comprising a control member and an escapement spring. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. A coupling assembly that couples the handle to the spindle rotates between a default orientation and a blocking orientation. The default orientation allows the escapement assembly to move into the locking position. The blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation. |
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BACKGROUND OF THE INVENTION
This invention relates to pile drivers arranged to be operated by a compressible fluid and is concerned with reducing the noise of operation of such machines.
A well-recognised disadvantage of conventional pile drivers is that they are very noisy in operation. This is partly because they rely on using a large mass as a hammer or ram to strike an anvil on the pile to drive the pile into the ground, and in the case of drivers operated by compressible fluid such as compressed air or steam partly because of the release and exhaust of pressure fluid at the required stages of a reciprocating cycle. Various attempts have been made to lessen the noise of operation, e.g. by constructing a sound-insulating enclosure within which the hammer or ram moves but this is extremely cumbersome.
It is known to place non-metallic shock-absorbing blocks or dollies between the striking parts to avoid metal-to-metal contact but this does not substantially reduce noise and does not have any effect at all on the noise produced by release of pressure fluid.
The admission of gas under pressure has also been proposed for producing a fluid cushion that prevents direct impact. In one arrangement (U.S. Pat. No. 3,714,789) compressible fluid is injected under the falling mass shortly before it reaches the bottom of its reciprocating stroke to produce a fluid cushion decelerating the mass and then accelerating its initial return upwards, after which the pressurised cushioning fluid is released. This proposed arrangement is very complex and therefore expensive to manufacture. In another arrangement (UK Pat. No. 1 396 575) a ram cylinder is alternately connected to a pressure source and to exhaust in order to produce a series of pressure pulses underneath a weighted ram piston to generate a periodic driving force, the pressure being so regulated that the ram piston is kept out of contact from a dolly or impact-absorbing pad on the pile. This result can only be achieved when the ground resistance to the pile is low because the peak cushioning pressures are limited by the delivery pressure of the pump supplying the ram, there being a return flow through the pressure delivery line when the cushion pressure exceeds the normal line pressure.
SUMMARY OF THE INVENTION
According to the invention, there is provided a pile driver comprising a piston mounted in a casing in a manner defining upper and lower annular chambers within the casing for a compressible working fluid and reciprocable therein to generate a driving pulse in each descending stroke, there being a lower space below the piston in which compressible fluid is arranged to be trapped during the descent of the piston to decelerate the piston and cause the driving pulse to be transmitted through the trapped fluid, and respective connecting means from said working chambers and said lower space to muffling or silencing means for an exhaust flow of the fluid from the driver.
It is preferably arranged that the lower space is supplied with fluid from a region directly upstream of the silencing means, e.g. said connection means, so that no additional pressure fluid is required for the fluid cushion, and indeed the inflow to the lower space can be at or near to atmospheric pressure. By providing an arrangement that does not rely on a supply of fluid under pressure to provide the cushioning effect, it is possible to develop greater peak forces for a given volume of cushioning chamber in retarding the falling mass, and thus higher driving forces on the pile.
In a preferred construction, said annular chambers are bounded by an inner peripheral wall within the casing closely fitting a bore in the piston to form an inner space therewith that contracts with the expansion of the lower space, and said connection means comprise at least one conduit between said inner and lower spaces for counterflow of the fluid between said spaces, said inner space being part of or adjacent to the silencing means.
Advantageously, the fluid from said annular chambers is arranged to exhaust into said inner space and it is then possible to achieve a particularly compact arrangement by disposing the silencing means at least partly within said inner space. In fact, by arranging that the maximum volume of said inner space is relatively large in comparison with the exhaust flow, it can itself contribute to the silencing function, while its own noise emission may be muffled to some extent by the jacketing effect of the annular working chambers.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawings
FIG. 1 is a diagrammatic axial section of one embodiment of pile driver according to the invention,
FIG. 2 is a diagrammatic half plan view of the casing of the driver in FIG. 1, illustrating the cushioning space connection means, and
FIG. 3 is a detail view of a modified silencing arrangement for the driver of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the drawings, the driver has an outer casing 2 comprising upper and lower outer cylinders 4, 6 bolted together and the upper cylinder having an internal bore 4a concentric with but of larger diameter than an internal bore 6a of the lower cylinder. A stepped piston 8 reciprocable in the outer casing has a head 10 sealingly fitting the upper internal bore 4a and a stem 12 depending below the head and sealingly fitting the lower bore 6a. The top of the upper cylinder bore 4a is closed by a cover 14 with a suspension eye 14a and from the cover there depends a tube 16 that projects into a central bore 18 in the piston. The upper cylinder bore 4a and the tube 16 together form an annular space divided by the piston head 10 into upper and lower annular chambers 20, 22 which function as working chambers for a compressible fluid to reciprocate the piston.
An inner space 24 exists within the tube 16 and piston bore 18, and since the piston stem 12 is closed at its bottom end there is a further separate lower space 26 formed in the casing lower outer cylinder between the bottom of the piston and a pressure plate 28, bolted to the casing, through which the working pulses of the driver are transmitted. In the inoperative state shown in the drawing the piston stem 12 rests on the pressure plate 28, but as will be clear from the description below of the operation of the pile driver, in use the stem does not descend so far as to contact the plate 28.
The spaces 24, 26 are able to communicate through a series of conduits 30 (FIG. 2). Each conduit extends between an opening 32 at the top of the space 24 and an opening 34 a small distance above the bottom of the space 26, as indicated in FIG. 1 (although these openings are actually offset from the plane of FIG. 1, as is clear from FIG. 2). The space 24 also communicates with the exterior through a silencer or muffler unit 36 extending into the space and comprising an open tube 38 with a lining 40 of sound-absorbent material, e.g. mineral wool, acting in known manner to attenuate pressure peaks and muffle exhaust noise. Other known forms of muffler can be used, such as the multiple chamber type comprising in its simpler forms a perforated jacket surrounding and spaced from an outlet conduit.
The driver is operated by a supply of compressible fluid, e.g. pressure air, to an inlet 42 of a control valve 44, substantially of the form described and illustrated in UK Pat. No. 1 212 975 to which reference can be made for a fuller description of the construction and functioning of the valve. With the control valve piston 46 at its rest position shown, the compressed fluid is first admitted through the valve to the annular working chamber 22 where it acts on the underside of the piston head 10 to raise the piston. In the resulting contraction of the upper annular working chamber 20, the pressure in that upper chamber increases and eventually acts through conduit 48 to switch the valve 44. The two chambers 20, 22 are then interconnected through the conduit 48, this producing changes in the chamber pressures that allow the piston to descend in its working stroke. Near the end of the fall of the piston, exhaust porting 50 in the tube 16 is uncovered and pressure fluid in the upper chamber escapes into the inner space 24 and thence, through the silencer unit 36, to the outside. The resulting pressure drop in the upper chamber causes the valve 44 to switch again to repeat the cycle.
During the rise of the piston, fluid in the contracting inner space 24 transfers through the conduits 30 to the expanding lower space 26, the pressures in these two spaces being close to atmospheric as there is little change in their combined volume and there is free communication to the exterior through the silencer unit 36. During the fall of the piston, the flow occurs in the opposite direction until the conduit openings 34 are closed as the piston stem approaches the pressure plate, so that fluid is then trapped in the space 26 to cushion the final part of the fall of the piston and metal-to-metal contact between the piston and plate is avoided. In this way the driving pulse is transmitted to the pile by the trapped cushion of fluid and the noise is lessened.
Because the pressure in the cushioning chamber is initially close to atmospheric there will at first be only insignificant retardation of the piston. The pressure will increase very rapidly as the piston comes closer to the pressure plate so that by the stage the piston's fall is stopped a very high peak pressure will have developed and will act as a driving pulse on the pile. By contrast, if pressure fluid were initially admitted to the space 24 it would immediately begin to reduce the momentum of the piston and the maximum peak force would be less. Although it might be possible to provide an arrangement that would develop a similar peak force using a high pressure supply, it would be necessary to reduce the size of the cushioning space, in particular the minimum volume would be smaller and a more complex structure and in particular elaborate sealing arrangements would then be necessary, as conventional piston sealing rings are effective only at some distance from the end of their piston.
As it may be expected that there will be a tendency for the driver to bounce from the pile when the piston reverses into its return stroke, lugs 52 are provided for the attachment of pile grips. The grips are not illustrated but preferably they take the form described in UK Pat. No. 1 320 146, obtaining their gripping action from pressure fluid tapped from the working fluid supply to the annular chambers. It can be arranged that the pile grips are cyclically released and re-engaged by controlling the compressed fluid supply to them in synchronism with the operation of the driver, in known manner, and in that case it is preferably also arranged that the compressed fluid released from the grips is exhausted by way of the inner space 24 and silencer unit 36.
The construction illustrated is a particularly compact arrangement although it is also possible for the silencer unit to be mounted externally of the casing. However, in the form shown, it is possible for the inner space 24 to function as a relatively large volume receiver for the pressure air emitted through the exhaust porting 50 so that the inner space itself contributes to the silencing effect.
The silencer unit can be relatively small since substantially all the flow through it will be represented by the exhaust flow from the annular working chambers and that flow is kept relatively small by virtue of the interchange of fluid between the upper and lower annular chambers during part of the working cycle. The flows that take place between the inner space 24 and lower space 26 are to a great extent self-balancing and at some stages there is in fact a net inflow through the silencer unit to these spaces.
FIG. 3 illustrates a modified silencer or muffler in which in addition to an internal tubular silencer 54 that can be of the lined form illustrated in FIG. 1 or of the perforated jacket form also described above, there is an outlet box 56 providing multiple paths 58 through sound-absorbing material 60 to an exhaust opening 62. The box is mounted on the outer casing cover 14 and has on its top face a lifting eye 64.
It is to be noted that since the illustrated arrangement requires only a single external pressure fluid supply line and single exhaust, it can be easily arranged for underwater operation. | A pile driver operated by a pressure supply of compressible fluid has a cushioning fluid chamber for transmitting the driving pulses to a pile. Both the cushioning chamber and the working chambers for generating the driving pulses are connected to an enclosed space from which the exhaust flow of fluid is able to escape by way of muffler means. The cushioning chamber draws in air at or near atmospheric pressure by way of said space which is in permanent communication with the exterior through the muffler means. |
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BACKGROUND OF THE INVENTION
Repair of sizable holes in hollow core walls such as gypsum board, furred plaster, or similar constructions has long been a time consuming and unsatisfying job. Holes may be caused by redecoration or repair, vandalism or moving accidents, among other causes, and often are too large to bridge with patching compounds to return the wall to a sound condition. Various methods are commonly employed to provide a backing for the patching material such as screen wire, or crumpled newspaper which are both time consuming, wasteful of material and generally produce a less than desirable end result, being more susceptible than other portions of the wall to future cracking.
SUMMARY OF THE INVENTION
A device is herein presented to aid in restoration of holes in hollow walls to a sound condition with a minimum of expenditure in time, effort and materials. The device comprises a tripod or similarly configured positioning device for supporting a backing plate bridging the hole behind the gypsum board or other surface. The backing plate is made in a manner which allows it to be easily configured to a shape which will fit through the hole to the hollow core area and completely bridge the hole from the rear. The patching material may then be applied over the backing plate extruding through holes in the backing plate to anchor the patch to the remaining wall. Removal of the positioning device from the backing plate and filling the resultant small hole completes the patch.
BRIEF DESCRIPTION OF THE DRAWING
Details of the preferred embodiments and the principles of the invention will be made clear by examination of the following description and accompanying drawing in which:
FIG. 1 is a side elevational view of a positioning device constructed in accordance with the principles of the present invention;
FIG. 2 is a plan view of one embodiment of a backing plate constructed in accordance with the present invention;
FIG. 3 is a plan view of a second embodiment of a backing plate of the present invention;
FIG. 4 is a perspective view of the positioning device and backing plate in position for the patching of a hole in a wall; and
FIG. 5 is a side elevational view of a postion of the positioning device and backing plate of the present invention, showing the patching of a hole in a wall in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1 and 4, a tripod or similarly configured positioning device 10 is provided comprised of legs 12 radially positioned about a central platform or portion 14. The legs 12 may be made from metal, plastic or other suitable materials and preferably are provided with soft tips 16 which will not mark or easily slip on the wall surface 18. The legs 12 preferably are pivotally mounted by means of pins 20 or similar fastenings to anchor points 22 on the central platform 14. The anchor points 22 may be formed as an integral part of the central platform 14 as shown, and preferably limit the outward rotation of the legs 12 to a convenient angle which forms the stable base required for the use of the present invention.
The central platform 14 may be formed of metal, plastic or another material of suitable structural integrity and is provided with a slot 24 and central aperture 26 or similar positioning means for locating the flange or enlarged head portion 28 of a tensioning screw 30.
The tensioning screw 30 preferably is formed of metal or another suitable material for long service life and comprises an elongated rod or shaft 32 terminating at one end in a threaded section 34 and at the opposite end in the head portion 28 and handle 36 suitable for manipulation and tightening by hand. Preferably, the shaft 32 slides freely within the slot 24 and aperture 26 in the central platform 14.
The backing plate 40 of the present invention may be made in a variety of shapes such as shown in FIGS. 2 and 3. The backing plate 40 is provided with a hole or holes 42 with which to engage the threaded section 34 of the sentioning screw 30. The backing plate 40 may be made from lightweight sheet metal, plastic, or another suitable material, and is provided with ribs or corrugations 44 for added rigidity. The backing plate 40 preferably is scored as indicated at 46 in a pattern that will allow for the breaking of various sections from the plate 40 to enable its use with various sized and shaped holes. Holes 48 are provided in the backing plate 40 at suitable intervals which allow the patching material 50 to extrude slightly through the plate 40 and grip the rear of the plate, as shown in FIG. 5.
In operation, a hole 52 in a hollow wall 18 is first cleaned of damaged material around the edges and rear surface 54. A convenient-sized backing plate 40 is chosen and sections are broken off along score lines 46 as required so that the backing plate 40 will slide freely through the hole 52.
The threaded end 34 of the tensioning screw 30 is started through a hole 42 in the backing plate 40. The backing plate 40 is then inserted through the hole 52 in the wall 18 and rotated or positioned to cover the entire hole 52. The tripod 10 is erected over the hole 52 with the tips 16 of the legs 10 resting against the areas of the wall 18 surrounding the hole 52.
The shaft 32 of the tension screw 30 is passed through the slot 24 and the head portion 28 is positioned in the aperture 26 in the central platform 14 of the tripod 10. Thereafter, the handle 36 on the tensioning screw 30 is turned until the backing plate 40 is securely positioned against the back 54 of the hole 52.
As shown in FIG. 5, patching material 50 may then be used to fill the hole 52 to match the remaining wall 18. Small amounts of the patching material 50 extrude through the holes 48 in the backing plate 40 which, when dry, forms a secure bond between the patching material 50 and the backing plate 40.
When the patching material 50 has dried, the tensioning screw 30 is rotated out of the backing plate 40 and the tripod is removed. The small hole left by the removal of the tensioning screw 30 is then patched, and the repaired wall 18 is ready for refinishing in any desired manner. | A tripod stand and tension screw rod are employed to position and hold a backing plate of varying dimensions to facilitate repair of holes in hollow wall construction such as gypsum board. |
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the repair and beautification of construction surfaces, preferably roofing surfaces. The present invention further relates to the use of an adhesive, double-sided tape in combination with construction material to repair a construction surface. Roofing material choices vary depending upon the type of building, e.g., a residential or commercial building, as well as functional and aesthetic considerations.
[0002] There are numerous types of roof materials. One family of roof materials has a granulated surface. The granule surface (exposed top coat) is intended to increase life, improve weather-ability and add beauty. It is typically available in rolled or sheet form. Roll form is often called a “modified roof” and is typically used for a low-slope applications. Low-slope roofs are primarily found on commercial buildings. There are generally two types of rolled form roof materials with granulated surfaces: one is commonly referred to as “conventional commercial rolled-roofing” which is asphalt based, the other is styrene-butadiene-styrene (SBS) based. A third roll formed roofing material for low-slope roofs is based on atactic polypropylene (APP). APP seldom has a granulated surface.
[0003] Sheet form roofing materials with a granulated surface are commonly known as asphalt shingle. Two types of asphalt shingles are organic and fiberglass or glass fiber shingles. Organic shingles are generally paper (felt) saturated with asphalt to make it waterproof. Roll form and shingle (sheet) form are both coated with a top coat of adhesive asphalt with granules embedded into the adhesive layer. In some cases, a portion of the granules contain leachable copper or more often tin to prevent moss growth on the roof. Organic shingles contain around 40% more asphalt than fiberglass shingles which makes them weigh more and gives them better durability and wind blow-off resistance.
[0004] Fiberglass shingles have a glass fiber reinforcing mat manufactured to the shape of the shingle. The mat is coated with asphalt which contains mineral fillers. The glass fiber mat is not waterproof by itself and is a wet laid fiberglass mat bonded with urea-formaldehyde resin used for reinforcement. The asphalt makes the fiberglass shingle waterproof. Fiberglass reinforcement was devised as the replacement for asbestos paper reinforcement of roofing shingles. The older asbestos versions were actually more durable and were harder to tear, an important property when considering wind lift of shingles in heavy storms. Fiberglass based asphalt shingles are commercially replacing the older felt reinforcement based asphalt shingles.
[0005] Included in the shingle family is a newer design of asphalt shingle, known as a laminated shingle, which uses two distinct layers and is heavier, more expensive and more durable than traditional designs. Laminated shingles also give a more 3-D effect to a roof surface. The granules embedded in the top coat of the rolled form or shingle roof materials vary in composition and appearance (e.g., color). In general, such granule medium are mineral granules (ceramic-coated natural rock, sand-sized) containing some portion of iron or other color producing component. Alternatively, Roofing granules may have surfaces treated with oil and an elastomeric rubber. The elastomeric rubber can be an organic block copolymer having elastomeric and nonelastomeric repeating units. The oil and rubber are applied to the roofing granules' surfaces as a thin film. The thin film of oil and rubber impedes granule staining from oils in asphalt roofing materials, and reduces dust formation during granule handling. Roofing granules are typically from about 1-4 millimeters in diameter.
[0006] Though roofing materials are engineered to withstand relatively harsh climate changes and weather, they ultimately wear out or become damaged. With such wear or damage the owner of the building generally has two choices: one, remove the old roofing material and apply a whole new roofing material or two, attempt to repair that portion of the roofing material that is worn or damaged. In general, flat roofs can be repaired by the application of hot-melt, polymer, caulk, or tar-based materials, with or without a tape-like solid sheet backing. Quite often the repair will include a mesh reinforcement embedded in the hot-melt, polymer, caulking or tar-like material applied to the damaged or leaking roof area. For residential surfaces, especially those comprised of individual tar-granule shingles, the entire roofing surface is torn off and a new roofing surface is applied to the entire roof. Alternatively, the old shingles are left in place and a new roofing shingle surface is applied over the old shingle surface, covering the entire roof.
[0007] In some cases, an owner may wish to save time and money by doing a limited re-roofing of a damaged or worn area. These types of repairs, however, are less common because the anesthetic look of a partially repaired roof is not attractive. This is due, primarily from the difficulty of blending the new roofing shingles with the remaining, old shingles, combined with the difficulty of getting loose, matching granule to remain adhered to the hot-melt, polymer, caulking or tar-like material patch. Therefore, re-roofing of residential, shingle based roofs is usually performed on the entire roof. Such efforts, however, are more costly than isolated repairs and, combined with time involved, are in many occurrences not performed until the roof is in serious need of repair. On low-slope roofs of all types (not limited to granulated rolled formed roofing) and metal roofs there is the need to seal around roof penetrations, along wall connections and valleys, and along the seams of the roof material once it is rolled out and laid side by side (the seam). Currently there are different methods of sealing these areas, such as factory edges with a sealant already applied requiring a heating medium to make the sealant viscous and sticky, or the removal of a release liner to expose a sealant, but in all cases at minimum a line between the different pieces of the rolled roof material is exposed, and in the worse cases an additional sealant such as hot-tar, caulking, a cover tape, or self-leveling sealant is applied over the seam leaving an aesthetically unpleasing, non-matching seal, and in cases where an attempt is made to beautify the patch with matching granule, difficulty of getting the loose matching granule to remain adhered to the repaired surface remains a challenge.
[0008] A need therefore exists for the provision of a product, system and method of use that allows for the isolated repair and/or sealing of roofs that results in matching, aesthetically pleasing finished product.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a repair product comprising a double-sided, adhesive tape and a top-coat medium. More specifically, the present invention is directed to a double-sided, adhesive roofing tape and quantity of roofing medium. The present invention is also directed to a double-sided, roofing tape with one side of the adhesive coated with a top-coat material, preferably roofing granules. The present invention is also directed to a roofing repair/sealing kit, system and methodology comprising a double-sided, adhesive roofing tape and a quantity of top-coat medium, preferably roofing granules.
[0010] The present invention is also directed to a method of repairing/sealing a construction surface, preferably a roof or concrete surface, comprising the application of one side of a double-sided, adhesive tape to the area requiring repair and the addition of a top coat medium, such as a roofing granule, sand, dry concrete, matching metal or single-ply membrane or matching roofing or other material to the other face of the double-sided, adhesive tape.
DETAILED DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top plan view of a repair kit of the present invention
[0012] FIG. 2 is a cross-section view of a repair tape of the present invention.
[0013] FIG. 3 is a cross-section of a repair tape of the present invention showing the partial release of a releasing liner.
[0014] FIG. 4 is a cross-section view of an alternative repair tape of the present invention with a reinforcing scrim embedded in the adhesive.
[0015] FIG. 5 is a view of a roofing surface requiring various repairs on a shingle type roof material.
[0016] FIG. 6 is a view of a roofing surface of FIG. 5 repaired with an embodiment of the present invention.
[0017] FIG. 7 is a view of a low-slope roofing surface requiring various repairs.
[0018] FIG. 8 is a view of a roofing surface of FIG. 7 repaired with an embodiment of the present invention.
[0019] FIG. 9 is a cross-sectional view of an alternative embodiment of the present invention wherein a release liner is replaced with roofing medium.
DETAILED DESCRIPTION
[0020] The present invention is directed to a two-sided material capable of adhering to a construction surface and a repair medium. More specifically, the present invention is directed to a double-sided adhesive tape, wherein one side of the tape adhesive can adhere to a surface and the other side of the tape adhesive can adhere to a repair medium. More specifically, the present invention is directed to a repair kit comprising a double-sided adhesive tape and a quantity of repair medium.
[0021] The present invention is also directed to a method of using the double-sided adhesive tape and repair medium to repair a construction surface. Although a preferred use of the present invention is for the repair or beautification of a roofing surface, the present invention can generally be used with any surface capable of receiving an adhesive layer of the tape of the present invention. The invention will be generally described with reference to a repair or beautification of a roofing surface but such description should generally be read more broadly to encompass use on other surfaces as well. Similarly, the present invention is generally described as being used to repair a surface but should be read more broadly to encompass repair as well as a beautification of the surface.
[0022] Referring to FIG. 1 , in an embodiment, the present invention is directed to kit 11 , comprised of double-sided tape 7 (shown in folded fashion) and medium container 9 , comprising medium 12 .
[0023] Referring to FIG. 2 , tape 1 comprises three layers: adhesive layer 4 and release liners 8 and 10 .
[0024] Adhesive layer 4 is intended for adherence to a surface requiring repair and for adherence to a repair medium. In general, layer 4 is intended to adhere to a surface and remain adhered through various weather conditions, e.g., rain, sleet, snow, hail, sunlight, and through a range of climate conditions, preferably of from about −56° to 126° Celsius. Additionally, the adhering strength of layer 4 to its respective surfaces or mediums will generally be about 5 lbs per inch width, more preferably 20 lbs per inch width and most preferably 30 lbs per inch width. The adhesive of layer 4 can be comprised any adhesive that provides the appropriate level of adherence and can withstand the weathering conditions of the surface to be repaired for a reasonable period of time, e.g., more than one year, preferably 5 years, and more preferably 15 or more years. Examples of adhesive compositions suitable for layer 4 include, but are not limited to extruded and/or hot melt technologies, to butyl and non-butyl rubber based adhesives and their derivatives, rubberized asphalt and bitumen and its derivatives. The cross-sectional thickness of layer of 4 will vary, depending on the application, but will range from about 25 to about 300 mils, typically will be of from about 40 mils to 120 mils, and preferably 60 mils and at times, preferably 80 mils. As used herein, “mils” refers to one thousandth (0.001) of an inch.
[0025] Release liners 8 and 10 can be comprised of the same or different material and thicknesses. Liners 8 and 10 can be comprised of a variety of materials suitable to allow release from layer 4 . Such materials will allow release from adhesive layer 4 with minimal force. Liners 8 and 10 protect adhesive layer 4 from becoming contaminated with materials, dust and the like and from sticking to unwanted surfaces. Examples of materials useful for employment as liners 8 and 10 include, but are not limited to, silconized paper, siliconized polyethylene, siliconized polypropylene. In general, layers 8 and 10 will have a cross-sectional thickness of from about 1 to about 10 mils, preferably about 2 to 4 mils.
[0026] Medium 12 comprises a variety of surfacing agents useful for applying to layer 4 . In general, medium 12 will comprise the same or similar surface material of the surface to repair. Such similarities allow for an aesthetically pleasing application of the present invention to a repair surface. If the surface to be repaired is a granulated roof material then medium 12 may comprise roofing granules similar to those coated on the roofing shingle or sheet to be repaired. If the surface to be repaired is a concrete material, then medium 12 may comprise sand or dry concrete similar in texture and color to the concrete to be repaired. If the surface to be repaired is a metal or copper material, then medium 12 may comprise metal or copper similar to those of the surface to be repaired. If the surface to be repaired is a single-ply roof material like EPDM, chlorosulfonated polyethylene (Hypalan), TPO, or PVC roof material, then medium 12 may comprise swatches of roofing similar to those comprising the single ply roof to be repaired.
[0027] Alternatively, the adhesive tape of the present invention may contain an embedded scrim within the adhesive layer. Referring to FIG. 3 , in an embodiment, tape 3 comprises five layers: scrim 5 , adhesive layers 14 and 16 and release liners 18 and 20 .
[0028] Scrim 5 can be comprised of a variety of materials including, but not limited to, woven nylon, open weave polyester, expanded polyester, open weave cotton and closed weave fabrics. Scrim 5 can provide structural quality or improve the shear strength of tape 3 . In general, scrim 5 will have a cross-sectional thickness of from about 1 to 10 mils, preferably 1 to 4 mils. Adhesive layers 14 and 16 , which can be comprised of the same or different materials, will be comprised of the same types of materials discussed above for adhesive layer 4 . Layers 14 and 16 can the same or different cross-sectional thicknesses and will generally be from about 20 to 200 mils and preferably from about 40 to 80 mils. Liners 18 and 20 will be comprised of the same or different materials and will be comprised of the same types of materials and cross-sectional thicknesses discussed above for liners 8 and 10 .
[0029] In operation, release liner 8 is removed from layer 4 by peeling away liner 8 from layer 4 (see FIG. 4 ). Layer 4 is then applied to the area desired for repair. An operator may use a pressing device, e.g., a roller, to ensure a good adherence of layer 4 to the surface for repair. Following application of layer 4 to the repair surface, liner 10 is removed by peeling away from layer 4 similar in manner to the peeling of liner 8 . The exposed layer 4 is now ready to receive and adhere to medium 12 , typically of the same surface material of the repair surface. Depending on the type of material comprising medium 12 , it can be added to layer 4 in a variety of methods. For example, if medium 12 is a roofing granule or powdered concrete, then medium 12 can be sprinkled onto layer 4 , to cover layer 4 with granules. If medium 12 is comprised of metal sheets, then medium 12 will be placed on top of layer 4 and pressed to create adherence.
[0030] Following initial application of medium 12 , an operator may optionally press medium 12 , e.g., with a roller, to more firmly adhere medium 12 to layer 4 .
[0031] Alternative embodiments of the present invention are illustrated in FIGS. 9 and 10 . In these embodiments, tape 13 and 15 are analogous to tapes 1 or 3 , except that one of the release liners is replaced with a surface medium. Tape 13 is comprised of three layers: adhesive layer 22 , release liner 26 and medium 24 . In the other alternative embodiment, tape 15 (see FIG. 10 ) is comprised of four layers: adhesive layers 30 and 32 , scrim 36 , medium 34 and release liner 40 . Adhesive layers 22 , 30 and 32 are comprised of the same materials described above for layer 4 . Adhesive layer 22 can be of similar cross-sectional thicknesses as described for layer 4 . Adhesive layers 30 and 32 can be independently of similar thicknesses as discussed above for layers 14 and 16 . Scrim 36 and release liners 26 and 40 are comprised of similar materials and thickness as those described above for scrim 5 , and release liners 8 and 18 , respectively. Mediums 24 and 34 are analogous and are comprised of material suitable to cover and finish exposed adhesive layers after application of the tapes to the surface of repair. Mediums 24 and 34 are generally comprised of the same or similar materials as the top coat of the surface to be repaired. Preferably, mediums 24 and 34 are comprised of roofing granules similar to those described above for medium 12 .
[0032] In operation, tapes 13 and 15 are applied to a surface for repair by first removing liners 26 and 40 , respectively, allowing layers 22 and 30 , respectively, to adhere to the surface to be repaired, and applying pressure to mediums 24 and 34 , respectively, to create a good adherence of the adhesive layers to the surface to be repaired.
[0033] The tapes described above can be of various widths and lengths, depending on ease of manufacture and use. In general, the tapes will have a width of from about 1 to about 48 inches and preferably about 3 to about 12 inches. In general, the tapes will have a length of from about 6 to about 50 feet and preferably about 10 to about 20 feet. Depending on the length of the tape, it will generally be packaged as either a roll, single flat pieces, or as a folded configuration. The present invention kit can be prepared for larger industrial uses, wherein the tape is packaged in larger quantities or for smaller, consumer uses, wherein the tape is packaged in smaller quantities.
[0034] The methods of the present invention comprise the provision of a double sided, adhesive tape capable of being adhered to a surface to be repaired and also a repair medium. The methods involve adhering one side of a double-sided adhesive tape to a surface of repair and applying a medium to the other, exposed side of the adhesive tape. The present invention methods can employ the present invention repair kits, described above, or can employ a double-sided adhesive tape, similar to those described in the above kits, and a medium supplied by the user.
[0035] FIGS. 5 and 6 illustrate the use of the present invention kit in the repair and improvement of the aesthetic appeal of a granule, shingle type of roof. FIGS. 7 and 8 illustrate the use of the present invention kit in the improvement of rolled asphalt sheet types of roofing, typically found on low-slope roofs. In those examples, the seams formed from the side-by-side rolls and the seams around a roofing stack are sealed with the tape and medium of the present invention. | A repair kit and method are provided. The repair kit is comprised of a double-sided adhesive tape and a quantity of medium. Alternatively, the tape contains an embedded, reinforcing scrim or added strength or utility. Another alternative embodiment provides a kit wherein one side of the adhesive of the tape is pre-fabricated with medium. In operation, a user removes a release liner of one of the sides of the adhesive tape, applies the exposed adhesive surface to the repair surface, then removes the other release liner of the opposite side of the tape and applies a coating of medium to cover the exposed top coat of adhesive. The kit is particularly useful in roofing repair, such as for the repair of tar-based granule containing shingles, commercial rolled granulated surfaces, metal surfaces, single-ply material based and concrete and masonry based surfaces. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending and co-owned U.S. patent application Ser. No. 10/245,611 entitled “Panel and Locking System for Panels”, now U.S. Pat. No. 7,146,772, filed with the U.S. Patent and Trademark Office on Sep. 17, 2002, by the inventor herein, the specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a locking system for panels with edge profiles provided on at least two opposite edges of the panels for the positive connection of similar panels, including an edge profile designed as a groove profile, with an upper groove wall and a lower groove wall, and an edge profile designed as a tongue profile, with a notch projection on the underside of the tongue that engages a notch recess in the lower groove wall of an adjacent panel in the assembled state, where the engaged edge profiles form an articulated joint that acts to restore the panels to their installation plane when deflected either up or down. The invention also relates to a panel with the locking system according to the invention.
[0004] 2. Background of the Prior Art
[0005] Locking systems of this kind are used for floor panels, for example, such as parquet panels with a natural wood surface or laminated panels. The latter have a core made of MDF, HDF, or particle board and are provided with a reproduced surface made of a decorative laminate.
[0006] 299 11 462 U1 discloses a generic locking system, whose connection has the function of an articulated joint. Locking systems of this kind are used for floor coverings, which, for example, lie on uneven bases or must bear deflection in the connection area due to the presence a soft backing, such as impact sound insulation. Deflection of the connection causes high stresses in the region of the tongue-and-groove profiles of two locked panels, because the connection bends under the load. The panel material cannot withstand the high stresses in the region of the edge profiles and fails in the connection area.
[0007] The ease of installation of the known jointed locking system leaves much to be desired. Its resistance to being pulled apart in the installation plane does not meet expected, future quality standards for floor coverings with mechanical locking systems. Furthermore, the known joint connection can be installed in two ways, where the second installation method described is associated with the undesirable side effect that the connection displays particularly low resistance to being pulled apart.
[0008] According to the first installation method, a new panel, preferably tongue-first, is placed at an angle against a laid panel and then folded or rotated downwards until it lies in the common installation plane of the panels and locks automatically.
[0009] In the second installation method, locking occurs when both panels are in the installation plane, namely by sliding the panels laterally towards one another. The panels can only be joined together in this way because the undercut between the notch projection of the tongue and the notch recess in the lower groove wall is designed to be correspondingly small. The notch connection achieved in this way is of such low strength that gaps can form between abutting surfaces of adjacent panels due to normal changes in length of the floor. This is the case, for example, when the temperature of the floor fluctuates. This method of jointing also results in immediate damage to the edge profiles, because they must be subjected to strong deformation in order for the undercut of the tongue and the lower groove wall to engage.
[0010] Furthermore, the tongue of the known locking system has a long, tapered shape. The top of the tongue has an inclined surface that is intended to facilitate insertion of the tongue tip into the groove. In reality, however, the tongue proves to be very easily damaged due to its tapered shape. This has a disadvantageous effect on the product's ease of installation, service life, and utility.
SUMMARY OF THE INVENTION
[0011] The object of the invention is to design a locking system for an articulated panel connection, which is easier to handle, displays greater resistance to being pulled apart, and has a longer service life than the known locking system.
[0012] According to the invention, the object is solved in that the upper groove wall has a flank on the inside that opens towards the free end of the groove wall.
[0013] Providing a flank on the upper groove wall creates a wide groove opening on the groove side of a panel, into which the tongue profile of an adjacent panel can be inserted more easily than the known, tapered tongue profile into the narrower groove opening of the known locking system.
[0014] The flank preferably transitions into a levelling surface extending towards the groove base, which ensures exact vertical positioning without vertical offset between locked panels. In other words, the segment of the inside of the upper groove wall running from the flank to the base of the groove forms the levelling surface, the distance of which to the surface of the panel is precisely equal to the distance of the top side of the tongue to the surface of the panel, meaning that no vertical offset occurs between locked panels.
[0015] The flank can be of curved or plane design, where a straight shape is expedient for manufacturing purposes and a curved shape is somewhat more favourable for the panel joining procedure in terms of stress. When the tongue profile comes into contact with the curved flank of the groove profile, the surface pressure is somewhat lower than in the case of contact between the tongue profile and the edge on the end of the plane flank.
[0016] A levelling surface is also provided on the top side of the tongue, which interacts with the levelling surface of the upper groove wall when the panels are joined. Since the upper groove wall has a flank on the free, front end, the levelling surface of the tongue is only in partial contact with the levelling surface of the upper groove wall, namely in the region of the free end of the tongue. If the levelling surface of the tongue were in contact with the upper groove wall along the entire length of the top tongue surface, a rigid connection would result. The flank lends the connection a degree of flexibility that favours the joint function of the connection and reduces stress in the material of the edge profiles.
[0017] In the event of deflection of the connection towards the installation base, in particular, the flank creates room for movement, so that the top side of the tongue can be moved towards the flank without coming up against it prematurely. The flexibility of the connection achieved in this way enables articulated movement without rupturing the tongue or damaging the groove walls due to excessive stress.
[0018] The handling and service life of the locking system are improved if the tongue length, meaning the distance by which the tongue protrudes beyond the upper edge of the panel, is less than or equal to the thickness of the upper groove wall of the groove profile. A tongue of this length is short compared to the prior art. The short tongue has the advantage that only a relatively short insertion path has to be traveled when the tongue is inserted at an angle into a groove profile. Consequently, the proposed locking system is particularly easy to handle during installation and can be installed much more quickly than the known locking system.
[0019] The tongue has a blunt surface on its free end, which is more robust and durable compared to the tapered shape of the tongue of the known locking system.
[0020] The groove depth of the groove profile, meaning the distance the groove recedes beyond the upper edge of the panel, is favourably greater than the tongue length described above by roughly half. In other words, if the groove depth starting from the upper edge of the panel is 3/3, the tongue protrudes into the groove by a tongue length of ⅔ when two panels are assembled, leaving a space with a residual depth of ⅓ the groove depth between the free end of the tongue and the groove base. Such a large groove depth would not be necessary to simply accommodate the tongue in the groove. However, the large groove depth influences the flexible length of the lower groove wall protruding freely from the edge of the one panel. This makes the connection flexible, reduces stress in the material, and thus increases the service life of the connection.
[0021] The flexible length of the lower groove wall preferably roughly corresponds to the thickness of the panel. This is because the spring travel required on the free end of the lower groove wall is then relatively short referred to the length of the tongue, and the elastic expansion occurring during joining of the panels causes only little stress in the material, which can be withstood without difficulty.
[0022] The depth of the recess in the lower groove wall expediently amounts to roughly one-third the thickness of the tongue. This results in a degree of undercut in the assembled state that prevents the panels from being pulled apart in installed state under normal conditions of use. Compared to conventional mechanical locking systems according to the prior art, which are locked by means of horizontal sliding in the installation plane, the degree of undercut of the locking system according to the invention is roughly doubled and, as a result, the resistance of panels against being pulled apart in the installation plane dramatically increased.
[0023] For the purpose of material-saving manufacture, the offcut dimensions on the edges of the panels are relatively small. They preferably differ on the groove side and the tongue side.
[0024] On the groove side of a panel, the resulting offcut of the decorated surface is favourably less than half the panel thickness.
[0025] On the tongue side of a panel, the resulting offcut of the decorated surface is preferably roughly between ⅓ and ¼ the thickness of the panel. It essentially corresponds to the length the tongue protrudes beyond the upper edge of the panel.
[0026] A panel, particularly a floor panel, is expediently equipped with a locking system according to the invention. The locking profile is preferably used for laminated flooring panels, which comprise a core material made of HDF, MDF, or particle board, where the edge profiles of the locking system are milled into the edges of the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] An example of the invention is illustrated in a drawing and described in detail below on the basis of figures. The figures show the following:
[0028] FIG. 1 : A locking system consisting of a tongue profile and a groove profile of two joined panels.
[0029] FIG. 2 : The locking system according to FIG. 1 during joining.
[0030] FIG. 3 : The locking system according to FIG. 1 , where the articulated connection is lifted off the base and deflected upwards.
[0031] FIG. 4 : Locking system according to FIG. 1 with a joint deflected downwards towards the installation base.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] According to the drawing, locking system 1 consists of two positively engaging edge profiles provided on the edges of panels 2 and 3 . The edge profiles are largely designed to be complementary to one another as groove profile 4 and tongue profile 5 . Groove profile 4 on one edge of a panel 2 or 3 is always opposite a tongue profile 5 on the opposite edge of the same panel 2 or 3 . In this way, identically profiled panels 2 and 3 can be connected to one another. Locking system 1 is expediently provided on all opposing sides of a panel 2 or 3 .
[0033] The configuration described relates to floor panels equipped with the locking system according to the invention. Of course, the locking system can also be used for wall and ceiling panels, or for panels for fence or house construction, where the problem of deflection occurs to a lesser degree.
[0034] FIG. 1 shows that the locking system according to the invention involves a modified tongue-and-groove profile. Groove walls 6 and 7 of groove profile 4 protrude different distances beyond the edge of panel 3 . Segments 8 and 9 adjacent to tongue 10 of tongue profile 5 recede different distances beyond the edge of panel 2 . Protruding groove walls 6 , 7 and receding areas 8 , 9 of groove profile 4 and tongue profile 5 are adapted to one another such that they can be joined. In order to secure the lock against panels 2 and 3 being pulled apart in the installation plane, a concave notch recess 11 is incorporated on the inside of lower groove wall 7 that is engaged by a convex notch projection 12 in the assembled state according to FIG. 1 . Convex notch projection 12 is provided on the underside of tongue 10 facing installation base U. On the free, protruding end of lower groove wall 7 , a shoulder 13 provides resistance to tongue 10 of panel 2 being pulled out of groove profile 4 of adjacent panel 3 in the horizontal plane.
[0035] FIG. 1 further shows that the edges of the edge profiles only contact one another in three areas. The first is the upper edge of the two panels 2 and 3 facing away from installation base U, where a tight, gapless joint is located. Abutting surfaces 14 and 15 are in contact here. The second contact area is the one between the top side of the tongue and the inside of the upper groove wall no more than 25 percent of the upper surface of the upper tongue surface contact the upper groove wall. Here, levelling surfaces 16 and 17 of the two edge profiles are in contact with one another, where both levelling surface 16 of tongue 10 and levelling surface 17 of upper groove wall 6 are at exactly the same distance from the top side of the respective panel 2 or 3 . A vertical offset between joined panels 2 and 3 is avoided in this way. The third contact area is the contact between concave notch recess 11 of lower groove wall 7 and convex notch projection 12 of tongue 10 . This contact area is located on the part of notch recess 11 facing the free end of lower groove wall 7 . Generously dimensioned spaces 18 , 19 and 20 are provided between these contact areas, meaning that contact really only ever occurs at the desired contact areas, a gapless, tight joint is ensured on the top side of the floor covering, and no vertical offset occurs.
[0036] In the present practical example, plane flank 21 is provided on the inside of upper groove wall 6 , the result being that only in the region of its free end does the top side of the tongue act as levelling surface 16 , which is in contact with levelling surface 17 of upper groove wall 6 . FIG. 1 shows tongue length f, by which tongue 10 protrudes beyond the upper edge of panel 2 . This tongue length f is less than or equal to thickness n of upper groove wall 6 . In this case, the protrusion of tongue 10 is relatively small. Inclined flank 21 on upper groove wall 6 results in the formation of mouth-like opening 22 , into which short tongue 10 can be inserted very easily. Moreover, short tongue 10 results in a very short insertion path until tongue 10 is completely inserted in the groove. The manual assembly of panels equipped with this locking system is very simple and substantially faster than with panels provided with the known locking system.
[0037] Groove depth t, by which the groove recedes beyond the upper edge of panel 3 , is greater than tongue length f by roughly half. A groove depth t of this kind would not be necessary to accommodate tongue 10 . However, it promotes the flexibility of groove walls 6 and 7 , particularly of lower groove wall 7 , which must be slightly elastically expanded in order to join panels 2 and 3 . The elasticity of the material results in a restoring action. Panels 2 and 3 spring back into the initial position shown in FIG. 1 , in which both panels are located in a common plane. Resulting space 19 further serves to accommodate dirt particles that can get into the joint during installation of panels 2 and 3 . In addition, the joint can be improved by adding glue in space 19 , in which case, however, the joint characteristics of the connection change, depending on the glue selected.
[0038] FIG. 2 shows the positioning of panel 2 with tongue profile 5 against groove profile 4 of panel 3 , which is already located on installation base U.
[0039] Blunt, free end 23 of tongue 10 can be inserted very easily at an angle and over a short insertion path into groove profile 4 of laid panel 3 , which has wide, mouth-like opening 22 due to the flank. Three contact points result in the initial position of the joining motion, as shown in FIG. 2 . A first edge contact 24 is formed on the upper edge of panels 2 and 3 . A second edge contact 25 is formed between the top side of the tongue and upper groove wall 6 , and a third contact 26 between convex notch projection 12 of tongue 10 and concave notch recess 11 of lower groove wall 7 . Starting in the position shown in FIG. 2 , continuation of the joining procedure causes minimal expansion, essentially due to the elastic deflection of lower groove wall 7 towards installation base U. In this way, convex notch projection 12 of tongue 10 is moved into notch recess 11 of lower groove wall 7 and the final position of panels 2 and 3 reached, as shown in FIG. 1 . In this position, notch projection 12 of tongue 10 engages the shoulder of lower groove wall 7 and ensures a secure hold against pulling apart in the horizontal plane.
[0040] FIGS. 3 and 4 show locking system 1 in such a way that the joint function of the connection is apparent.
[0041] Locking system 1 is used, for example, for floor coverings lying on uneven installation bases U. With uneven installation bases U of this kind, it can occur that panels 2 and 3 have no contact with the ground in the region of a joint and a space exists. When a load is applied in the region of the joint, it bends. Consequently, deflection of the edge profiles must be tolerable in the joint region. The joint may also bend on a level installation base U. This can happen when panels 2 and 3 are laid on a soft backing, such as impact sound insulation.
[0042] In order to withstand such loads, design measures are provided that lend the joint the articulated flexibility it needs. This flexibility prevents deflection of the joint from causing such high stresses in the region of groove profile 4 and tongue profile 5 that the material of panels 2 and 3 fails under the high stress. The positions shown in FIGS. 3 and 4 are arbitrary positions of movement and do not represent limit positions of the joint motion.
[0043] FIG. 3 shows the joint deflected upwards, i.e. away from installation base U. In this position, slight elastic deflection again occurs essentially on lower groove wall 7 . Due to its elasticity, lower groove wall 7 has a restoring effect on panels 2 and 3 , as soon as the load is removed. The movement of the joint reduces space 20 between the root of tongue 10 and shoulder 13 of lower groove wall 7 . In this way, existing space 20 permits articulated flexibility of the joint. In contrast, space 18 becomes larger.
[0044] FIG. 4 shows deflection of the locking system in the opposite direction, towards installation base U. Elastic expansion, essentially of lower groove wall 7 , is again evident in this case, which likewise has a restoring effect on panels 2 and 3 when the load is removed. The movement of the joint reduces space 18 between tongue 10 and flank 21 of upper groove wall 6 .
[0045] In this case, space 18 permits the articulated flexibility of the joint. In contrast, space 20 becomes larger. | The invention relates to a panel and a locking system for panels with edge profiles provided on at least two opposite edges of the panels for the positive connection of similar panels, including an edge profile designed as a groove profile, with an upper groove wall and a lower groove wall, and an edge profile designed as a tongue profile, with a notch projection on the underside of the tongue that engages a notch recess in a the lower groove wall on an adjacent panel in the assembled state, where the engaged edge profiles form an articulated joint that acts to restore the panels to their installation plane when deflected either up or down, where the upper groove wall has a flank on the inside that opens towards the free end of the groove wall. |
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FIELD OF THE INVENTION
This invention relates to wells drilled in the earth and more particularly to the sampling of gas entrained in the drilling fluids.
BACKGROUND OF THE INVENTION
The rotary drilling process creates a borehole in the earth by use of a drill bit which is attached to a drill stem, The drill bit and drill stem are lowered and rotated into the earth creating a bore hole by breaking, abrading and fracturing the earth beneath the drill bit. During this process drilling fluid is circulated by means of a pump down the inside of the drill stem and up the annular space between the outside of the drill stem and the wall of the bore hole, the drilling mud is typically a mixture of water and clay, but other drilling muds such as diesel oil, foam, and air have been used. Materials which are products of the drilling process such as rock chips (cuttings and cavings), pieces of casing, cement, the drill stem, hydrocarbon gases such as, but not limited to methane, ethane, propane, other gases associated with hydrocarbon gases such as, but not limited to carbon dioxide and hydrogen sulfide and oil are entrained in the drilling fluid as it circulates from the drill bit up the annular space between the outside of the drill stem and the borehole wall.
Other functions of the drilling fluid include cooling and lubricating the bit and maintaining a hydrostatic pressure on the bore hole which is greater than the pressure in the earth. This hydrostatic pressure prevents uncontrolled flows of oil, gas and water from the earth into the borehole.
Gas mudlogging is a technique for determining the amount and constituent components of the gas which entrained in the drilling fluid. Heretofore, gas was sampled by a mechanically agitated device called a gas trap, which was placed in the shale shaker box. The gas extracted from the gas trap was mixed with air and drawn though tubing to a gas analyzer. The typical gas analyzers used in mudlogging are flame ionization detectors (FID), catalytic combustion detectors (hot wires) and thermal conductivity detectors (TDC). Constituent components of the entrained gas are typically analyzed by chromatography.
Difficulties in assuring good gas sample quality and consistency have been known and studied for many years. The major difficulty of gas sampling has involved the placement and efficiency of the gas trap. Placement within the shaker box and depth of placement of the gas trap in the drilling mud caused major variations in sampling efficiency.
During drilling the shale shaker is often bypassed and the mud level in the shaker box drops to a level which causes the gas trap to be out of the drilling mud. Common reasons for bypassing the shale are to build viscosity by allowing drilled native clay to be recirculated, allowing lost circulation material which is larger than the shale shaker screen to remain in the drilling mud and the failure of gates in the mud tanks to close properly.
Conversely, slugs of drilling mud caused by raising and lowering the drill stem, air trapped in the drill stem and gas, water or oil entering the well bore can cause the level in the shaker box to rise rapidly causing a blockage of the gas trap exhaust port, covering the motor which drives the mechanical agitator, and the drawing of drilling mud into the sample tubing. Drilling mud in the sample tubing causes blockage, damage to the gas analyzers which are designed for a gas environment, and variation in the gas sample rate which adversely affects the accurate measurement of the gas.
Gas traps are typically designed with a mechanical agitator which is rotated by an electric or air driven motor. The environment above the shale shaker box is rated as Class 1, Division 1, Group D by the American Pertroleum Institute. In these environments ignitible concentrations of flammable gases or vapors can exist under normal operating conditions. This requires special procedures and equipment. The agitator with electrical motors must be rated as explosion proof. Many gas traps use air motors to rotate the agitators. This practice reduces the potential danger of electrical sparking. However bearing failure is common in both electrical and air motors and this can cause sparking.
Electrical gas trap motors are turned off when the electrical generator is turned off for repair and maintenance. Smaller drilling rigs typically turn off the electricity during day light hours to save on expenses.
Air motor gas traps are turned off when the rig compressor is turned off for repair and maintenance. Air motors which are driven by rig compressors do not rotate at a constant speed due to fluctuations in air use on the rig. During cold weather water in the air supply often freezes causing the air motor and agitator to stop rotating.
During cold weather drilling mud and condensed water in the gas sample tubing freeze and stop or constrict the gas sample flow. The shale shaker box and the gas trap are usually not enclosed, insulated or heated in cold weather.
The placement of the gas trap in the shale shaker box and the ancillary tubing lines and hoses are often moved by drilling rig personnel during normal maintenance of the shale shaker, desilters, desander, degasser and other drilling mud conditioning equipment. Often the drilling rig personnel disconnect or alter the gas trap configuration to accomplish normal rig maintenance. This adversely affects the quality of the gas sample.
SUMMARY OF THE INVENTION
The present invention is a gas sampling device. A gas sampling tube and pump withdraw gas which evolves into the atmosphere as the drilling fluid in the annular space exits the well bore. Drilling fluid and debris which may be entrained in the gas sample are separated by gravity settling in a separation device. A purge line may be used to agitate drilling mud and force gas toward the gas sampling tube.
BRIEF DESCRIPTION OF THE DRAWINGS
FIg. 1 is a representational plan of the rotary drilling system with which the present invention may be utilized.
FIG. 2 illustrates equipment used in the present invention to sample the gas entrained in the drilling mud, separate any drilling mud or other material which may be entrained in the gas sample and draw the gas sample to a gas analyzer
FIG. 3 through FIG. 6 illustrates some possible configurations of the gas sample tube.
FIG. 7 through FIG. 9 illustrate some possible configurations of the gas channeling devices
FIG. 10 illustrates a possible configuration of the separation device.
FIG. 11 illustrates a configuration using the purge line.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a mast 20 is located over the bore hole 54 being drilled in the earth by rotary drilling. A drill stem, which consists of a kelly 22, drill pipe 56 and drill collars 58, is connected to a drill bit 60 and is suspended within the bore hole 54. A prime mover (not shown) turns the rotary table drive 30, which turns the rotary table 26 and the kelly bushing 28. A long fluted or polygonal shaped axle called the kelly 22 is attached to the drill pipe and causes the drill pipe, drill collars and drill bit 60 to rotate. A hoisting mechanism consisting of a draw works, crown block, travelling block, hook, swivel and drilling lines (not shown) enable the drill stem and drill bit 60 to be raised and lowered by raising or lowering the kelly 22. During most drilling operations one or more strings of casing 50 are installed and cement 52 is placed about the casing 50. The blow out preventer 44 is attached to the drilling spool 46, which is attahced to the top of the casing 50. The drilling nipple 34 is set atop the blow out preventer 44 and the mud return line 36 tees off the drilling nipple 34. The mud return line 36 ends at the shale shaker box 38. Stripping rubbers 32 are placed atop the drilling nipple 34 to wipe drilling mud from the outside of the drill stem while it is being hoisted from the bore hole 54.
The drilling mud system circulates drilling mud 42 from the mud tanks 48 through the following equipment, which is not shown in FIG. 1, mud pumps, stand pipe, rotary hose, goose neck and swivel. The swivel channels drilling mud 42 into the hollow center of the kelly 22. From there the drilling mud 42 flows into the drill pipe 56 and drill collars 58 and then through the drill bit 60. The drilling mud 42 exits the drill bit 60 and travels up the annular space between the bore hole 54 and the outside of the drill stem. While traveling this span the drilling mud 44 entrains rock chips, caving, gas, oil, water and other material which is produced by the drilling process. The drilling mud 42 continues up the annular space between the casing 50 and the outside of the drill stem. At the earth's surface the drilling mud 42 circulates in the annular space between the drilling spool 46 and the drill stem, then the annular space between the blow out preventer 44 and the drill stem, then the annular space between the drilling nipple 34 and drill stem. Near the top of drilling nipple 34 the drilling mud 42 makes an abrupt turn into the mud return line 36. Then the mud flows down the sloping mud return line 36 into the shale shaker box 38 and into the mud tank 48. Solid material in the drilling mud 42 is separated by means of a screen above the mud tank 48 called the shale shaker 40.
It is the intent of this invention, as shown in FIG. 2, to use to advantage the natural turbulence in the drilling mud 42 caused by the abrupt turn of the drilling mud 42 from the drilling nipple 34 into the mud return line 36, and the agitation provided by the rotating drill stem in the annular space between the drilling nipple 34 and the drill stem. The physical properties of the gases entrained in the drilling mud 42 also are used to advantage in this invention. Also, the warm drilling mud which circulates in the annular space will be used in this invention to advantage. None of the prior art has used this novel approach.
In the typical drilling operation, as shown in FIG. 2, three hundred gallons a minute of drilling mud 42 travels in the annular space bounded by an eleven inch diameter drilling nipple 34 and a five inch diameter fluted or polygonal shaped kelly 22. The kelly 22 typically rotates at fifty to three hundred revolutions per minute. Rotation is typically not stopped except when the drilling mud pumps and thus drilling mud circulation is stopped. The typical gas found while drilling for oil, gas and coal is methane. Methane is eighty percent or more of the gas detected by gas analyzers. Methane is lighter than air at the pressure and temperature conditions found above the drilling mud 42 surface at the drilling nipple 34. The agitation of the drilling mud 42 caused by the abrupt turn and the rotation of the drill stem in the drilling nipple 34, coupled with the fact that methane is lighter than air offer a unique combination which allows for gas sampling without a conventional gas trap.
The earth tends to be warmer towards its center. In typical drilling operations the earth is one degree Fahrenheit warmer per hundred feet of depth. The drilling mud 42 circulated to the surface is heated. Generally the drilling mud 42 at the surface from a five thousand foot well is over one hundred degrees Fahrenheit. Placing the gas sampling tube 82 and separation device 62 near the drilling nipple 34 prevents freezing.
Refer to FIG. 2 for an overview, a gas sampling tube 82 is placed in and near the top of the drilling nipple 34. The gas sample is drawn into the gas sampling tube 82 by means of the pump 84 downstream of the separation device 62. If any drilling mud 42, other liquid debris or solid debris is drawn into the gas sampling tube 82 it is separated from the gas sample by gravity settling in the separation device 62. The liquid debris is expelled from the separation device 62 through an exit line 68.
In the preferred embodiment, the gas sampling tube 82 is placed on the inside wall and near the top lip of the drilling nipple 34 (see FIG. 3). The gas sampling tube 82 is designed so that it is not hit, struck or rubbed by the drill stem. In an alternative embodiment, the gas sampling tube 82 is placed below the drilling floor 24 above the drilling nipple 34 (see FIG. 4). In another alternative embodiment (see FIG. 5) the gas sampling tube 82 is placed in the wall of the drilling nipples 34. This usually requires cutting a hole or tapping the drilling nipple 34. In another alternative embodiment the gas sampling tube 82 is placed in the wall of the mud return line 36 near the drilling nipple 34 (see FIG. 6). This usually requires cutting a hole or tapping the mud return line 36. Placement of the gas sampling tube in, out, above, or about the drilling nipple 34 may be necessary depending on the configuraton of the drilling nipple 34.
The gas sampling tube 82 may constructed of any solid material, however solid materials with low specific gravities and which are easily abraded are used. Low specific gravity materials and easily abraded materials are used to prevent the sampling tube 82 from sinking in the drilling mud 42 and falling down the bore hole 54. Plastic, rubber and wood have been used to construct the gas sampling tubes 82. In the unlikely event that part or all of the gas sampling tube 82 falls into the drilling nipple 34 the drilling mud 42 carries it into the mud return line 36.
The gas sampling tube positioner 86, shown in FIG. 3, keeps the gas sampling tube 82 securely fastened and positioned. Tape is used to secure the gas sampling tube positioner 86 to the drilling nipple 34. The gas sampling tube positioner 86 is incorporated into the design of the gas sample tube 82 in alternative embodiments. In FIG. 7, the gas sampling tube 82 incorporates a channeling device 88 which reduces the amount of air from entering the space in the drilling nipple 34 and prevents the gas liberated from the drilling mud 42 from escaping. This channeling device 88 is a cap placed over the upper lip of the drilling nipple 34 with an opening in the center of the cap which allows the drill stem to enter. FIGS. 8 and 9 illustrate the channeling device when the gas sampling tube 88 is placed in the drilling nipple 34 and mud return line 36, respectively. The channeling device 88 in alternative embodiments is secured to the drilling nipple 34. A channeling device fastener 94 (see FIG. 11) is secured at one end to the circumference of the channeling device 88 at various points and, at the other end is attached to the outside of the drilling nipple 34.
In the alternative embodiments which employ the channeling device 88, the channeling device is constructed from a solid, low specific gravity, flexible and elastic material such as rubber or plastic. The material in the channeling device 88 may be subjected to striking, rubbing and hitting by the motion of the drill stem and kelly 22. The channeling device 88 should be elastic enough to accommodate the withdrawl and entry of the drill bit 60.
The gas in the gas sampling tube 82 flows into a separation device 62 which separates any drilling mud, other liquid debris and solid debris which may enter the gas sampling tube 82. FIG. 10 is a cross sectional representation of the preferred embodiment. The separator inlet line 80, which at one end is attached to the gas sampling tube 82, enters the top of the separation device 62 and extends to near the bottom of the separation device 62. A separator outlet line 76 extends down a short distance from the top of the separation device 62. The other end of the separator outlet line 76 is connected to the gas sample line 78. Baffles 74 (see FIG. 2), screens and diverters are placed to prevent any entrained mud from entering the separator outlet line 76. In FIG. 10, at the base of the separation device 62, is an exit line 68 which allows solid and liquid debris to exit the separation device 62. The base of the separation device 62 is filled with water 66 to a depth sufficient to fill the exit line 68. A liquid drying agent such as ethylene gycol is substituted for water 66, if excessive gas simple line 78 condensation is a problem. The top of the exit line 68 is fitted with a mechanical sealing device such as a flapper valve 92 (see FIG. 10) or a ball 70 and cage 72 arrangement (see FIG. 2). Mechanical sealing devices will prevent air from entering the exit line 68, if water 66 or the other liquid, which offer an air tight seal is drained or expelled from the separation device 62.
The separation device 62 is attached to the drilling nipple 34 or blow out preventer 44 by means of a separator fastener 64 (see FIG. 2). This placement is not intrusive and the heat radiating from the hot drilling mud 42 prevents drilling mud 42 or water 66 in the sample tube 82 or separation device 62 from freezing.
The gas sample flows into the gas sampling tube 82, through the separation device 62, through the gas sample line 78 and to the gas analyzers by the creation of a pressure which is lower in the gas sampling tube 82 than the area about it. In the preferred embodiment (see FIG. 2) a pump 84 is placed downstream and is connected to the separation device 62 by means of a gas sample line 78 of sufficient length ot keep the pump 84 away from the drilling nipple 34. If the pump 84 failed or sparked it would not cause the gas about the drilling nipple 34 to ignite.
An alternative embodiment (see FIG. 11) places a purge line 96 above and downstream of the drilling spool 46 and up steam of the shale shaker box 38, preferably in the drilling nipple 34. The purge line 96, by forcing gas into the drilling nipple 42 raises the pressure in the drilling nipple 34. The gas which is liberated from the drilling mud 42 flows toward the lower pressure at the gas sampling tube 82 inlet. The purge line 96, also, agitates the drilling mud 42, which helps liberate the entrained gas from the drilling mud 42. The gas used in the purge line 96 is any gas which will not interfere with the detection of gas in the gas analyzer. Compressed nitrogen or air are recommended purge gases.
While my above description contains many specificities, these should not be construed as limitation on the scope of the invention, but rather as an exemplification of embodiments thereof. For example the gas sample tube 82 may be circular, square, or rectangular. The channeling device 88 may be conical rather than a cap in shape. The baffles 74 in the separation device 62 may be omitted. The pump 84 and the purge line 96 may be run simultaneously. Accordingly, the scope of the invention should be determined not by the embodiment(s) illustrated, but by the appended claims and their legal equivalents. | The present invention is a gas sampling device. A gas sampling tube and pump withdraw gas which evolves into the atmosphere as the drilling fluid in the annular space exits the wall bore. Drilling fluid and debris which may be entrained in the gas sample are separated by gravity settling in a separation device. A purge line may be used to agitate drilling mud and force gas toward the gas sampling tube. |
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FIELD OF THE INVENTION
The present invention relates to a door and a decorative attachment for the door.
BACKGROUND OF THE INVENTION
A wide spread custom is the decorating of doors, particularly during various holiday seasons. The doors which are decorated are entrance doors into homes and apartments, and doors for rooms within homes and in offices. These decorations are applied in order enhance the celebration of the holiday, decorations being frequently applied at Halloween, Thanksgiving and during the Christmas-New Year season.
These door decorations were traditionally such objects as corn husks and wreaths which were attached to the exterior of entrance doors to homes, and paper covering of various kinds for a face of a door. Such paper coverings include, for example, sheets of paper attached to a face of the door by adhesive tape, the paper being printed with scenes appropriate to the season, or printed with fancy designs as used for wrapping. Individual decorators sometimes paste silhouette figures or paint or color representation of appropriate persons or articles to the paper covering.
Where wreathes or corn husks were attached to the door, this was frequently done by a nail which penetrated into the door, marring its appearance when the decorative object and the nail were withdrawn, and in the case of an exterior door, breaking the water impervious coating on the face of the door.
The door coverings which were applied so as to cover an entire face of the door, and secured by adhesive tape, were time consuming; persons, including the staff of businesses, often expend a substantial amount of time in applying the paper covering, and in the other ornamentation which their imagination and skills dictated. In addition, a substantial amount of time was consumed in removing and discarding the decorative paper covering, leaving the entire process to be repeated at the next season, with attendant expense and consumption of time.
SUMMARY OF THE INVENTION
The present invention is directed to a door and a decorative attachment for the door, the decorative attachment comprising a sheet of material, preferably cloth or paper, which covers all or a substantial portion of a face of the door, this sheet being provided with elements to hold it on the door, which permit the sheet to be readily removed from the door. The releasable holding devices may take any of a number of forms, including one or more elastic loops or a plurality of pockets provided at the corners of the doors. The pockets may have elastic elements, or a pair of the pockets may be joined by an elastic strip o band. Other forms of non-penetrating and non-attaching releasable constructions usable as part of the present invention are linearly extending elements, such as loops, particularly elastic loops, which are attached to the sheet and which can extend over the corners of the door.
The sheet may have on it a support for a decorative element, such as wreath, the support being in the form of a hook secured to the sheet in a permanent manner, as by a permanent adhesive, or may be releasably attached to the sheet, as by a releasable adhesive coating. Further, the sheet may be provided with decorative elements printed or pasted thereon, or woven into the fabric, where a woven textile fabric is utilized as the material of the sheet. The sheet may cover the entire face of a door, in which case it may be provided with a hole for any discontinuity on or in the door such as a peephole or a door handle, or there may be provided weakened lines permitting a portion of the sheet to be removed, leaving a hole. In either case, the hole will be in registry with the discontinuity, that is, with such elements as a peephole and a door handle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a door and decorative attachment therefor in accordance with the present invention.
FIG. 2 is a perspective view of a door with an alternate embodiment of the decorative attachment in accordance with the present invention.
FIG. 3 is a rear view of the door and decorative attachment shown in FIG. 2.
FIG. 4 is a perspective view of a door and another embodiment of a decorative attachment in accordance with the present invention.
FIG. 5 is a perspective view of a door with an alternate embodiment of a decorative attachment in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like or corresponding reference numerals are used for like or corresponding parts throughout the several views, there is shown in FIG. 1 a door 10 which is of standard construction, being rectangular, having hinges 12, 14, 16 and 18 at one edge 20 thereof, the opposite edge 22 of which has a discontinuity, specifically a door handle 24 adjacent to it, there being shown a latch bolt 26 which is operated by the handle 24 in conventional manner. There also is shown the top edge 28 and the bottom edge 30. The edges 20, 22, 28 and 30 bound the opposite spaced vertical faces of the door 10 which, in conventional manner, extend between the edges. The hinges 12, 14, 16, 18 support the door for swinging movement about a vertical axis which is adjacent to the vertical longitudinal edge 20 of the door 10.
A decorative attachment 50 is shown in FIG. 1, and comprises a sheet 52 which extends over substantially one entire face of the door, that face being as shown in FIG. 1, completely covered by the sheet 52. The sheet 52 may be made of any of a number of different materials, which in the preferred embodiment are flaccid, so that the attachment 50 may be removed, stored in a compact manner, and re-used at the next season. The material of sheet 52 may comprise paper, vinyl or textile. It may be printed, dyed or otherwise have visual decorative elements: alternatively, the sheet 52 may be of uniform color and texture.
The decorative attachment 50 further comprises loops 54 made of linearly extending elements which have their ends attached to the sheet 52, and which have portions which engage the face of the door which is opposite to that which is covered by the sheet 52. One or more of the loops 54 may be elastic.
A support 56, in the form of a hook, is permanently secured to the sheet 52, extending outwardly therefrom, and a decorative wreath 58, parts of which are shown broken away, is supported by the hook 56. As will be understood, hook 56 may be attached to the sheet 52 by bonding, by a releasable adhesive, or by other suitable means.
In order to provide access to the handle 24, the sheet 52 has a hole 60 in registry with the discontinuity of the door 10 provided by the handle 24.
The decorative attachment 50 is able to be folded for storage, with the support 56 in place or removed from it. It may be readily placed in position on the door 10 by manipulation of the loops 54, by placing them over the corners of the door 10 and passing the hole 60 over the door handle 24. The hole 60 may be provided in the sheet 52 as manufactured, or may be defined by weakened lines separating the sheet 52 from the portion thereof removed later to provide the hole 60. As will be apparent, where a door is to be decorated which does not have a handle, such as so-called "swinging doors", the sheet 52 will not have a hole, but may have weakened lines, so that the decorative attachment 50 may be used either on a swinging door without a handle or a door 10, as shown in FIG. 1.
In FIGS. 2 and 3, there is shown a door 10 and a decorative attachment 62 comprising a sheet 52 having pockets 64 at the corners thereof. These pockets 64 are formed by connecting portion 66, extending over two of the edges of the door 10, such as the edges 22 and 28, and as shown in FIG. 3, the connecting portion 66 being integral with a portion 68 on the face 32 of the door 10, which is the face opposite to that which is substantially covered by the sheet 52.
Referring again to FIG. 2, the sheet 52 will be seen to be provided with a hole 60 for the handle 24. The support 56, shown spaced from the sheet 52, is provided with a releasable adhesive layer 56a. Thus, the support 56 may be releasably adhered to the sheet 52. As shown in FIG. 3, one or more of the pockets 64 has a diagonally extending edge 70 of the portion 68, in which is an elastic element 72, permitting elongation of the length of the diagonal edge 70 which, together with shirring of the material of the pocket 64, particularly the connecting portion 66 and portion 68, enables the pocket 64 to be stretched so as to be placed over the corner of the door 10. Preferably, all four pockets 64 are provided with the elastic element 72 and shirring, but fewer than four of the pockets 64 may be made in this manner.
In FIG. 4, there is shown an alternate construction in which a decorative attachment 74 is provided, including a sheet 52, the upper edge of which i shown in FIG. 4. There are also provided pockets 76 at each of the corners of the door 10. Extending between two of the pockets 76, such as the two upper pockets 76, there is an elastic band or strap 78. The decorative attachment 74 may be readily applied to the door 10 by first engaging the door with the two lower pockets 76, and then placing the upper two pockets 76 over the upper corners of the door 10, the elastic band 78 serving to assist in holding the pockets to which it is connected securely on the door 10. As will be understood, the flaccidity of the material of the pockets 76 will enable them to be manipulated over the corner of the door 10. The decorative attachment 74 could have the strap 78 along the lower edge of the door 10, and the elastic strap 78 may extend between two other pockets than those located at the top or at the bottom of the door 10.
In FIG. 5, there is shown an alternate embodiment in which on the door 10 there is a decorative attachment 80 comprising a sheet 82 extending over substantially less than the entire face 34 of the door 10. By way of illustration, the sheet 82 is rectangular, having vertical and horizontal edges of lesser length than the vertical and horizontal edges of the door 10. There are provided on the sheet 82 linearly extending straps 54, one or more of which may be elastic and portions of which engage the face of the door 10 which is opposite to the face 34.
Shown on the sheet 82 are visual elements 84, 86, which may be cutouts adhered to the surface of sheet 82, or printed or painted thereon, or woven into the sheet 82, where sheet 82 is a woven textile. As illustrated, the decorative attachment 80 does not have a support 56, as in FIGS. 1 and 2, although it will be appreciated that the sheet 82 may be provided with such a support. Also, as will be appreciated, the sheet 52 may be provided with visual elements, such as visual elements 84 and 86 of sheet 82.
The sheet 82 may have different decorations on its opposite faces, which may be for different seasons or holidays, and may be held on the door with either face exposed. This aspect of the invention may also be applied to any embodiment in which the support 56 is not permanently secured.
There have been provided decorative attachments for application to a door which include a sheet which covers all of a face of a door or a substantial portion of a face of a door, the decorative attachment element including, also, attachment structures or elements which enable ready holding of the decorative attachment to a door without the use of adhesive tape or elements which would penetrate the door, particularly the opposed vertical surfaces 32 and 34 of the door. The decorative attachment may be provided with a permanently attached or temporarily adhered support for a decorative element such as wreath, and/or may be provided with visual elements, such as adhered, imprinted or woven objects, elements or scenes.
The decorative attachment herein provided may not only be readily applied to and removed from a door, but may be readily stored in a compact manner, due to the flaccid nature of the sheet forming a part thereof.
The claims and specification describe the invention presented, and the terms that are employed in the claims draw their meaning from the us of such terms in the specification. Some terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such term as used in the prior art and the more specific use of the term herein, the more specific meaning is meant. | A door and decorative attachment therefor comprises a sheet covering all or a portion of the surface of a door, and having linear elements or pockets for readily and releasably holding the sheet to the door. The sheet may have visual elements, such as objects or scenes thereon, as by pasting, gluing, printing or weaving, and may have a support permanently or detachably secured to the sheet, for supporting an object such as wreath. The sheet may have a hole in registry with, for example, a handle, which extends through the hole. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to provisional patent application 60/598,952 filed Aug. 5, 2004.
FIELD OF THE INVENTION
[0002] This invention relates in general to earth boring bits, and in particular to the spacing between the rows of cutting elements of a roller cone bit.
BACKGROUND OF THE INVENTION
[0003] A typical roller cone earth boring bit, such as used to drill wells, has three cones that roll around a common axis. The cones are mounted to bearing pins that depend from head sections. The head sections are welded together to form a body that is threaded at the upper end for connection to a drill string.
[0004] FIGS. 1-3 illustrate a typical prior art rolling cone bit 11 . Bit 11 has three cones 13 , 15 and 17 . Cone 13 has a spear point cutting element 19 on its inner end and a heel or outer row 21 of cutting elements on its outer end. The outer side of each tooth of outer row 21 joins a gage surface 22 . The cutting elements in this instance comprise teeth that are integrally formed with cone 13 and milled into desired shapes. Milled teeth are generally chisel-shaped, each having a crest 28 that is perpendicular to the direction of rotation of the bit. Alternately, the cutting elements could be cast with the body of the cone or comprise tungsten carbide inserts pressed into mating holes.
[0005] Cone 13 also has an inner row 23 spaced a short distance from outer row 21 . A groove 25 locates between outer row 21 and inner row 23 . A layer of hardfacing 27 , shown by phantom lines, covers each cutting element in outer row 21 and inner row 23 . Groove 25 is generally triangular in cross-section and has a width 26 that may be measured between tips of teeth 21 , 23 at the crests 28 . In the prior art, width 26 is normally less than the width of crest 28 of a cutting element of inner row 23 or of outer row 21 .
[0006] Referring to FIG. 1 , cone 15 has an outer row 29 and an inner row 31 spaced apart by a groove 33 . Groove 33 has a much wider width 34 than width 26 of cone 13 . In the prior art, width 34 is typically equal or greater than the width of crest 28 of one of the teeth of inner row 31 . Cone 17 has an outer row 35 and an inner row 37 spaced apart by a groove 39 . Groove 39 has a width 40 that is wider than width 34 and width 26 . Width 40 is greater than the width of crest 28 of one of the outer row teeth 35 or inner row teeth 37 .
[0007] The various rows 21 , 23 , 29 , 31 , 35 and 37 are arranged for a desired bottom hole coverage, as indicated in FIG. 2 . In FIG. 2 , all of the rows of teeth are rotated into a single sectional plane. Some of the teeth intermesh with each other as shown in FIG. 1 . The number of rows per cone in the prior art can be more or less than those shown in FIG. 1 . In the prior art example shown, there are a total of seven rows, and the narrowest groove width 26 is located on cone number one, which has the spear point. In an eight row bit, the narrowest groove width 26 would be normally on cone 17 , which is cone number two. In a nine row bit, the narrowest groove width 26 would be on cone 15 , which is cone number three. A narrow groove on one of the cones has been necessary in the prior art in order to achieve intermesh and the desired bottom coverage. While workable, in certain formations such as shales, the cuttings tend to ball up in rows separated by narrow grooves, reducing the rate of penetration.
SUMMARY OF THE INVENTION
[0008] The bit of this invention has first, second, and third cones, each cone being mounted for rotation about a cone axis while the bit rotates about a bit axis. An outer row and an adjacent row of cutting elements are located on each of the cones. Each of the cutting elements of the adjacent row on each of the cones has a crest extending perpendicular to a direction of rotation of the cone. An annular space or groove is located between the outer row and the adjacent row on each of the cones.
[0009] To reduce balling, the narrowest groove between the outer and adjacent rows is made larger than in comparable sized bits of the prior art. The increased width is accomplished by reducing the widths of the crests and re-positioning the rows for bottom coverage. The inner side of the outer row of one of the cones is moved inward a considerable distance for bottom coverage between the widest groove.
[0010] Each of the grooves has a width, measured between tips of the outer and adjacent rows, that is greater than a width of the crests of the adjacent row on the same cone. In the embodiments shown, each of the grooves has a width that is greater than one-half of a width of at least one, and preferably all of the other grooves on the same cone. The outer row of one of the cones has an inner side that is tangent to an inner side plane perpendicular to the cone axis. The inner side plane is closer to the bit axis than to a plane containing a backface of said one of the cones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a layout of a prior art three-cone bit.
[0012] FIG. 2 is a layout of the prior art bit of FIG. 1 , with the teeth of the cones rotated into a single section plane.
[0013] FIG. 3 is a side view of the number one cone of the prior art bit of FIG. 1 before the application of hardfacing.
[0014] FIG. 4 is a side view of a comparably sized number one cone before the application of hardfacing and constructed in accordance with this invention.
[0015] FIG. 5 is a layout of a three-cone bit constructed in accordance with this invention, the bit including the number one cone shown in FIG. 4 .
[0016] FIG. 6 is a layout of the bit of FIG. 5 , with the teeth of the cones shown rotated into a single section plane to show bottom coverage.
[0017] FIG. 7 is a layout of an alternate embodiment of a bit constructed in accordance with this invention.
[0018] FIG. 8 is a layout of the bit of FIG. 7 , with the teeth of the cones shown rotated into a single section plane to show bottom coverage.
[0019] FIG. 9 is a top view of the third cone of the bit of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIG. 5 , bit 41 has three cones 43 , 45 and 47 . Cone 43 has a cutting element 49 referred to as a spear point on its inner end and a heel or outer row 51 on its outer end. Cutting element 49 extends closer to the bit axis of rotation 50 than any cutting structure on cones 45 and 47 . Cone 43 has an outermost adjacent row 53 , referred to herein as adjacent row 53 , spaced from outer row 51 by an annular space or groove 55 . The teeth or cutting elements of cones 43 , 45 and 47 are covered with hardfacing 54 , shown by the fragmentary lines. The teeth of cones 43 , 45 and 47 are milled teeth that are machined from the metal of the body of the cones. Alternately, the teeth could be cast with the body of the cone, or comprise tungsten carbide compacts press-fitted into holes in the bodies of cones 43 , 45 and 47 .
[0021] Groove 55 is triangular in cross-section and has a width 57 measured between the tips (after hardfacing 54 is applied) of the teeth in outer and inner rows 51 , 53 . Width 57 is considerably greater than width 26 of groove 25 ( FIG. 1 ) of a comparably sized bit of the prior art. Preferably, width 57 is greater than the width of a crest 59 of one of the teeth of adjacent row 53 or outer row 51 , including hardfacing 54 contained on each tooth. Crest 59 on each tooth is perpendicular to the direction of rotation of cone 43 . In this embodiment, the width of crest 59 of each tooth of adjacent row 53 or outer row 51 is less than the width of crest 28 ( FIG. 1 ) of each tooth of inner row 23 or outer row 21 of a comparably sized prior art bit. The reduction in widths of crests 59 over the prior art bit partly accounts for the increase in width 57 of groove 55 .
[0022] Cone 45 has an outer row 61 and an adjacent row 63 separated by a groove 65 . Groove 65 has a width 66 measured at the tips of the teeth between rows 61 , 63 that is greater than width 57 of groove 55 . However, the amount of difference is not so much as in the prior art bit of FIGS. 1-3 . In this example, width 57 is more than half the amount of width 66 . In the prior art bit of FIG. 1 , width 26 is only about one-third of width 34 . In this example, width 66 is greater than width 34 of the comparably sized prior art bit 11 of FIG. 1 . The inner side of adjacent row 63 is preferably spaced closer to the inner end of cone 45 than in the comparably sized prior art bit of FIG. 1 .
[0023] Cone 47 has an outer row 67 that has an outer side spaced inward from gage surface 68 in this example. In this embodiment, the outer side of outer row 67 is spaced inward from gage surface 68 by an annular space 69 having a width 70 . Annular space width 70 is slightly less than the width of crest 59 of each of the teeth of outer row 67 in this example. The width of each tooth of outer row 67 is less than a comparably sized tooth of outer row 35 ( FIG. 1 ).
[0024] The inner side of outer row 67 is closer to bit axis 50 than the inner side of outer rows 51 and 61 of cones 43 and 45 . Furthermore, the inner side of each tooth of outer row 67 is located more inward than the comparable teeth of prior art outer row 35 ( FIG. 1 ). Referring to FIG. 6 , plane 71 is perpendicular to cone axis of rotation 73 and is tangent to the inner side of outer row 67 of cone 47 . Plane 71 is spaced a distance d 1 from the cone backface 75 and a distance d 2 from bit axis 50 . Distance d 2 is smaller than distance d 1 , placing the inner side of outer row 67 of cone 47 closer to bit axis 50 than to cone backface 75 . A similar plane (not shown) in the prior art example of FIG. 2 would intersect the cone axis closer to the backface than the bit axis.
[0025] Adjacent row 77 of cone 47 is spaced from outer row 67 by a groove 79 . Groove 79 has a width 81 that is approximately the same as width 40 of a comparably sized prior art bit 11 ( FIG. 1 ). The width of the crest 59 of each tooth of adjacent row 77 is less than the width of crest 28 of prior art bit 11 ( FIG. 1 ).
[0026] Referring still to FIG. 6 , the reduction in widths of crests 59 of some of the rows and the placement of the various rows provides approximately the same bottom coverage as in the prior art bit of FIG. 2 . In the first embodiment of this invention, the center line of outer row 67 of cone 47 locates equidistant between outer row 51 and adjacent row 53 of cone 43 . Outer row 67 of cone 47 and adjacent row 53 of cone 43 locate between rows 61 and 63 of cone 45 . Both cone 43 adjacent row 53 and cone 45 adjacent row 63 locate between cone 47 outer row 67 and cone 47 adjacent row 77 .
[0027] When the bit has more or less than seven rows of teeth, the location of narrowest width 57 might be on cone 45 or cone 47 . When the bit has more or less than seven rows of teeth, the location of outer row 67 , which has reduced width crests 59 and is off-gage, might be on cone 43 or cone 45 . Increasing the narrowest width 57 does not necessarily require providing an outer row 67 that has reduced width crests 59 and is off-gage. Outer row 67 could have crests 59 of conventional width and have its outer sides flush with the gage. Alternately, outer row 67 could be staggered, with alternating teeth of varying width crests.
[0028] A second embodiment is shown in FIGS. 7-9 . Cone 83 has an outer row 85 and an adjacent row 87 separated by a groove 89 . FIG. 8 shows width 91 between the tips of outer row 85 and adjacent row 87 after the application of hardfacing 93 . Cone 95 has an outer row 97 in which all of the teeth have outer sides flush with gage surface 99 , unlike outer row 67 of FIG. 5 . An adjacent row 101 is separated from outer row 97 by annular groove 103 . Groove 103 has a width 105 that is less than width 91 , as shown in FIG. 8 . This differs from the first embodiment where width 57 is less than width 81 ( FIG. 5 ).
[0029] Cone 107 has a staggered outer row with outward cutting elements 109 a and inward cutting elements 109 b . As shown in FIG. 9 , cutting elements 109 a and 109 b alternate with each other, with each cutting element 109 b located equidistant between two cutting elements 109 a . The number of cutting elements 109 a is the same as the number of cutting elements 109 b in this example. The outer sides of outward cutting elements 109 a are flush with gage surface 99 ( FIG. 7 ). The outer sides of inward cutting elements 109 b are spaced inward from gage surface 99 . In the embodiment shown, the outer sides of inward cutting elements 109 b are inward from the inner sides of outward cutting elements 109 a . Adjacent row 111 is not staggered and is located inward from inward cutting elements 109 b.
[0030] An annular groove 112 is located between outer row cutting elements 109 a , 109 b and adjacent row 111 . Groove 112 has a width 113 a from outward cutting elements 109 a to adjacent row 111 and a width 113 b from inward cutting elements 109 b to adjacent row 111 , as shown in FIG. 8 . Width 113 a is larger than widths 91 and 105 . Width 91 is larger than width 105 in this embodiment, thus the narrowest annular groove between adjacent and outer rows in this embodiment is groove 103 of cone 95 . Although smaller, width 105 of groove 103 is greater than one-half the widths 91 , 113 a or 113 b . Also, width 105 of groove 103 is greater than the width of the crests of adjacent row 101 .
[0031] The inner side of the outer row of cone 107 is considered to be the inner sides of inward cutting elements 109 b , which is spaced farther inward than outer rows 85 and 97 . Plane 115 is tangent to the tips of outer row cutting elements 109 b on the inner side and perpendicular to cone axis 117 . Plane 115 intersects cone axis 117 closer to bit axis 119 than backface 121 .
[0032] The invention has significant advantages. The arrangement of the teeth reduces balling of shale in the rows adjacent to the narrower grooves and improves removal of drill cuttings because of the greater widths than in the prior art for comparable sized bits. The reduction in balling and better cuttings removal has resulted in greater performance of the bit.
[0033] While the invention has been shown in only a few 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. | An earth boring bit has three cones, each cone being mounted for rotation about a cone axis while the bit rotates about a bit axis. An outer row and an adjacent row of cutting elements are integrally formed on each of the cones. Each of the cutting elements of the adjacent row on each of the cones has a crest extending perpendicular to a direction of rotation of the cone. Annular spaces are located between the outer row and the adjacent row on each of the cones. The annular space on one cone has a width that is less than the annular spaces on the other cones. The width of the narrowest annular space is greater than the width of the crests of the adjacent row. |
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REFERENCE TO OTHER APPLLICATION
Night Depository or Similar Article, co-pending design application, Ser. No. 033,541, filed on even date herewith, invented by Alex Tarkeny, John P. Caldwell and Jay Sucre, assigned to NCR Corporation.
BACKGROUND OF THE INVENTION
In order to meet the demands of customers who must make deposits during non-business hours, banks and similar establishments frequently provide night depositories for receiving such deposits, which may be in the form of packages or containers holding substantial amounts of checks, currency, coins and other materials. Since bank employees are not on duty during non-business hours, access to night depositories must normally rely on a key or similar device given to the customer by the bank. No other means of establishing customer identification is normally provided, nor is means for issuing a receipt to establish that such a deposit has been made.
Some banking transactions can be carried on during non-business hours by the use of customer-operated automated teller machines, which are capable of performing customer identification functions, receiving deposits, issuing currency and providing an internal record and a printed receipt to the customer concerning the various transactions made.
The use of an automated teller machine in combination with a night depository enables the functions of customer identification, record keeping and receipt issuing to be performed in connection with use of the night depository. For convenience in use, the automated teller machine and the night depository should be located in close proximity to each other, and the night depository should be capable of receiving and holding a relatively large number of deposit packages or containers in a relatively limited space.
SUMMARY OF THE INVENTION
This invention relates to a night depository method and apparatus, and more particularly relates to the combination of an automated teller machine (ATM) and a night depository, whereby the customer can conveniently utilize both facilities in a single location, and whereby use of the night depository can be controlled by customer interaction with the ATM. The combination of the ATM and the night depository provides several advantages to financial institutions, including the following: receipt generation to the customer after a deposit has been made, which provides a dated record of the transaction; the ability for the ATM to sense a "full" condition in the depository and report to an associated host processor that such a condition exists; the ability of the ATM to prevent access to the depository during a "full" condition to prevent further deposits from being made which may otherwise not reach the safety of the interior of the depository due to a clog in the chute area; the ability to sense that the depository drawer was opened and that presumably a deposit was made; and the ability to provide the host processor with initial data regarding depository balances, based on reported entries by the ATM.
In accordance with a first embodiment of the invention, a method for receiving customer deposits in a night depository operatively associated with an ATM comprises the following steps: receiving at the ATM a customer entry of personal identification and transaction data; verifying the identity of the customer; releasing a latch means to enable the customer to open a closure of the night depository, make a deposit in the depository, and close the closure; enabling a deposit to drop into a conveyor area, which includes a conveyor, in the night depository; sensing, by a sensor, the height of deposits reposing in the conveyor area; operating the conveyor to reposition the deposits in the night depository when the height of the accumulated deposits exceeds a predetermined value as determined by the sensor; generating a signal by the depository to the ATM that the deposit has been made; recording the data pertaining to the transaction in the ATM; and issuing a receipt to the customer by the ATM relating to the deposit.
In accordance with a second embodiment of the invention, a night depository system for receiving customer deposits, maintaining a record of such deposits, and providing a receipt to a customer making such a deposit comprises, in combination: customer operated means for receiving customer identification and transaction data and for controlling access to a night depository; means for verifying the identity of the customer; a night depository for receiving customer deposits; closure means for the night depository to enable deposits to be placed within said night depository; latch means for said closure means controlled by said customer operated means; switch means operatively coupled to said closure means to provide a signal to said customer operated means as to whether said closure is opened or closed; conveyor means for transporting deposits which have been placed in the night depository to prevent such deposits from accumulating in a position adjacent to said closure means; sensing means for sensing when an accumulation of deposits adjacent said closure means exceeds a predetermined quantity; and motor means controlled by said sensing means for operating said conveyor means for moving said accumulated deposits from said position adjacent said closure means to a remote position.
It is accordingly an object of the present invention to provide a night depository for use in association with an ATM.
Another object is to provide a method for use of a night depository in association with an ATM.
Another object is to provide a night depository apparatus in which a record is issued to a customer making a deposit.
Another object is to provide a night depository apparatus in which access to the depository is prevented when the depository is full.
Another object is to provide a night depository apparatus in which customer identification must be verified as a condition for access to the depository.
Another object is to provide a night depository apparatus in which an ATM is positioned atop a night depository in such a manner that the night depository closure is positioned directly beneath the customer interface portion of the ATM for convenience in use by the customer.
With these and other objects, which will become apparent from the following description, in view, the invention includes certain novel features of construction and combinations of parts, a preferred form or embodiment of which is hereinafter described with reference to the drawings which accompany and form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the night depository system of the present invention, including a night depository and an automated teller machine in assembled relationship.
FIG. 2 is a rear view of the assembly of FIG. 2.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a rear view of the night depository with the rear door removed.
FIG. 6 is a block diagram illustrating various elements of the night depository system of the present invention and the manner in which they are interrelated.
FIGS. 7A and 7B together comprise a flow diagram showing the manner in which the system of FIG. 6 operates during a customer deposit operation.
DETAILED DESCRIPTION
FIG. 1 shows, in a perspective view, a system 10 which comprises a combination of an automated teller machine (ATM) 12 and a night depository 14. The ATM may, for example, be an NCR 5085 ATM, manufactured by NCR Corporation, Dayton, Ohio. The night depository rests upon a floor or other supporting surface (not shown) and is configured to provide an upper external horizontal surface 16 upon which feet protruding from a complementary flat bottom surface 18 of a supporting frame 20 of the ATM 12 rest. It will be seen that this arrangement places a door 22 of a depository drum 24 (FIG. 3) directly below a customer interface area 26 of the ATM 12, so that a customer can conveniently operate both the ATM 12 and the door 22 while standing in one place. The customer interface area 26 of the ATM 12 normally includes such elements as a lamp 28, a display 30, an envelope receptacle 32, function control keys 34, a keyboard 36, a card slot 38 for receiving a customer's credit or bank card, receipt and statement dispensing slots 40 and 42, a slot 44 from which currency and associated documentation are dispensed, an envelope slot 46 for receiving deposits and similar items from a customer, and a display 48 indicating whether or not the ATM is in service. The deposits placed through the slot 46 are normally relatively small in size and are received in a relatively small safe area within the ATM proper, while deposits placed into the night depository 14 through door 22 are normally large and bulky deposits. At its rear, the ATM 12 is provided with a lockable door 50 for its self-contained safe and with access panels 52 and 53 to enable the internal mechanism and electronics of the ATM to be serviced.
The night depository door 22 is located in an outwardly projecting portion 54 of the night depository 14. Access to the interior of the night deposit 14 through the door 22 is controlled by a solenoid latch 58 which is actuated under control of the ATM 12, as will subsequently be described. Alternatively, if desired, access to the night depository 14 may be controlled by a conventional key lock 56. The combined ATM 12 and night depository 14 structure is customarily located so that the customer interface area 26 of the ATM 12 and the outwardly projecting portion 54 of the depository 14 extend through a wall 55 which conceals the remainder of the structure from view. Moldings or trim bezels 60 and 62 for the ATM 12 and depository 14 are provided for weatherproofing and to enhance the appearance of the assembly when installed.
FIGS. 3 and 4 show the interior of the depository 14, which is fabricated from penetrationresistant materials, such as high-strength steel plate, including a base 64 and walls 66, 68, 70 and 72. As previously indicated, at one end, the depository is provided with a door or closure 22, through which deposits may be placed into the depository 14 by a customer. The drum 24 is associated with the door 22, to receive a deposit when the door is open and to cause the deposit to drop through an aperture 72 into the interior of the depository 14 when the door is closed. The door 22 and drum 24 are of conventional design. A switch 74 is located in proximity to the drum 24 and is actuated by rotation of the drum from open to closed position to provide an indication to the ATM 12 that the drum 24 has been operated.
When a deposit 76 is introduced into the depository 14 via the door 22, the drum 24, and a drum flap 77, and drops through the aperture 72, it is guided by a first deflector 78 and a second deflector 80 to land on a conveyor 82, or on other deposits which have already been dropped into the same area. The first deflector 78 is located adjacent to the drum 24, while the second deflector 80 is placed within the depository 14 and secured to the front wall thereof. These deflectors guide the deposit 76 in its drop and prevent it from landing in a position between the front wall 68 and the end of the conveyor 82, where it might cause a jam. In addition to the front deflector 80, side deflectors 84, 86 and a rear deflector 88 are also provided to keep the deposits in proper position with respect to the conveyor 82.
The conveyor 82 is an endless belt mounted on a front roller 90 and a rear roller 92, which in turn are mounted on the base 64. The rear roller 92 is driven through a chain 94 and gears 96 and 98 by a motor 100 which is also located within the depository 14.
At the end of the night depository 14 which is opposite from the door 22, and located adjacent to the rear roller 92 of the conveyor 82, is a second door 102 which is hinged by hinges 104 at one side of its aperture 106, and which is provided with a lock 108 and a handle 110 for secured opening and closing. This door 102 is used by employees of the bank or other institution which owns the night depository 14 for the purpose of periodically removing accumulated deposits 76. Positioned within reach of an employee who opens the door 102 is a switch 112 (FIG. 5) which may be actuated to operate the motor 100 to run the conveyor 82 to bring all deposits 76 to the rearmost position of the conveyor, from which position they can readily be removed from the depository 14 by the employee.
As deposits 76 are dropped through the aperture 72, they will accumulate at the forward end of the depository 14, and could, if left untended, form a pile high enough to jam the operation of the drum 24, so that the drum 24 and door 22 would not close, and might provide access to the night depository 14 and the deposits 76 therein to unauthorized persons. Accordingly, a sensor 114, comprising a combined light source and photocell, is positioned in cooperative relation with a reflector 116 to detect when a pile or deposits 76 reaches a height which breaks the double beam of light extending between the sensor 114 and the reflector 116. Of course, this same double beam of light will be broken momentarily by deposits 76 as they drop through the aperture 72 and onto the conveyor 82, but the circuitry associated with the sensor 114 can be designed, in a well-known manner, to ignore such momentary interruptions and to be operated only by a light beam interruption of relatively longer duration. Such circuit actuation will cause operation of the motor 100 to, in turn, operate the conveyor 82 and carry the accumulated deposits 76 to the rear of the night depository 14, from where they can be removed through the door 102 by an employee of the institution utilizing the night depository system.
Shown in FIG. 6 is a block diagram illustrating the relationship of the various elements described above. It will be noted that the customer 118 communicates with the ATM 12 by means of the keyboard 36 and the card slot 38 into which the customer introduces a bank or credit card for identification verification purposes. Such verification customarily involves the entry of a personal identification number on the keyboard 36 which is compared by the ATM 12 or a host processor 120 with data on the bank or credit card to establish customer identity. The ATM 12 then, at the direction of the customer 118, operates the solenoid latch 58 associated with the drum 24 of the depository 14, to enable the customer to open the door 22 to make the desired deposit.
Piling up of a plurality of deposits 76 breaks the double light beam between the sensor 114 and the reflector 116, which actuates a motor control and timer 122 to operate the conveyor belt motor 100 for a predetermined length of time to cause the conveyor 82 to shift accumulated deposits 76 to the rear of the night depository 14 to make room for additional deposits 76 to be dropped onto the forward end of the conveyor 82. The sensor 114 also sends a signal to the ATM 12, indicating a "full" condition, which causes the ATM to "close" the depository until the condition has been corrected. An employee can open the rear door 102 of the night depository 14 and operate the motor timer override switch 112 which actuates the motor control and timer 122 to operate the conveyor belt motor 100 for as long as may be necessary to bring all of the deposits 76 to the rear of the depository 14 for removal by the employee.
A typical customer-initiated sequence of operation of the depository system of the present invention is shown in the flow diagram of FIGS. 7A and 7B. Following the "start" block 124, as indicated in block 126, a customer having a deposit 76 to be placed in the depository 14 first approaches the system and accesses the ATM 12 by entering a personal identification number (pin) in the keyboard 36 and inserting a credit or bank card in the slot 38 of the ATM 12.
The host processor 120 then performs a customer identification verification operation (block 128). If the verification is positive, the customer 118 is permitted to use the ATM 12, while if the identification is not positive, the ATM 12 refuses a transaction, as indicated in block 130, and the process normally returns to block 126 for a retry, unless retries are not permitted under the designed constraints of a particular system. Assuming that the identification is positive, the customer then chooses a "commercial deposit" transaction, enters an appropriate amount on the keyboard 36 and signals "ready" to the ATM 12 by an appropriate function key 34, in response to a "ready" signal from the ATM 12, all as indicated in block 132. The solenoid drum latch 58 is then pulled or withdrawn by the ATM 12 (block 134), which permits the customer 118 to open the door 22, insert a deposit 76 into the drum 24, and close the drum 24 (block 136).
A determination is then made by the system (block 138) as to whether or not the drum switch 74 signals a proper closure to the ATM 12. If not, the customer decides whether or not to attempt to continue with the operation (block 140). If the customer attempts in some way to continue operation of the system, the process returns to block 138 to determine whether the status of the drum switch 74 has changed. If the customer takes no action, the system goes to a "wait" mode (block 142), which is resolved only by proper closing of the drum 24.
Assuming that the drum switch has signaled a closure, the deposit 76 has fallen into the depository 14, the ATM 12 issues a receipt and returns the card of the customer 118, and records appropriate data relating to the transaction, all as indicated in block 144 of FIG. 7B. The process then returns over path 146 to block 126 of FIG. 7A. At the same time, as represented by path 145, a determination is made (block 147) as to whether or not the sensor 114 has been tripped by a deposit 76 which has been prevented by an accumulation of other deposits from falling fully into the depository 14. If the sensor 114 has not been tripped, the conveyor 82 is not operated, as represented by block 148, and the system will continue to operate in the normal manner.
If the sensor 114 has been tripped, the conveyor 82 is operated to move the accumulated deposits 76 to the rear end of the depository 14, as indicated in block 150. The motor 100 is operated for a predetermined length of time under control of the motor controller and timer 122, after which a determination is made (block 152) as to whether or not the tripped sensor condition has been remedied.
If the condition has been remedied, the system may continue to operate in a normal manner, and at some appropriate time, an employee will open the door 102 of the depository 14 and remove the accumulated deposits 76, as represented by block 154. It will be noted that this action may also follow any individual operation of the system, as represented by path 156 extending from blcok 144 to block 154. The employee may use the override switch 112, if necessary, to cause the conveyor 82 to move all of the accumulated deposits 76 to a position in which they may readily be retrieved through the opening 106 of the rear door 102.
If the condition is not remedied by operation of the conveyor 82, the conveyor will then continue to make a number (represented by "n") of tries to clear the sensor 114, as indicated in block 158. For each try up to "n", the system follows the path 160 back to block 147. If this is unsuccessful in remedying the condition, on the "nth" try, the ATM 12 will sense a full condition and will close the depository 14, as represented in block 162.
While the form of the invention illustrated and described herein is particularly adapted to fulfill the objects aforesaid, it is to be understood that other and further modifications within the scope of the following claims may be made without departing from the spirit of the invention. | A night depository is configured to be placed beneath and to support an automated teller machine, which is used by a customer to provide access to the night depository, and which provides documentation of customer access to the night depository. Access to the night depository is provided by a closure positioned vertically beneath the front of the automated teller machine. A conveyor within the night depository prevents piling up of deposits within the night depository beneath the closure. The conveyor carries the deposits to the vincinity of a second closure which may be opened by an authorized person to remove the accumulated deposits. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my application Ser. No. 689,458 filed May 24, 1976, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a portable and collapsible umbrella shelter for use on a stadium bench or in other situations where persons may wish to have protection from the weather.
Portable, collapsible shelters heretofore proposed for this purpose have been too complicated and expensive to be practical. For use on a stadium bench, such a shelter must have a rectangular shape because of the necessarily compact seating arrangement of the spectators. Umbrella type shelters heretofore proposed for other purposes are not suitable for use in a stadium because they do not lend themselves to a close seating arrangement of spectators and because the space under a conventional umbrella is obstructed by its supporting pole.
Objects of the present invention are therefore to provide an improved umbrella shelter which is suitable for stadium use, to provide an umbrella shelter in which the supporting pole does not obstruct the space under the umbrella, to provide an umbrella shelter which is also suitable and advantageous for various other types of use and to provide a construction of the type described which is light in weight, inexpensive to manufacture, easy to erect and easy to collapse into a compact package.
SUMMARY OF THE INVENTION
The present umbrella is rectangular in order to accommodate two people seated side by side on a stadium bench without interfering with other spectators seated closely on opposite sides and behind the umbrella. In order to provide unobstructed space under the umbrella, its supporting pole is positioned in the middle of the back side. A vertical sheet of fabric hangs from the back edge and portions of the side edges of the umbrella. This partial enclosure is completed by a removable front panel having a transparent upper portion and attachment means for connection with the umbrella and forward side edges of said vertical back sheet. The front panel may be detached at any point for ventilation and its upper portion may be detached and turned down on the laps of occupants.
The umbrella pole is supported by a base which attaches to the bench. For single person occupancy, the umbrella may be square with its pole directly behind the back of the occupant. This is not possible with most other known types of umbrellas because portions of the umbrellas project back of the pole, interfering with spectators to the rear and obstructing the walk way between benches.
The base for the pole is also adapted for mounting on the seat of a boat for use of the shelter by fishermen or for use as a duck blind by duck hunters. A spike may be mounted on the lower end of the umbrella pole permitting it to be thrust into the ground to provide a shelter for hunters on land. Still other uses and adaptations will suggest themselves, making the present shelter useful and advantageous for a considerable variety of purposes.
The invention will be better understood and additional objects and advantages will become apparent from the following description of the preferred embodiments illustrated in the accompanying drawings. Various changes may be made in the details of construction and arrangement of parts and certain features may be used without others. All such modifications within the scope of the appended claims are included in the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an umbrella shelter embodying the invention.
FIG. 2 is a view on the line 2--2 in FIG. 1.
FIG. 3 is a view on the line 3--3 in FIG. 1.
FIG. 4 is a perspective view of the umbrella frame.
FIG. 5 is a view on the line 5--5 in FIG. 4.
FIG. 6 is a view on the line 6--6 in FIG. 1.
FIG. 7 is a side elevation view of the umbrella shelter mounted on a stadium bench.
FIG. 8 is a front view.
FIG. 9 is a front view of a square umbrella shelter to accommodate a single person.
FIG. 10 is an elevation view of an umbrella pole equipped with a spike to be driven into the ground.
FIG. 11 is a view similar to FIG. 4 showing a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a rectangular umbrella shelter 10 for two spectators, mounted on a stadium bench 11. The umbrella pole 12 is inserted in a tubular socket 13 which is upstanding from the back edge of a forwardly extending base member 14. The front end of base 14 has a return bend to provide a flange 15 hooking the front edge of bench 11.
The umbrella frame is covered with a rectangular top piece of fabric 20 having a front edge 21, a back edge 22 and shorter right and left side edges 23 and 24. Thus, the top fabric has two front corners 25 and 26 and two back corners 27 and 28.
As seen in FIGS. 1 and 4, the umbrella frame comprises pole 12, a rib 31 extending to front corner 25, a rib 32 extending to front corner 26, a rib 33 extending to back corner 27, a rib 34 extending to back corner 28 and a rib 35 extending to the middle of front edge 21. These ribs radiate from a top rib holder 40 which is fixedly mounted on the upper end of pole 12.
As shown in FIG. 5, the inner ends of ribs 31-35 are pivotally mounted on a wire 41 contained in a circumferential groove 42 in rib holder 40. The ends of wire 41 are secured together at 43 to retain the wire in groove 42. The front side of rib holder 40 is circular, while the back side is flat at 44. The ribs pivot in vertical slots 45 in the rib holder.
It is thus apparent in FIGS. 1, 4 and 5 that back ribs 33 and 34 pivot in a vertical plane through the back edge 22 of rectangular top fabric 20. Back edge 22 of the top fabric extends along and is secured to the ribs 33 and 34 throughout the length of these ribs. When the umbrella is open, the inner ends of ribs 33 and 34 are aligned with each other. The outer ends of these ribs may bow downward to some extent in typical umbrella contour, but nevertheless the entire ribs 33 and 34 lie in a common vertical plane which is a vertical plane through the back edge 22 of the top fabric. This places the pole 12 at the back edge of the umbrella so that the pole does not obstruct the space under the top fabric.
Slide ring 47 is similar to rib holder 40, except that it is formed as a sleeve to slide up and down on pole 12 for opening and closing the umbrella in conventional manner. Pole 12 is provided with an upper spring catch 48 engageable with slide ring 47 to hold the umbrella open and a lower spring catch 49 engageable with the slide ring to hold the umbrella closed as in conventional umbrella construction.
Ribs 31-35 are raised and lowered by strut links 51-55, the upper end of each link being pivotally connected to its corresponding rib at 56. The lower ends of links 51-55 are pivotally connected to slide ring 47 in the same manner that the ribs are pivotally connected to rib holder 40 as shown in FIG. 5. Thus, the back strut links 53 and 54 pivot in a common vertical plane which is the vertical plane of ribs 33 and 34 and the vertical plane through the back edge 22 of the top fabric 20.
For improved durability and stiffness each of the ribs and strut links just described is made as a double rib and double strut link as seen in FIG. 5. For the purpose of the present description, however, each such pair of ribs and strut links will be referred to as a single member.
Means are provided to hold back strut links 53 and 54 and back ribs 33 and 34 in a common vertical plane with the back edge 22 of top fabric 20 when the umbrella is open, to prevent distortion as a result of the tension of the fabric and the eccentric position of pole 12. This holding means comprises a bracket 60 fixedly mounted on pole 12 by screw 61 so that wings 62 extend approximately in the vertical plane of back edge 22 of top fabric 20.
The upper ends 63 and lower ends 64 of wings 62 are bent forward as seen in FIG. 6. When the umbrella is opened, strut links 53 and 54 pass upward behind the wings 62 and are thereby held in the desired common vertical plane as shown in FIGS. 1 and 4 and prevented from swinging forward under the tension of top fabric 20. Strut links 53 and 54 thereby hold ribs 33 and 34 and also the back edge 22 of the top fabric in the desired vertical plane to maintain the rectangular shape of the umbrella without distortion.
When the umbrella is closed, the strut links 53 and 54 slide downward free of the lower ends of wings 62 and ribs 33 and 34 pass downward behind the wings.
A vertical fabric sheet 70 forms back and side portions of the shelter. The upper edge of sheet 70 is permanently connected with back edge 22 and the rear portions of side edges 23 and 24 of top fabric 20 to suspend sheet 70 from the umbrella. Sheet 70 has vertical front edges at 71 on opposite sides of the umbrella. A removable front panel 72 completes the enclosure when desired. Panel 72 has a transparent upper portion 73 forming a window extending across the front of the umbrella and around each side, back to the front edges 71 of back sheet 70. Front panel 72 drapes over the knees and legs of the occupants in front and on opposite sides of the occupants as shown in FIG. 7.
Suitable fastening means are provided for convenient attachment and removal of front panel 72. Such fastening means may comprise slide fasteners, snap fasteners or buttons. A flexible plastic hook and loop fastener sold under the trademark VELCRO manufactured by Velcro, Inc. in Manchester, New Hampshire, may also be used. This fastener material is furnished in strips which may be sewed to the sheets to be fastened together. This type of fastener is secured by merely pressing two of the strips together and it is unfastened by simply pulling them apart.
The fastener strips for front panel 72 are indicated at 75 in FIGS. 1 and 2. Thus, fastener strips 75 extend along front edge 21 and front portions of side edges 23 and 24 of top fabric 20 and along the front edges 71 of back sheet 70. Front panel 72 is provided with fastener strips 75 in corresponding positions so that the fastener strips may be pressed together as shown in FIG. 2. For ventilation, the fastener strips may be separated at any desired point and when desired, the upper portion of panel 72 may be unfastened and folded down over the laps of occupants.
Any suitable fabric may be used for the shelter and the fabric may be coated to make it wind proof or water proof as desired. In preparation for folding the umbrella, the front panel 72 is first removed. When the umbrella is folded, the back sheet 70 may be wrapped around the folded umbrella and then the front panel 72 may be folded separately or wrapped around the folded umbrella and back sheet 70 to make a compact package.
The present form of construction is particularly well adapted to a square umbrella 85 for single occupancy as shown in FIG. 9. The occupant sits on base 14 to hold the base firmly against bench 11 in the event of wind, making the shelter exceptionally stable under adverse weather conditions. Pole 12 is behind the back of the occupant along side back sheet 70 so that the pole in no way interferes with the occupant. As seen in FIG. 7, no part of the umbrella projects behind pole 12 and bench seat 11 to obstruct the walk way 80 or interfere with the occupants on the next bench to the rear. Any umbrella projecting behind the bench 11 obviously could not be used in a stadium.
In FIG. 10, pole 12 is equipped with a spike 90 to be thrust into the ground to support the umbrella.
FIG. 11 shows an alternative form of holding device to hold back strut links 53 and 54 and back ribs 33 and 34 in a common vertical plane with the back edge 22 of top fabric 20 when the umbrella is open, to prevent distortion as a result of the tension of the fabric and the eccentric position of pole 12. This holding means comprises a transverse bracket arm 160 fixedly mounted on pole 12 by screw 61 so as to extend approximately in the vertical plane of back edge 22 of top fabric 20.
The upper ends of depending arms 162 and 163 are mounted on horizontal pivots 164 in the opposite ends of stationary bracket arm 160. When the umbrella is opened, arm 162 is pivoted out in front of strut link 53 and arm 163 is pivoted out in front of strut link 54 to hold these strut links in the desired common vertical plane the same as shown in FIGS. 1 and 4 and prevent them from swinging forward under the tension of top fabric 20. Strut links 53 and 54 thereby hold ribs 33 and 34 and also the back edge 22 of the top fabric in the desired vertical plane to maintain the rectangular shape of the umbrella without distortion. When the umbrella is closed, the strut links 53 and 54 slide downward free of the lower ends of these arms without requiring any manipulation by the operator. | A rectangular umbrella has its supporting pole positioned at the middle of the back edge so as not to obstruct the space under the umbrella. A vertical sheet of fabric hangs from the back edge and portions of the side edges of the umbrella. This partial enclosure is completed by a removable front panel having a transparent upper portion and attachment means for connection with the umbrella and forward side edges of said vertical back fabric. The umbrella pole may be mounted on a stadium bench for sports spectators, on a boat seat for fishermen or duck hunters, or thrust into the ground for bird and big game hunters. |
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BACKGROUND OF THE INVENTION
The present invention relates to improvements in sealing mechanisms for toilets and to flush means associated therewith. In particular, the invention pertains to toilets of the type wherein the toilet bowl discharges to a holding tank and a closure member is provided for opening and closing the discharge outlet from the bowl to the holding tank. In toilets of this character, which may be used in mobile homes, recreational vehicles, marine vessels and the like, the closure member must function to provide a sealed closure of the discharge outlet except during the flushing cycle of the toilet.
Known toilets of the type to which the present invention relates are disclosed, for example, in U.S. Pat. Nos. 3,939,500 and 4,032,996. The former patent discloses toilet apparatus wherein a pan serves to close the discharge outlet and a flush means cooperates with the pan to provide a water seal at the closed discharge outlet. The flush means provides an accumulation chamber which functions to discharge a volume of water into the pan after the flushing operation is terminated to fill the pan partially to form the water seal. A ball valve in the flush circuit is operatively connected with the actuator mechanism for pivoting the pan during the flushing so that flush water will flow to the bowl when the pan is pivoted to its open position.
U.S. Pat. No. 4,032,996 discloses a sealing mechanism for the discharge outlet of the toilet bowl wherein a blade is pivoted generally in a horizontal plane between a closed position wherein the blade is seated against an elastomeric sleeve projecting downward from the outlet, and movement of the blade provides a wiping action on the surface of the blade.
SUMMARY OF THE INVENTION
The present invention is directed toward improvements in various of the features embodied in the toilet apparatus disclosed in the above-cited U.S. Pat. Nos. 3,939,500 and 4,032,996.
According to one form of the present invention, a toilet apparatus is provided having a bowl with a discharge outlet at the bottom, a housing supporting the bowl, flush means for discharging flush water into the bowl, and a sealing mechanism for closing and opening the bowl outlet, the sealing mechanism having a seal member mounted on the bowl around the outlet and projecting downward below the lower extremity of the outlet, a blade of larger area than said bowl outlet, and an actuator arm for movement of the blade between a first position wherein said blade is located under the bowl outlet and is urged upward into engagement with the seal member for closing the bottom of the bowl and a second position wherein said blade is at one side of the outlet.
One of the features of the present invention is that actuating means for opening and closing the bowl outlet are provided which are operatively associated with the actuator arm and the blade, the actuating means being operable when actuated for opening the bowl outlet to reduce initially the magnitude of the upward pressure of the blade on the sealing member to a pressure of lower magnitude and thereafter to move the blade substantially horizontally toward the second position while the pressure of lower magnitude exerted by the blade on the sealing member is maintained. This feature assures that the blade remains in an engaged position at a preselected lower pressure with the sealing member so that the blade is properly wiped and so that a buildup of undesirable materials on the surface of the blade is avoided.
Another feature of the present invention is the construction and arrangement that is provided whereby an overflow tube assembly is arranged in association with the flush means so that a water seal is assured at all times in the overflow tube and limited quantities of water are provided for discharge onto the top surface of the blade when in its open position. For this purpose a check valve is positioned at the lower end of the overflow tube to allow limited quantities of water to be discharged from the tube while preventing return flow or pressure surges from breaking the water seal above in the overflow tube.
Still another feature of the invention is a track means that is mounted on the lower end of the bowl and extends to one side thereof. The track means includes an enclosure in which the lower end of the overflow tube and its check valve are enclosed, and the enclosure is open at the bottom to provide tracks at its lower edges on which the blade can travel to and from its open position, thereby also assuring that the blade will remain in its proper position on the actuator arm.
The improved features in the flush means of the present invention includes the construction and arrangement of the control valve in the flush water circuit, whereby the inlet end of the control valve can be connected to a water supply duct without concern about causing damage to the valve or the supporting housing on which the valve is mounted. Damage of this type has frequently occurred in the past when wrenches are used to tighten the fittings when connecting the inlet duct to the valve. The significant feature embodied in the present invention provides a fitting which fits into the valve body so that the fitting will turn freely therein but will be retained against axial displacement. To permit securing the inlet duct to the freely rotatable fitting, a wrench head is made an integral part of the fitting so that the jaws of a wrench can be fitted into the wrench head to hold the fitting against turning, and thereby, the wrench will absorb the torque that is applied to the fitting for fastening the inlet duct thereto.
The present invention has still another feature in that a reservoir is provided in the flush circuit so that a standard quantity of water will always flow into the bowl after the flush operation is terminated, thereby assuring that a uniform depth of water is provided in the bowl after the blade has assumed its closed position. For this purpose a riser tube extending through the bottom wall of the reservoir forms the only outlet from the reservoir to a flush tube leading to a discharge nozzle in the bowl. When the valve in the flush circuit is open, flush water can fill the reservoir to the level of the open upper end of the tube after which rapid flow of flush water to the nozzle will occur, the tube having a small orifice adjacent to the bottom wall of the reservoir so that after the valve is closed and the level of the water is at or below the upper end of the tube the remaining water in the reservoir can flow at a slow rate to the nozzle and from there into the bottom of the closed bowl.
Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view, with parts broken away for illustrational purposes, of a toilet apparatus embodying the present invention;
FIG. 2 is a fragmentary rear elevational view with portions broken away for illustrational purposes;
FIG. 3 is an enlarged fragmentary top plan view;
FIG. 4 is an enlarged fragmentary section taken on the lines 4--4, showing the riser tube in the reservoir;
FIG. 5 is a front elevational view of the reservoir, as seen from the arrow 5 but shown apart from the remainder of the toilet apparatus;
FIG. 6 is an enlarged fragmentary top plan view of the actuator means when only the water level is pivoted to an open position of the control valve;
FIG. 7 is a similar view to that of FIG. 6, but showing both the flush and water levers in closed positions;
FIG. 8 is a similar view but showing the flush and water levers moved to a location wherein the actuator arm has been depressed;
FIG. 9 is a similar view but showing the flush and water levers after they have been pivoted to their fully open positions;
FIG. 10 is a fragmentary sectional view of the lower end of the bowl taken on the lines 10--10 of FIG. 9;
FIG. 11 is a fragmentary sectional view taken on the lines 11--11 of FIG. 7;
FIG. 12 is a fragmentary sectional view taken on the lines 12--12 of FIG. 8;
FIG. 13 is a fragmentary sectional view taken through the control valve;
FIG. 14 is a sectional view taken on the lines 14--14 of FIG. 4;
FIG. 15 is a fragmentary top plan view of the riser tube shown in FIG. 14;
FIG. 16 is a sectional view taken on the lines 16--16 of FIG. 13; and
FIG. 17 is a fragmentary sectional view taken on the lines 17--17 of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
Referring now to the drawings, the invention will be described in greater detail. The toilet apparatus 10 comprises the bowl 12 having at its bottom a discharge outlet 14 defined by the downwardly projecting flange 16. The upper end of the bowl 12 is open and has an outwardly directed peripheral flange 18 that is supported on and is secured to the housing 20. The housing 20 defines an outlet 22 leading to a holding tank (not shown) via the conduit 24. Waste material from the bowl 12 can be discharged through the outlet 22 when the sealing mechanism 26 is in an open position.
The sealing mechanism 26 can move between open and closed positions for opening and closing the bowl outlet 16. The sealing mechanism 26 includes a blade 28, and it has a downwardly opening socket 30, FIG. 10, located centrally of the blade 28 and a beveled edge 32 around the periphery of the blade 28. The sealing mechanism also includes a crank arm 34 that has a shaft portion 36 providing an essentially vertical axis about which the crank arm 34 can pivot. The crank arm 34 also has a finger 40 at its radially outer end for supporting the blade 28 surrounded by a collar 42 which extends into the socket 30. As best seen in FIG. 10, a secondary spring means 44, comprising a secondary coil spring 46 and a sleeve 48 for driving the blade horizontally between its open and closed positions, is seated on and integrally attached to the collar 42. In the illustrated position wherein the blade 28 is in its open position, the blade 28 is lifted off the finger 40 by the spring 46, and the latter is exerting a pressure of a relatively low magnitude against the blade 28. As will be explained hereafter, when the blade 28 is in its closed position shown in FIG. 1, the crank arm 34 will be in an elevated position causing the blade 28 to be seated on the finger 40, and a primary spring, to be described, will then exert upward pressure, through the crank arm 34 and thereby to the blade 28, of a higher magnitude.
Attention is direction next to FIG. 11 which shows the crank arm 34 when in the closed position of the blade 28. The shaft portion 36 is supported on the post 50 of the housing 20 and is guided for pivotal movement in the cylindrical bearing surface 52 of flange 18 which is integrally joined to housing 20. Primary spring means 54, comprising a coil spring capable of exerting greater spring forces than the secondary coil spring 46, is positioned between the post 50 and the shaft portion 36 to urge the crank arm 34 in an upward direction. Since the primary spring 54 has greater strength than the secondary spring 46, the primary spring 54 will overcome the secondary spring 46 causing the latter to collapse sufficiently so that blade 28 is seated on the finger 40 and the spring pressure of higher magnitude will then be imparted by the primary spring means 54 to the blade 28.
In a manner to be described hereafter, as an initial step in the flush cycle, the crank arm 34 is vertically or axially depressed to the position shown in FIG. 12. When this occurs, the primary spring means 54 is compressed, as shown, and the finger 40 and its collar 42 will be lowered an amount equal to the vertical movement of crank arm 34. By virtue of this action, the secondary spring means 44 will now become dominant and the blade 28 will be held in the elevated position shown in FIG. 10 because of the pressure of lower magnitude exerted by the secondary spring 46. Thus, when the primary spring means 54 is the dominant force acting on blade 28, a pressure of relative high magnitude is exerted and when secondary spring means 44 is the dominant force acting on blade 28, a pressure of lower magnitude is exerted on blade 28.
Also constituting a part of the sealing mechanism 26 is a seal member 56 that is mounted in a sealing relationship to the bottom of the bowl 12 around the outlet 14. The seal member 56 is an elastomeric sleeve which projects below the lower edge of the outlet 14 so as to provide an elastic curtain or a projecting portion 58 below the lower edge of the flange in a similar manner that is disclosed in the aforesaid U.S. Pat. No. 4,032,996. In its condition shown in FIG. 10, when the blade 28 has been moved to its open position, the projecting portion 58 provides an inward tapered lower edge. When the sealing mechanism 26 is in the closed position shown in FIGS. 1 and 11, the blade 28 will be urged upward against the projecting portion 58 of seal member 56 at the pressure of higher magnitude exerted by primary spring means 54, and when the actuating means, to be described, has caused the crank arm 34 to be axially displaced so that the secondary spring means 44 becomes the dominant spring force, the blade will be urged upward against the seal member 56 at the pressure of lower magnitude to the extent shown in FIG. 12. Now when the actuating means is further actuated, as will be described, the blade 28 will move horizontally in a plane that would contain the projecting portion 58 in a relatively lower stress condition. The upward pressure of lower magnitude assures uniform operation and proper wiping action at a preset pressure. It also assures proper maintenance of the blade on track means to one side of the outlet 14.
The seal member 56 is enclosed around its outer periphery by a collar 60 that is snap-fitted onto the bowl 12 around the outlet 14. An enclosure 62 is connected to one side of the collar 60 and projects horizontally outwardly therefrom. The enclosure 62 is open at the bottom to provide bottom edges 64 that serve as rails on which the blade 28 is adapted to travel when it has been moved out of its closed position to its open position shown in FIG. 10. During this travel of blade 28 and while at its open position the secondary spring means 44 will continue to exert the aforesaid pressure of lower magnitude against the rails or edges 64.
Attention is next directed to FIGS. 6-9 and 11, 12 and 17 for a description of the actuating means 66 for moving the sealing mechanism 26 to its open and closed positions. A pivot or post 68 is mounted on the flange 18 and secured in place by the screw 70. Mounted on the post 68 for pivotal movement with respect thereto are the lower flush lever 72 and the upper water lever 74. The flush lever 72 has a finger catch 76 that extends upward and over the water lever 74 so that when the user engages the finger catch 76 and pivots it clockwise, both levers will be moved together. Similarly, when the finger catch 76 is released, a torsion spring 78, FIG. 6, will return the water lever 74 to its original position FIG. 7, and because of the overlapping of the finger catch 76, the flush lever will also be returned to the FIG. 7 position. The torsion spring 78 has its one end secured to the water lever 74 by the clip arrangement 80 and its other end is in engagement with the abutment 82 in the flange 84 that is integrally connected to housing 20.
The flush lever 72 is operatively associated with the crank arm 34 to impart the various movements required. For this purpose, the upper end of the shaft portion 36 of crank arm 34 has a cam follower 86, FIG. 17, and a small crank arm 88. The small crank arm 88 has a follower head 90 at its end for traveling in the slot 92 in flush lever 72. The slot 92 is shaped so that when the flush lever 72 is moved clockwise from the position in FIG. 7 to the position in FIG. 8, the small crank arm 88 will not change its radial position, but the cam follower 86 of shaft portion 36 will be engaged by the cam 94 that is located on the underside of flush lever 72 to move the crank arm 34 downward against first spring means 54 so that the lower pressure is applied to the seal member 56, as shown in the FIG. 12 position.
Now when the flush lever 72 is advanced further in a clockwise direction, the follower head 90 will continue to travel in slot 92 from the FIG. 8 position to the FIG. 9 position causing crank arm 34 to be pivoted from the closed position to the open position of FIG. 9 and 10.
When the flush lever 72 is released, the lever 72 will be returned to its position of FIG. 7 by operation of torsion spring 78, as was previously described. When this occurs the crank arm 34 will be moved in a reverse order of that described when the flush lever 72 was manually actuated in a clockwise direction.
Flush means 94 are provided for discharging flush water into the bowl 12 during the flush cycle, including the nozzle 96 for directing the water into the bowl; a control valve 98, FIG. 13, for controlling flow of water from an external source that will be connected to the inlet fitting 100; a water reservoir 102, FIG. 5, into which the control valve 98 directly discharges; and a flush tube 104 that is connected to the outlet of the reservoir 102 and to the nozzle 96.
The water lever 74, previously described, has one end of a linkage 106 connected to it, as shown in FIG. 3, and the other end of the linkage 106 is connected to a crank 108 so that when the water lever 74 is pivoted either with flush lever 72 or indpendently thereof, movement in a clockwise direction will cause crank 108 to pivot causing ball valve element 110 to rotate about its axis to an open position, allowing water to flow from the source of supply through the fitting 100, the flow control seal 112, through the conventional vacuum breaker 114 to passageway 116 and into the water reservoir 102 at its inlet 118.
The water reservoir is a closed compartment except for the inlet at 118 and an outlet through riser tube 120. As seen best in FIGS. 4, 14, and 15, the riser tube 120 extends through bottom wall 122 of reservoir 102 to a preselected elevation so that when water enters the reservoir 102, the reservoir will be charged with water until the level rises above the opening in the top of riser tube 120 at which time water will be discharged rapidly through the riser tube 120 and into flush tube 124, and from there to nozzle 96.
The riser tube 120 has a groove 126 therein which opens at the bottom to the small orifice 128. After the control valve 98 is closed and the level of the water is at or below the upper end, the remaining water in the reservoir can flow at a slow rate to the nozzle 96. Since the blade 28 will be in its closed position when the control valve 98 is closed, the water that is discharged from reservoir 102 through the orifice 128 will now collect in the bowl 12 to provide a pool therein of a desired depth.
The nozzle 96 is mounted in the bowl 12 to direct a jet of water into the bowl 12 for flow in a vortex pattern. The nozzle 96 has a small aperture 130 therein to allow small quantities of water to descend during flushing into the overflow drain outlet 132 so as to maintain water in the overflow tube 134. The tube is supported adjacent to its midportion by a hook 136, which is molded in the bowl 12; so as to provide a water trap to prevent odors, gases, and the like escaping from the regions below the bowl 12 through the overflow tube 134. The latter has its lower end terminating in the enclosure 62 so that limited quantities of water that flow through the overflow tube 134 can drop onto the blade 28 while the latter is in its open position. A unique feature is the utilization of a check valve 138 at the lower end to prevent the water seal from being broken by back flow or pressure surges that may occur within housing 20.
Another feature of the flush means is the improved control valve which has a valve body 140 with a water inlet end and the tubular fitting 100 has its upper end mounted in the water inlet end in a retained relationship for free rotation about its axis. The fitting has in its midportion an external wrench head 142, preferably hexagonal-shaped to receive a conventional end wrench, said head 142 being adapted to be gripped by the jaws of the wrench. The lower or other end of the fitting 100 is externally threaded at 144 for receiving a fitting associated with a water supply duct (not shown).
The water inlet fitting 100 includes the fitting retainer 146 which snaps into the valve body 140 and is secured by the two barbed fingers 148 that engage the valve body 140 in the slots 150, and disallow rotary and axial movement of the fitting retainer within the valve body.
The water inlet fitting 100 is axially secured in the fitting retainer 146 by means of a continuous barbed radial flange 152 which has an outside diameter slightly larger than the inside diameter of the retainer ledge 154 allowing the barbed radial flange to pass through the ledge during insertion as the semi-flexible retainer ledge material expands slightly but preventing reverse movement. The water inlet fitting is further sealed to the valve body 140 by engaging the seal 112. Thus, the water inlet fitting 100 is free to rotate while maintaining a sealing condition with the valve body 140 so that the valve body 140 is protected from breakage which could result from over-tightening of a water supply fitting (not shown) without corresponding counter-torque being applied to the water inlet fitting 100. Removal of the fitting retainer 146, and thus the fitting from the valve body 140 can be accomplished by radially depressing the two barbed fingers 148 until they are disengaged from the slots 150 in the valve body 140. | Toilet apparatus that has a plurality of improved features including: a sealing mechanism for closing the bottom opening of a toilet bowl so that the effectiveness of the seal is maintained over extended periods of time, a flushing circuit that has a water reservoir that assures proper depth is achieved in the pool of water that is formed after the sealing mechanism is closed, an over flow tube which assures that the water seal therein is maintained, and a control valve which has an inlet fitting that assures that damage to the valve or related parts does not occur during installation of the toilet apparatus. |
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BACKGROUND OF THE INVENTION
A. Field of the Invention
This present invention relates generally to a window frame assembly for a garage door and, more specifically, to such a window frame assembly that is able to withstand high winds and flying objects and to a method of installation for such a window frame assembly.
B. Description of the Prior Art
Modern garage door systems are typically comprised of doors having horizontally arrayed sections joined by hinges into a door unit. The door is mounted in a vertical track which curves upwardly into a horizontal position so that the door may be opened upwardly and supported horizontally in an open position. The sections are joined by the hinges along the longitudinal edges of the sections so that the overall door structure will generally conform to the radius of curvature of the track as it changes from vertical to horizontal. Customarily, each of the sections are fabricated separately and thereafter hinged together along a longitudinal edge to provide the complete overhead door structure. Historically, the sections are fabricated from a galvanized and/or prepainted sheet metal stock which has been rolled or otherwise formed into the particular section facing, web and parallel interior flange configurations. Vertical stiles are usually secured to the section facing and interior flanges at spaced locations by spotweld or rivet techniques. Most prior art overhead door systems use hinges that are secured directly to the section stiles. While a majority of garage doors continue to be manufactured from mild steel stock, some manufacturers offer overhead doors made from synthetic materials such as from various types of vinyl.
Particularly in the area of residential garage doors, a number of manufacturers offer plastic or metal window frame assemblies which are fitted within openings provided in the garage door and which typically feature a central opening which contains a transparent pane which may be of glass, plastic or such newer materials as acrylics and polycarbonates. The central opening in the window frame assembly may also contain a decorative trim member which is sandwiched between the transparent pane and other framing components.
While the prior art window frame assemblies of this type are acceptable in many situations, there exists a special need for window frame assemblies which are more capable of withstanding high winds and flying debris in some areas of the country, for example where hurricanes or tornadoes may occur more frequently. Local construction codes include wind tests that often require reinforcements of these window frame assemblies and many times these added structures detract from the aesthetics of the window design. They also add to the cost of the window frames and add to the complexity of the window frame installation.
Thus, despite the advantages offered by the prior art window frame constructions known in the art, there continues to exist a need for improvements in the area of garage door window frame construction and installation techniques.
A particular need exists for improvements in such window frame designs intended for use in high wind situations where flying debris and other hazards may exist.
SUMMARY OF THE INVENTION
It is one of the main objects of the present invention to provide a window assembly for garage door panels that is capable of withstanding high winds and flying objects by, in part, absorbing and distributing any impact energy into the frame assembly itself.
It is a further object of the present invention to provide a window frame assembly for an overhead garage door which provides a decorative and aesthetically pleasing appearance, while securely supporting the various window frame components of the overall assembly.
It is a further object to provide a versatile window frame assembly that can accommodate various other trim components that may abut the frame components.
Another object of the invention is to provide a garage door window frame design which ensures that the assembled frame will more nearly provide even pressure on all four sides of the transparent pane which is contained within the window opening provided in the window frame. Likewise, the preferred frame construction will ensure that constant and even pressure are maintained on the garage door panel by the assembled frame, making sure the exterior frame member maintains contact with the outside of the garage door panel around the full perimeter of the frame.
It is still another object of the present invention to provide a window assembly for garage door panels that is easy to install and which is relatively inexpensive to manufacture and maintain while retaining its effectiveness in high wind prone areas of the country.
It has been found that prior art window frame assemblies are typically prone to breakage in the presence of flying debris in that impact energy exposes the frame components to stress and shear forces that can cause them to break. The present invention absorbs impact energy created, for example, from flying debris produced by high winds, and more effectively distributes this energy so as to avoid damage to the window pane or to the surrounding garage door panel. By protecting the transparent panel, the improved frame assembly prevents any wind or objects from coming inside the protected interior of the garage.
In one preferred form, the present invention provides an improved garage door and window frame assembly for an overhead garage door having front and rear exposed surfaces separated by a door thickness, and at least one window opening therein. A front and rear frame members cooperate, upon assembly, to securely grip a transparent pane sandwiched there between. The front window frame member has a periphery sized to circumscribe the window opening from the front exposed surface of the door. The front frame member also has an inner peripheral portion which circumscribes the transparent pane once the pane is installed in the assembly.
The rear frame member also circumscribes the window opening from the rear exposed surface of the door. The rear frame member has an inner peripheral region which forms a plurality of honeycomb regions upon assembly of the front and rear frame members. The inner peripheral region of the rear frame member has a circumferential rib provided thereon which is received within a mating groove provided about an outer periphery of the transparent pane on an interior side thereof. In this way, impact forces transmitted to the transparent pane are absorbed in the honeycomb regions of the assembled frame while the cooperating rib and groove arrangement securely grips the transparent pane between the front and rear frame members.
The present invention, described in more detail in the written description which follows, this provides a simple window assembly design which includes frame members that can be readily installed around the edges of the aperture defining the window opening of a garage door. The claimed window assembly includes a transparent panel with a peripheral groove that cooperatively receives the edge of a mating frame member. The assembly is thus capable of retaining the transparent panel while absorbing the impact energy of high winds and flying objects.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is partial perspective view of a garage door having window frame assemblies of the invention installed therein.
FIG. 2 is an exploded view of a window frame assembly of the invention showing the front and rear frame members with a transparent pane located there between.
FIG. 3 is a perspective view of the frame of the invention with the front and rear frame members shown being assembled together.
FIG. 4 is a cross-sectional view taken along lines 4 - 4 in FIG. 3 .
FIG. 5 is a perspective view of the isolated, assembled window frame illustrating, in simplified fashion, how the impact forces of a wind borne object are distributed by the frame.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the invention presented in the following written description and the various features and advantageous details thereof are explained more fully with reference to the non-limiting examples included in the accompanying drawings and detailed in the description which follows. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the principle features of the invention as described herein. The examples used in the description which follows are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.
As discussed briefly above, commercially available garage doors used at the present time are typically assembled from a series of door sections aligned horizontally in an edge-to-edge configuration to form a vertically oriented door for the garage opening. The sections are hinged together as a series along their abutting, horizontal edges to allow the garage door to be raised upwardly in a track to an overhead, horizontal position. The track includes a curved section between the vertical and the overhead positions. The hinged sections allow the garage door to traverse this curved section during the transition of the garage door from the vertical to the overhead, horizontal position.
In many of the presently available garage door systems, a series of plain or decorative windows are incorporated the garage door, typically within an upper section of the garage door. These windows are formed in individual panels of the upper section and provide daylight illumination of the closed garage and can provide a decorative appearance, as well. A window opening is formed in each panel. Applicant's FIG. 1 shows a typical garage door 13 having window assemblies 15 installed into openings provided in a top section thereof. The garage door illustrated in FIG. 1 is shown in a simplified, stylized form for ease of illustration. Those skilled in the art will understand that such doors are typically provided, for example with a decorative surface treatment which is designed to mimic conventional wood panels while structurally imparting a certain degree of dimensional stability to garage door section. In many cases, a decorative overlay or “trim” (not shown) is mounted in the exterior frame of the window frame assembly.
The present invention is concerned with further improvements and refinements in garage window frame design which designs are particularly suited for use in high wind prone area, for example, in South Florida. The combination garage door and improved window frame assembly of the invention will now be described with respect to FIGS. 1-4 of the drawings. As previously mentioned, FIG. 1 shows a typical residential garage door which includes the metal overhead garage door 13 having front and rear exposed surfaces 17 , 19 ( FIGS. 1 and 6 ) and at least one window opening (shown generally at 21 in FIG. 6 ) therein.
As shown in FIG. 2 , a front window frame member 23 is formed of a suitable material such as a lightweight metal, or from a suitable synthetic, polymeric material. Preferably, the frame member 23 is formed of metal. The frame member 23 has a periphery 25 which is sized to circumscribe the window opening 21 from the front exposed surface 17 of the door 13 . The member 23 also has a windowpane opening 26 for receiving a transparent pane 27 . The transparent pane will conveniently be formed of glass, plastic or acrylic or other suitable synthetic material, such as a suitable polycarbonate material. Preferably, for this intended application, the pane 27 will be a high strength plastic, acrylic, or polycarbonate material, with the polycarbonate material being preferred.
A rear window frame member 29 is also formed of metal and has a periphery 31 which is sized to circumscribe the window opening 21 from the rear exposed surface 19 of the door 13 . As will be appreciated from FIG. 3 , the front and rear window frame members 23 , 29 , fit together in mating fashion to form a continuous channel region ( 35 in FIG. 3 ) which circumscribes the window opening and the outer edges of the transparent pane 27 . The channel region 35 forms a generally rectangular trough which is sized to receive the thickness of the particular garage door panel which contains the window opening, the frame members “sandwiching” the door panel in between the members upon assembly in the window opening. By varying the width of the rectangular “trough” 35 , garage doors of varying thicknesses can be accommodated.
It will be appreciated that, during assembly of a window frame of the type described within a garage door, the previously described window frame members are placed in the frame opening with a transparent pane sandwiched in between. While the figure illustrations show only a single transparent pane installed within the window frame assembly, it will be understood that a decorative trim insert could be installed, for example, in front of the pane 27 within the frame assembly. Such decorative trim assemblies are commercially available and known in the prior art. For example, such “Design Trim” is commercially available from National Door Industries, Inc. of Fort Worth, Tex.
Turning now to FIG. 4 , there is shown a cross-sectional view of the window frame assembly of the invention, as taken along lines 4 - 4 in FIG. 3 of the drawings. FIG. 4 shows the cross-section of the door 13 which is sandwiched between the front frame member 17 and the rear frame member 19 . The front frame member 17 has an inner peripheral portion 37 which circumscribes the transparent pane 27 once the pane is installed in the assembly. The innermost region of the peripheral portion 37 comprises a flange region which overlays an outer periphery of the transparent pane 27 . An internal wall 39 extends perpendicularly from the innermost region of the portion 37 generally perpendicular thereto, and creates a right-angled cavity in the interior of the frame assembly. The internal wall 39 also forms one side of an internal baffle or cavity 41 . More importantly, the right angled cavity which is formed by the internal wall 39 and outer peripheral wall 37 form a positive stop region for the outer periphery of the transparent pane 27 , holding it securely in position.
With reference now to the rear frame member 19 of the window frame assembly shown in FIG. 4 , this member of the assembly also has an inner peripheral portion which depends downwardly form the region (shown as 19 in FIG. 4 ) surrounding the door panel. This inner peripheral region forms a plurality of honeycomb regions (shown as 42 , 43 and 45 in FIG. 4 ) when viewed in cross-section. The lowermost honeycomb region, as viewed in FIG. 4 , has an outer circumferential rib 49 which is received within a mating recess or groove 51 provided about the outer periphery of the transparent pane 27 on the interior surface thereof. The groove 51 completely circumscribes the outer periphery of the transparent pane 27 . With the internal wall 39 of the front frame member 17 coincident with and fully contacting the interior wall portion 53 of the honeycomb region 42 of the rear frame member, and with the circumferential rib 49 engaged in the circumferential groove 51 , the pane is securely retained in the frame assembly.
To further secure the assembly, a series of holes (such as hole 55 in FIG. 3 ) can be provided on the interior of the rear frame member 19 . The holes 55 can be aligned with mating openings or screw bosses or other receiving structures provided on the front frame member, whereby screws can be installed into the receiving structures provided on the front frame member. The thus installed screws, in conjunction with the engagement of the front and rear frame members and transparent pane previously described, make the assembly a much stronger and more durable frame package.
FIG. 5 is intended to represent, in simplified fashion, the distribution of forces which occurs when an object, such as flying debris, strikes the transparent pane 27 . Because of the fact that the outer circumferential rib 49 of the rear frame member is received within the mating groove 51 provided about the outer periphery of the transparent pane 27 , forces that are directly perpendicularly toward the surface of the pane are captured by the assembled frame members. The rib and cooperating groove arrangement, in effect, provides a “wind lock” which captures the polycarbonate pane and keeps it from being blown through the door window opening, even in high wind conditions. Note that the edges of the transparent pane ( 27 in FIG. 4 ) do not overlap the door panel 13 , as in some prior art designs. As a result, the load from flying debris is not distributed over the exterior of the door panel 13 , as in certain of the prior designs. Rather, the load is largely absorbed by the honeycomb structures ( 42 , 43 and 45 in FIG. 4 ) of the front and rear frame members as the transparent pane 27 itself is securely gripped by the rib and groove arrangement of the cooperating frame members.
An invention has been provided with several advantages. The garage door window frame assembly of the invention is simple in design and economical to manufacture using frame members which can be fabricated from a variety of conveniently available materials. The front and rear frame members and associated transparent pane are provided with mating engagement means in the form of a cooperating rib and groove type mechanism which securely grips the transparent pane once the frame assembly is installed in the door window opening. The rib and groove feature of the assembled frame prevents the transparent pane from blowing through into the interior of the structure, even if struck by flying debris of the type commonly encountered in high wind and hurricane conditions.
While the invention has been shown in one of its forms, it is not thus limited and is susceptible to various changes and modifications without departing from the spirit thereof. | A window frame assembly for installation within a garage door having front and rear exposed surfaces and one or more window openings. The assembly includes front and rear window frame members which are installed within the door opening on the front and rear exposed surfaces. The front and rear members are brought toward each other to sandwich the borders of the door panel defining the window opening and while also capturing an associated transparent pane. The rear frame member has a rib formed about an inner peripheral edge which is received in locking engagement within a cooperating peripheral groove provided on an inner side of the transparent panel. The rib and groove locking arrangement transfers impact forces on the pane to deformation forces on the front and rear frame members. A series of fastening members are used to hold the front and rear frame members securely against each other. |
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BACKGROUND OF THE INVENTION
The invention is in the field of rock boring machines, and more specifically such machines for reaming substantially vertical holes, or holes at a slight angle from true vertical, by initiating rock boring at ground level and boring a predetermined distance underground. No known down reaming apparatus is capable of boring substantially larger holes (preferably having a diameter of at least four meters) in a substantially continuous manner.
U.S. Pat. No. 3,965,995 issued to Sugden discloses a machine for boring a large diameter blind hole in a sequential, non-continuous manner. The cutterwheel is mounted at the lower end of the machine for rotation about a horizontal tubular support. A gripper assembly secures the machine against the tunnel wall while thrust cylinders thrust the rotatable cutterhead downwardly. As the machine is advanced, the cutterwheel is rotated to make a first cut in the shape of the leading portion of the cutterwheel. The cutterwheel is then retracted out from the cut and is rotated about the axis of the hole. This repositions the cutterwheel so that when it is advanced again, during the next cutting step, it will make a second cut which crosses the first This procedure is repeated until the desired cross-sectional configuration (e.g. circular) of the hole is obtained The above described sequential boring method employing a gripper assembly and thrust cylinders has been found to be time consuming and requires a complex and expensive machine. U.S. Pat. No. 3,965,995 lists numerous prior art shaft forming machines, the disclosures of which are incorporated herein by reference.
U.S. Pat. No. 4,270,618 issued to Owens teaches an earth boring apparatus which is used for boring a blind pilot hole of a relatively small diameter which is subsequently enlarged by raise boring. Initially, the earth boring apparatus is employed to bore a blind pilot hole. Then the apparatus is removed from the hole and a room is blasted at the blind end of the hole. Next, the pilot hole cutterhead is replaced by a reamer and the apparatus is again inserted into the hole. The reamer is an adjustable diameter type and its diameter is increased once it is within the blasted room. The diameter of the reamer is increased by a plurality of cutter carrying arms which swing outwardly from the axis of rotation of the reamer. The earth boring apparatus is then raised from the room upwardly towards the ground surface to bore a hole of the desired diameter.
Similarly, U.S. Pat. No. 4,646,853 issued to Sugden et al. discloses a shaft boring machine having step-wise operation. The machine includes a cutterwheel assembly having a substantially horizontal axis of rotation and having multiple peripherally mounted roller cutter units. Motors are provided for rotating the cutterwheel assembly about its horizontal axis. A cutterwheel carriage and vertical guide columns support the cutterwheel assembly and allow movement of the cutterwheel assembly in a vertical plane. A base frame supports the vertical guide columns. The base frame is slewed in a substantially horizontal plane by a slew drive system. Plunge cylinders mounted on the cutterwheel carriage and the base frame lower and raise the cutterwheel assembly in a vertical plane. A lower gripper ring stabilizes the machine in the shaft and includes a circular track for supporting the base frame and further includes a lower gripper cylinder system for holding the gripper ring stationary in the shaft. An upper gripper ring provides further stabilization of the machine in the shaft and includes an upper gripper cylinder system for holding the upper gripper ring stationary in the shaft. Walking cylinders are mounted on the lower and upper gripper rings for raising and lowering the rings. U.S. Pat. No. 4,646,853 discloses additional prior art patents pertaining to shaft boring machines, the U.S. patent disclosures of which are incorporated herein by reference.
U.S. Pat. No. 4,270,618 issued to Owens cites prior art patents for drilling machines located at an upper level which bore a large diameter hole in a single downward pass, drilling machines at an upper level which first drill a small pilot hole on a single downward pass and then enlarge the pilot hole in a single upward pass, and machines having expandable reamers. These prior art patents are incorporated herein by reference.
U.S. Pat. No. 3,840,272 issued to Crane et al.; U.S. Pat. No. 3,999,616 issued to Crane et al.; U.S. Pat. No. 4,009,909 issued to Robbins et al.; and patents cited therein disclose machines for upward tunneling, as opposed to down reaming.
A need thus exists for a down reaming apparatus capable of boring a large diameter hole in a substantially continuous manner.
A need also exists for this type of down reaming apparatus which is stabilized in the bored shaft by means of non-gripping stabilizer assemblies having rotatable elements which allow vertical movement of the down reaming apparatus within the tunnel.
A need also exists for this type of down reaming apparatus in which a gear assembly is employed to multiply the torque transmitted from the drill string to the cutterhead.
A need also exists for this type of down reaming apparatus in which a weight assembly is secured on the frame of the down reaming apparatus such that loads from rotation of the cutterhead are transmitted through the frame and into the weight assembly.
A need also exists for this type of down reaming apparatus in which the weight stack has a manway therethrough for access by workers to the cutterhead for cutterhead repair and/or reconfiguration.
A need also exists for this type of down reaming apparatus of this type in which the cutterhead diameter can be increased by the addition of a single spacer having a cutter assembly thereon.
SUMMARY OF THE INVENTION
A down reaming apparatus attached to a drill string includes a frame and a rotatable cutterhead. Support for the down reaming apparatus in the tunnel is provided by an upper stabilizer and a lower stabilizer. The upper stabilizer includes an upper stabilizer hub circumferentially disposed around the drill string such that the drill string rotates relative to the upper stabilizer hub. A plurality of wheel assemblies are radially attached to the upper stabilizer hub. Each of the wheel assemblies has rotatable tires adapted to be oriented against the tunnel wall and a rotatable overload wheel which contacts the tunnel wall to stabilize the down reaming apparatus upon compression of the tires.
The lower stabilizer provides additional support for the down reaming apparatus and includes a lower stabilizer hub below the cutterhead such that the cutterhead rotates relative to the lower stabilizer hub. A plurality of wheel assemblies are radially attached to the lower stabilizer hub. Each of the wheel assemblies has a wheel support pivotally attached to the lower stabilizer hub and spaced therefrom by a compressible bumper. The rotatable wheel on the wheel support reacts against the tunnel wall to stabilize the down reaming apparatus.
The weight assembly, comprising a plurality of stacked plates, is secured to the frame of the rock boring apparatus by a plurality of tie rods such that loads from boring with the cutterhead are transmitted through the frame and into the weight assembly. Manways in the weight assembly allow passage of workers therethrough.
In the preferred embodiment of the present invention the upper stabilizer includes six wheel assemblies having removable extensions to accommodate tunnels of varied diameter. Each of the wheel assemblies is comprised of one overload wheel between two compressible tires. Additionally, a torque multiplier assembly is located in the stabilizer hub and includes a rotatable input shaft attached to the drill string. A sun gear meshes with the input shaft, planet gears mesh with the sun gear and are supported by a planet carrier and a ring gear meshes with the planet gears. A rotatable output shaft either meshes with the ring gear while the planet carrier is held stable, or meshes with the planet carrier while the ring gear is held stable, to produce a torque component greater than that of the input shaft.
Preferably, each of the plates of the weight assembly is comprised of a plurality of wedge shaped sections which are radially offset from the adjoining layer of plates. Additionally, the plurality of tie rods are secured through the weight plates by a top plate brace, a bottom plate brace, and jacks which apply a compressive force against the plates to brace them on the frame of the down reaming appartus.
Preferably, the cutterhead of the down reaming apparatus includes a cutterhead body and a plurality of arms radially disposed on the cutterhead body with cutter assemblies on each arm. Each arm is of a different length and the arms are oriented on the cutterhead body such that the lengths of the arms are successively decreased by the same amount from each arm to the next. A plurality of arm extenders having assemblies thereon are oriented in a first position in which each of the arm extenders is attached to one of the arms such that the combined length of each arm and the attached arm extender is substantially equal. To increase the diameter of the cutterhead, a spacer having a cutter assembly is attached to the shortest of the arms and each of the arm extenders is relocated from its first position to a second position on one of the arms that is adjacent to the arm on which the arm extender was attached in the first position. In this manner, the combined length of each of the arms and attached arm extender in the second position is substantially equal, and is greater than the combined length of each of the arms and attached arm extender in the first position, thus increasing the diameter of the cutterhead. To increase the diameter of the cutterhead further, an additional spacer, or spacers, in conjunction with additional relocation of the arm extenders to a position on an adjacent arm is employed. The cutterhead also includes a plurality of cutter assemblies repositionable on the cutterhead at a plurality of locations between the radially disposed arms to balance the cutterhead. Preferably, five radially disposed arms are located on the cutterhead.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will be evident when considered in light of the following specification and drawing in which:
FIG. 1 is a side elevational view, partially in section, of a down boring apparatus typifying the present invention;
FIG. 2 is an enlarged cross-sectional view of the upper stabilizer hub of the down boring apparatus of FIG. 1 taken along lines 2--2;
FIG. 3 is a cross-sectional view showing the upper stabilizer of the down boring apparatus of FIG. 1 taken along lines 3--3;
FIG. 4 is an enlarged view of the wheel assembly of the upper stabilizer of the down boring apparatus typifying the invention;
FIG. 5 is an enlarged cross-sectional view of the wheel assembly of the upper stabilizer of the down boring apparatus of FIG. 3 taken along lines 5--5;
FIG. 6 is a partially exposed top view of the upper stabiizer of the down boring apparatus typifying the present invention having a torque multiplier assembly;
FIG. 7 is a side elevational view, partially in section, of a first embodiment of the upper stabilizer of the down boring, apparatus of the present invention having a torque multiplier assembly with the planet carrier fixed.
FIG. 8 is a side elevational view, partially in section, of a second embodiment of the upper stabilizer of a down boring apparatus typifying the present invention having a torque multiplier assembly with the ring gear fixed.
FIG. 9 is a cross-sectional view of the weight clamp and of the down boring apparatus of FIG. 1 taken along lines 9--9;
FIG. 10 is a cross-sectional view of the weight plates of the down boring apparatus of FIG. 1 taken along lines 10--10;
FIG. 11 is a cross-sectional view of the spider, or lower weight plate support, of the down boring apparatus of FIG. 1 taken along lines 11--11;
FIG. 12 is an end view of the lower stabilizer of the down boring apparatus typifying the present invention;
FIG. 13 is an enlarged view, partially in section, of the wheel assembly of the lower stabilizer of the down boring apparatus typifying the present invention;
FIG. 14 is a cross-sectional view of the cutterhead of the down boring apparatus of FIG. 1 taken at lines 14--14 and showing a first cutterhead diameter;
FIG. 15 is a cross-sectional view of the cutterhead of the down boring apparatus of FIG. 1 taken at the same location as FIG. 14 and showing a second cutterhead diameter;
FIG. 16 is an enlarged top view of the spacer of the cutterhead of the down boring apparatus typifying the present invention;
FIG. 17 is an enlarged side view of the spacer of the cutterhead of the down boring apparatus typifying the present invention;
FIG. 18 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention having a first diameter;
FIG. 19 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a second larger diameter by the addition of a single spacer;
FIG. 20 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a third larger diameter by the addition of two spacers;
FIG. 21 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a fourth larger diameter by the addition of five spacers; and
FIG. 22 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a fifth larger diameter by the addition of four single spacers and the substitution of a double spacer for the fifth single spacer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention pertains to an apparatus for reaming, or boring, holes in rock. These holes are preferably substantially vertical holes but may also be oriented at a slight angle from true vertical. More particularly the present invention pertains to down reaming of relatively large holes through rock. The term down reaming pertains to the method of rock boring in which the reaming apparatus initiates rock boring downwardly, as opposed to raise boring in which the apparatus initiates boring a predetermined distance below ground level and is raised towards the earth's surface. The preferred system of down reaming employing the present invention contemplates first boring a relatively small hole (having a diameter of between about nine and fourteen inches) downwardly from the ground surface, or from an underground level, to a predetermined distance therebelow with an apparatus generally known in the art. Next, this initial down hole is expanded to a pilot hole (having a diameter of preferably between about two meters and four meters) by employing a raise boring apparatus known in the art. Finally, this pilot hole is expanded (preferably to a diameter of between about four meters and eight meters) by boring downwardly through this pilot hole from the ground surface to a predetermined location therebelow with a down reamer according to the present invention.
Referring to FIG. 1, such a down reamer 10 is secured to drill string 12 so that various elements of down reamer 10 as described herein rotate with drill string 12 while other elements of down reamer 10 are immobile relative to drill string 12. Drill string 12, which is rotated by a motor means known in the art, passes downwardly through upper stabilizer 14 and weight plates 16. Weight plates 16 are supported by spider 18, and the lower end of drill string 12, designated as stinger 20, passes into spider 18 and is fixedly secured in box insert 22 of spider 18. Torque tube 24 and spider support arms 26 are fixedly secured to the underside of spider 18 and to the upper portion of cutterhead 28. Lower stabilizer 30 is located directly under the central portion of cutterhead 28. As drill string 12 is rotated, upper stabilizer 14 and lower stabilizer 30, being braced against the wall of the bored hole, do not rotate with the drill string 12. Weight plates 16, spider 18, torque tube 24, spider support arms 26, and cutterhead 28 all rotate with drill string 12 in order to facilitate down reaming, with the boring of rock by cutterhead 28 augmented by the downward force applied thereon by the mass of weight plates 16.
Referring now to FIG. 2, the attachment of upper stabilizer 14 onto drill string 12, which allows relative rotation of drill string 12 and inner race 31 with respect to upper stabilizer 14, is now described in detail. Upper stabilizer hub 32 has stabilizer bearings 34 located at each end thereof. Stabilizer bearings 34 allow relative rotation of drill string 12 and inner race 31 with respect to upper stailizer 14. Upper stabilizer 14 is preferably divided into two halves which are joined around drill string 12 and connected by fastening means such as bolts or the like. The inner race 31 located adjacent the upper portion of upper stabilizer hub 32 has an annular seal 36 located therearound. Segmented clamp 38 is attached to drill string 12. Load isolator 40 is located between segmented clamp 38 and drill string 12.
Referring now to FIGS. 3 through 5, the upper stabilizer 14 is described in detail. Upper stabilizer 14 is comprised of a plurality, preferably six, stabilizer legs 42 radially secured to upper stailizer hub 32. Disposed over stabilizer legs 42 are support plates 44. Stabilizer legs 42 include wheel assembly 46 and, optionally, leg extensions 48 bracketed between wheel assemblies 46 and upper stabilizer hub 32. Leg extensions can be of numerous predetermined lengths in order to allow down boring of tunnels of various diameters.
Referring to FIGS. 4 and 5, wheel assemblies 46 are comprised of a pair of wheels 50, each of which includes a hub 52 and a tire 54 which is preferably filled with an elastomeric material such as polyurethane. Alternatively, wheel 50 may be a dulled roller cutter known in the art which is attached to a compressible bumper described below. Hub 52 is rotatable around strut 56. Axle 58 connects hub 52 to strut 56. Located between the two wheels 50 on axle 58 is overload wheel 60 which, like wheels 50, is rotatable on axle 58 relative to struts 56. Overload wheel 60 is preferably comprised of a metal alloy or other nondeformable material. Overload wheel 60 provides additional support for down reamer 10 during boring operations where excessive side forces are encountered which overcompress tires 54 of wheel assemblies 46, due to, for example, narrowing of the bored hole diameter. Thus, it is readily apparent that overload wheel 60 has a radius which is less than that of wheels 50 and the difference between these two radii is selected based upon the amount of compression of wheels 50 that is desired during boring operations. Rotation of wheels 50 and overload wheels 60 allow vertical movement of down reamer 10 during stabilization.
Referring now to FIGS. 6 through 8, two optional torque multiplying gearing assemblies 62 for upper stabilizer 14 are disclosed. These two torque multiplier gearing assemblies 62 are configured to be located within upper stabilizer hub 32. The torque multiplier assembly 62 increases the torque from drill string 12 to cutterhead 28, and reduces the rate of rotation of cutterhead 28 as compared to that of drill string 12. Torque multiplication is desired because, to bore relatively larger diameter holes efficiently, it is necessary to employ greater torque than drill string 12 can transmit without breaking.
Referring specifically to FIG. 6, torque multiplier assembly 62 includes planetary gearing comprising a sun gear 64 axially oriented in upper stabilizer hub 32. Planet gears 66 mesh with sun gears 64. Preferably three planet gears 66 are employed but more or less can also be used in order to obtain a desired amount of torque multiplication. Planet gears 66 mesh with ring gear 68 located adjacent the external periphery of upper stabilizer hub 32. Referring to FIG. 7 a first embodiment of torque multiplier assembly 62 is shown in which approximately a 2:1 ratio for example, of torque multiplication is achieved by employing a fixed planet carrier and output from the ring gear. Specifically, input shaft 70 is attached to drill string 12 and has input shaft seal 72 and input shaft bearings 74 located adjacent thereto. Sun gear 64 meshes with input shaft 70 by means of spline 76. As stated above, sun gear 64 also meshes with planet gears 66, which in turn mesh with ring gear 68. Planet gears 66 rotate on planet gear bearings 78 around planet gear shaft 80. Planet gears 66 are supported by planet carrier 82. As previously stated, planet carrier 82 is fixed in this embodiment. Planet gears 66 in turn mesh with ring gear 68, the output of which is transmitted to output shaft 84. Output shaft 84 is located adjacent the lower portion of upper stabilizer hub 32 and is rotatable by means of output shaft bearings 86. Output shaft seals 88 are located adjacent output shaft 84. In operation, rotation of drill string 12 causes rotation of input shaft 70, spline 76, sun gear 64, planet gear 66, ring gear 68 and output shaft 84.
Referring now to FIG. 8, a second embodiment of torque multiplier assembly 62 is disclosed in which a greater than 2:1 ratio of torque multiplication is obtained. The second embodiment of the torque multiplier assembly 62 of FIG. 8 is substantially identical to the first embodiment of the torque multiplier assembly 62 of FIG. 7 with the exception that in the second embodiment of the torque multiplier assembly 62 ring gear 68 is fixed and output is from planet carrier 82. Thus, in operation of the second embodiment of the torque multiplier assembly 62 of the present invention, rotation of drill string 12 causes corresponding rotation of input shaft 70, sun gear 64, planet gear 66, planet carrier 82, and output shaft 84.
In the above two embodiments of torque multiplier assembly 82, either the ring gear 68 or planet carrier 82 is fixed by the torque reaction applied by the frictional forces of the wheel assemblies 46 and stabilizer legs 42. If the frictional forces are deemed inadequate to react the torque from torque multiplier assembly 62, the above-mentioned dulled roller cutter can be employed as wheel 50 to cut into the rock to increase the torque reaction capabiities.
Referring now to FIGS. 9 through 11, weight assembly 90 of down reamer 10 is described in detail. Weight assembly 90 includes top weight clamp 92, positioned above a plurality of weight plates 16 and spider 18 oriented below weight plates 16. Spider 18 is also termable as a lower weight clamp. Referring to FIG. 9, upper weight clamp 92 includes weight clamp hub 94 oriented around drill string 12. A plurality of weight clamp arms 96 are radially disposed around weight clamp hub 94. Each of weight clamp arms 96 has a tie rod platform 98 on its end remote from weight clamp hub 94. Each tie rod platform 98 has one or more tie rod openings 100 therein.
Referring now to FIGS. 9 and 10, weight plates 16 of weight assembly 90 are described in detail. Each of weight plates 16 is comprised of a high mass material such as lead or a high mass metal alloy. Each weight plate 16 is preferaly comprised of a plurality of wedge shaped sections 102, which may be, for example, five in number. Wedge shaped sections 102 are radially disposed around opening 104 through which drill string 12 passes. Each of wedge shaped sections 102 has tie rod openings 106 therein which are adapted to be aligned with tie rod openings 100 of upper weight clamp 92. Additionally, one or more of wedge shaped sections 102 has a manway hole 108 therethrough. Manway hole 108 has rung 110 therein. Tie rod openings 106 and manway hole 108 are oriented in wedge shaped sections 102 of successive layers of stacked weight plates 16 such that tie rods can pass through the tie rod openings 102 in weight plates 16, and a manway is formed by the manway holes 108 of the stacked weight plates 16 such that an individual can pass therethrough to access cutterhead 28 for modification and/or maintenance thereof. Adjacent layers of weight plates 16 are preferably configured such that the wedge shaped sections 102 of each of the adjacent weight plates 16 are offset to maximize structure integrity of weigh assembly 90.
Now referring to FIG. 11, the spider 18, or lower weight clamp, of weight assembly 90 of down reamer 10 is described in detail. Spider 18 includes a spider hub 112 having a center portion in which stinger 20 of drill string 12 is securedly attached. A plurality of spider arms 114, preferably five in number, are radially disposed on spider hub 112. Each spider arm 114 has tie rod openings 116 passing therethrough. Tie rod openings 116 are oriented on each of spider arms 114 such that tie rod openings 116 are aligned with tie rod openings 106 of weight plates 116 and tie rod openings 100 of upper weight clamp 92 such that tie rods 118 pass through tie rod openings 100, 106, and 116. As shown in FIG. 1, tie rods 118 are secured through upper weight clamp 92, weight plates 16, and spider 18 of weight assembly 90 by jack 120. Thus, tie rods 118 secure weight plates 16 with upper weight clamp 92 and spider 18 of weight assembly 90 such that loads from rotation of cutterhead 28 are transmitted into weight assembly 90 as opposed to into stinger 20 of drill string 12. More specifically, rotation of drill string 12 results in rotation of upper weight clamp 92, weight plate 16 and spider 18 of weight assembly 90, as well as rotation of torque tube 24 and spider support arms 26 located between spider 18 and cutterhead 28, and also rotation of cutterhead 28. Thus, over-turning loads encountered by cutterhead 28 during boring pass from cutterhead 28 through torque tube 24 and spider support arms 26, and into weight assembly 90 and upper stabilizer 14 where the relatively larger diameter of weight plates 16, as compared to that of drill string 12, results in a greater section modulus which allows weight assembly 90 to withstand greater over-turning loads than drill string 12.
Referring now to FIGS. 12 and 13, the lower stabilizer 30 of the down reamer 10 is described in detail. Lower stabilizer 30 includes a lower stabilizer hub 122 comprised of an inner race 124 fixedly secured to rotatable cutterhead 28 and an outer race 126 rotatably attached to inner race 124 by bearings 128. A plurality of wheel assemblies 130 are radially secured to outer race 126. Preferably five wheel assemblies 130 are present. Attachment of wheel assemblies 130 to outer race 126 is by means of pin 132, which is fixedly secured to outer race 126, and pivot sleeve 134 located over pin 132 which is rotatable therearound. Wheel arm 136 is attached to pivot sleeve 134 and is also supported on outer race 126 by a compressible bumper 138. Wheel arm 136 holds wheel mount 142 in which is located rotatable wheel 144.
In operation, as cutterhead 128 rotates, inner race 124 of lower stabilizer 30 rotates as well. However, outer race 126, and wheel assemblies 130 do not rotate with cutterhead 28. Rotatable wheels 144 contact the tunnel wall to provide stabilization for down reamer 10. As compressive forces are encountered by lower stabilizer 30 due, for example, to narrowing of the bored hole diameter, wheel arm 136 pivots on pivot sleeve 134 around pin 132 to stabilize down reamer 10. The length of the pivot stroke of wheel arm 136 is dictated by the degree of compressibility of bumper 138. Rotatable wheels 144 allow vertical movement of down reamer 10 while stabilization is provided by lower stabilizer 30. Rotatable wheels 144 can be, for example, dulled roller cutters known in the art, or, alternatively compressible tires with or without the above described overload wheels.
Referring to FIGS. 14 through 17, cutterhead 28 of down reamer 10 is described in detail. Cutterhead 28 includes a cutterhead body 146 and the plurality of arms 148 radially disposed around cutterhead body 146. Each of arms 148 has attached thereto an arm extender 150. Each arm 148 and arm extender 150 have one or more cutter assemblies 152 secured thereon. Cutter assemblies 152 can include disc cutters or gauge cutters generally known in the art. Cutterhead assemblies 152 are preferably removable from the upper portion of the cutterhead 28 by means of manway holes 108 of weight assembly 90, or adjacent the exterior of down reamer 10. Spacer 154 is adapted to be attached between arm 148 and arm extender 150 to increase the diameter of the cutterhead, as further detailed below. Braces 153 attached adjacent arm extenders 150 and secured thereto are additional cutter assemblies 152 which "float". By "float" it is meant that cutter assemblies 152 can be configured at various locations on any of braces 153. The locations of floating cutter assemblies 152 are varied to load balance the cutterhead when the cutter diameter is increased. More specifically, the forces and moments of each cutter assembly 152, either floating or not, are summed to balance the cutterhead 28. The factors considered in ascertaining the forces and moments of each cutter assembly 152 include the hardness and fracture toughness of the rock being bored.
As shown in FIGS. 16 and 17, spacer 154 includes cutter assembly 156 preferably having a disc cutter 158 known in the art. Spacer 154 is fixedly secured between arm 148 and ar extender 150 by means of bolts 160 or the like.
Referring now to FIGS. 18 and 19, the use of spacers 154 to increase the diameter of cutterhead 28 is further described. Referring specifically to FIG. 18, cutterhead 28 having a first, initial diameter is comprised of a plurality of arms 148. As shown in FIG. 18, five arms 148 are designated therein as 148A, 148B, 148C, 148D, and 148E. However it is to be understood that more or less than five arms 148 may be employed. Each of arms 148A through 148E has a different length, and the length difference between any two adjoining arms 148A through 148E is equal. More specifically, arm 148A has the shortest length of all of arms 148A through 148E. Arm 148E has the greatest length of all arms 148A through 148E. Additionally, the length of arms 148E through 148A preferably decreases in a radial direction around cutterhead 28 such that, as shown in FIG. 18, arm 148D is shorter than arm 148E, arm 148C is shorter than arm 148D, arm 148B is shorter than arm 148C, and, finally, arm 148A is shorter than arm 148B. As stated above, the length difference between any two adjoining arms is the same. An arm extender 150 is attached to each of arms 148A through 148E. Each arm extender is designated as 150A, 150B, 150C, 150D, and 150E based on which of respective arms 148A through 148E the arm extender is attached. Thus, for example, arm extender 150A is attached to arm 148A in FIG. 18. Each of arm extenders 150A through 150E has a length such that the combined length of each of arms 148A through 148E and its attached arm extender 150A through 150E are substantially equal.
Now referring to FIG. 19, the diameter of cutterhead 28 has there been increased from the diameter shown in FIG. 18. Increasing the diameter of the cutterhead 28 is accomplished by the attachment of spacer 154A to arm 148A as shown in FIG. 19. Preferably spacer 154A is attached to the shortest of arms 148A through 148E of cutterhead 28. Next, arm extenders 150A through 150E are reconfigured on arms 148A through 148E by removing each arm extender 150A through 150E from the arm 148A through 148E to which it is attached and reattaching each arm extender 150A through 150E to an arm 148A through 148E adjacent to the arm 148A through 148E to which that particular arm extender 150A through 150E was previously attached. Thus, as shown in FIG. 19, each of arm extenders 150A through 150E has been rotated one position in the counterclockwise direction so that arm extender 150A is now attached to arm 148B, arm extender 150B is attached to arm 148C, arm extender 150C is attached to arm 148D, arm extender 150D is attached to arm 148E and arm extender 150E is attached to spacer 154A which is secured to arm 148A. Thus, the repositioning of arm extenders 150A through 150E on arms 148A through 148E, and the addition of spacer 154A, results in a new, greater length that is substantially equal for each arm and attached, repositioned arm extender. By "substantially equal length" it is meant that upon addition of spacer 154A, arms 148A through 148E and attached arm extenders 150A through 150E have lengths which maintain the desired cutterhead profile (i.e. the relative relationship of the various cutter assemblies 152 on cutterhead 28). Preferably, in order to achieve the desired increase in diameter of cutterhead 28, the above-mentioned difference in length between any two adjacent arms 148A through 148E, multiplied by the number of arms 148A through 148E will be substantially equal to the length of the spacer 154 added to cutterhead 28. In other words, if five arms 148A through 148E are present, the difference in length between any two adjacent arms 148A through 148E will equal one-fifth of the length of spacer 154. Thus, the increase in diameter of cutterhead 28 is equal to the length of spacer 154 divided by the number of arms 148A through 148E. If five arms 148A through 148E are present, the increase in diameter of cutterhead 28 will therefore be equal to one-fifth of the length of spacer 154.
FIG. 20 shows an increase in the diameter of cutterhead 28 over the diameter shown in FIG. 19 by the addition of yet another spacer 154. In FIG. 20, spacer 154B has been attached to arm 148B and all of arm extenders 150A through 150E have been rotated an additional position in the counterclockwise direction so that arm extender 150A is now attached to arm 148C, arm extender 150B is attached to arm 148D, arm extender 150C is attached to arm 148E, arm extender 150D is attached to spacer 154A which is secured to arm 148A, and arm extender 150E is attached to newly added spacer 154B which is secured to arm 148B. Note that newly added spacer 154B has been added to the next shortest arm, namely 148B. It is readily apparent that the diameter of cutterhead 28 can be repeatedly, incrementally increased by the further addition of spacers 154 so that a cutterhead 28 having a diameter as shown in FIG. 21 can be obtained.
In FIG. 21, five spacers, 154A through 154E have been added to the five arms 148A through 148E, respectively. During each incremental spacer addition, arm extenders 150A through 150E were rotated one position in the counterclockwise direction and attached to the adjacent arm 148A through 148E.
FIG. 22 shows a cutterhead 28 having a diameter greater than the diameter shown in FIG. 21 in which five spacers 154A through 154E were added. In FIG. 22, spacer 154A has been removed and spacer 154A' has been added. Spacer 154A' has a length greater than that of spacer 154A, and preferably includes an additional cutter assembly thereon. In addition to the substitution of spacer 154A' for spacer 154A on arm 148A, each of arm extenders 150A through 150E were rotated one position in the counterclockwise direction and attached to the adjacent arm 148A through 148E as previously described. It is readily apparent that the diameter of cutterhead 28 can be further increased from the diameter shown in FIG. 22 by the addition of even more spacers 154A' through 154E' having lengths greater than spacers 154A through 154E. Each of spacers 154A' through 154E' would be incrementally substituted for spacers 154A through 154E, respectively. Furthermore, spacers having a length greater than 154A' through 154E', and preferably having more than two cutter assemblies thereon, could subsequently be added to increase the diameter of cutterhead 28 even further.
While the above described use of spacers 154A through 154E and sequential repositioning of arm extenders 150A through 150E on arms 148A through 148E was made with reference to down reamer 10, it is readily apparent that a cutterhead 28 capable of this type of increase in diameter can be employed on any apparatus employing a rotatable cutterhead, such as a down reamer, a raise borer, a tunnel boring machine, a mobile mining machine, and any and all machines employed in mining tunneling and excavation operations.
It is also to be understood that while the arm extenders 150A through 150E have been described as being repositioned in a counterclockwise direction, arm extenders 150A through 150E may also be repositioned in a clockwise direction, or, alternatively, may be repositioned onto respective arm 148A through 148E which are not necessarily adjacent provided that said repositioning results in a length that is substantially equal for each arm and attached, repositioned arm extender.
The above described embodiments are intended to be descriptive, not restrictive. The full scope of the invention is described by the claims, and any and all equivalents are included. | A down remaining apparatus has an upper stabilizer which supports the down reaming apparatus in the bored hole. A plurality of wheel assemblies are radially attached to the hub of the upper stabilizer. Each of the wheel assemblies has rotatable tires oriented against the bored hole wall, and a rotatable overload wheel which contacts the tunnel wall upon compression of the tires. A weight assembly comprising a plurality of stacked plates is secured to the frame of the down reaming apparatus and has manways therethrough which allow passage of workers. A lower stabilizer provides additional support for the down reaming apparatus. A plurality of wheel assemblies are radially attached to the hub of the lower stabilizer. Each of the wheel assemblies has a rotatable wheel pivotally attached to the lower stabilizer hub and spaced therefrom by a compressible bumper which reacts against the bored hole wall to stabilize the down reaming apparatus. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/344,964, filed on Feb. 1, 2006, which is a continuation of U.S. patent application Ser. No. 10/801,123, filed Mar. 15, 2004, now U.S. Pat. No. 7,018,141 issued on Mar. 28, 2006, which is a continuation of U.S. patent application Ser. No. 09/918,693, filed on Jul. 30, 2001, now U.S. Pat. No. 6,715,964, which claims the benefit of U.S. Provisional Patent Application No. 60/221,594, filed Jul. 28, 2000. These applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an earth retaining system, and more particularly to a sheet pile retaining system having integral soil anchors.
2. Description of the Related Art
Marine related bulkheads constructed along the coast of Alaska experience some of the most severe environmental conditions known, including high waves and wave scour, earthquakes, ice, high tide variations, high phreatic water levels, weak soils, heavy live loads and difficult construction conditions. The need for low-cost, high load capacity docks and structures has resulted in a development of various sheet pile retaining structures.
Flat steel sheet piles have been used in perhaps the most simple form of structures featuring tension or membrane action primarily. Foundation designs of cellular cofferdams are discussed in detail in the text by Joseph E. Bowles, Foundation Analysis and Design (1977) herein incorporated in its entirety by reference. One configuration, a closed cell flat sheet pile structure, had been successfully used for many years for a wide variety of structures including cofferdams and docks. As shown in FIG. 1A , the most common use for flat sheet piles has been in closed cellular bulkhead structures of various geometrical arrangements. FIG. 1B illustrates another configuration, a diaphragm cell structure. By closing the cell structure, the entire structure acted as a deadman anchor in the retaining system to provide additional retaining support. However, positive structural aspects of this closed cell structure type were often offset by high construction costs. Several factors have contributed to higher costs, including: multiple templates required for construction alignment; close tolerances; difficulty with driving through obstacles and holding tolerance; backfilling operations using buckets or conveyors; and difficulty compacting the backfill. Modification of the closed cell to an open cell configuration provided higher accessibility and tolerance, but at a significant increase in material costs to offset the reduced load capacity of the cell configuration.
Yet another sheet pile retaining form has been the tied back wall masterpile system with flat sheet piles acting as a curved tension face. Tieback anchors with deadmen are connected to the curved tension face to provide lateral retaining strength as shown in FIG. 1C . This configuration allowed a higher load to be retained with fewer sheet piles used as the anchors and the sheets work in concert to retain the earth load. Tied back sheet pile walls often require deep toe embedment for lateral strength and if that toe embedment is removed for any number of reasons, wall failure will result. This method further required excavation for placement of the soil anchors, or an expensive and time consuming drilling operation to install the soil anchors, at the appropriate depth to integrate them with the sheet pile wall. Additionally, tied back walls are at risk in environments where waves overtop the wall and result in scour. Scour undermines the base of the bulkhead and the needed toe support resulting in failure of the bulkhead.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the prior art and provides additional benefits. Under one aspect of the invention, a soil retaining system combining flat sheet pile walls in an open cell configuration with soil anchors integral to the sheet pile provides an improved earth retaining system. In one embodiment of the invention, the integral soil anchors are angular interlock soil bearing surfaces which provide higher load resistance. Another aspect of the invention is a method of designing and installing a soil retaining system with an open sheet pile cell structure having integral soil anchors. The method includes, inter alia, calculating soil resistance by taking into account soil friction against the sheet pile in combination with the strength of the integral soil anchor, selecting sheet pile size and length based on these calculations; and installation of sheet pile to form a soil retaining system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1A-1C are plan views illustrating existing sheet pile wall configurations in accordance with the prior art.
FIG. 2 is a plan view of theoretical forces on a sheet pile wall in accordance with the prior art.
FIG. 3 is a plan view of an open cell sheet pile wall in accordance with principles of the present invention.
FIG. 4 is a cross sectional view along line 44 shown in FIG. 4 of forces on a sheet pile wall in accordance with principles of the present invention.
FIGS. 5A-G are cross-sectional views of additional embodiments of a first sheet pile connected to a second sheet pile illustrating integral soil anchors in accordance with principles of the present invention.
FIG. 6 is a cross-sectional view of a wye or anchor in accordance with principles of the present invention.
FIG. 7 is a cross-sectional view of yet another embodiment of the present invention illustrating a composite material sheet pile in accordance with principles of the present invention.
FIG. 8 is a cross-sectional view of an alternative embodiment illustrating a cell configuration in accordance with principles of the present invention.
FIG. 9 is a graph of soil friction and ultimate tension force in accordance with principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A soil retaining system, and in particular, an apparatus and corresponding method for design and installation of an open cell sheet pile retaining wall having integral soil anchors is described in detail herein. In the following description, numerous specific details are provided, such as specific sheet pile configurations and interlock details as well as material selection, to provide a thorough siding of embodiments of the invention. One skilled in the relevant are however, will recognize that the invention can be practiced without one or more of the specific details. In other instances, well-known structures or operations are not shown or not described in detail to avoid obscuring aspects of the invention.
FIG. 2 illustrates a typical open cell sheet pile structure 200 . The cell 200 is typically constructed of vertical, flat sheet pile walls 210 . FIG. 2 illustrates an exemplary configuration for a sheet pile wall, namely, a “U” shaped configuration. Each “U” shaped configuration forms a cell. The closed loop of the “U” is the front face of the wall and may be exposed on one side. The legs of the “U” are typically not exposed except on an end cell. The legs of the “U” are typically referred to as tail walls 220 .
Open cell structures gain strength from the portion of the sheet pile buried in the soil fill. As illustrated in FIG. 2 , the soil contained within the open cell structure and any load placed atop that soil, namely the dead and the live load, exert a pressure P on the face of the structure. The weight of soil fill surrounding the tail walls 220 presses against sheet pile surfaces with enough force N to keep tail walls from being pulled out. Under traditional soil analysis, the theoretical soil friction resistance is based on an assumed soil failure plane μN that is assumed to be parallel to the sheet pile wall facing as shown in FIG. 2 .
In the present invention, a soil anchor integral with the sheet pile is designed to provide increased pull-out resistance and therefore yields a higher ultimate tension force. This higher ultimate tension force or effective overburden pressure yields a stronger retaining wall. Increased strength allowed fewer materials to be used and a more cost efficient wall to be built. These modifications of the typical closed cell to an open cellular shape with integral soil anchors serve to solve the problems associated with the closed cell configuration.
FIG. 3 , illustrates a plurality of open cell structures connected together to form an open cell sheet pile retaining system 300 . The open cell system 300 configuration is a first cellular structure 302 connect to and sharing a tail wall 220 with an adjacent second open cell structure 304 . A third adjacent open cell structure 306 shares a tail wall 220 with the second open cell 304 . The sheet pile tail walls 220 connects to a curved sheet pile cell face 210 . The tail walls 220 act as anchors for curved sheet pile cell faces 210 .
Operations and material cost savings are a significant improvement of the present invention over the prior art. By not closing the cell and by leaving the tail walls unconnected at the landward side, significant cost savings are realized from lower materials cost, increased construction tolerance and adjustment capability, and easier backfilling and compacting operations. Further, integral soil anchors in the sheet pile provide increased load resistance and allow shorter lengths of sheets to be used or lighter weight sheet pile materials to be used. The increased load resistance can result in a shorter depth of sheet penetration or a shorter overall length of tail wall to be used depending on the soil design characteristics. Open cell sheet pile structure construction can be used for various structures including oil containment, erosion control, docks in severe ice, wave or seismic environments.
FIG. 4 illustrates one embodiment of an integral soil anchor. A first sheet 440 connected to a second sheet 442 via a soil anchor 444 that includes a first interlock 446 at one end of the first sheet 440 mated to a second interlock 448 at on end of the second sheet 442 . Force lines 450 illustrate angled soil resistant anchor forces. The sheets 440 , 442 provide soil friction resistance normal to the sheets while the soil anchor 444 provides bearing and pull-out resistance at an angle greater than normal shown by force lines 450 .
The greater the size of the soil anchor the greater the resistance. A preferable soil anchor width is greater than ½″ and a more preferable soil anchor width is 3″ to an effective over burden pressure or greater and a most preferable soil anchor width is 4″ or greater as shown in FIGS. 5A-C . This configuration provides a combination that is an improved soil retaining system of greater strength than traditional sheet pile retaining walls.
FIG. 5A illustrates another embodiment of an integral soil anchor. A first sheet 540 is connected to a second sheet 542 via connection means 546 , 548 . The connection includes a first connection means 546 coupled to a second connection means 548 . The connection means 546 , 548 are shown integral to the sheets 540 , 542 , but may be affixed to the sheets such as in the rolling process by any mechanical means such as welding, bolting or other generally known attachment devices. The novel soil anchor of the present embodiment may be integral to the connection means wherein the sheet, connection means and soil anchor are formed simultaneously, or may be individually assembled components. A soil anchor 550 , 552 is integral to the coupling means 546 , 548 . The soil anchor 550 , 552 is shown as a squared off, corner of the coupling means 546 , 548 . The shape of the soil anchor is relevant to the increased resistance to force. A square shape has been shown in testing to resist higher forces than a round or angled shape. The square shape provides a greater bearing resistance against the soil.
FIG. 5B illustrates yet another embodiment of the present invention wherein the integral soil anchor, 554 , 556 is an “L” bracket affixed to an exterior side of the first and/or second connection means 546 , 548 at one end of the L and to the web of the sheet 540 , 542 at the other end of the L.
This soil anchor may be affixed subsequent to the rolling or manufacturing of the sheet pile.
FIG. 5C illustrates yet another embodiment of the present invention wherein the integral soil anchor is positioned other than at the intersection of two sheets. An intermediate integral anchor 570 is positioned between connection means 548 , 549 on the second sheet 542 . The intermediate anchor 570 is shown as a solid block incorporated into the sheet 542 itself. Alternatively, the integral anchor 550 may be any geometric configuration and may be adhered to either an inside or an outside face of the sheet or both, or may be an integral composite component of the sheet.
FIG. 5D illustrates another embodiment of the intermediate integral soil anchor. The intermediate soil anchor 580 is a “C” shaped angle welded or otherwise affixed to the exterior of the sheet 542 . FIG. 5E illustrates an intermediate integral soil anchor 590 that is an “L” bracket affixed to a face of the sheet 542 .
The greater the size of the soil anchor the greater the resistance. A preferable soil anchor width is greater than ½″ and a more preferable soil anchor width is 3″ to an effective over burden pressure or greater and a most preferable soil anchor width is 4″ or greater as shown in FIGS. 5A-C . This configuration provides a combination that is an improved soil retaining system of greater strength than traditional sheet pile retaining walls.
Any variety of geometric shapes could be used to form the integral soil anchor. Further, the soil anchors may be positioned at any point along the sheet pile wall including at a connection point between adjacent sheet pile walls. Intermediate integral soil anchors may be combined with integral soil anchors at the connection point as shown, for example, in FIGS. 5F and 5G . FIG. 5F illustrates the intermediate soil anchor 570 that protrudes through sheet 542 . The embodiment illustrated in FIG. 5F also has integral soil anchors 554 , 556 that are “L” brackets affixed to the connection means 546 , 548 . FIG. 5G illustrates the intermediate soil anchor 580 that is a “C” shaped angle welded or otherwise affixed to the exterior of the sheet 542 . The “L” brackets are affixed to the connection means 546 , 548 . Alternatively intermediate integral soil anchors may be used independently. Furthermore, multiple intermediate integral soil anchors may be positioned on a single sheet pile.
The integral soil anchors may extend the full height of the wall or may extend down the sheet pile wall some distance less than full height. Further, the integral soil anchors may be placed vertically on the sheet pile wall or may be placed at an angle. Length and positioning of soil anchors integral to the sheet pile wall is dependent on various design load parameters.
The soil anchors 544 , 550 , 552 , 554 shown in FIGS. 5-D have angular configurations to provide a greater soil resistant anchor force. Increase in the size of the soil anchor shape has been shown to increase the soil resistant anchor force linearly. The soil anchor resists forces by acting as microanchors or deadman. The soil anchor shape effects anchor resistance by a factor of up to cos 45°. A variety of soil anchor shapes, for example, round, angular, blocks, triangular or hexagonal may be used. Testing has shown that square shapes yield a greater resistance than alternative shapes.
The main structural components of open-cell construction are accomplished without the use of field welding, bolted connections, or an independent tieback system because the soil anchor is integral to the sheet piles of the retaining wall. Additionally, open-cell construction does not require sheet pile cell closure and allows for easy backfilling, since the cell is open in the back. This combination structure has the ability to resist large loads from ice and vehicles, and are highly insensitive to erosion conditions when compared with conventional sheet pile walls. The dock face can further be modified to include face ladders, mooring systems, fender systems, and varying access elevations. These features reduce costs and time required for construction. Construction costs for open-cell structures are therefore less than for other dock or bulkhead types.
Many problems are encountered in sheet pile construction and during the life of the retaining wall. An open cell sheet pile wall with integral soil anchors is a versatile retaining system that overcomes many of these problems.
One example of a design consideration to overcome is waves. Waves will produce forces on walls, but the most critical factor is wave overtopping. Open cells can withstand wave overtopping, with damage being limited to minimal loss of backfill. Further, just as river scour occurs around bridge piers, the forces from waves and associated currents cause scour at the base of impacted bulkheads. Tied back or cantilever sheet pile structures have a significant problem with any type scour because of loss of needed toe ground support. Conversely, the open cell structure with integral soil anchors is designed independent from exterior soil support, thus, scour can progress nearly to the cell bottom without any serious consequence.
Another design consideration is phreatic water. Phreatic water refers to water levels within bulkhead fill such as from tidal action which lags or leads tide levels. Very large forces from hydraulic head can be developed on bulkhead structures. Attempts to reduce this action by use of weep holes have not been totally successful because of possible drainage channel plugging and oxygenated corrosive water introduction into backfill. Open cell structures with integral soil anchors are readily designed to handle phreatic water and the associated forces without elaborate drainage or internal cell corrosion control measures.
Along with phreatic water levels, bulkhead stability is usually controlled by seismic forces. Analysis often follows classic wedge or slip circle theory that tests the overall mass stability. Open cell anchor wall resistance outside of failure planes is used to provide bulkhead stability safety factors, an important feature of this type structure. If design conditions warrant, an end anchor such as a large “H” pile may be added as an additional safety factor.
Open cell structures with integral soil anchors may be built in ice environments where ice thickness can reach one to two meters without damage to the structure. One explanation for this and a factor in design is strength of frozen bulkhead fill. As ice growth develops on water bodies, depth of frost in granular open cell backfill will often surpass the level of ice. Since frozen ground is usually stronger than ice, a naturally reinforced structure is created. Rubble ice formation early in the season, although usually impressive, is usually not a severe loading for open cells. As with seismic design, mass stability of bulkheads subject to large lateral ice loads is important.
Open cell tail wall extension having integral soil anchors can often effectively spread out dead and live loads if weak soils are encountered. Concern with such conditions is structure settlement. Flexibility of open cell wall structures with integral soil anchors readily handle unusual deformation.
The nature of large live loads, such as from cranes, cargo, stored containers, forklifts and heavy equipment is ideally suited to open cells with integral soil anchors because compacted earth fill provides sound support and the resistance nature of tail walls with integral soil anchors actually increases from such loads.
Wall heights of about 3 meters-20 meters are easily retainable for open cell construction with integral soil anchors, although longer or shorter sheets may be used. However, practical limitations are present, for example, longer sheets are difficult to handle and drive and are therefore less preferred. Cell width is preferably about 10 meters, but can be varied to account for end conditions and low wall height transitions. Tail wall lengths vary significantly subject a wide number of design parameters.
Sheet pile construction involves driving sheets a distance below the ground surface, which by its very nature, can be difficult. If very deep driving is required, difficulty can almost always be expected. Open cell structures with integral soil anchors of the present invention do not require deep embedment for stability due to the increased soil resistance provided by the integral soil anchors, and as a result are easier to construct and have redundancy for unusual conditions such as toe scour, toe liquification or overloads. Additionally, sheets of the present invention may be driven with fast vibratory hammers. Alternatively, open-cell structures with integral soil anchors may include deep embedment for additional stability.
Usually a one level template is adequate for open cell construction and wall tolerance is maintained by close attention to position and plumbness of “wye” shapes at intersections. Attention to wye position are carried through backfill operations which consists of controlled compacted layer construction. Cells are usually filled from the land using trucks, the result being the least costly method.
FIG. 6 illustrates one embodiment of a wye configuration that may be used in the present invention. The wye 600 may be used to couple a face sheet of a first cell to a face sheet of a second cell to the shared tail wall of the two cells.
Tail wall driving tolerance can be large and tail walls may be curved around obstructions. By dead ending tail walls, no close tolerance connections are required such as with closed cells. Flexibility in the position and driving tolerance of tail walls yields a significant cost savings. The cost effectiveness of this feature cannot be overemphasized.
There are numerous advantages and uses for open cell bulkheads with integral soil anchors. Higher soil resistance to pull-out forces from the integral soil anchors allow shorter tail walls to be used. This results in lower transportation and material procurement costs. Further, time and cost savings are realized because the cell is faster to construct. Furthermore, the open cell dock presents a pleasing scalloped appearance from the water side, and a neat uniform flat appearance from topside.
Open cells further include health and cleanliness advantages. An open cell dock consists of solid earth fill, providing no access under the dock for nesting disease-carrying rats and vermin common to platform-type docks. The elimination of this health risk is particularly important around food processing plants. In areas previously subjected to use, construction of the new dock encapsulates debris and hazardous materials existing on the sea floor behind the sheet pile wall and within the fill. Additionally, the open cell dock offers no space below the dock for the collection of future debris junk, and drift. Furthermore, open cell dock surfaces can be sloped away from the water so that oil and wastes, if spilled, drain away from the water-side of the dock. If not cleaned up directly, a spill could seep into the fill where it would be contained against seeping into nearby waters by the surrounding sheet pile wall.
Yet another advantage of the present invention is with respect to the protection of utilities. Utilities and fuel lines can be buried by conventional methods in the fill, where they are protected from freezing and from vehicle and vessel impact. If utility leakage should occur, any spillage is contained in the fill. Damaged utilities are readily accessible for repair. These are great advantages over conventional docks, where utilities are normally suspended under the deck or run along surfaces.
Runoff water can be kept from draining directly into marine waters. Instead, runoff may be either collected in a drain system, or seeped into the fill where it must travel long distances through filtering fill before it enters marine waters.
The present invention is adapted well to marine habitats. The protected area between fender piles and the scalloped faces of sheet pile cells can serve as a refuge for marine life. In addition, sheet pile faces and fender pile surfaces provide clean hard surfaces where anemones, urchins, and mollusks can attach themselves. Special hanging chain fish habitats have also been devised along structure faces.
Very little maintenance is required once the present system is in place. Open cell docks of the present invention consist of essentially two materials, earth fill and sheet piles with integral soil anchors. Earth fill, properly contained behind a bulkhead, and sheet piles, if properly protected against corrosion, are virtually maintenance free. There is no need for riprap under the dock, as with pile-supported docks. Riprap under pile-supported docks often subsides or can be wave-displaced over time, and may become a difficult and expensive maintenance item.
Properly constructed, the open cell dock with integral soil anchors is capable of supporting huge loads such as large cranes, heavy forklifts and heavy storage loads, without danger of collapse. Furthermore, the steel cells which are filled with earth and rock have tremendous resistance to damage by ice pans, vessel impact, and other drift forces. There are no weak elements such as vertical bearing piles, pile caps, or walers to be damaged by drift forces. Additionally, mooring devices on open cell docks have exceptionally high capacity because they are tied to the large deadweight of the dock. The components of open cell docks, earth and sheet piles, are extremely fire resistant. In addition, the dock can be used to provide a safe platform from which fire fighters could combat fires occurring on nearby boats or in waterfront buildings.
The present system is very cost effective as compared to conventional building systems. Open cell docks having integral soil anchors typically may be built for about half the cost of a heavy-duty pile-supported dock based on an “area created” basis. Furthermore, one of the two primary dock materials, earthfill can usually be obtained locally at minimal cost.
Ease of construction of the present invention allows cost savings in both time and materials. Open cell docks having integral soil anchors can be constructed entirely from the land. This eliminates the need for cumbersome barge-based construction and related oil spill hazards. Construction is so repetitive that local labor forces, inexperienced with pile driving or dock construction, have built then. Fill can be end-dumped into place since the rear side of each cell is open. Little siltation results from this construction method. No detail work such as installation of traditional walers and tiebacks is required in the tidal zone.
Yet another advantage of the present invention is that minimal embedment of sheets is required along the front face of the dock below the existing ocean bottom. This makes the open cell dock having integral soil anchors particularly attractive where bedrock is at or near the surface. Drilling and/or blasting for rock anchors or embedment would be required for other types of docks in this situation, with resulting environmental disruption. Furthermore, the open cell concept creates flat land both at the new dock and at the borrow source. If the borrow source is a hill immediately behind the dock, then valuable staging area is created. The economics of an open cell dock project look even better if the value of this additional staging area is factored in the cost.
FIG. 7 illustrates yet another embodiment of the present invention. The sheet 700 of FIG. 7 is of a shorter horizontal length L than a typical sheet and may be constructed of a composite material. Furthermore, the connection means 710 may be of a width W greater than conventional connection means. A preferable W of the connection means or soil anchor is 4″ or more. The coupling means 710 of this embodiment is shown as a block for illustrative purposes. The size of the coupling means may be increased as needed for the given design considerations to increase to soil resistance of the integral anchor.
Composite material used to construct the sheet may, for example, include formed plastics, extruded plastics, composite metal and plastic, fiberglass, carbon fibers, aluminum and the like. Composite materials have the additional advantage of flexibility of design of the coupling means.
FIG. 8 illustrates a specialized use of the composite sheets and yet another embodiment of the present invention illustrating a sleeved pile repair 800 of an existing pipe pile 820 . Special sheet piles 810 can be formed or bent to accomplish a number of tasks, including sleeved pile repair, column forming, conduits and covers. The connection means 830 can easily be slipped together to instantly form a variety of shapes for many uses. Concrete, grout or other materials 840 can be used to fill any annulus created thus creating a structural section.
An improved soil retaining system including an open cell design including integral soil anchors has lead to a versatile structure capable of wide adaptation. Resolution of not only design, but also construction problems has further reduced cost of these structures and created another tool for developing an economical solution.
The following failure testing example is provided as an illustration.
EXAMPLE 1
Testing by: D). Nottingham
C. Canfield
Apparatus: A test box 2′×2′×4″ high to hold sand was constructed of plywood and pressed board.
Materials: Silica sand in the sand of #30 to #70 sieve was obtained.
Two end sections of PS32 sheet piles were cut to about 3″ height.
Test Procedure: The silica sand was dampened and packed around the sheet pile sections. A wire was run through a hole in the box to one end of the sheets, and connected.
The assembly was pulled into the sand until stress cracks formed in the sand. The test was photographed and observed as to nature and direction cracks. Test was repeated numerous times.
Results: Cracks in sand did not form parallel to sheet pile sides, but did so at about 30 degree±angles emanating from sheet pile interlocks. This was a result of the interlocks acting as an integral microanchor. Soil friction against sheet pile sides did not appear to be present at time of soil cracking. This testing verifies the theory that the interlock provides soil resistance in addition to the normal forces resisted by the sheets themselves.
FIG. 9 illustrates a comparison of sheet pile tension resistance theories in granular soils in accordance with the above testing and in accordance with the principles of the present invention. As is shown from the graph the integral soil anchors provide greater resistance to soil forces, thus allowing lighter materials or shorter pile to resist the same forces as conventional retaining systems.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims. | A soil raining system combining flat sheet pile walls in an open cell configuration includes integral soil anchors providing an improved earth retaining system. Another aspect of the invention is a method of designing and installing a soil retaining system with an open sheet pile cell structure having integral soil anchors. The method includes, inter alia, calculating soil forces by taking into account material strength of sheet pile, soil friction against the sheet pile in combination with the strength of the integral soil anchor, selecting sheet pile size and length based on soil forces calculation; and installation of sheet pile to form a soil retaining system. The integral soil anchors serve to provide higher load resistance to the improved earth retaining system. |
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CROSS REFERENCE TO RELATED APPLICATION
The subject matter of this application is related to and comprises a continuation-in-part of the application of the same inventor herein, having Ser. No. 174,569, filed on Aug. 4, 1980, and owned by a common assignee.
BACKGROUND OF THE INVENTION
A great many and variety of hand floats are available in the art, and primarily include a plate means having a handle rigidly fixed therewith, either by way of welding, or some other type of fastener, and wherein the float is then usable by the finisher for smoothing out concrete poured in place. These floats normally are of integral construction, having no means for providing adjustment to its interconnecting handle, and therefore, must be used by the concrete finisher as is, and as obtained and acquired from the supply house.
This invention relates generally to a hand float, and more particularly one having an adjustable handle that can be manipulated at the desire of its user.
The principal object of this invention is to provide a hand float wherein its handle may be slid along its length and fixed into that position found most desirable and which complements the skills of its user.
Another object of this invention is to provide a hand float having guide means arranged integrally from its upper surface, and for accommodating an adjustable handle therewith.
Still another object of this invention is to provide a hand float, which may include a plate means of extra length, and having an adjustable handle connected therewith and which can be slid along the length of said plate in order to provide for its disposition at that position most convenient to its skilled user.
Still another object of this invention is to provide fastening that means interconnect within guide means upon a hand float to facilitate the rapid connection of its handle therewith.
These and other objects will become more apparent to those skilled in the art upon reviewing the summary of this invention, and upon undertaking a study of the description of its preferred embodiment, in view of the drawings.
SUMMARY OF THE INVENTION
In accordance with this invention, a hand float is formed having a plate means of usual or extra length, with the bottom of the plate means normally containing a smooth surface so as to function as both a means for smoothing out and finishing a poured concrete surface, and having sufficient straight edges so as to enhance its utility during the performance of such a finishing function. The plate means includes a pair of integral guides extending upwardly from its upper surface, normally extending coextensively along the length of the float, and which guides include inturned edges for accommodating fastener means for securing a handle to the said float. A pair of fastenings may comprise a nut and bolt combination, with perhaps the head of the bolt being configured in the shape of a "T," so as to allow their accommodation within the space intermediate the guide means for securement of the handle therewith, upon tightening of said fasteners. And, the float may be constructed to differing configurations, either of the squared end type, the half round, round ends, tapering top, or to those usual shapes generally desired by the finisher for his tools for use in providing a pleasing and smooth surface upon a freshly poured slab of concrete.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, FIG. 1 provides a plan view of a jumbo hand float;
FIG. 2 provides an end view of the hand float shown in FIG. 1;
FIG. 3 provides a side view of the hand flaot shown in FIG. 1;
FIG. 4 provides a plan view of a squared end hand float;
FIG. 5 provides a side view of the hand float shown in FIG. 4, and further disclosing its tapered top;
FIG. 6 provides an end view of the hand float shown in FIG. 4;
FIG. 7 shows a plan view of a rounded end hand float;
FIG. 8 provides a side view of the hand float shown in FIG. 7; and
FIG. 9 provides an end view of the hand float shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In referring to the drawings, and in particular FIGS. 1 through 3, there is shown what is identified as the jumbo hand float, incorporating a plate means 1 of substantial length, and having guide means 2 and 3 extending upwardly from the upward surface of the said plate means, all as more clearly shown in FIGS. 2 and 3. The upper edges of the guide means include integrally formed inturned edges, as at 4, and which are designed for embracing the nut or head 5 of a fastening means, as at 6, with one of said fastening means being provided at both ends of the handle 7. When the fastening means are tightly engaged in place, the handle becomes fixed to the plate means, by binding against the said upper lips of the guide means, thereby providing for its grasp by the concrete finisher in performing his task. On the other hand, should the finisher desire, as due to his own talents, that the handle means be located at some other position along the length of plate means, the fasteners 6 can be simply loosened, and the handle can be slid along the guide means 2 and 3, to its desired position, and then fastened once again in place for locking the handle securely with the said plate means.
This hand float, like all of the other hand floats to be described in this application, may be constructed, and more specifically its plate means, of a variety of metals, or even some polymer, but preferably the plate means, due to its integral construction in the formation of its guide means, its inturned lips, and the plate means itself, as can be more clearly seen in FIG. 2, may be fabricated as an extruded metal, such as aluminum, so that the entire assembly, with the exception of its handle and fastening means, can be fabricated as a single extrusion.
As can be seen in FIGS. 4 through 6, a slight modification to the configuration of the plate means is shown, although the principle of operation and attachment of the handle with said plate means is very similar to that previously described. As can be seen in FIG. 4, the plate means 8 incorporates a pair of guide means 9 and 10, having the integral inturned lips 11, and then with the fasteners 12 of the handle means 13 may secure the same rigidly in place. Or, in the alternative, the fasteners 12 may be loosened, and the handle 13 slid along the length of the shown guide means, for repositioning and refastening at an adjusted location. In this particular instance, the plate means is defined as a tapered top form of plate means, and as can be seen in FIG. 5, the guide means 9 and 10 are tapered, as at 14 and 15, at its forward and rear edges, to provide for ease of assembly of the handle into the guide means, for locking therewith during tightening of its fasteners 12. Another feature of this particular style of hand float is the preferably integral formation of sidewalk edges, as at 16 and 17, provided along the length of both side marginal edges of the plate means 8, and which are useful for aiding the finisher in moving slight accumulations of concrete for repositioning, in order to complete a concrete finishing operation. Once again, as can be seen, the entire plate means 8, with all of its various edges 16 and 17, and guide means 9 and 10, can be fabricated as one complete extrusion, as from aluminum, or other material, and then simply machined at those locations to eliminate its rough edges, as at the corner of the plate means, or for providing the tapers or bevels, such as at 14 and 15, at the ends of the guide means.
Another style of hand float is shown in FIGS. 7 through 9, having a slightly differing appearance, but operating upon the same principle as that described for the two previous floats. As can be seen, the plate 18 has the guide means 19 and 20 provided along its length, and having the integral inturned edges, as at 21, for cooperating with the fasteners 22 of the handle 23. The end edges of the plate means 18, in this particular instance, are rounded, as at 24, to provide attributes for the float that may aid the concrete finisher in completing a finishing operation.
Variations or modifications to the structure of these hand floats may occur to those skilled in the art upon reviewing the subject matter of this invention. Such variations or modifications, if within the spirit of this invention, or intended to be encompassed within the scope of any claims to patent protection issuing thereon. The description of the preferred embodiment set forth herein is done so for illustrative purposes only. | In a hand float of the type used by a concrete finisher, a plate includes a pair of integral guides extending upwardly therefrom, the upper edges of the guides being inturned, for accommodating fastening means from a handle, so that the handle may be rigidly fixed in place, when adjusted, or loosened for repositioning and before tightening for the convenience of its user. |
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[0001] This invention was made with government support under Contract Number: FA9302-10-M-0011 awarded by The United States of America as represented by the Department of the Interior, Washington, DC. The government has certain rights in the invention.
TECHNICAL FIELD
[0002] The invention relates to a method for denying soaring and migratory birds access to critical areas of airports and aircrafts and paths of taking off and landing aircrafts. More particularly, the inventions provides a method of eliminating a potential formation of thermals or up-draughts essential for lifting soaring and migratory birds, thereby avoiding conflicts between taking off and landing aircrafts and soaring or migratory birds.
BACKGROUND
[0003] Bird strikes happen most often during takeoff or landing, or during low altitude flight of aircrafts. The majority of bird collisions occur near or on airports (90%, according to the International Civil Aviation Organization (ICAO)) during takeoff, landing and associated phases. According to the FAA Wildlife Hazard Management Manual (2005), less than 8% of strikes occur above 900 m (2,953 ft) and 61% occur at less than 30 m (100 ft). The point of impact is usually any forward-facing edge of the vehicle such as a wing leading edge, nose cone, jet engine cowling or engine inlet. For example, turkey vultures and red-tailed hawks account for the majority and more costly of damaging raptor strikes to USAF aircrafts, which amount to 31% and 32%, respectively. As of Jan. 1, 2008, turkey vultures were responsible for 798 bird strikes costing about 52 million dollars while the red-tailed hawks were responsible for 814 strikes with about 14.6 million dollars in damages. Both turkey vultures and red-tailed hawks showed a marked increase in the number of bird strikes during the summer. This was due to the relationship between thermal activity and strike rate for these two species. Both forage by soaring on thermals, without which they are unlikely to reach the height required to bring them into conflict with aircraft. Thermals are formed on dark earth, black tops, roadways, towns, urban areas plowed fields and exhaust gas from power plants in the presence of cumulus clouds. On the other hand, sun reflective surfaces, marshes, and white coated surfaces do not support thermals. The most pronounced damage was caused by the American white pelican reaching about 257.65 million dollars in spite of their low number of strikes. Other thermal soaring birds responsible for the top 50 USAF wildlife strikes include buzzards, eagles, kites, gulls, herons, pelicans and terns.
[0004] The typical lift-off speed for an F-15 fighter plane is 150 knots. A Boeing 747, for example, spends longer time in critical path. The aircraft acceleration during takeoff and landing hinders any birds' reaction to avoid collision. Reaction time of birds relative to the motion of the aircrafts is very important for survival of the birds and the avoidance of damage to the aircraft. Such reaction time for soaring birds will be much longer compared to free flying birds.
[0005] Accordingly, there is a need to eliminate soaring and migratory birds' conflicts with aircrafts. There is also a need to eliminate the formation of atmospheric thermal currents or thermals in the immediate vicinity of the airports and airfields proper and along the paths of taking off and landing of aircrafts. In addition, there is a need to provide high albedo surfaces in the airport including surfaces of the buildings, runways, roads and the surrounding terrain while preserving the aesthetics of the surfaces. Furthermore, there is a need to conserve/protect migratory birds and soaring birds by providing them with sanctuaries and/or habitat away from airways.
SUMMARY
[0006] The invention provides a method for creating a thermals-free zone that may include the expanse of airports and airfields proper and at the same time denying soaring and migratory birds' access to such zone.
[0007] According to one embodiment consistent with the claimed invention, a method is provided for denying soaring and migratory birds access to critical areas of airports and airfields and paths of taking off and landing aircrafts, comprising eliminating a potential formation of thermals or up-draughts essential for lifting soaring and migratory birds and dividing the critical areas of airports and airfields and paths of taking off and landing aircrafts into a plurality of zones.
[0008] In one aspect of the invention, the plurality of zones include an airport zone 1 or a thermals-free zone 1 that includes an airside area and a landside area of the airports and airfields and the paths of taking off and landing aircrafts; an unrestricted zone 3 of open and public spaces that are not under the control of operators of the airports and airfields; an exclusion zone 2 that separates the thermals-free zone 1 from the unrestricted zone 3 ; a green area zone 4 that provides protection, sanctuary and abundant food and water supply for the soaring and migratory birds; a bird sanctuary zone 5 for conservation and creation of a habitat for the soaring and migratory birds; and a water body zone 6 that is immune to the potential formation of thermals surrounding the thermals-free zone 1 from the unrestricted zone 3 .
[0009] Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, by illustrating a number of exemplary embodiments and implementations, including the best mode contemplated for carrying out the present invention. The present invention is also capable of other and different embodiments, and its several details can be modified in various respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a top view of an overall layout of a sample airport that include an airport zone 1 or a thermals-free zone 1 , an exclusion zone 2 and an unrestricted zone 3 (not drawn to scale);
[0011] FIG. 2 shows a cross-section of the ground of the airside and landside areas of thermals-free zone 1 , buildings, exclusion zone 2 and unrestricted zone 3 of the sample airport shown in FIG. 1 ;
[0012] FIG. 3 illustrates the use of a gravel easement 114 on each side of the pavement of the airside and landside of thermals-free zone 1 ;
[0013] FIG. 4 illustrates the active cooling of each of the gravel easements 114 as depicted in FIG. 3 ;
[0014] FIG. 5 illustrates the active cooling of the pavement of the airside of the thermals-free zone 1 using a plurality of water pipes 162 ;
[0015] FIG. 6 illustrates the construction of a bird sanctuary zone 5 ; and
[0016] FIG. 7 illustrates the construction of a green zone 4 for soaring and migratory birds.
DETAILED DESCRIPTION
[0017] The degree of solar heating of the ground depends on many factors, e.g. solar insolation in the area; color, mass and condition of the exposed surface; specific heat and thermal conductivity of the substance of the exposed surface, and location of the substance on the surface of the earth in relation to other nearby objects.
[0018] Surface color, as known in the law of physics, plays a very important role in the phenomena of radiant heat absorption and emission. Therefore, a white body surface can, under similar conditions, emit a lesser amount of sensible heat than a black body per unit surface.
[0019] In consistent with the features of the invention, it is desirable to have a cold body surface surrounded by a warmer body surface to mitigate the conditions that lead to the formation of thermal currents. By doing so, it allows for an exclusion distance (exclusion zone 2 ) that would avoid stray birds and, at the same time, accommodate planes that overshoot their planned flight path. Under these conditions, cool air from the cold area will not only continually flow over the hot area but will also be raised in temperature, expand, decrease in specific gravity, and eventually rise up. Based on the above, it becomes possible to provide migratory bird species and other birds with a non-restricted protected area (unrestricted zone 3 ) or a sanctuary (bird sanctuary zone 5 ) at a distance far enough from flight paths so that they can roost, nest, feed and forge freely while avoiding conflicts with arriving and departing aircrafts.
[0020] In the airport proper (thermals-free zone 1 ), the whole airside areas (including all areas accessible to aircrafts, e.g., runways, taxiways, ramps and tank farms) may be kept at a temperature close to that of the air temperature of a cold body or white body using passive means, e.g., high-albedo surface-coating and/or reflective materials. In areas where in the summer heat is excessive and characterized by higher insolation over extended periods, active means may be used, e.g., application of cooling water. Exposed surfaces of terminal buildings, hangers, cargo storages, service buildings and tank farms, etc., may be coated with white coating and/or reflective materials. Landside areas including parking lots, public transportation train stations (if any), and access roads may have at least off-white colors on their surfaces.
[0021] U.S. Pat. No. 7,198,427 to Carr et al. discloses a safety system for airports and airfields that includes (1) an aesthetically pleasing artificial turf that retards birds and other animals and (2) a sub-surface that supports the weight of an aircraft, enhances water drainage and enables the accessibility of airport vehicles to all parts of runway or taxiway, and methods for installing the safety system. However, the green color of the artificial turf according to Carr et al. supports thermal formations that attract gatherings of soaring birds having a free-lift to collide with planes at relatively low altitude.
[0022] In fact, work by others promoted the formation of artificial thermals in favor of facilitating the flights of sailplanes and gliders. For example, in U.S. Pat. No. 2,268,320, Brandt describes the production of atmospheric or thermal air currents in the immediate vicinity of the airport by heating large volumes of air either by solar or artificial means to provide up-draughts that are essential to soaring or gliding flights. In addition, U.S. Pat. No. 2,371,629 to Lee discloses a means for forming an artificial thermal or ascending warm air current for sail-plane soaring that can be actuated by solar radiation.
[0023] The method, in consistent with the features of the claimed invention, may provide an extension of the thermals-free zone 1 around the expanse of airports and airfields, which, in turn, allows ample distances for aircraft flight paths during aircraft take-offs and landings, without creating conflicts between any size aircrafts and soaring and migratory birds. It may also secure the thermals-free zone 1 , particularly on the airsides of airports or airfields by active cooling the surfaces of the pavements of the airsides. It may also provide an exclusion area 2 of sufficient width around the thermals-free zone 1 for separating the zone from birds' habitats, sanctuaries and roosting areas, thereby preventing possible collision between stray soaring birds and aircrafts that divert from their flight paths. It may further provide a safe protected area for birds to roost, nest, feed and soar freely away from air traffic.
[0024] Hereinafter, the invention will be described more specifically by way of examples. It is to be noted, however, the invention is by no means limited to these examples.
EXAMPLES
[0025] As described in FIG. 1 , there are a plurality of zones that can be contemplated in accordance with the features of the claimed invention. The plurality of zones include an airport area 1 or a thermals-free zone 1 , an unrestricted zone 3 , an exclusion zone 2 that separates thermals-free zone 1 from unrestricted zone 3 ; a green zone 4 that is located on the unrestricted zone 3 and includes grass, shrubs, trees, etc.; a bird sanctuary zone 5 that serves as a protected area for birds to nest, rest, roost and soar; a water body zone 6 such as a lake, man-made pond or alike along the runway may protect the aircrafts during takeoff from collisions with soaring birds at a relatively higher altitude. Although the sketch in FIG. 1 applies to one runway in a small airport, the principle may be applied to multi-runway airports.
[0026] As shown in FIG. 2 , the exposed surfaces and sidings 112 of the control tower, terminal buildings 11 , tarmacs 13 , cargo 14 , hangars and other structures, such as service buildings, may be made of reflective materials. The roofs 111 may be coated with special coating material, such as a mixture of various silica and ceramic beads immersed in a high quality latex base with acrylic binders; e.g., Temp-Coat® (manufactured by SPAN-WORLD Distribution, LLC) and Thermal-Coat™ (manufactured by Innovative Coating Solution, Inc.) and the like or better.
[0027] As illustrated in FIG. 2 , the creation of cold or white body requires the use of high-albedo pavements constructed from white cement concrete 161 . Accordingly, the airside areas of the airport area 1 or thermals-free zone 1 , including taxiways 16 , runways 17 , tarmacs 13 and the ground around tank farms 15 may be paved with white cement concrete 161 directly over the earth surface 7 and may be surfaced with a white coating, e.g., white cement coating.
[0028] Also described in FIG. 2 , the landside areas of the airport area 1 or thermals-free zone 1 , including terminal 11 , parking lots 12 , cargo 14 , public transportation train stations (if any), and access roads may be paved with an asphalt layer 101 with an upper layer 102 made of light-colored, non-heat absorptive material that acts as a thermal insulator. The material of upper layer 102 needs to be water-insoluble so that it will remain intact during wet seasons. Examples of the material for upper layer 102 may include aggregates (e.g., granite, limestone or water insoluble salts, such as chalk, crystallized gypsum, magnesium oxide, etc.). Additionally, the pavement may be surfaced with a top-coat 103 made up of mixed chippings of sand and oyster shells, etc., as shown in FIG. 2 .
[0029] An artificial turf may also be constructed in the exclusion zone 2 , in accordance with the disclosure of U.S. Pat. No. 7,198,427 to Carr et al., with the selection of a lighter color artificial turf instead. This is due to the ability of the artificial turf to discourage birds' presence. However, it is well-known fact that plowed fields and well groomed grass are good source of thermals. Accordingly, one embodiment of the invention, as shown in FIG. 2 , is the use of an off-white color for top layer 201 in the exclusion zone 2 . The top layer 201 is over the asphalt 101 and may be constructed from gravel mixed chippings of sand and oyster shells.
[0030] In FIG. 3 , the white concrete pavement 161 of the airside of the airport area 1 or thermals-free zone 1 , may have a first and a second gravel easements 114 on each side of the white concrete pavement 161 . Each of the gravel easements 114 may extend to each side part of the layered pavement of the landside to replace the upper layer 102 and top-coat 103 .
[0031] The first and second gravel easements 114 , may be further artificially cooled by formation of a thin water film 115 . The thin water film 115 may be maintained during times of high insolation through a timed spray system 116 , as shown in FIG. 4 . The thin water film 115 can provide evaporative cooling to the gravel easement 114 , which has a porous like structure.
[0032] As illustrated in FIG. 5 , the white concrete pavement 161 of the airside of the airport area 1 or thermals-free zone 1 is actively cooled by means of a plurality of water pipes 162 that are embedded in the white concrete pavement 161 . The plurality of water pipes 162 may be made of PVC or any other durable plastic material. Cooling water may be circulated through the plurality of water pipes 162 with the aid of a pumping station 163 to maintain water temperature and flow sufficient to provide a thermal equilibrium between the surface of the white concrete pavement 161 and ambient air. The benefit gained from this arrangement is that the plurality of water pipes 162 may be utilized for transporting warm water during winter season in cold regions to prevent the surface of the white concrete pavement 161 from freezing.
[0033] The layout and construction of the bird sanctuary zone 5 may enhance the formation of thermals to attract soaring birds, which sense the presence of thermals through the emitted infrared and infrasonic waves, as well as the associated humidity. The bird protected areas or bird sanctuary zone 5 may be constructed according to the disclosure of either U.S. Pat. No. 2,268,320 to Brandt or U.S. Pat. No. 2,371,629 to Lee or any of one of similar designs.
[0034] An exemplary bird sanctuary zone 5 , according to the features of the invention, is shown in FIG. 6 . One side of the bird sanctuary zone 5 may include a water body zone 6 and a top layer 201 of the exclusion zone 2 . The bird sanctuary zone 5 may include a dark-colored or black body 51 and a reflecting light colored or white surface 52 , which rests on the earth surface 7 and extends underneath the dark-colored or black body 51 . The dark-colored or black body 51 is formed from a porous heat absorptive material such as peat moss. The light colored or white surface 52 may be formed from sandy soil topped with oyster shells or similar heat reflective material of albedo significantly higher than that of the dark-colored or black body 51 .
[0035] Through solar heating, the dark-colored or black body 51 absorbs heat and transfers the radiant heat to sensible heat, which, in turn, heats the air in contact with it by conduction means. At the same time, the light colored or white surface 52 reflect the solar radiant heat causing the temperature of the air in contact with the dark-colored or black body 51 to be raised, expanded and then risen to form a steady up-draught of air, as shown in FIG. 6 .
[0036] Similarly, the green area zone 4 can be constructed from natural grass and shrubs to provide a habitat for birds where they can nest, feed and breed. Furthered by natural grass, birds and other animals, including gulls, waterfowl, raptors such as hawks and other species flock to airfields to eat, drink and reproduce. By doing so, they pose a potentially dangerous safety problem for departing and arriving aircrafts. Birds eat insects and grubs, which live in natural grass up to six inches (15 cm) below the soil surface. Birds also eat rodents that feed on the insects. Standing water, particularly after fresh rains, attracts many species of birds, including waterfowl. Large birds, such as ducks or geese, also create dangerous conditions for aircrafts (classified herein as foreign object damage (FOD)). Natural grass further provides material and cover for birds to nest and breed.
[0037] FIG. 7 shows the construction of the green zone 4 . On one side of the bird sanctuary zone 5 are the water body 6 and the top layer 201 of the exclusion zone 2 . The green zone 4 includes a tall grass area 41 , which is in direct contact with the earth surface 7 and a reflecting light colored or white surface 42 that also rests on the earth surface 7 . The tall grass area 41 may include natural grass, shrubs and may also contain drainage water or narrow streams of water. The white surface 42 may be formed from sandy soil topped with oyster shells or similar heat reflective material of albedo that is significantly higher than that of the tall grass area 41 . This arrangement is conducive to the formation of up-draught particularly in the presence of cumulus clouds 8 .
[0038] The invention disclosed herein may also be applied to military airfields, as well as civilian airports of any type or size.
[0039] In addition to attracting soaring birds (e.g., herring gull; great blue heron; ring-billed gull; Swainson's hawk; sharp-shinned hawk; laughing gull; Australian pelican; Franklin's gull; Caspian tern; common black-headed gull; other gulls, terns; hawks; eagles, kites (e.g. Mississippi kite and etc.)) to protected areas where thermals are likely to be formed, other factors such as the availability of food, water, safe locations for nests and rest may also attract other birds beside those mentioned above. Other birds may include the barn swallow/swallow; dark-eyed junco; mallard; American mourning dove; snow goose; horned lark; common/great northern loon/diver; killdeer; rock dove/pigeon; perching birds; common Turkey; lesser scaup; common starling; eastern meadow lark; American robin; double-crested cormorant; American cliff swallow; American kestrel; lark bunting; northern pintail/pintail; gadwall; common buzzard/buzzard; western meadowlark; chimney swift; yellow-rumped warbler; common wood-pigeon; kittiwakes; Mexican/Do.-Str. stone-curlew/thick-knee; sparrows; buntings; and finches. All of these bird species were responsible for the top 50 collisions with USAF aircrafts by First of January 2008. Hence, it is important to attract them away from the paths of aircrafts during taking off or landing. This is in addition to denying them access to critical areas of airports and aircrafts and paths of taking off and landing aircrafts.
[0040] Although a limited number of exemplary embodiments of the claimed inventions have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the inventions. Therefore, the scope of the inventions is to be determined solely by the following claims and their equivalents. | A method is provided for mitigation of aircraft bird strikes through the provision of conditions on the ground that totally prevents the formation of atmospheric thermals in the proximity of airports and airfields, whereby conflicts between soaring and migratory birds and aircrafts may be avoided. This is accomplished by modification of the topography of the field into a plurality of zones, as described herein and through construction of high albedo pavements, roads, artificial turfs and cool terrains. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application, the contents of which are related to United States U.S. non-provisional patent application Ser. No. 11/483,076 filed on Jul. 7, 2006, which claims priority from non-provisional patent application having Ser. No. 10/410,486 filed on Apr. 3, 2003, now U.S. Pat. No. 7,084,766, which in turn claims priority to a provisional application having Ser. No. 60/371,063 filed on Apr. 8, 2002, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to security tags in general, and in particular to a tag body containing at least one frangible vial containing a detrimental substance and an attaching means for use in electronic article surveillance (EAS) tags.
BACKGROUND OF THE INVENTION
Various types of electronic article surveillance (EAS) systems are known having the common feature of employing a marker or tag which is affixed to an article to be protected against theft, such as merchandise in a store. When a legitimate purchase of the article is made, the marker can either be removed from the article, or converted from an activated state to a deactivated state. Such systems employ a detection arrangement, commonly placed at all exits of a store, and if an activated marker passes through the detection system, it is detected by the detection system and an alarm is triggered. In addition, other tags are known that utilize ink vials that break and release a permanent staining fluid onto the article if the tag is not removed by an authorized individual.
For example, U.S. Pat. No. 5,426,419 to Nguyen et al., and assigned to Sensormatic Electronics Corporation, discloses an EAS tag having an arcuate channel that extends from an opening thereof to the actual attaching assembly and the detaching mechanism thereof. The channel increases the susceptibility of defeat of the attaching assembly because it guides an object that is inserted by an unauthorized individual directly to the attaching assembly and allows disengagement thereof. In addition, that the tag may be cut in half at the store such that the electronic components are left at the retail location and the unscrupulous individual absconds with the garment because the electronic detectors cannot detect the tag. In a safe environment away from the retail location and without any urgency, the unscrupulous individual is able to defeat the attaching pin.
U.S. Pat. No. 6,373,390 to Hogan et al., assigned to the same assignee as the '419 patent, is an improvement patent issued in light of the shortcomings of the '419 patent. The '390 patent admits that the EAS tag of the '419 patent “can be defeated by insertion of a segment of relatively rigid metal bent in an arcuate manner to simulate the arcuate probe of the associated detacher device.” Furthermore, the '390 patent describes a fish tape which may be formed to resemble the requisite arcuate probe in order to defeat the EAS tag of the '419 patent, “the formed fish tape 50 is strong enough to hold its form when pushed into arcuate channel 7 until it can be manipulated into and against member 6, which then can be rotated to release tack assembly 4.” However, the improvement does not address the cutting of the tags by unscrupulous individuals to defeat detection of the electronic components.
With respect to the '419 and '390 patent, many free standing arcuate probes have been either manufactured or misappropriated by unscrupulous individuals by dismantling the detacher components with which the probes are associated. The arcuate probe is inserted into the arcuate channel by hand and is led directly to the preventing mechanism. In the '390 device, the arcuate channel leads the manipulated arcuate probe to the opening or slot located in the arcuate channel, wherein the opening further aligns and guides the hand manipulated probe directly to the preventing mechanism or member. In addition, the force required to release the preventing mechanism of the '419 and '390 device is less than the force required to release the preventing mechanism of the instant invention. Accordingly, an unscrupulous individual may easily defeat the preventing mechanism of the '419 and '390 devices by manipulating an illicitly acquired freestanding arcuate probe.
The '419 and '390 devices may be defeated by penetrating the bottom housing in proximal relation to the preventing mechanism and inserting a rigid and elongated element and forcing metal clip to rotate, whereby the preventing mechanism will release the pin. The instant device is more difficult to defeat in this manner because it will result in breakage of the ink vial to release the permanent staining substance onto the article.
In addition, the preventing mechanism of the '419 and '390 patents is attached on only one end thereof, thus allowing movement out of the horizontal plane. Consequently, the vertical movement of the clamp increases the susceptibility of defeat of the attaching assembly because the jaws expand more easily because the angle of the clamp varies between the first end and second end as a result of the vertical movement of the non-secure end. The pull force to disengage a pin from the instant device and the '419 device was conducted by using an Imada product model DPS220R, obtainable from 450 Skikie Blvd. #503, N. Brook, Ill. 60062.
The prior art does not address the need for an EAS tag that is difficult to defeat. In addition, the prior art fails to provide a clamp assembly that requires greater pull force to disengage a pin from the clamp assembly. In addition, the prior art fails to provide a tag that is more difficult to defeat even when an unscrupulous individual has illicitly acquired a freestanding arcuate probe. Further, the prior art fails to address the severance of the electronic component from the attaching component as a way to unscrupulously remove the article from the retail environment. Therefore, there remains a long standing and continuing need for an advance in the art of EAS tags that is more difficult to defeat, is simpler in both design and use, is more economical, efficient in its construction and use, and provides a more secure engagement of the article.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.
Therefore, it is a primary objective of the invention to provide an EAS tag that is more difficult to defeat.
It is another objective of the invention to provide a cost-efficient EAS tag.
It is another objective of the invention to provide an EAS tag that releases a detrimental substance if it is tampered with.
It is yet another objective of the invention to provide an EAS tag that decreases the likelihood of defeat by an unscrupulous individual.
It is a further objective of the invention to provide an EAS tag that is detachable when used with an authorized detaching unit.
In keeping with the principles of the present invention, a unique EAS tag is disclosed wherein an ink vial is housed within the tag body to prevent cutting off of the electronic region of the tag body from the attachment region of the tag that attaches the tag to the object to be monitored. In addition, the ink vial deters unscrupulous individuals from tampering with tags that are capable of functioning with probes that disengage the attaching mechanisms.
Such stated objects and advantages of the invention are only examples and should not be construed as limiting the present invention. These and other objects, features, aspects, and advantages of the invention herein will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
It is to be understood that the drawings are to be used for the purposes of illustration only and not as a definition of the limits of the invention. In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 is a side elevational view of the tag of the instant invention in an assembled state.
FIG. 2 is a side elevational view of the tag of the instant invention in an unassembled state.
FIG. 3 is a perspective exploded view of the tag of the instant invention and the components thereof.
FIG. 4 is a top plan view of the interior of second half of the instant tag with the tracks installed.
FIG. 5 is a top plan view of the interior of second half of the instant tag with the tracks and the attaching member installed.
FIG. 5A is an exploded view of an alternate preferred embodiment of the tag body incorporating the vial.
FIG. 5B is an exploded view of another alternate preferred embodiment of the tag body incorporating the vial.
FIG. 5C is an exploded view of another alternate preferred embodiment of the tag body incorporating the vial.
FIG. 6 is a top plan view of the interior of first half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member.
FIG. 7 is a top plan view of the interior of second half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member that attaches to first half illustrated in FIG. 6 .
FIG. 8 is a top plan view of the interior of first half of the instant tag illustrating an alternate preferred embodiment for accommodating an alternate resilient member.
FIG. 9 is a top plan view of the interior of second half of the instant tag with the attaching member installed illustrating an alternate preferred embodiment for accommodating an alternate resilient member that attaches to first half illustrated in FIG. 8 .
FIG. 10 is a perspective view of the interior of first half of the instant invention.
FIG. 11 is a perspective view of the interior of second half of the instant invention without the components therein.
FIG. 11A is a perspective view of the interior of second half of the instant invention with the tracks and attaching member installed.
FIG. 12 is a perspective view of a pin used with the instant invention.
FIG. 12A is a frontal perspective view of the attaching member of the instant invention.
FIG. 12B is a front elevational view of the attaching member of the instant invention.
FIG. 12C is a side perspective view of the attaching member of the instant invention.
FIG. 12D is a top perspective view of the first and second tracks used in the instant invention.
FIG. 13 is a top plan view of the interior of the first half of an alternate preferred embodiment of the instant invention illustrating additional pillars and walls that may be placed within the tag to thwart an unauthorized probe insertion.
FIG. 13A is a top plan view of the interior of the second half of an alternate preferred embodiment of the instant invention illustrating additional pillars and walls that may be placed within the tag to thwart an unauthorized probe insertion that attaches to first half illustrated in FIG. 13 .
FIG. 14 is a top plan view of the interior of the first half of an alternate preferred embodiment of the instant invention illustrating additional pillars that may be placed within the tag to thwart an unauthorized probe insertion.
FIG. 14A is a top plan view of the interior of the second half of an alternate preferred embodiment of the instant invention illustrating additional pillars that may be placed within the tag to thwart an unauthorized probe insertion and attaches to the first half illustrated in FIG. 14 .
FIG. 15 is an electrical schematic diagram of the resonant tag circuit.
FIG. 16 is a perspective view of the resonant tag circuit.
FIG. 17 is a block diagram of an article surveillance system incorporating the resonant tag circuit.
FIG. 18 is a cross-sectional view of a resonant tag system taken along line 18 - 18 of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 , a tag 20 is illustrated having a first half 22 and a second half 24 . First and second halves 22 and 24 are preferably made of a hard or rigid material. A usable rigid or hard material might be a hard plastic such as, for purposes of illustration but not limitation, an injection molded ABS plastic. If a plastic material is used, the mating of a first side wall 26 to a second side wall 28 can accomplished via an ultrasonic weld or like joining mechanism. However, it is to be understood that other joining methods, such as adhesives, may also be used. When first half 22 and second half 24 are securely joined, first sidewall 26 and second sidewall 28 form a peripheral outer wall of tag 20 . Second half 24 has an apex region 25 that extends therefrom in an opposing direction to first half 22 .
Now referring to FIGS. 3 , 4 , 5 , 11 , and 11 A, an exploded perspective view, top plan view, and perspective views illustrate the interior of second half 24 . Second half 24 receives at least a first track 30 therein, and in a preferred embodiment it also receives a second track 32 . First track 30 is tightly received within at least a first slot 31 and second track 32 is received tightly within at least a second slot 33 , such that tracks 30 and 32 are maintained in substantially parallel relations. Tracks 30 and 32 are made of a hard material such as, but not limited to, metal, which enhances the durability and performance of the tag 20 .
An attaching member 34 , as described in greater detail hereinafter, slideably rests on at least first track 30 , but in a preferred embodiment, rests on both first and second tracks 30 and 32 . Attaching member 34 has a resilient member 36 that normally maintains an opening 38 defined on said attaching member 34 in axial alignment with an aperture 40 defined on the inside of second half 24 and a hole 42 defined on the interior of first half 22 . In one preferred embodiment, attaching member 34 is made of spring sheet metal. Resilient member 36 may be a resilient lever arm 43 and in an alternate preferred embodiment, as illustrated in FIGS. 7 and 9 , at least one spring 44 may be substituted for the resilient lever arm 43 . Resilient member 36 is maintained in proximal relations to a barrier 45 , such that attaching member 34 is maintained in axial alignment described above.
Now referring to FIGS. 6 , 8 , and 10 , the interior of first half 22 is illustrated having a reinforcement means 46 defining opening 42 . Reinforcement means 46 extends inwardly but does not interfere with the sliding action of attaching member 34 on first and second tracks 30 and 32 . At least a first ridge 48 extends inwardly from the interior of first half 22 and is in proximal relation to first track 30 . In a preferred embodiment, a second ridge 50 also extends inwardly from the interior of first half 22 and is in proximal relation to second track 32 . Ridges 48 and 50 prevent upward movement of attaching member 34 , yet do not interfere with the sliding arrangement of attaching member 34 over first and second tracks 30 and 32 . Ridges 48 and 50 are in substantially parallel relations to one another.
Now referring to FIG. 12 and FIGS. 11 and 11A again in particular, in addition to the previous FIGS, a plurality of devices has been provided to prevent unauthorized manipulation and disengagement of attaching member 34 . When first half 22 and second half 24 are assembled, a shaft 52 , having a plurality of indentations 54 at predetermined intervals along the length thereof, is inserted through hole 42 and is received securely yet removably within opening 38 of attaching member 34 . Shaft 52 further extends into aperture 40 , which is defined by a tubular formation 41 extending inwardly from second half 24 . A top 55 is securely maintained at one end of shaft 52 , such that an opposing end of shaft 52 traverses an article to be monitored and is maintained within opening 38 of attaching member 34 and aperture 40 , whereby the article is securely bound between top 55 and outer surface of tag 20 .
Now also referring to FIGS. 12A , 12 B, and 12 C, attaching member 34 has a forward edge 75 and a distal rearward edge 77 . An attaching region 78 is defined proximal to the forward edge 75 and resilient member 36 is located proximal to rearward edge 77 . A first region 80 and a second region 82 are divided by attaching region 78 . A first lip 84 extends downwardly from first region 80 and a second lip 86 extends downwardly from second region 82 , such that first lip 84 and second lip 86 are in substantially parallel relations to one another, and each of the lips 84 and 86 are in substantially perpendicular relation to first and second regions 80 and 82 respectively. A first interior wall 88 and a second interior wall 90 are created by lips 84 and 86 respectively. First lip 84 and second lip 86 extend beyond rearward edge 77 and form a first outward curve 92 and a second outward curve 94 respectively, on a side of attaching member 34 proximal to resilient member 36 . Opening 38 of attaching member 34 is defined by a first jaw 96 and an opposing second jaw 98 . Jaws 96 and 98 extend downwardly from the plane of first and second regions 80 and 82 and are in proximal relations when they define opening 38 . However, jaws 96 and 98 are flexible such that they can move towards one another to decrease the size of opening 38 or they can move away from one another to increase the size of opening 38 . As a result, shaft 52 is maintained within opening 38 as defined by jaws 96 and 98 in a secure, yet removable, manner.
Now also referring to FIG. 12D , first track 30 has a first top edge 100 and a first bottom edge 104 which are distal to one another and are interconnected by a first front edge 108 and an opposing first back edge 112 . Second track 30 has a second top edge 102 and a second bottom edge 106 which are distal to one another and are interconnected by a second front edge 110 and an opposing second back edge 114 . First back edge 112 and second back edge 114 are curved to accommodate the curved portion of second side wall 28 where apex 25 is created. First track 30 has a first outer surface 116 and a first inner surface 120 and second track 32 has a second outer surface 118 and a second inner surface 122 .
In order to disengage shaft 52 from jaws 96 and 98 , enough force must be applied to forward edge 75 of attaching member 34 to overcome the force exerted by the resilient member 36 , and to move attaching member 34 towards rearward edge 75 . In addition, the force must be sufficient to overcome the frictional force created between first interior wall 88 and second outer surface 118 and the frictional force created between second interior wall 90 and first outer surface 116 . In order to do so, a probe 8 of a predetermined shape and length must be inserted through entrance 56 of tag 20 and extend to attaching member 34 to apply the sufficient necessary force to forward edge 75 to overcome the force exerted by the resilient member 36 and the frictional force described above to allow sufficient linear movement along first and second tracks 30 and 32 to disengage and remove shaft 52 from first and second jaws 96 and 98 . U.S. Pat. No. 4,738,258 is hereby incorporated by reference for teaching the probe 8 required and the necessary actuation thereof for insertion into entrance 56 . U.S. Pat. No. 4,738,258 can be modified into the disengagement apparatus illustrated in U.S. Pat. Nos. 5,426,419 and 5,535,606, the teachings of the detachers are also incorporated herein by reference.
To determine the force required to disengage the shaft 52 from jaws 96 and 98 of attaching member 34 of the instant invention as compared to the tag of the '419 patent, the following experiment was conducted on ten tags 10 of the instant invention and ten tags produced in accordance with the specification of the '419 patent. A spring balance was hung on a wall, with its spring loading hook at the bottom. Two ends of a cotton sling were tied to form a loop. One end of the loop was secured on the hook of the balance whereas the other end was wound through the handle such that a downward pull force on the detacher (as illustrated in FIGS. 11 and 12 of the '419 patent) led to the squeezing of the detacher's trigger. Because the spring balance is in series with the sling, a measure of the triggering force to detach the tack shaft 52 could be measured. On average, approximately five pounds more force was required to detach the shaft 52 from the attaching member 34 of the instant invention than the tag of the '419 patent.
In order to defeat the introduction of unauthorized probes into entrance 56 , several false paths and barriers are provided within tag 20 and the arcuate channel of the '419 patent and the '390 patent are completely eliminated. Because apex region 25 of tag 20 is constructed to be securely retained within a nesting or cradle area of a detacher, as taught by the '419 patent, tag 20 does not require any arcuate channels to lead the detaching probe 8 to the forward edge 75 of the attaching member 34 . The predetermined shape of the detaching probe 8 and the predetermined positioning of the attaching member 34 allow an authorized individual using an authorized detacher to disengage the shaft 52 from jaws 96 and 98 , thereby releasing the attached article. Dashed line 99 , of FIG. 5 , illustrates a proper path that may be taken by the detaching probe 8 .
However, to defeat even the introduction of a probe that has been illicitly disassembled from an authorized detacher, a first partition 58 prevents entrance of the unauthorized probe if at an incorrect plane. A second partition 60 having a greater height than first partition 58 , also prevents the introduction of an unauthorized probe to attaching member 34 . A first pillar 62 and a second pillar 64 also prevent application of force to attaching member 34 by an unauthorized probe by deflecting the same. A third partition 66 , a fourth partition 68 , a fifth partition 70 , and sixth partition 72 are at different levels and define a plurality of cavities 74 therebetween. Cavities 74 extend within apex region 25 and are substantially perpendicular to the plane of attaching member 34 , such that an unauthorized probe inserted through apex region 25 will be retained within a single cavity 74 and will not be able to manipulate attaching member 34 laterally to disengage shaft 52 .
Furthermore, if an unauthorized probe is being manipulated by hand, the probe will not be inserted at the correct plane to make proper contact with forward edge 75 of attaching member 34 to disengage the same. Instead, the unauthorized probe will go into the space defined between attaching member 34 and the different partitions 66 , 68 , 70 , and 72 . FIGS. 13 and 13A teach an alternate preferred embodiment with different barriers to prevent access to the attaching member 34 of tag 20 . FIG. 14 and 14A teach an alternate preferred embodiment with further different barrier arrangements to prevent access to the attaching member 34 of tag 20 .
Referring now also to FIG. 15 , therein is illustrated a schematic diagram of a resonant tag circuit 124 . In a preferred embodiment, circuit 124 has at least an inductive element 126 and at least a capacitance element 128 connected in a series loop and forming an inductive capacitance (LC) resonant circuit 124 . The resonant tag circuit is employed in connection with electronic article security systems particularly electronic article security systems of the radio frequency or RF electromagnetic field type. Such electronic article security systems are well known in the art and a complete detailed description of the structure and operation of such electronic article security systems is consequently not necessary for an understanding of the present invention.
However, as illustrated in FIG. 17 , such electronic article security systems employing resonant tag circuits include a transmitting means 130 for transmitting electromagnetic energy at or near the resonant frequency of the resonant tag into or through a surveillance zone 132 . A detecting means 134 monitors the surveillance zone 132 for the presence of a resonant tag within the surveillance zone 132 . Surveillance zone 132 is generally proximate to an entrance and/or exit of a facility such as, but not limited to, a retail store. The security system's function is to detect the presence within the surveillance zone 132 a monitored article having a resonant tag circuit 124 attached thereto in a secure fashion.
In such a system, transmitting means 130 transmits pulses in the form of RF bursts at a frequency in the low radio-frequency range, such as 58 kHz in a preferred embodiment but may be adapted to be at any appropriate frequency as desired. The pulses (bursts) are emitted (transmitted) at a repetition rate of, for example 60 Hz AC cycle, with a pause between successive pulses. The detecting means 134 includes a receiver 136 which is synchronized (gated) with the transmitting means 130 so that it is activated only during the pauses between the pulses emitted by the transmitting means 130 . The receiver 136 expects to detect nothing in these pauses between the pulses. If an activated tag is present within the surveillance zone 132 , however, the resonator therein is excited by the transmitted pulses, and will be caused to oscillate at the transmitter frequency, i.e., at 58 kHz in the above example. The resonator emits a signal which rings at the resonator frequency, with an exponential decay time (“ring-down time”). The signal emitted by the activated tag, if it is present between transmitting means 130 and the receiver 136 , is detected by the receiver 136 in the pauses between the transmitted pulses and the receiver accordingly triggers an alarm 138 . Alarm 138 may be audible and/or visual or can be a silent alarm that is detected by any means known in the art.
In a preferred embodiment, to minimize false alarms, the detecting means 134 usually must detect a signal in at least two, and preferably four, successive pauses; however, it is to be understood that the present invention can be adapted to function within one pause. Furthermore, in order to further minimize false alarms, such as due to signals produced by other RF sources, the receiver 136 employs two detection windows within each pause. The receiver 136 integrates any 58 kHz signal (in this example) which is present in each window, and compares the integration results of the respective signals integrated in the windows. Since the signal produced by the tag is a decaying signal, if the detected signal originates from a resonator in a tag it will exhibit decreasing amplitude (integration result) in the windows. By contrast, an RF signal from another RF source, which may coincidentally be at, or have harmonics at, the predetermined resonant frequency, would be expected to exhibit substantially the same amplitude (integration result) in each window. Therefore, alarm 138 is triggered only if the signal detected in both windows in a pause exhibits the aforementioned decreasing amplitude characteristic in each of a number of successive pauses.
For this purpose, as noted above, the receiver electronics is synchronized by a synchronization circuit with the transmitter electronics. The receiver electronics is activated by the synchronization circuit to look for the presence of a signal at the predetermined resonant frequency in a first activation window of about 1.7 ms after the end of each transmitted pulse. For reliably distinguishing the signal (if it originated from the resonator) integrated within this first window from the signal integrated in the second window, a high signal amplitude is desirable in the first window. Subsequently, the receiver electronics is deactivated, and is then re-activated in a second detection window at approximately 6 ms after the original resonator excitation, in order to again look for and integrate a signal at the predetermined resonant frequency. If such a signal is integrated with approximately the same result as in the first detection window, the evaluation electronics assumes that the signal detected in the first window did not originate from a marker, but instead originated from noise or some other external RF source, and alarm 138 therefore is not triggered.
Now also referring to FIGS. 16 and 18 , therein is illustrated a preferred embodiment of the resonant tag circuit 124 . Inductive element 126 is formed by a conducting member 140 that is made of any material that is capable of conducting electricity, and in a preferred embodiment is made of copper. Conducting member 140 is coiled around a first member 142 that is preferably constructed of a non-conductive material such as, but not limited to, plastic and rubber. First member 142 has a first wall 144 and a second wall 146 that are interconnected by a middle portion 148 . First wall 144 , second wall 146 , and middle portion 148 axially define a cavity 150 extending therethrough.
Middle portion 148 is adapted to receive conducting member 140 thereon in a coiled fashion on an outer surface 152 thereof between first wall 144 and second wall 146 . Middle portion 148 has an inner surface 154 that defines cavity 150 . A magnetic member 156 is adapted to be received within cavity 150 and to be frictionally retained within inner surface 154 of middle portion 148 . Magnetic member 156 may be a ferromagnetic material or any other material having magnetic properties, and in a preferred embodiment, magnetic member 156 is made of amorphous metals.
Capacitance element 128 is a parallel plate capacitor formed of conductive material on a first plate and a second plate (not shown) that are known in the art. Capacitance element 128 is adapted to be received on first member 142 , and in a preferred embodiment is received on first wall 144 thereof. First plate and second plate of capacitance element 128 are attached to opposing ends of conducting member 140 to form a series circuit.
When resonant tag circuit 124 enters a surveillance zone 132 it is subjected to an electromagnetic field and magnetic member 156 is charged. As the electromagnetic field is removed, the stored magnetic energy stored in the magnetic member 156 is released and thus an ac current is generated within inductive element 126 and capacitance element 128 . When an ac voltage is applied to the resonant tag circuit 124 , the current depends on the frequency thereof. The resonant frequency of circuit 124 can be determined by the following equation:
fo
=
1
2
π
LC
Wherein f 0 is the resonant frequency of the circuit and L is the inductance and C is the capacitance. As can be ascertained from the equation, many possible combinations yield the desired resonant frequency, however, the L to C ratio is preferably kept high in order for the circuit to be selective and minimize undesirable resonances to disturbances close to the resonant frequency thus minimizing false alarms. In a preferred embodiment, optimal values were determined to be L=2.08 mH and C=3.6 nF thus yielding an L to C ratio of 577,777.78.
It is to be understood that resonant tag circuit 124 is of sufficient size to be stored within casings used in article surveillance systems. Specifically, tag circuit 124 is of sufficient size to be received and enclosed within compartment 76 of tag 20 . Compartment 76 is defined by a peripheral wall 158 extending inwardly from second half 24 to enclose the resonant tag circuit 124 therein. A false path 160 is created between second side wall 28 and peripheral wall 158 .
If an article having resonant tag circuit 124 attached thereto via tag 20 is moved into the surveillance zone 132 , the alarm 138 will be activated by circuit 124 to signify unauthorized removal of the article through a specified area. For purposes of illustration but not limitation, in a preferred embodiment, the length of circuit 124 is less than 2 cm and the radius thereof is less than 1 cm. However, it is to be understood that alternate sizes and shapes of circuit 124 will also function as taught and alternate electronic detection circuits as are known in the art may also be used.
Now also referring to FIGS. 5 , 5 A, 5 B and 5 C, unscrupulous individuals have taken a garment protected by tag 20 into a dressing room of a retail location and used tools, such as hand held cutters, to sever the body of the tag 20 to remove and discard the resonant tag circuit 124 in the dressing room. The unscrupulous individuals are then able to abscond with the garment with the shaft 52 and attaching member 34 attached to the garment without setting off the electronic detection circuit. In the safety of their own home, the unscrupulous individual has the necessary time and larger equipment to manipulate the attaching member 34 to disengage the shaft 52 from the garment.
At least one vial 170 is positioned within first half 22 and second half 24 such that it does not interfere with the movement of attaching member 34 . The vial 170 is known in the art and is preferably made of breakable glass which can be modified to break at a predetermined pressure application. Vial 170 contains a heavily staining and/or ill-smelling substance, preferably a liquid or gas under pressure, which is able to adhere durably to article to which tag 20 is attached, thereby rendering the article unusable. If an unauthorized person attempts to cut tag 20 or uses force to disengage the pin from the article being monitored, vial 170 will break causing said staining and/or ill-smelling substance to be expelled onto the article. To aid in the expulsion of the staining and/or ill-smelling substance, at least an orifice 172 is defined through first half 22 and second half 24 .
To prevent unauthorized insertions of foreign objects through orifice 172 , vial 170 can be positioned within first half 22 and second half 24 to occlude orifice 172 . Vial 170 may be maintained in position by frictional engagement, adhesive, or resilient protrusions that extend inwardly from either first half 22 or second half 24 and firmly engage vial 170 therebetween. In one preferred embodiment, vial 170 is frictionally maintained within false path 160 between second side wall 28 and peripheral wall 158 . Vial 170 , however, may also be positioned in other desirable locations as illustrated in the figures to prevent the cutting of the body of tag 20 . Vial 170 is positioned to cover an area 173 between the resonant tag circuit 124 and the attaching member 134 .
Now referring to FIG. 13 A, in order to increase the susceptibility of the vial 170 to breakage, a pressure point 174 extends inwardly from either first half 22 or second half 24 and engages a portion of vial 170 . Thereby, an application of force to the outside of tag 20 by unauthorized tools will force pressure point 174 toward vial 170 and cause breakage thereof and expulsion of the staining or ill-smelling fluid or substance.
While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible without departing from the essential spirit of this invention. Accordingly, the scope of the invention should be determined not by the embodiment illustrated, but by the appended claims and their legal equivalents. | An electronic article surveillance (EAS) tag having an attaching member 34 located therein and adapted to securely and releasably receive a shaft of a pin therein, whereby a predetermined arcuate probe is inserted through an opening and applies a requisite force to the attaching member to release the shaft. At least one frangible vial containing a detrimental substance positioned within the tag body to deter unauthorized manipulation of the tag. |
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FIELD OF THE INVENTION
[0001] The present invention relates to removable banknote cassettes used in banknote validators.
BACKGROUND OF THE INVENTION
[0002] A number of automated payment systems include banknote cassettes which receive and stack banknotes and allow authorized removal of the cassette from the payment system. Typically the cassette is locked such that access to the stacked banknotes is restricted. The banknote cassettes can be removed and transported to a secure environment where they are unlocked and appropriately processed. When a banknote cassette is removed, a replacement banknote cassette is inserted. In many cases, a series of automated payment devices are being serviced at the same point in time and the banknote cassettes are typically removed and stored in a further device for transport to the secure environment.
[0003] Automatic payment systems typically include a banknote validator for confirming the authenticity of a banknote and a drive arrangement for moving the banknote from the validator to the banknote cassette. Preferably, the automatic payment systems are associated with a vending, gaming or other self-serve type device. In many of these applications, the space available within the gaming or vending machine is quite limited and therefore an efficient design and effective space utilization of the automatic payment system is required.
[0004] A number of banknote cassettes have been designed with a fixed handle on one face thereof to provide an effective means for manipulating the banknote cassette during insertion of the cassette into an automatic payment system and to allow simple removal of the banknote cassette from such an automatic payment system. Unfortunately, the fixed projecting handle requires additional space within the device which may not be available. Other banknote cassettes have included recessed finger grip portions in the sides of the cassette for of the banknote cassette but the width of the cassette makes this arrangement awkward.
[0005] The present invention provides an effective handle arrangement which adds convenience while still effectively utilizing the space available in the related vending, gaming or other device.
SUMMARY OF THE INVENTION
[0006] A banknote cassette for storing of banknotes in a stacked manner comprises a generally rectangular case having a slot through which banknotes are received and stacked interior to the case. The case includes a foldable handle secured to a face of the rectangular case. The foldable handle is movable from a storage position generally parallel to the face to a lockable operating position with a handle generally perpendicular to the face.
[0007] In a preferred aspect of the invention, the handle includes a bias arrangement for urging the handle to the storage position.
[0008] In a further aspect of the invention, the handle in the operating position cooperates with the cassette to lock the handle and maintain the orientation of the handle in a locked position relative to the face. The arrangement also includes a release for the handle allowing movement of the handle from the locked operating position to the storage position.
[0009] In yet a further aspect of the invention, the handle includes two opposed handle segments with each segment including a gear portion with the gear portions of opposed handle segments being in mesh. With this arrangement, movement of one handle segment causes a corresponding movement of the other handle segment.
[0010] In yet a further aspect of the invention, the handle segments are of the identical construction.
[0011] In yet a further aspect of the invention, each handle segment includes a projecting releasable locking tab and a locking recess located such that the projected locking tab of one handle segment is received in the locking recess of the other handle segment when the handle segments are moved to the operating position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the invention are shown in the drawings, wherein:
[0013] [0013]FIG. 1 is a perspective view of the banknote cassette with the foldable handle in a storage position;
[0014] [0014]FIG. 2 is a perspective view of the banknote cassette with the foldable handle segments being moved from the storage position to an operating position;
[0015] [0015]FIG. 3 is a perspective view of the banknote cassette with the handles in the operating position and connected one to the other;
[0016] [0016]FIG. 4 is a perspective view of a backside of the handle; and
[0017] [0017]FIG. 5 is a perspective view of a front side of the handle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The banknote cassette 2 , as shown in the Figures, includes a rectangular casing with part of the casing including the planar face 4 . A foldable handle 6 is secured on the planar face 4 and is movable from the storage position shown in FIG. 1 to the operating position shown in FIG. 3.
[0019] The foldable handle 6 includes identical handle segments 8 and 10 which are secured in an opposed relationship. The one handle is rotated 180 degrees relative to the other handle. In this way, the same handle segment is used for both sides of the foldable handle.
[0020] Each handle segment includes fixed gears as part of the handle with each end of the handle segment including a gear. Segment 8 includes fixed gears 12 and 14 whereas handle segment 10 includes fixed gears 16 and 18 . Each of the handles is secured to the casing by means of a lock pin 28 which passes through a bracket secured to the face 4 and passes through the end portion 17 or 19 of the handle segment. This pin also passes through the associated fixed gear. Each of the gears includes a cylindrical port 21 through which the lock pin 28 extends.
[0021] A torsion spring 30 can be secured to one of the handle segments at one end of the casing and the opposite handle segment at the other end of the casing includes the torsion spring 30 . In this way, each handle includes the torsion spring which creates a bias urging the handles to the storage position of FIG. 1. One torsions spring is sufficient, however, two springs are preferred.
[0022] The torsion spring is sleeved on the pin 28 and one end of the torsion spring overlies the pin of the adjacent handle. The other end of the torsion spring is engaged by and moves with the opposite handle segment.
[0023] As shown in FIGS. 1, 4 and 5 , fixed gears 12 and 16 are in mesh and fixed gears 14 and 18 are in mesh. Rotation of one of the handle segments 8 or 10 causes the opposed handle segment to move corresponding but in the opposite direction. Thus movement of one of the handle segments causes the other handle segment to move in relation therewith as indicated in FIG. 2. This movement is opposed by the torsion springs 30 which are being distorted due to movement of the handle segments. Further movement of the handle segments to the locked position shown in FIG. 3 causes further winding of the torsion springs.
[0024] Each of the handle segments includes a projecting tab and recess. Handle segment 8 includes projecting tab 20 which is aligned with, and will be received in the recess 26 of the handle segment 10 . Handle segment 10 includes projecting tab 24 which will be received in the recess 22 of handle segment 8 . A releasable snap fit relationship is provided between the projections 20 and 24 with their respective recesses 22 and 26 . In the operative position as shown in FIG. 3, the handle segments are secured one to the other and also have a secured orientation relative to the planar face 4 . As can be appreciated, the gears at each end of the handle segment effectively provide a lock maintaining the orientation of the handle relative to the planar face 4 . Thus the handle is not freely pivoting relative to the planar face 4 when it is in the locked position of FIG. 3. This secure orientation is advantageous in removing of the banknote cassette, loading of the banknote cassette, movement of the banknote cassette to a transport vehicle or manual transport of a cassette.
[0025] As clearly shown in FIGS. 1 and 3, the foldable handle in the storage position of FIG. 1 is flat, such that the amount of additional space required within a device is relatively small. When the handle segments are moved to the operative position as shown in FIG. 3, more space is required but the device is open. When the banknote cassette is placed in an automated payment device, the handle segments move to the storage position and the handle is relatively compact. When the handle is required, the handle segments may be rotated and locked and a positive orientation of the handle relative to the banknote cassette is provided.
[0026] The torsion springs 30 in addition to providing a bias moving the handles to the storage position of FIG. 1 also serve to maintain the handles in the storage position and reduce vibration. Such vibration can lead to noise which can be quite annoying during transport of the cassettes if the handles are moved to the storage position. Furthermore, in normal use, the springs also reduce noise caused by vibration.
[0027] Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims. | A banknote cassette includes a generally rectangular casing for receiving and storing banknotes in a stacked manner. The case includes a foldable handle, movable from a storage position to a locked operating position with the handle maintaining the locked operating position. In a preferred aspect, the foldable handle includes two opposed handle segments which cooperate with each other during movement of the handle segments from the storage position to the operating position. |
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BACKGROUND OF THE DISCLOSURE
The present invention is directed to an improved wall framing system, particularly, to an external veneer cap mounted to an existing wall system of a building and the method of installation of the veneer cap.
Wall framing systems for buildings have been used for some time. In such systems, structural members such as sills, jambs, and mullions grip the edges of glass panels or the like to form the wall system. Such a wall system, for example, may be of the curtain wall, skylight, or slopped glazing type. Typically, the wall framing members include two primary parts, an interior part and an exterior part. The glass panels are captured between the interior and exterior frame members to form the completed system. The interior and exterior frame members are connected together by various means for securely gripping the glass panels. Seals or gaskets are typically installed along the connection, thereby forming a watertight seal between the wall frame members and the glass panels.
A common problem encountered with most, if not all, wall systems is intrusion of water and air past the gasket seals or other type of connection and into the building interior. Rain water, condensation, and water from window washing are the typical sources of water intruding into the wall framing system. Most buildings encounter this problem. After a period of time, the panel gasket seals become brittle and crack. The gasket seals may also be abraded by particles in the air or by routine maintenance, such as window washing. Consequently, most a relatively short period of time, most building wall systems require extensive maintenance to repair the panel gasket seals, which maintenance may include the replacement or recaulking of the panel gasket seals.
A significant problem associated with maintenance of the panel gasket seals is that repairs must often be made both from the interior and exterior of the wall system. This is always objectionable to the occupants of the building which are inconvenienced by the interruption in their work schedule.
It is, therefore, an object of the present disclosure to provide an external wall maintenance system which is watertight.
It is a further object of the invention is to provide an external wall maintenance system which may be completely installed from the exterior of the building.
It is yet another object of the invention to provide a method of installing the wall maintenance system.
SUMMARY OF THE INVENTION
The invention of the present disclosure is directed to a veneer cap installed on the external surface of a wall system and the method of installation. The veneer cap of the invention comprises a series of both vertical and horizontal members which bridge the existing system mullion, sill and jamb connections thereby providing a panel-to-panel seal over the panel gasket seals of the wall system. The veneer cap includes a bridging member having a pair of parallel, spaced legs extending therefrom. The legs terminate at flange members which extend substantially perpendicular to the leg members. A double sides adhesive tape initially secures the veneer cap to the external surface of the wall system over the panel gasket junction. A structural silicone adhesive sealant permanently bonds the veneer cap to the external surface of the wall system.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are, therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a perspective view of a portion of a wall system having the veneer cap of the invention mounted thereon;
FIG. 2 is a sectional view showing the veneer cap of the invention bridging over the panel connection of the wall system;
FIG. 3 is a partial, exploded view showing the vertical and horizontal components forming the veneer cap of the invention;
FIG. 4 is an enlarged plan view showing the junction of the vertical and horizontal components of the veneer cap of the invention;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 4;
FIG. 7 is a sectional view of an alternate embodiment of the veneer cap of the invention; and
FIG. 8 is a sectional view of yet another alternate embodiment of the veneer cap of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a portion of an existing wall system of a building is shown and generally designated by the numeral 10. The wall system 10 includes a series of glass panels 12 connected by mullions 14 and sills 16. As best shown in FIG. 2, the mullion 14 of the wall system 10 is of typical construction known in the prior art. The mullion 14 includes an interior metal connector 18 and an external connector seal 20. The forward end of the metal connector 18 is provided with a pair of channels 22 which extend the full length of the metal connector 18. The walls of the channels 22 are provided with serrations or teeth 24 for gripping a pair of legs 26 which project from the bottom surface of the external connector seal 20 and are received within the channels 22. The metal connector 18 is also provided with connector clips 28 which fasten thereon. The connector clips 28 include gripping flanges 30 which secure an internal seal 32 against the interior edges of the glass panels 12. The sill 16 is of similar construction for gripping the horizontal edges of the glass panels 12 as shown in FIG. 1. It will be observed that the glass panels 12 of the wall system 10 shown in FIGS. 1 and 2 are gripped between an interior and exterior member which are joined together and grip the panels 12 along the edges thereof. The wall system 10 is typical of many wall systems on existing buildings.
Referring again to FIG. 2, it is readily apparent that water intrusion into the building is highly likely along the external connector seal 20 and the internal seal 32. Climatic conditions and any number of other factors may quickly weaken the seal structure of the wall system 10 permitting intrusion of water and/or air. Prior to the present disclosure, costly repairs and business disruptions were required to remedy such a problem.
Referring now to FIG. 3, the veneer cap of the invention is generally identified by the numeral 40. The veneer cap 40 comprises a series of vertical members 42 and horizontal members 44. The veneer cap members 42 and 44 are fabricated of extruded aluminum and may be cut to any desired length as required for a particular wall system. Aluminum is a lightweight material and particularly suited for this purpose, however, the veneer cap 40 of the invention may be fabricated of any material suitable for external wall systems. For example, extruded plastic or vinyl is well suited for this purpose.
The veneer cap 40 is mounted to the external surface of the wall system 10 and is secured directly to the panels 12. The mullion, sill and jamb structures and the seals associated therewith are not affected or altered during the installation of the veneer cap 40. The intersection of vertical and horizontal external connector seals 20 is bridged over by a channel splice 46 which will be described in greater detail hereinafter.
Returning again to FIG. 2, it will be observed that the vertical veneer cap member 42 defines a substantially channel-like configuration formed by a cover plate 48 and a pair of spaced, parallel leg members 50 extending therefrom. The leg members 50 terminate in L-shaped flanges 52 which extend inwardly from the leg members 50 and are substantially parallel to the cover plate 48.
The veneer cap 40 is initially secured to the panels 12 by a double sided adhesive tape 54. The tape 54 has some thickness and for purposes of illustration, may be approximately 3/16 inch by 1/4 inch. Thus, upon securing the veneer cap 40 to the panels 12, a gap of approximately 3/16 of an inch is defined between the surface of the panels 12 and the flanges 52 of the veneer cap 40. The gap is filled with structural silicon 56. The consistency of the silicon 56 is much like that of caulk used in weather stripping and therefore it does not tend to run. The silicone 56 is smoothed out to present a clean appearance. The cure time for the structural silicon 56 may vary depending on the type used. The cure time for Dow Cornig 795 silicone, which has been found to be particularly suitable for this purpose, is approximately 21 days. Once the silicon 56 has cured, a permanent and waterproof panel-to-panel seal is formed about the external connector seal 20.
For purposes of illustration only, the veneer cap 40 is shown as having a substantially U-shaped channel-like configuration. It is understood, however, that the shape of the veneer cap 40 is not particularly significant and may be any shape which will bridge over the external connector seal 20 or external connecting member of the wall structure to provide a panel-to-panel seal. The profile of the vertical veneer cap member 42 and horizontal veneer cap member 44 is substantially the same, however, the horizontal veneer cap member 44 is slotted to receive the channel splice 46 as shown in FIG. 3.
Referring now collectively to FIGS. 4, 5 and 6, the junction of the vertical cap member 42 and the horizontal cap member 44 is shown. To bridge the external connector seal 20 at a four corner junction, the channel splice 46 is adhesively mounted to the horizontal veneer cap member 44. The member 44 is measured and slotted so that the channel splice 46 may be centered over the vertical external connector seal 20. Likewise, the channel splice 46 includes a slot 49 which bridges over the horizontally extending external connector seal 20. The channel splice 46 is substantially U-shaped in profile having a longitudinal length slightly greater than the width of the horizontal veneer cap member 44 so that each end of the channel splice 46 projects outwardly from the member 44 when it is adhesively mounted thereto as shown in FIG. 5. The channel splice 46 is dimensioned so that the projecting ends thereof fit snugly within the channel formed by the vertical veneer cap member 42. The projecting ends of the channel splice 46 are wrapped with bond breaker tape and the vertical veneer cap member 42 is slid about the projecting ends of the channel splice 46 and aligned with the horizontal veneer cap member 44 and slightly spaced therefrom. Thus, a gap 43 is defined between the end of the vertical veneer cap member 42 and a side leg member of the horizontal veneer cap member 44 as shown in FIGS. 4 and 5. The gap 43 is filled with the silicone 56, thereby forming a seal at the junction of the veneer cap sealant members 42 and 44 which extends from one panel 12 across the top of the channel splice 46 to the opposite panel 12. In this manner, a seal is provided between the channel splice 46, the vertical veneer cap member 42 and the horizontal veneer cap member 44, thereby completely sealing about the four corner junction.
Referring now to FIGS. 7 and 8, alternate embodiments of the veneer cap 40 are shown. In the embodiment of FIG. 7, the veneer cap 40 has been modified to provide a bridging seal between a panel 12 and a wall member 60. The veneer cap 40 is modified along one longitudinal end to include a flange 62 extending inwardly and substantially parallel to the leg member 50. The adhesive tape 54 is positioned interiorly of the flange 62 and adhesively mounts an edge of the cover plate 48 adjacent to the flange 62 and to the top face of the external connector seal 20. A bond breaker tape 64 extends from the flange 62 to the wall 60 to cover the gasket seal of the wall system. The gap formed between the flange 62 and wall 60 is filled with the silicone sealant 56 in the same manner as previously described.
The alternate embodiment of FIG. 8 is substantially similar to the embodiment shown in FIG. 7. However, the veneer cap 40 has been modified to include a leg member 68 which extends outwardly from the cover plate 48 in a direction opposite the leg member 50. A cross member 70 connects the leg member 68 to a flange 72. The flange 72 provides a surface for adhesively mounting the veneer cap 40 to the wall 60. The gap defined therebetween is filled with silicone sealant 56 to complete the installation of the veneer cap 40 bridging between the plate 12 and the wall 60.
The veneer cap 40 of the invention may be installed on most existing wall systems. The veneer cap 40 is installed from the exterior of the building and therefore does not interrupt the daily routine of the building occupants. Prior to installation, the panels 12 are cleaned thoroughly along the area adjacent the external connector seal 20. The external connector seal 20 is also wiped clean with a solvent so that all contact areas are clean. If not already prepared, the horizontal veneer cap member 44 is cut to length and slotted to receive the channel splice 46. The channel splice 46 then is adhesively mounted to the horizontal veneer cap member 44 in the slotted area. The veneer cap member 44 is then aligned to bridge over a horizontal external connector seal 20 of the wall system 10. Backing tape on the adhesive tape 54 is removed and the horizontal veneer cap member 44 is pressed against the panels 12. The process is repeated to secure the horizontal veneer cap member 44 to the panels 12 until all the horizontal veneer cap members 44 to be installed are adhesively secured to the panels 12.
The vertical veneer cap members 42 are prepared in a similar fashion. Each vertical veneer cap member 42 is first tested to insure that there is a proper fit about the projecting ends of the channel splice 46. The vertical veneer cap member 42 is then aligned and the tape backing is removed from the tape 54 permitting the vertical veneer cap member 42 to be adhesively mounted to the panels 12. After installation of the vertical veneer cap members 42 is completed, the silicone sealant 56 is applied and smoothed to complete the installation.
While the foregoing is directed to the preferred 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 which follow. | Disclosed is a wall system having vertical and horizontal panel gripping members connecting a plurality of panel members. The vertical and horizontal panel gripping members are covered by a veneer cap extending over the vertical and horizontal panel gripping members and being bonded to the panel members providing a panel-to-panel seal about the panel gripping members on the exterior of the wall system. |
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of concrete construction blocks. In particular, the present invention provides a sound barrier fence made from concrete blocks that is easy to assemble, maintain and repair. Some of the blocks of the present invention are also useful for construction of foundation and other walls of buildings.
BACKGROUND OF THE INVENTION
[0002] Sound barrier fences are located beside highways, in urban areas, and serve to deaden vehicular noise from the highway, so that it is not a nuisance in surrounding neighbourhoods. Sound barrier fences may be made from wood, metal or concrete, but are most effective when made of concrete, because of the superior sound deadening characteristics of concrete.
[0003] Typically, a sound barrier fence comprises a series of posts, with panels extending between them. The panels may be unitary, or may be made of a series of stacked narrow concrete panels or blocks. The advantage of narrow stacked panels is that each extends from post to post, but the disadvantage is that a long narrow panel is both fragile and very heavy. It must be maneuvered into place by heavy equipment.
[0004] A less fragile concrete sound deadening fence construction is shown in U.S. Pat. No. 5,623,797, which shows a sound barrier made of stacked blocks. The blocks interlock loosely at their top and bottom surfaces, but neighbouring blocks in a course of blocks do not interlock.
[0005] The present invention provides novel fence blocks for use in constructing a sound barrier fence.
[0006] In a broad aspect, therefore, the present invention relates to a block for use in erecting a fence, said block having opposed front and rear surfaces, opposed top and bottom surfaces, and a pair of opposed ends, the top and bottom surfaces being complementarity profiled to mutually interfit, and the end surfaces being shaped to permit a plurality of blocks to be laid in a course with no mortar in between blocks in a course.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In drawings that illustrate the present invention by way of example:
[0008] [0008]FIG. 1 is an end view of a column for use with the blocks of the present invention;
[0009] [0009]FIG. 2 is an end view of a cap for use with the blocks of the present invention;
[0010] [0010]FIG. 3 is an end view of a block according to the present invention, said end view being applicable to each embodiment of the blocks of the present invention;
[0011] [0011]FIG. 4 is an end view of stacked blocks according to the present invention;
[0012] [0012]FIG. 5 is a front view of a stacked fence wall according to the present invention;
[0013] [0013]FIG. 6 is a top view of the wall of FIG. 5, but without a cap;
[0014] [0014]FIG. 7 is a top view of a course of blocks exhibiting a preferred form of the present invention;
[0015] [0015]FIG. 7A is an end view of one of the blocks of FIG. 7, adapted for use in general construction;
[0016] [0016]FIG. 8 is a top view of a course of blocks exhibiting another preferred form of the present invention; and
[0017] [0017]FIG. 9 is a top view of a corner block for use with the block of FIG. 7A.
DETAILED DESCRIPTION
[0018] Referring now to the drawings, in FIG. 1 there is illustrated a column element 1 with flanges extending from the front 3 and rear 4 faces thereof to define channels 5 for receiving the ends of the blocks.
[0019] As shown in FIG. 5, the column may be of any desired length. It is anchored firmly to the ground, for instance by being bolted and grouted to a footing. Additional columns are spaced at regular intervals to define fence posts between which the blocks of the present invention are stacked. The blocks are also stacked on a suitably prepared surface, that may be bevelled and provided with footings if desired. Such preparation is conventional. Moreover, a column element 1 may be fabricated from block-height column element blocks, appropriately cemented together to form a column of any desired length.
[0020] A cap 6 for use especially along the top edge of a sound barrier fence according to the present invention is shown in FIG. 2 and FIG. 5. It consists of a main body 7 , with flanges 8 depending downwardly therefrom. The cap 6 , which is also of indeterminate length, may also be used to finish and end of a wall section, where a full column 1 is not required.
[0021] Blocks for use in connection with the present invention are fabricated from concrete, and are shown, in top or plan view in FIGS. 6, 7 and 8 . In FIG. 6, a basic form of the block of the present invention is shown. It consists of a front wall 9 , a rear wall 10 , and angled end walls 11 , 12 . The front and rear walls 9 / 10 , are joined by a web 13 that is at the mid-point of the block. The web reinforces the block structurally, and forms a convenience point to break the block in two as shown in FIG. 6, as will be necessary to insert the block into a column on alternate courses of a wall, if a running bond pattern of block placement is utilized. As shown in FIGS. 3 and 4, the upper edges 13 of the block are bevelled, and the lower surface is provided with a shallow groove 14 to interfit with the top surface 15 of the block, with the edges 16 of the groove bearing against the bevelled edges of the top surface 15 of the block, to permit the block to be stacked easily.
[0022] The outermost end edges 17 of the blocks of the embodiment shown in FIG. 6 are bevelled, so that each block in a wall is outlined by top bevelled edges 13 and side bevelled edges 17 , to provide a pleasing masonry appearance.
[0023] Referring to FIG. 8, a block that is similar to that shown in FIG. 6 is shown. However, moisture 18 , and tension 19 elements are formed in opposing ends of the block, to permit a strong interlocking fit between blocks in a course.
[0024] Another preferred embodiment of intermitting block is shown in plan in FIG. 7. Each end of the block of FIG. 7 is provided with a zig-zag profile having a major 20 and a minor 21 peak, and a valley 22 between them. The block exhibits rotational symmetry, whereby the major peak 20 at one end is on the opposite side of the block from the major peak at the other, so that the major peak will fit neatly into the valley of an adjoining block. It will be noted that the blocks of FIGS. 7 and 8, especially FIG. 7, because they interfit, do not have to be laid in a running bond pattern, which makes them more economical to use, and makes it less necessary to waste any block material during construction. The block of FIG. 7, moreover, may also be used as a dry stack block, with only minor modification. That is, if the top surfaces of the ends and central web of the FIG. 7 block are recessed in a semicircular pattern 24 , as shown in the block marked ‘A’ in FIG. 7, the blocks may be stacked together to form a wall with a substantially hollow core, into which concrete may he poured. The purpose of recess 24 is to permit concrete poured into the hollow core of a wall formed with such blocks to flow into all block cores smoothly and efficiently.
[0025] In FIG. 9 are illustrated corner blocks 25 a and 25 b for use with the construction block embodiment of FIG. 7A. Corner blocks 25 a and 25 b include a corner element 26 formed in their side surfaces at one end thereof, and bevelled notches 27 in their upper surface corresponding to the lateral edges of the lower surface of the block flanking the edges 16 of groove 14 , thereby to permit a block to be laid at 90° on top of corner block 25 .
[0026] Corner element 26 , it will be observed, corresponds in shape to the zig-zag profile of the end of the block of FIG. 7A. The blocks shown in FIG. 9 are a left corner block 25 a and a right corner block 25 b which is a mirror image thereof.
[0027] It is to be understood that the examples described above are not meant to limit the scope of the present invention. It is expected that numerous variants will be obvious to the person skilled in the field of concrete block design without any departure from the spirit of the invention. The appended claims, properly construed, form the only limitation upon the scope of the invention. | A block for use in construction has opposed front and rear surfaces, opposed top and bottom surfaces, and a pair of opposed ends. The top and bottom surfaces are complementarity profiled to mutually interfit. The end surfaces are shaped to permit a plurality of blocks to be laid in a course with no mortar in between blocks in a course. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Provisional Application Ser. No. 60/312,917, filed Aug. 16, 2001, for Tape and Joint Compound Dispenser for Taping Drywall Joints.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a drywall or wallboard tape and joint compound dispenser or taping gun. More specifically, the present invention relates to a taping tool or taper for use in applying tape and joint compound to drywall or wallboard joints.
[0004] 2. Description of the Prior Art
[0005] Taping tools or applicators have been in use in the drywall installation industry for many years. One manufacturer of such a device is Wallboard Tool Co., Inc. of Long Beach Calif., which has since as early as 1994, sold a product identified as the “Wal-Board ‘Quick-Load’ Drywall Taper.” The Wal-Board taper has a box or housing defining an interior chamber containing drywall joint compound. Drywall joint tape from a roll supply carried on the box is passed through the chamber in which it receives a coating of joint compound. The coated tape is then applied to a wallboard or drywall joint. The tool is refilled with the joint compound when necessary by opening the box cover, using both hands to lift the wet tape carefully away from the bottom of the chamber, and then adding a supply of joint compound to the chamber between the tape and the bottom of the chamber.
[0006] A self-loading drywall tape applicator is shown in U.S. Pat. No. 3,707,427. Drywall joint compound is supplied by a pump from a hopper to the joint compound chamber of the tool through which drywall tape is passed for the application of joint compound thereto and the subsequent application of the coated tape to a drywall joint.
SUMMARY OF THE INVENTION
[0007] The present invention is embodied in a tape gun for applying joint tape and joint compound to drywall joints. The taper is formed by a housing having opposed side walls spaced apart a width determined by the width of the drywall tape being applied, and peripheral top, bottom, and end walls. The housing defines therein a chamber for holding joint compound for application to the tape. The housing further defines an entrance slot in one end wall opening into the chamber for receiving tape for the application of joint compound thereto, and an exit slot for supplying tape with joint compound thereon to the drywall joint. The chamber has an upper arcuate top wall and a lower elongated bottom wall.
[0008] A tape lifter is swingably mounted in the housing chamber and extends into the chamber between the tape entrance slot and the tape exit slot. When the tape gun is in use, the lifter is positioned adjacent the lower chamber wall with the tape positioned between the lifter and the upper chamber wall.
[0009] For actuating the tape lifter, a handle is swingably mounted exteriorly on the housing and is operatively connected to the tape lifter for swinging the lifter to lift the tape and position it against the upper wall of the chamber. The handle retracts the lifter to position the same adjacent the bottom wall of the chamber.
[0010] The housing further defines in one wall a valved port through which joint compound is introduced into the chamber below the lifted tape. In this manner, joint compound can be supplied to the chamber through the port and below the tape for subsequent application to the tape as the tape passes through the slots for application to drywall joints.
DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a left front perspective view of the tape and joint compound dispenser embodying the present invention.
[0012] [0012]FIG. 2 is a right front perspective view thereof.
[0013] [0013]FIG. 3 is a right rear perspective view thereof.
[0014] [0014]FIG. 4 is a left rear perspective view thereof.
[0015] [0015]FIG. 5 is a top plan view thereof.
[0016] [0016]FIG. 6 is a bottom plan view thereof.
[0017] [0017]FIG. 7 is a front elevation view thereof.
[0018] [0018]FIG. 8 is a rear elevation view thereof.
[0019] [0019]FIG. 9 is a right end view thereof.
[0020] [0020]FIG. 10 is a left end view thereof.
[0021] [0021]FIG. 11 is a section view taken substantially in the plane of line 11 - 11 on FIG. 5 and showing the lifter in retracted position.
[0022] [0022]FIG. 12 is a view similar to FIG. 11 but showing the lifter in a partially raised position.
[0023] [0023]FIG. 13 is a view similar to FIG. 11 but showing the lifter in a further raised position.
[0024] FIGS. 14 A-D are a diagrammatic series of illustrations showing the lifting of the tape by the tape lifter.
[0025] FIGS. 15 A-D are a diagrammatic series of illustrations showing retracting of the lifter, loading of the joint compound and application of the tape and joint compound to the wallboard joint.
DESCRIPTION OF THE INVENTION
[0026] This invention is an applicator tool or tape gun 20 for continuously coating drywall or wallboard joint tape 21 with joint compound 22 , sometimes referred to as mastic or mud, and continuously applying the mud coated tape 21 to a joint 24 between two drywall panels 25 . The tool contains both a supply of tape 21 conveniently provided on a roll or spool 26 supported on the tool, and a supply of joint compound or mud 22 in a chamber 28 defined in a box or housing 29 and through which tape 21 from the roll 26 is fed for the application of mud thereto and the subsequent application of the coated tape to a drywall joint 24 .
[0027] The box for containing the joint compound 22 for application to the tape 21 is formed by a rear or back panel 30 , a top panel or wall 31 , a bottom panel or wall 32 , a right side or end wall or panel 33 , a sloping left side or end wall or panel 34 , and a front panel or cover 35 . The cover 35 is hinged or swingably mounted by a hinge 36 mounted along one edge of the cover 35 to a front panel 37 secured to the right side or end wall 33 and extending between the top wall 31 and bottom wall 32 of the housing 29 . The cover 35 is releaseably secured to the left side wall 33 by a toggle or pull latch 38 . The box 29 defines the interior chamber 28 for containing joint compound or mud 22 and including a tape entrance slot 39 through which joint tape 21 passes from the roll 26 into the chamber 28 for the application of mud 22 thereto, and a tape exit slot 40 through which coated tape 21 extends for application to a drywall joint 24 .
[0028] A back panel extension 41 and a hinged panel 42 spaced apart and extending from the right side of the box support a shaft 44 therebetween, which shaft 44 in turn supports a roll or spool 26 of tape 21 . The hinged panel 42 is supported by a hinge 45 at one edge to the box 29 , and is releasably secured by a latch 46 at its other end to an end wall 48 extending forwardly from the back panel extension 41 to facilitate loading of the spool 26 of tape 21 .
[0029] The box door or cover 35 includes side flanges or lips 49 extending rearwardly from the cover panel 35 for overlapping the side and end walls of the box to provide a seal to prevent leakage of joint compound from the chamber. Sealing strips 50 of rubber, felt or the like may be included between the side flanges 49 and the box walls.
[0030] The interior chamber 28 defined in the box 29 is defined by a bottom wall 51 , a sloping front or left side wall 52 , a curved upper and right side wall 54 , the box back panel 30 and the cover panel or door 35 . The sloping front wall and upper and right side wall together form an upper arcuate wall. Inserts 55 , 56 having curved lower walls 57 , 58 , may be placed in the upper left and right corners 59 , 60 respectively of the box 29 in order to define the upper curved wall 54 of the chamber 28 .
[0031] In order to initially load the interior chamber 28 with tape 21 and joint compound or mud 22 , the door panel 35 is opened and the tape 21 is manually pulled from the spool 26 and inserted through the entrance slot 39 and exit slot 40 . The tape 21 is then raised or lifted upwardly against the upper curved surface or wall 54 of the chamber 28 , and joint compound 22 is manually filled into the portion of the chamber space defined below the tape 21 and above the bottom wall 51 of the chamber 28 . The door panel or cover 36 is closed and latched, and the tool is used to apply mud coated tape to a drywall joint 24 in the conventional manner by pulling the coated tape from the exit slot of the tool.
[0032] When the initial supply of mud 22 in the tool is exhausted, in accordance with the present invention the supply is replenished quickly and easily without opening the door panel or cover 35 . To this end, in accordance with the present invention, the portion of the tape remaining in the chamber is lifted and positioned against the upper curved surface 54 and the front surface 52 of the chamber by a lifter mechanism 61 , and joint compound 22 is supplied to the chamber below the tape 21 from a container or reservoir thereof (not shown).
[0033] The tape lifter mechanism 61 is formed by a lower elongated spring steel leaf 62 and an upper superimposed elongated spring plastic leaf 64 , both secured at corresponding ends to a shaft 65 which extends between the box front and rear panels adjacent the entrance slot and is journaled on the panels for rotation by an operating handle or crank 66 exterior of the box and operatively connected thereto. At its end opposite from the shaft connection, each leaf spring is provided with a transverse cylindrical knob, nose or bobbin 68 , 69 respectively for engaging and lifting the tape.
[0034] The lower lifter spring leaf 62 is formed of stiffly flexible steel or clock spring material. The upper lifter spring leaf 64 is formed of stiffly flexible plastic material and defines a pair of parallel longitudinal slots 70 therein that assist in preventing the wet tape from sticking to leaf 64 .
[0035] The leaves are lifted to lift the tape in the chamber by swinging the handle in a clockwise direction, and retracted away from the tape by swinging the handle in the opposite direction. For engaging and holding the mud coated joint tape in the lifted position against the sloping front chamber wall 52 and curved upper chamber wall 54 for the replenishment of mud into the chamber after the lifter mechanism 61 is retracted, the upper front sloping wall 52 of the chamber is provided with an abrasive strip 71 which engages and grips the lifted tape 21 . To this end, the lifter leaves 62 , 64 lift and press the tape against the upper sloping chamber wall 52 so that the tape is retained against the wall. The tape is held in contact with the upper arcuate top wall surface 54 by the mud with which it is coated. The steel spring leaf 62 when rotated by the handle initially engages the tape and presses it against the chamber wall with sufficient force to cause the tape to stick to the abrasive strip or surface 71 on the wall 52 . As the tape is lifted, the upper plastic leaf 64 lifts and presses the tape against the upper portion of the arcuate chamber wall 54 where it sticks until pulled free. The plastic leaf 64 is sufficiently flexible so that it gently lifts but does not tear the wet tape. The cylindrical nose 68 , 69 on each leaf rides against the tape and further aids in preventing tearing of the wet tape 21 .
[0036] A carrying handle 72 including a handle grip 73 secured to a handle bracket 74 is mounted on the top of the box. A side handle 75 formed by a flexible fabric strap 76 is secured at to the back side wall of the box. The latter handle is adjustable by an adjustment clamp 78 including a bracket 79 , clamping plate 80 bolts 81 and wing nuts 82 securing the bracket 79 to the clamping plate 80 .
[0037] An adjustable bracket 83 forming a dam plate 84 and cutter blade 85 is provided adjacent the exit slot 40 at the front of the tool. The bracket 83 is adjustably secured to the sloping front or left wall 34 of the tool by appropriate bolts 86 and wing nuts 88 and may be adjusted upwardly or downwardly to vary the width of the exit slot 40 and thereby control the amount of mud applied to the tape 21 . The cutter blade 85 includes a sharp front edge 89 for cutting or tearing the tape 21 and appropriate finger slots 90 , 91 for use by the tape installer for gripping the tape or pulling the tape manually through the chamber.
[0038] When periodically loading the chamber 28 with joint compound 22 , the tape 21 extending through the exit slot 40 is gripped by the user through the central finger slot 90 in the cutter blade 85 to prevent withdrawal of the tape back into the chamber as it is lifted. The handle 66 is then rotated to cause the lifter leaves 62 , 64 to lift the tape 21 above and away from the bottom wall 51 of the chamber 28 and into contact with the front sloping wall 52 and upper curved wall 54 of the chamber 28 . The handle is then swung in the opposite direction to place the leaves 62 , 64 against the bottom wall 51 of the chamber. At this point, the replenishment supply of mud is pumped into the chamber 28 through a valved port fitting 92 connected by a quick-connect connector fitting 95 to the mud reservoir (not shown). The port 92 is located between the lifter leaves 62 , 64 and the raised tape. When the chamber 28 is full, as observed through a window 94 in the back wall panel 30 of the box 29 , supply of the mud to the chamber is stopped and the gun is disconnected from the supply reservoir. The fitting desirably includes an interior anti-backflow valve to prevent joint compound from leaking through the filling port when the tool is in use. Alternatively, after lifting the tape, joint compound can be supplied to the chamber 28 by opening the cover 35 and manually filling the chamber with compound.
[0039] When loading the tool with tape and joint compound, tape 21 is fed from the roll or spool 26 thereof through the entrance slot 39 and under a tape guide 96 defining the upper edge of the entrance slot 39 . To facilitate feeding of the tape 21 into the chamber 28 , an adjustable width tape entrance throat or slot 39 is provided by mounting the entrance tape guide cylinder or bobbin 96 on a plate 98 which is adjustably secured to the end wall 33 of the housing by releasable fasteners such as bolts 99 and wing nuts 100 or their equivalents. By loosening the wing nuts 100 , the cylinder 96 can be moved toward or away from the base or bottom wall or panel 32 of the housing 29 to reduce or enlarge the entrance slot 39 .
[0040] From the entrance tape guide cylinder 96 , the tape is fed over an idler cylinder or guide 101 into the chamber 28 and out through the exit slot 40 . The idler cylinder 101 is supported on an arcuate, stiffly flexible, panel 102 carrying the idler on one edge and secured adjacent its other edge to the bottom panel 32 of the housing 29 .
[0041] The action of the tape lifter 61 and lifter leaves 62 , 64 is illustrated in FIGS. 14 A-H, which figures show the sequence of movement and positions of the lifter leaves 62 , 64 as the handle 66 is swung clockwise to lift the tape 21 and counter-clockwise to lower the lifter leaves 62 , 64 , leaving the tape 21 in raised position and the chamber 28 ready to receive a supply of joint compound.
[0042] As shown schematically in FIG. 14A, the lifter springs 62 , 64 initially lie adjacent the bottom panel 32 of the housing 29 with the plastic spring leaf 64 on top of the steel spring leaf 62 and the cylinder or bobbin 69 of the upper plastic leaf 64 lying behind the cylinder or bobbin 68 of the lower leaf 62 . As the handle 66 is swung further forward or clockwise as shown in FIG. 14B, The wet tape is lifted away from the bottom panel 32 . The nose 68 of the lower lifter leaf 62 presses the tape against the abrasive surface 71 of the sloping wall 52 , while the nose 69 of the upper leaf 64 lifts the tape 21 .
[0043] Further rotation of the handle 66 as shown in FIG. 14C raises the leaves 62 , 64 with the nose 68 of the lower leaf sliding upon and along the tape 21 to press the tape against the sloping abrasive surface and causing the lower leaf to bow slightly. The nose of the upper leaf 64 further lifts the tape away from the lower leaf and positions it against the upper curved surface 54 .
[0044] As the lifter is further raised by rotating the handle, as shown in FIG. 14D, the nose 68 of the lower leaf 62 holds the tape against the abrasive front sloping surface 71 while the upper leaf bows to engage and press the wet tape 21 against the upper curved surface 54 , to which it adheres because of the mud with which is coated. At this point, as shown in FIG. 14D, the tape is fully lifted. It should be noted that the upper leaf 64 bows and presses the tape along its length against the upper curved surface.
[0045] With the tape lying against the abrasive surface and upper curved surface, the direction of movement of the handle 66 is reversed and the handle swung in a counterclockwise direction. As shown in FIG. 15A, the leaves 62 , 64 drop away from the tape 21 which adheres to the upper curved surface 54 . The slots in the upper leaf help prevent the leaf from pulling the tape away from the curved surface. Counterclockwise rotation of the handle 66 positions the leaves 62 , 64 together in their original position adjacent the lower housing wall 32 , leaving the tape stuck to the sloping surface and upper curved surface of the chamber. At this point joint compound can be introduced into the chamber as shown in FIG. 15B between the lower wall 32 and lifter 61 at the bottom, and the tape 21 at the top of the chamber.
[0046] As the drywall tape installer applies tape and joint compound 37 to a drywall joint 43 , the tape is continuously coated with the joint compound 27 as shown in FIG. 15C. When the joint compound in the compound chamber has been substantially depleted, as shown in FIG. 15D, it is a simple matter for the user to swing the handle to lift the tape, then swing the handle back to lower the tape lifter to a position against the bottom wall of the chamber, connect the chamber input port to a mud supply through a quick connect connector, or open the front cover, and refill the chamber with joint compound. Taping of the wall joints is continued and this process is repeated until the drywall application is complete. With the taping tool embodying the present invention, the burdensome task of loading the tool with joint compound is substantially relieved, the speed of the taping work is increased, waste of joint compound is reduced, tearing or jamming of the tape is avoided, and physical contact of the user with the compound reduced thereby leading to cleanliness of the work area and less need for clean-up.
[0047] While a certain illustrative embodiment of the present invention has been shown in the drawings and described above in detail, it should be understood that there is no intention to limit the invention to the specific form disclosed. On the contrary the intention is to cover modifications, alternative constructions, equivalents, and uses falling within the spirit and scope of the invention as expressed in the appended claims. | A tape and joint compound dispenser is formed by a housing defining an interior chamber for receiving joint compound and joint tape. A valved port in the housing opens into the chamber for supplying joint compound. A tape lifter in the chamber enables the user to lift the tape in the chamber to facilitate supplying joint compound to the chamber through the port and below the tape. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/884,302 entitled Panel System and the specification thereof is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a wall system comprising one or more posts and one or more panels which may be easily interconnected by unskilled labor providing a very cost effective wall system that can be quickly and inexpensively installed.
[0003] Wall systems are used for a variety of purposes, such as a fence in outdoor applications, or interior or exterior walls of a building for commercial, office or residential use. Wall systems typically include posts forming vertical structural members for corners where walls intersect typically at a right angle or intermediate the ends as structural members between adjoining panels that are coplanar. Both walls and fences may have various lengths and thus may be assembled from a plurality of intermediate posts and interconnected panels. Such wall systems may utilize pre-fabricated panels fabricated from a variety of materials or the panels may be assembled on site. A number of means for connecting the panels to a post have been utilized including fasteners such as rivets, screws, and nails, or in the case of metal, posts and panels, by welding, brazing or similar metal joining methods.
[0004] Fences are typically constructed from wooden materials, utilizing wooden fence posts and panels of wooden construction. The fabrication of the panel may be on site by using upper and lower stringers between a pair of spaced apart posts and then assembling wooden boards between the stringers to form the panel. Or the panel may be prefabricated as a single unit having upper and lower rails and vertical end portions fastened at their upper and lower ends to the rails with the center portion of the panel comprising a variety of materials such as wood slats, arranged in vertical or horizontal position, and forming a solid surface or spaced apart slats or boards. The panel may also be constructed of a variety of materials other than wood.
[0005] Despite the use of wall systems in various applications for many years, the present wall system has advantages over such prior art systems as will become clear from the following description.
SUMMARY OF THE INVENTION
[0006] This invention comprises a wall system including one or more posts and panels, each panel having vertical end portions with a given thickness, each post comprising a first elongated substantially flat member, a second elongated substantially flat member attached at one proximal longitudinal edge to a first lateral location adjacent one longitudinal edge of the first member, a third elongated substantially flat member attached at one proximal longitudinal edge to the first member at a laterally spaced location from the first location, the distal edges of the second and third elongated members spaced a predetermined distance that is less than the thickness of the panel end portions, and at least one of said second or third elongated flat members being resilient, whereby the end portion of the panel may be inserted between the distal edges of the second and third elongated members and is clampingly retained therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will be further understood from the following description with reference to the drawings in which:
[0008] FIG. 1 illustrates an elevation view of one embodiment of a wall system in accordance with the present invention;
[0009] FIG. 2A is an elevation view of one embodiment of a building having walls constructed in accordance with the present invention;
[0010] FIG. 2B is a front elevation view of the building shown in FIG. 2A ;
[0011] FIG. 3 is a sectional view of one embodiment of a post constructed in accordance with the present invention;
[0012] FIG. 4 is a sectional view of a second embodiment of a post;
[0013] FIG. 5 is a sectional view of the embodiment of the post showing the panel and post in fixed relationship;
[0014] FIG. 6 is a sectional view of a third embodiment of a post;
[0015] FIG. 7 is a sectional view of a fourth embodiment of a post;
[0016] FIG. 8 is a sectional view of the post shown in FIG. 6 with the vertical end portions of a wall panel retained by the post;
[0017] FIG. 9 is a sectional view of a fifth embodiment of a post;
[0018] FIG. 10 is a sectional view of a sixth embodiment of a post;
[0019] FIG. 11 is a sectional view of a pair of posts showing a hinged panel and portions of two adjacent panels;
[0020] FIG. 12 is a sectional view of a seventh embodiment of a post;
[0021] FIGS. 13A , 13 B, 13 C and 13 D show details of one embodiment of cross members and anchoring structure of a post;
[0022] FIG. 14 is a sectional view of an eighth embodiment of a post;
[0023] FIG. 15 illustrates the biasing member shown in FIG. 14 ;
[0024] FIG. 16 is a sectional view of a ninth embodiment of a post showing the use of the biasing member in FIG. 15 ;
[0025] FIG. 17 is a sectional view of a tenth embodiment of a post;
[0026] FIG. 18 illustrates the biasing member of the embodiment shown in FIG. 17 ;
[0027] FIG. 19 is a sectional view of an eleventh embodiment of a post;
[0028] FIG. 20 is a sectional view of a twelfth embodiment of a post;
[0029] FIG. 21 illustrates the biasing member of the embodiment shown in FIG. 20 ;
[0030] FIG. 22 is a sectional view of a thirteenth embodiment of a post;
[0031] FIG. 23 is a right side elevation view of the embodiment shown in FIG. 22 ;
[0032] FIG. 24 is a vertical sectional view of the thirteenth embodiment shown in FIG. 22 ;
[0033] FIG. 25 is a sectional view of a fourteenth embodiment of a post;
[0034] FIG. 26 is a sectional view of a fifteenth embodiment of a post; and
[0035] FIGS. 27A-27D are sectional views of the fifteenth embodiment in various combinations.
DETAILED DESCRIPTION
[0036] The wall system of the present invention is useful in many applications, two of which are shown in FIGS. 1 and 2 . In FIG. 1 , the wall system comprises a portion of a fence 10 and as shown comprises three identical posts 20 and two identical wall panels indicated at 30 . The posts 20 are vertically oriented and are spaced apart so as to received the panels 30 . The panels 30 are of a general rectangular configuration having two vertical end portions that engage the posts 20 . The wall panels may be fabricated from a wide variety of materials including metal, plastic, fiberglass, composite materials, or other suitable materials which may be formed in a single monolithic panel, or comprised of numerous individual longitudinally extending horizontal or vertical slats formed from material such as wood. Preferably, the panels are pre-fabricated and available in various heights and lengths as well as different thicknesses depending upon the application and other structural requirements of the panel.
[0037] The posts 20 for the fence 10 are embedded in the soil either directly or through an anchoring structure 40 which may comprise a concrete footing 42 poured into an opening in the ground and retaining a post 20 which has its lower end embedded in the concrete 42 as will be explained in greater detail in reference to FIG. 14 . Depending upon the type of fence and the environmental conditions it may be desirable to strengthen the wall panels through the use of cross wires, bars, or straps such as shown at 45 . It will be understood by those having ordinary skill in the art that cross bracing may be unnecessary and it will also be appreciated that there are a variety of anchoring structures that may be used for the post of the fence 10 .
[0038] In FIGS. 2A and 2B there is shown another application of the wall system of the present invention embodied in a simple building 50 having four walls 52 one of which is illustrated in FIG. 2A and one of which is illustrated in FIG. 2B . The building may have a pitched roof although the roof construction may be flat, or various other architectural configurations. The floor of the building is raised off the ground. As shown in FIG. 2A , the wall 52 may include three panels, 54 , each of which has a generally rectangular configuration. The building floor is shown at 56 and is of conventional construction. The wall 52 includes four posts, two of which at 58 are intermediate and frame the center panel 54 . The corners of the building 50 have posts 60 . The corner posts 60 are embedded in the anchoring structure such as that shown at 40 in FIG. 1 . The floor 56 of the building 50 may be additionally supported by short pillars 62 attached to the floor 56 and embedded in an anchoring structure such as at 40 .
[0039] The front elevation view shown in FIG. 2B illustrates that the wall 53 may also comprise three panels one of which is similar to panel 54 , one of which is a door 64 , and one of which comprises a sliding panel 66 . The door 64 may be constructed of glass. Panel 66 is mounted on tracks and may be moved so as to cover the door 64 exposing an additional panel such as 54 not shown in FIG. 2B since it is behind sliding panel 66 . The wall 53 includes at the corners the two posts 60 as shown in FIG. 2A . Door panel 64 may be constructed so as to open on hinges as will be described in conjunction with FIG. 11 , or may be slidable. The door 64 is framed by posts which will also be described in FIG. 11 . The panel 54 has a post 58 spaced apart from the post 60 . The panel 66 has post members 58 that attach to a top rail and a bottom rail.
[0040] It will therefore be appreciated that the wall system of the present invention may be used in various applications including but not limited to fences and building sidewalls. The wall system may comprise one or more panels each of which are attached to a post that clamps and retains the vertical end portions of the panel. It will also be appreciated from these illustrations that the wall system may comprise a flat wall or two walls that form a corner. As will be described below, the walls may be oriented with respect to a post so as to radiate in four directions as may be desirable in certain applications and is described in greater detail in reference to FIGS. 9 and 10 .
[0041] The post of the wall system of the present invention may be rendered in various embodiments and these will now be described and those of ordinary skill in the art will appreciate that the different configurations may be suitable for various wall configurations and thus will meet a large variety of applications for wall systems. FIG. 3 illustrates a first embodiment of a post 80 of the present invention, shown in section, and comprising two elongated substantially flat structural members that in this embodiment define plates, a first plate 82 , and a second plate 84 that are attached or joined along their longitudinal proximal edges at an angle of substantially 90° at a first lateral location. The post 80 has a third elongated substantially flat member 86 attached at its proximal longitudinal edge 88 to structural plate 82 along a vertical line that is laterally spaced from the intersection of plates 82 , 84 and forms an acute angle with plate 82 . In this embodiment, the third elongated flat member 86 is resilient and defines a biasing member. The word “bias” is used to denote the force that arises when a resilient member at rest is forcibly displaced; a “biasing member” is one that is made of resilient material, in whole or in part, that when deflected will apply a restoring force against the source of deflection. When a biasing member is spaced from a fixed member or another biasing member and an object is placed between such member that displaces or alters the position of the biasing member at rest, the biasing member or members will clamp the object with a force that resists removal of the object. The word plate means a substantially flat elongated member that, relative to a biasing member has more resistance to elastic deformation thus providing structural strength to the post; the resistance may be due to the thickness of the member(s), type of material or other factors that affect the modules of elasticity. The distal edge 90 of biasing member 86 is spaced from the elongated substantially flat structural plate 84 at a pre-determined dimension, distance or space shown at 92 . At least a portion of biasing member 86 is resilient and biases the distal edge 90 toward the structural plate 84 for the purpose to be described.
[0042] FIG. 4 shows a second embodiment of a post 100 adapted to hold two panels in coplanar relationship comprised of two joined subassemblies 102 and 104 which may be used to vertically support two in-line panels. Post subassembly 102 comprises at least two elongated substantially flat structural plates 106 , 108 attached along their proximal longitudinal edges at an angle of substantially 90° as in the embodiment of FIG. 3 . Post subassembly 102 additionally includes at least one elongated V-shaped member 110 that includes a biasing member 112 that comprises one leg of the V-shaped member 110 attached to a second leg 114 that is fixedly attached to the substantially flat structural plate 108 . Holding member 112 has a distal end 116 and is similar to holding member 86 as shown in FIG. 3 except that the proximal vertical edge of the holding member 112 is attached to the second leg 114 of V-shaped member 110 which in turn is attached to structural member 108 . In this second embodiment, the proximal edge 118 of holding member 112 is also laterally spaced from structural member 106 a pre-determined lateral distance greater than the distal edge 116 of biasing member 112 with respect to structural plate 106 . It will be readily understood by those having ordinary skill in the art that subassembly 104 of the second embodiment 100 is identical to subassembly 102 but allochirally oriented with respect to subassembly 102 . It will also be understood that the subassembly 102 may be used alone at the end of a wall, like post 80 . Thus, it will be unnecessary to describe the elements that comprise subassembly 104 . Moreover, the two longitudinally extending flat plates 106 , 108 may be integral, such as a common “angle iron” or L-shaped extrusion.
[0043] In FIG. 5 , the second embodiment of FIG. 4 is shown in combination with two wall panels having vertical end portions 120 . With attention drawn to subassembly 102 , it will be seen that the end portion 120 is held between the elongated substantially flat structural plate 106 and biasing member 112 . The biasing member 112 is, all or a portion, resilient and biases the distal edge 116 toward structural plate 106 . Since a portion of biasing member 112 is resilient, distal edge 116 is positionally altered when the panel end portion is forced between the distal edge 116 and flat plate 106 because the distance 92 is less than the thickness of the wall panel end portion 120 whereby the end portion is clamped and retained between the holding member 112 and the flat structural plate 106 . It will therefore be appreciated that the biasing force of the clamping structure portion of member 112 will securely retain the end portion of the panel and thus the panel itself in engagement with the post 100 without requiring any fasteners, glue, welding, or other similar methods for retaining two elements in fixed relationship. There is no requirement for any specialized tools to engage the wall panel with a post obviating the need for expensive assembly tools such as drills, welding equipment, glue dispensers, or the like.
[0044] A third embodiment of a post 130 comprises two subassemblies, 102 , 104 that are identical to one another and also to the subassemblies, 102 , 104 in the second embodiment shown in FIG. 4 . However, in FIG. 6 , the subassembly 104 has been reoriented so that structural plate 106 of subassembly 104 is attached to structural plate 108 of subassembly 102 as compared to the orientation of the subassemblies 102 , 104 in FIG. 4 . By reorienting subassembly 104 the post 130 is suitable for a corner as shown in FIG. 8 .
[0045] FIG. 7 shows a fourth embodiment of a post 140 comprising post subassemblies 142 and 144 . Subassembly 142 is identical in all respects to post member 80 shown in FIG. 3 . Thus, subassembly 142 includes a first elongated substantially flat structural plate 82 and a second structural plate 84 intersecting along their longitudinal edges at an angle of substantially 90°. An elongated substantially flat member 86 is attached at a proximal longitudinal edge 88 to structural plate 82 along a vertical line laterally spaced from the intersection of plates 82 and 84 and having a distal edge 90 spaced from the structural plate 84 so as to define a predetermined space 92 . Member 86 is formed of resilient material and defines a biasing member. The embodiment 140 has an additional subassembly 144 , identical to subassembly 142 , but oriented such that when wall panels are inserted and clamped into the biasing member and clamping structure of post members 142 , 144 the panels will be oriented in a 90° or orthogonal position. Comparing the fourth embodiment in FIG. 7 to the third embodiment in FIG. 6 it will be appreciated that the difference is that post 140 in FIG. 7 has subassemblies 142 and 144 that are identical to post 80 in FIG. 3 whereas the fourth embodiment 130 in FIG. 6 has subassemblies members 102 , 104 identical to those shown in FIG. 4 .
[0046] In FIG. 9 , there is a fifth embodiment, post 150 , comprising a four-way juncture for four wall panels the end portions of which are shown at 120 . With reference to FIG. 4 , it will be seen that post 150 comprises four subassemblies, identical to subassemblies 102 and 104 shown in FIG. 6 and an additional two subassemblies 152 , 154 which are identical in all respects, other than orientation, to subassemblies 102 , 104 .
[0047] In FIG. 10 , a sixth embodiment of a post is shown at 160 comprising the four subassemblies 102 , 104 , 152 and 154 shown in FIG. 9 oriented such that the structural member 108 of subassembly 154 and 106 of subassembly 104 are joined back-to-back and structural members 108 of subassemblies 104 and 154 are joined back-to-back while structural member 106 of subassembly 154 is joined to structural member 108 of subassembly 102 back-to-back. Thus the four-way post in FIG. 10 orients the four panels in a cross configuration as in FIG. 9 but the subassemblies 102 and 154 panel end portions are spaced from one another a lateral distance equal to the width of structural plate 108 .
[0048] In FIGS. 11A and 11B , it will be seen that a fence may be provided with a gate, or a building may be provided with a door, by using the posts as shown in any of the previous embodiments, first through fourth. Specifically, the door or gate 179 includes a panel 171 with a door handle assembly indicated generally at 172 . As seen in FIG. 11A , one end 173 of panel 170 is retained in a subassembly 102 and the adjacent fixed wall panel 174 has an end 175 retained by a second subassembly 102 which are of course identical in construction but oriented so as to receive a panel from the left rather than the right. A hinge 176 is positioned between structural plates 108 of the two post members 102 . At the opposite end of panel 171 , as seen in FIG. 11B the end portion 177 is retained in a post member 102 that is oriented in the same direction as post member 102 that engages panel 174 by retaining end portion 175 . The fixed wall section 178 adjacent to the end 177 of panel 171 has an end portion 179 received and retained by a second post member 102 oriented 180° to post member 102 that retains end portion 177 of door or gate panel 171 .
[0049] FIG. 12 shows a seventh embodiment of a post 250 suitable for a corner. This embodiment shows two subassemblies, each identical to member 80 shown in FIG. 3 . Each of the posts 80 includes substantially flat elongated structural plates 82 and 84 as well as a biasing member 86 . The vertical end portion 120 is clampingly engaged between the structural plate 84 and the biasing member 86 . In order to fix the two plate members 82 in a right angle configuration, there is provided a reinforcement tube 252 that attaches on one face to plate 82 of one of the subassemblies 80 and on another face to the plate 82 of the second subassembly 80 .
[0050] FIGS. 13A-13D show the details of the termination of the cross members (beams, straps or wires) at the bottom and top of a post 260 . Post 260 includes two subassemblies 262 and 264 having their structural plates 266 and 268 attached back-to-back so as to form a T-cross section post as shown in FIG. 5 . Mounting structure 40 includes an L-shaped post base 41 that may be embedded in concrete 42 (see FIG. 1 ). The L-shaped member, may comprise a round bar bent at a 90° angle at its lower end and at its top end is secured by welding or the like to an angle iron 270 having a leg 272 horizontally disposed and a vertically disposed leg 274 having a slot 276 as seen best in FIG. 13C which together with fasteners permit the post to be vertically adjusted relative to the anchoring structure. A pair of diagonally oriented cross beams 280 are attached to post members 262 and 264 and at their upper end to two identical post members 290 , 292 as seen in FIG. 13D . This particular anchoring structure is highly suitable for use of the wall system as a fence and the cross beams are structurally desirable where wind or other forces must be resisted by the wall system.
[0051] FIG. 14 shows an eighth embodiment of a post 300 for the wall system of this invention. The cross section of FIG. 14 shows a first elongated substantially flat member in the form of a structural plate 302 disposed in a vertical position when in use. A second elongated substantially flat member 304 is attached at its longitudinal proximal edge 306 to structural plate 302 . A third elongated substantially flat member 308 is attached at its proximal longitudinal edge to said structural plate 302 so that the distal longitudinal edges 312 , 314 of biasing members 304 , 308 define a predetermined space or distance 316 . In post 300 , the second and third flat members 304 , 308 are formed from resilient material and define biasing members. FIG. 14 also shows that the post 300 may be used as a post in an in-line wall by including a biasing member 320 attached to the structural plate 302 at 322 and having a distal end 324 . Similarly, opposite the biasing member 308 there may be a biasing member 326 attached to structural plate 302 at 328 and having a distal end 330 which, together with distal end 324 of biasing member 320 , defines a space 332 identical to space 316 .
[0052] As shown in FIG. 15 , the biasing members 304 , 320 (and similarly the biasing members 308 and 326 ) may be formed from a single resilient sheet of material which has a central region 340 that complements the shape of the vertical end portions 342 and 344 of structural plate 302 . Structural member 302 is provided with a pair of longitudinally extending notches on opposite sides of structural plate 302 spaced laterally inwardly from the edge of the end portions 342 and 344 of structural plate 302 . The biasing member comprising the sections 304 , 320 and 340 , at the point at which the biasing members 304 and 320 connect to the central portion 340 , define ridges at 350 that are spaced apart a distance less than the thickness of the end portions of structural plate 302 . To assemble the post 300 , the biasing member 304 , 320 and 340 is forcibly pushed over the longitudinal end 342 of structural plate 302 until the ridges 350 snap into the vertical notches in the opposite faces of structural plate 302 . It will therefore be appreciated that when assembled, the space 316 defined by the distal ends 312 , 314 of biasing members 304 and the space 332 defined by the distal ends 324 , 330 of biasing members 320 , 326 is less than the thickness of the end portion of a panel that may be inserted between the biasing members to thereby firmly clamp the end portion of the panel to the post 300 .
[0053] FIG. 16 shows a ninth embodiment of the invention, a post 350 , in which the biasing member 304 , 320 , 340 , as shown in FIG. 15 and described above is used in conjunction with two structural subassemblies 360 , 362 the former comprised of first and second flat members 364 , 366 attached at one longitudinal edge to form the L-shaped subassembly 360 comprised of first and second flat members 368 , 370 attached at one longitudinal edge to form the L-shaped subassembly 362 . The L-shaped subassemblies are attached back-to-back. The exposed surfaces of flat members 366 , 370 have a longitudinally extending notch as in the embodiment of FIG. 14 . The clip is then inserted over the free ends of legs 366 , 370 until the ridges 350 snap into the notches in the respective flat members or legs 366 , 370 . Accordingly, the ninth embodiment post 350 comprises elongated substantially flat structural members 366 and 370 of L-shaped subassemblies 360 , 362 , a substantially flat biasing member 304 attached at a proximal edge through the interconnection of ridges 350 with the notches in members 366 , 370 , and an additional elongated substantially flat structural member 368 attached at its proximal longitudinal edge to member 370 so as to define a predetermined space 316 for receiving and clamping the vertical end portion of a wall panel.
[0054] It will therefore be seen that in the embodiment shown in FIG. 14 the end portion of the panel is clamped between the distal edges 312 , 314 of biasing members 304 and 308 whereas in the ninth embodiment of FIG. 16 the end portion of the panel is inserted in the space 316 so that the distal end 312 of biasing member 304 will clamp the end portion of the panel against member 368 of L-shaped subassembly 362 that comprises post 350 . In one case the panel is clamped between two biasing members, and in the other, between one biasing member and one structural member as in the embodiments shown in FIGS. 3-10 , 12 and 14 - 16 . Of course, the clamping force can be adjusted to be equal if desired. The clamping force can be altered by a change in material, material thickness, or the pre-selected dimension between the biasing member distal edge and the adjacent biasing or structural member.
[0055] FIGS. 17 , 18 and 19 are similar views to FIGS. 14 , 15 and 16 showing a tenth embodiment 375 again comprising the same components, i.e., biasing member 304 , 340 and 324 , formed as a single piece from a single sheet of resilient material and a structural member 302 . However, post 375 has a different ridge and notch engagement structure but to effect the same result. The post 375 in FIG. 17 may also be configured, similar to FIG. 16 , as an eleventh embodiment, post 385 ( FIG. 19 ), so as comprising two L-shaped subassemblies 390 , 392 .
[0056] In FIG. 20 a twelfth embodiment 400 of the invention is shown in cross section. The post 400 includes an elongated substantially flat structural plate 402 , that in use, is vertically disposed. Two biasing members 404 , 406 are configured, as seen best in FIG. 21 as a shallow V-shaped resilient member comprising two resilient flat members 412 , 414 that intersect at an obtuse angle. The biasing member 404 comprises resilient flat members 408 , 410 and is identical to the biasing member 406 . The center section of the biasing members 404 and 406 , are secured to the end portions 416 , 418 of plate 402 in a permanent manner such that the distal ends of the wings 408 , 412 are spaced a predetermined distance, equivalent to the distance between the distal ends of the biasing members 410 , 414 on the opposite side of the structural plate 402 . In the preferred embodiment, the obtuse angle between the wings 412 , 414 and 408 , 410 is 160°. Depending upon the material of the structural plate 402 , and the material of the biasing members 404 and 406 , if made of metal, they may be attached by welding, spot welding, brazing, or other metal joining technique. Alternatively, the entire post may be extruded as a single integral piece, cut off in selected lengths. If the V-shaped resilient member and structural plate are formed of non-metallic material, they may be attached by various methods including glue or may be pultruded as a one-piece integral component. Alternatively, regardless of the material the resilient members and structural plate may be jointed with fasteners.
[0057] Referring to FIGS. 22-25 , a thirteenth embodiment of the invention, post 440 , is shown in FIG. 22 comprising a generally U-shaped member including a pair of substantially flat biasing members 442 and 444 that are attached at their longitudinal edges to base member 446 or may be formed from a single sheet of resilient material bent to the configuration shown. The base member 446 is shown in a front elevation view in FIG. 23 and in a series of sectional views in FIG. 24 illustrating the joining of the components of the post 440 . The post 440 base member 446 has an interlocking structure comprising a cleat 450 that is stamped out of the base member leaving an opening 452 . In a preferred embodiment of the post 440 , fabricated from metal, the distance between the adjoining openings 452 , 456 and cleats 450 , 454 may be on the order of six inches. It will be understood by those of ordinary skill in the art that a post 440 may be combined with an identical post 480 , as shown in FIG. 25 as subassemblies to comprise the post 500 . The subassemblies may be connected back-to-back to form a structural member by inverting one of the subassemblies to the position shown at 448 in FIG. 24 permitting the base member 446 of subassembly 440 to interconnect or interlock with the base member 446 of subassembly 480 . Alternatively, the two base members 446 could be attached back-to-back with fasteners, glue, welding or the like. After assembly, the post 500 comprising interlocked pairs of subassemblies 440 and 480 has the same sectional configuration as the post 400 as shown in FIG. 20 . The two layers of base member 446 from subassemblies 440 and 480 , by doubling the thickness of the base members, provides a substantially flat structural plate as shown at 482 .
[0058] Post 440 may be varied so that the interlocking structure is formed in one or more than one of the three resilient members as shown on post 550 in FIG. 26 . With interlocking structure on two of the resilient members, the subassembly of FIG. 26 may be combined and arranged in various configurations such as those shown in FIGS. 27A-27D . The post 550 as shown in FIG. 26 has three resilient members 552 , 554 , and 556 . 556 comprises the base member comparable to the base member in FIG. 22 ; however, base member 556 is attached to resilient member 554 at a right angle whereas resilient member 552 is attached at an acute angle. Base 556 and biasing member 554 each have interlocking structure as described in reference to FIGS. 23 and 24 . The post 550 may be used alone as an end post for a wall. As seen in FIG. 27A , two posts identical to post 550 may be interlocked at bases 556 so as to form a post suitable for an inline connection of panels in a wall system. In FIG. 27B , two posts 550 are oriented so as to form a corner post. In FIG. 27C , three posts 550 are arranged so as to provide both a right angle or corner post as well as an inline post. And finally, as shown in FIG. 27D , there are four posts 550 arranged so as to form a four-way corner similar to that shown in FIG. 9 . Thus, it will be apparent to one of ordinary skill in the art that a wide variety of posts can be configured from the single post 550 as may be desirable for various applications of a wall system. An advantage of the post shown in FIGS. 22-27 is that the U-shaped elongated structures are formed from a single thickness of material and thus may be suitable for fabrication by bending a flat sheet of metal without requiring any welding or similar means for attaching two of the resilient members to a third.
[0059] It is to be understood that the invention is not limited to the exact details of construction, assembly, materials, or the many embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. As noted above, various types of material may be used. Furthermore, the wall system, including the post members and panel, are scalable such that panels of various thickness may be used in accordance with the invention for applications where the wall system is intended to provide a building wall that is sufficiently thick and of a type of material that provides insulation, noise suppression, and the like. As also indicated above, a panel may be formed from glass so as to provide for a window when the wall system is used for building construction. It will also be understood that a wide variety of anchoring structures may be used for vertically supporting the wall system depending upon the application of the wall system, that is, when used as a fence or a building wall. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | A wall system suitable for use in applications such as a fence or a wall of a building which comprises posts and panels which are interconnected or interengaged so that the wall may comprise a series of inline panels or corners formed by two panels and a single post, the interconnection or interengagement of the panels being effected without use of mechanical fasteners, glue, welding, or similar modes of attachment. |
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FIELD OF THE INVENTION
The present invention relates to a method of activating a downhole system arranged in an annular space formed between a tubular element extending into a borehole formed into an earth formation and a cylindrical wall surrounding the tubular element. The cylindrical can be, for example, the borehole wall or the wall of a casing extending into the borehole.
BACKGROUND OF THE INVENTION
For many wellbore applications, activation of such downhole system is required to perform a downhole process or to initiate such process. It has been tried to activate the downhole systems by means of hydraulic or electrical control lines extending from surface into the borehole. However, such control lines are vulnerable to damage and generally hamper construction of the well. For example, if the tubular element is a wellbore casing and electrical control lines are used at the outer surface of the casing, an electrical connector has to be applied at each connection of two adjacent casing sections.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a method of activating a downhole system arranged in an annular space formed between a radially expandable tubular element extending into a borehole formed into an earth formation and a cylindrical wall surrounding the tubular element, the downhole system being arranged so as to be activated by movement of an annular movement device along the tubular element, the method comprising:
arranging said annular moving device around the tubular element, the moving device having an inner diameter slightly larger than the outer diameter of the tubular element in its unexpanded shape; gradually expanding a portion of the tubular element by moving an expander through the tubular element in the direction of the moving device, whereby a transition zone of the tubular element is defined between the expanded an unexpanded portions of the tubular element; upon contact of the transition zone with the moving device, continuing movement of the expander through the tubular element so as to move the moving device in axial direction along the tubular element whereby the moving device activates the downhole system.
It is thus achieved that, upon expansion of the tubular element, the downhole system is triggered by the moving device to perform a downhole process. Such triggering occurs without the requirement for control lines extending from surface into the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter in more detail and by way of example with reference to the accompanying drawings in which:
FIGS. 1A–1C schematically show a first embodiment of a borehole system for use in the method of the invention, during various stages of use thereof;
FIGS. 2A–2B schematically show a second embodiment of a borehole system for use in the method of the invention, during various stages of use thereof;
FIGS. 3A–3C schematically show a third embodiment of a borehole system for use in the method of the invention, during various stages of use thereof; and
FIGS. 4A–4C schematically show a fourth embodiment of a borehole system for use in the method of the invention, during various stages of use thereof.
In the Figures like reference numerals relate to like components.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1A there is shown a borehole 1 formed into an earth formation 3 whereby the borehole wall is indicated by reference numeral 4 . A tubular member in the form of metal borehole casing 6 with longitudinal axis 7 extends substantially concentrically into the borehole 1 . Thus, an annular space 8 is formed between said cylindrical members. It is to be understood that the borehole wall 4 does not need to be perfectly cylindrical as it generally is of irregular shape due to, for example, washouts which occur during the drilling process.
The casing 6 is provided with a downhole system in the form of a set of three annular seal elements 10 , 12 , 14 arranged around the casing 6 and being mutually displaced in axial direction thereof, and with a stop device in the form of annular stopper 16 fixedly connected to the casing 6 and arranged at one side of the set of sealing elements. Furthermore, the casing is provided with a moving device in the form of metal compression sleeve 17 arranged at the other side of the set of seal elements 10 , 12 , 14 . The compression sleeve 17 is movable relative to the casing 6 in axial direction thereof.
The seal elements 10 , 12 , 14 are made of a flexible material such as rubber, and are optionally strengthened in axial direction by axially extending reinforcement bars (not shown) embedded in the flexible material. Seal element 10 has a tapered edge 18 adjacent seal element 12 , seal element 12 has a tapered edge 20 adjacent seal element 10 and a tapered edge 22 adjacent seal element 14 , and seal element 14 has a tapered edge 24 adjacent seal element 12 and a tapered edge 26 adjacent stopper 16 . The stopper 16 has a tapered edge 28 adjacent seal element 14 . The tapered edges 18 , 20 are oriented such that seal element 10 is induced to slide along radial outer surface 30 of seal element 12 when seal element 10 is pushed in the direction of seal element 12 . Similarly, the tapered edges 22 , 24 are oriented such that seal element 12 is induced to slide along radial outer surface 32 of seal element 14 when seal element 12 is pushed in the direction of seal element 14 . Furthermore, the tapered edges 26 , 28 are oriented such that seal element 14 is induced to slide along radial outer surface 34 of stopper 16 when seal element 14 is pushed in the direction of stopper 16 .
The casing 6 has a radially expanded portion 40 , a radially unexpanded portion 42 , and a transition portion 44 located between the expanded and unexpanded portions 40 , 42 and a having a diameter varying from the unexpanded diameter to the expanded diameter.
The stopper 16 , the seal elements 10 , 12 , 14 , and the compression sleeve 17 are all arranged around the unexpanded portion 42 of the casing whereby the compression sleeve 17 is arranged adjacent the transition portion 44 of the casing.
The compression sleeve 17 has an edge 46 adjacent the expanded portion 40 of the casing 6 , which is provided with an axial bearing which ensures low friction between the edge and the transition portion 44 of the casing 6 . The bearing can be, for example, a bronze or Teflon (Trade Mark) bushing, a thrust bearing (e.g. set of bearing balls regularly spaced along the circumference of the edge), or a hydrostatic bearing.
Referring to FIGS. 2A , 2 B there is shown a downhole system in the form of an annular injection device 51 arranged around the casing 6 , which injection device 51 upon activation thereof injects a selected fluid into the annular space 8 . The injection device includes an annular pump 52 arranged to pump the selected fluid via a conduit 54 and a plurality of circumferentially spaced annular nozzles 56 into the annular space 8 upon activation by the compression sleeve 17 . The selected fluid is, for example, a chemical activator for hardening a body of cement slurry (not shown) present in the annular space 8 , or a catalyst or chemical for triggering a chemical reaction of a body of resin (not shown) present in the annular space 8 . Several said annular injection devices 51 are arranged at selected mutual axial distances along the casing 6 , however for the sake of simplicity only one injection device 51 is shown.
Referring to FIGS. 3A–3C there is shown a downhole system in the form of a casing centraliser 60 arranged around the casing 6 , which centraliser is largely similar to a conventional bow centraliser. The centraliser 60 has spring arms 62 which bend upon axial compression of the centraliser 60 and thereby expand radially against the borehole wall. The centraliser 60 has an end part 64 (remote from the compression sleeve 17 ) which is fixedly connected to the casing 6 , and an end part 66 (adjacent the compression sleeve 17 ) which axially slideable along the casing 6 .
Referring to FIGS. 4A–4C there is shown a downhole system which includes a slideable sleeve 70 arranged around the casing 6 , the sleeve 70 having an inner diameter slightly larger than the outer diameter of the casing 6 . The wall of casing 6 is provided with a number of openings 72 which provide fluid communication between the interior and the exterior of the casing 6 .
During normal operation of the first embodiment, the casing 6 is installed in the borehole 1 with the stopper 16 , the seal elements 10 , 12 , 14 , and the compression sleeve 17 arranged around the casing 6 as shown in FIG. 1A . An expander (not shown) is then pushed or pulled through the casing 6 to radially expand the casing 6 and thereby to form the initial expanded portion 40 thereof. A suitable expander is, for example, a conical expander or a conical expander provided with rollers along the contact surface with the casing. By the expansion process the casing 6 is plastically deformed.
Referring further to FIG. 1B , the expander is moved through the casing 1 in the direction of stopper 16 thereby increasing the length of the expanded portion 40 and moving the transition portion 44 in the direction of stopper 16 . Upon contact of the transition portion 44 with the edge 46 of the compression sleeve 17 , continued movement of the transition portion 44 induces the compression sleeve to move in the direction of stopper 16 . The compression sleeve 17 thereby induces seal element 10 to move against seal element 12 and subsequently to slide along the radial outer surface 30 thereof. When seal element 10 becomes fully arranged around seal element 12 , continued movement of the transition portion 44 induces the compression sleeve 17 to move seal element 12 against seal element 14 and subsequently to slide along the radial outer surface 32 thereof. When seal elements 10 , 12 become fully arranged around seal element 14 , continued movement of the transition portion 44 induces the compression sleeve 17 to move seal element 14 against stopper 16 and subsequently to slide along the radial outer surface 34 thereof. A set 50 of radially stacked seal elements has thus been formed.
Referring further to FIG. 1C , movement of the expander is continued so that movement of the transition portion 44 is continued. Since the stopper 16 prevents any further axial movement of the compression sleeve 17 and the set 50 of radially stacked seal elements, continued movement of the transition portion 44 leads to radial expansion of the compression sleeve 17 , the stopper 16 and the set 50 of radially stacked seal elements. The set 50 of radially stacked seal elements thereby becomes firmly compressed between the stopper 16 and the borehole wall 4 so as to form an annular seal there between.
In this manner it is achieved that an annular seal is created between the casing 6 and the borehole wall 1 , whereby a relatively large annular space is initially present there between and whereby the individual components of the seal are relatively thin so that installation of the casing 6 in the borehole 1 is not hampered by the seal.
During normal operation of the second embodiment, the casing 6 is installed in the borehole 1 with the compression sleeve 17 and the injection device 51 arranged around it whereby injection device 51 is fixedly connected to the casing 6 . Cement slurry is then pumped into the annular space 8 , which slurry hardens upon contact with a selected chemical activator. The injection device 51 contains an amount of such chemical activator sufficient to induce hardening a portion of the cement slurry in-between the injection device and another injection device arranged at some axial distance. The expander is then pushed or pulled through the casing 6 to radially expand the casing 6 and thereby to form the initial expanded portion 40 . As shown in FIG. 2B , the expander is moved through the casing 1 in the direction of injection device 51 thereby moving the transition portion 44 in the direction of the injection device 51 . Upon contact of the transition portion 44 with the edge 46 of the compression sleeve 17 , continued movement of the transition portion 44 induces the compression sleeve to move against the annular pump 52 of injection device 51 . Thereby the pump 52 pumps the chemical activator via conduit 54 and the nozzles 56 into the body of cement slurry present in the annular space 8 . As a result the portion of the cement slurry in-between the injection device and the other injection device hardens and thereby seals the annular space 8 . Further movement of the expander past the injection device 51 causes the injection device 51 to be flattened due to its radial expansion. It is thus achieved that hardening of the cement occurs only at those portions of the cement slurry where the casing 6 has been successfully expanded. Should the expander become stuck in the casing 6 , the unexpanded casing portion then can be retrieved to surface. Alternatively the remainder of the cement can be of a composition such that the cement will set after a prolonged period of time (i.e. in the order of days) and therefore will result into a conventionally cemented annulus.
During normal operation of the third embodiment, the casing 6 is installed in the borehole 1 with the compression sleeve 17 and the casing centraliser 60 provided around the casing 6 . The expander is then pushed or pulled through the casing 6 in the direction of centraliser 60 so as to radially expand the casing 6 and thereby to form the initial expanded portion 40 . As shown in FIG. 3B , continued movement of the transition portion 44 causes the compression sleeve 17 to move against the centraliser 60 and thereby to move end part 66 in the direction of end part 64 . As a result the centraliser is compressed so that the spring arms 62 become radially expanded against the borehole wall. As shown in FIG. 3C , further movement of the expander past the compression sleeve 17 and the centraliser 60 causes the end parts 64 , 66 of centraliser 60 to be radially expanded. Thereby the spring arms 62 become even more compressed against the borehole wall and thus the casing 6 becomes adequately centralised in the borehole 1 .
During normal operation of the fourth embodiment, the casing 6 is installed in the borehole 1 with the compression sleeve 17 and the slideable sleeve 70 provided around the casing 6 whereby the openings 72 are uncovered. The openings 72 are used to pump cement from the interior of the casing 6 into the annular space 8 (which is a conventional operation).
Thereafter the expander is pushed or pulled through the casing 6 in the direction of sleeve 70 so as to radially expand the casing 6 and thereby to form the initial expanded portion 40 . As shown in FIG. 4B , continued movement of the transition portion 44 causes the compression sleeve 17 to move against the sleeve 70 and thereby causes the sleeve 70 to slide over the casing portion with the openings 72 and thereby to cover the openings 72 . As shown in FIG. 4C , further movement of the expander past the slideable sleeve 70 causes the compression sleeve 17 and the slideable sleeve 70 to be radially expanded. In this manner it is achieved that the slideable sleeve 70 adequately covers the openings 72 and seals the interior of the casing 6 from the exterior thereof.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be readily apparent to, and can be easily made by one skilled in the art without departing from the spirit of the invention. Accordingly, it is not intended that the scope of the following claims be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | A method is provided for activating a downhole system arranged in an annular space formed between a radially expandable tubular element extending into a borehole formed into an earth formation and a cylindrical wall surrounding the tubular element. The downhole system is arranged so as to be activated by movement of an annular movement device along the tubular element. The method involves arranging the annular moving device around the tubular element, the moving device having an inner diameter slightly larger than the outer diameter of the tubular element in its unexpanded shape, and gradually expanding a portion of the tubular element by moving an expander through the tubular element in the direction of the moving device, whereby a transition zone of the tubular element is defined between the expanded an unexpanded portions of the tubular element. Upon contact of the transition zone with the moving device, continuing movement of the expander through the tubular element causes the moving device to move in axial direction along the tubular element whereby the moving device activates the downhole system. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
[0003] The present invention relates generally to equipment for handing pipe in an oilfield environment. More particularly, the present invention relates to elevators used to engage and lift vertically oriented tubular members.
[0004] Many different types of tubular members are handled during drilling, completion, and workover of wells. Among the tubular members used in well construction and servicing are drill pipe, drill collars, casing and tubing. Many different specialized types of equipment are used in handling tubular members during various phases of the drilling, completion, and workover processes.
[0005] Elevators are often used when handling tubular members when the tubular members are in or being moved to a vertical, or close to vertical, orientation. Most elevators are configured to interface with a shoulder, or upset, on the outer surface of the tubular member. The engagement of the elevator with this shoulder allows the elevator to support the weight of the tubular member and prevents the tubular member from falling through the elevator.
[0006] Many elevators are equipped with swinging doors that open to allow the tubular member to be received in the elevator and are then secured in a closed position to retain the member. These doors are often characterized by hinges that support the swinging doors and lock assemblies that keep the doors closed. These doors and lock assemblies are often manually operated and have thus been a focus of efforts to improve the safety and operation of these devices.
[0007] There remains a need to develop methods and apparatus for pipe elevators that overcome some of the foregoing difficulties while providing more advantageous overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0008] The embodiments of the present invention are directed toward an elevator comprising a body having a longitudinal axis therethrough. The body is operable to at least partially surround and support a tubular member aligned with the longitudinal axis. The body also has a longitudinal opening that is sized so as to allow the tubular member to pass therethrough. A door is rotatable about the longitudinal axis of the body and has a closed position wherein the tubular member is retained within the body and an opened position wherein the tubular member can pass through the longitudinal opening.
[0009] Thus, the present invention comprises a combination of features and advantages that 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
[0010] For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
[0011] FIG. 1 shows a top view of an elevator constructed in accordance with embodiments of the invention;
[0012] FIG. 2 shows a partial sectional view of the elevator of FIG. 1 ;
[0013] FIG. 3 shows a partial sectional view of an open elevator constructed in accordance with embodiments of the invention;
[0014] FIG. 4 shows a cross-section view of the locking pin of the elevator of FIG. 3 ;
[0015] FIG. 5 shows a partial sectional view of a closed elevator constructed in accordance with embodiments of the invention;
[0016] FIG. 6 shows a cross-section view of the locking pin of the elevator of FIG. 5 ;
[0017] FIG. 7 shows a tubular member being received by an elevator constructed in accordance with embodiments of the invention;
[0018] FIG. 8 shows a tubular member fully engaged by an elevator constructed in accordance with embodiments of the invention;
[0019] FIG. 9 shows a cross-sectional view of the engaged elevator of FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to FIGS. 1 and 2 , elevator assembly 1 0 comprises body 12 , bottom ring 14 , door 16 , top ring 18 , and locking pin 20 . FIG. 2 is a sectional view of elevator assembly 10 taken along section line A-A of FIG. 1 . Body 12 comprises lower shoulder 22 , upper shoulder 24 , bail pins 26 , handle 28 , and locking slot 30 . Bottom ring 14 and top ring are rotatably fixed relative to body 12 by pins 32 and 33 , respectively. Locking pin 20 is coupled to door 16 and is guided by locking slot 30 . Snap ring 32 engages body 12 and holds top ring 18 , door 16 , and bottom ring 14 within the body.
[0021] Body 12 has a substantially cylindrical shape having an opening 34 on one side. Bail pins 26 are arranged on opposite sides of body 12 for attaching to bails, or other lifting members. In certain embodiments, bail pins 26 may be replaced by lugs, lifting ears, or other means for connecting elevator 10 to a lifting appliance. Locking slot 30 extends through body 12 and includes counterbore 36 sized so as to interface with locking pin 20 .
[0022] FIGS. 3 and 5 show a cross-section of elevator assembly 10 , taken along section line B-B of FIG. 2 . FIG. 3 shows elevator assembly 10 is shown in an open position wherein door opening 38 is aligned with body opening 34 . In the open position, bushing 40 of locking pin 20 is retracted and rests against body 12 . Referring now to FIG. 4 , locking pin 20 comprises bushing 40 , rod 42 , bushing spring 44 , lock button 46 , and button spring 48 . Bushing 40 comprises shoulder 50 and counterbore 52 . Rod 42 comprises T-shaped front end 54 that engages door 16 and flanged back end 56 that slidably engages lock button 46 , such as with a dove-tail slot. Bushing spring 44 is disposed between shoulder 50 and back end 56 so as to bias bushing 40 toward front end 54 of rod 42 . In order to move bushing 40 toward back end 56 , lock button 46 must be centered so as to move past counterbore 52 . Lock button 46 is biased to an offset position by button spring 48 .
[0023] Door 16 is rotated to a closed position, as shown in FIG. 5 , by moving locking pin 20 through slot 30 until locking pin 20 engages counterbore 36 . The engaged locking pin is shown in FIG. 6 . In the closed position, door 16 completely closes body opening 34 and locking pin 20 is disposed at the end of slot 30 . Bushing 40 is urged into counterbore 36 by bushing spring 44 . As bushing 40 moves into counterbore 36 , lock button 46 enters bushing counterbore 52 and is urged to one side by button spring 48 .
[0024] From the locked position the only way to unlock and rotate door 16 is to follow the steps described below. First, lock button 46 us centered within bushing 40 . This allows bushing 40 to be pulled out of counterbore 36 . Once bushing 40 is out of counterbore 36 , door 16 can be rotated by moving locking pin 20 through slot 30 to the open position shown in FIG. 4 .
[0025] FIGS. 7-9 illustrate the engagement of a tubular member 100 with elevator assembly 10 . As shown in FIG. 7 , elevator assembly 10 is in the open position wherein door opening 38 is aligned with body opening 34 . Tubular member 100 is inserted into openings 34 , 38 such that elevator 10 is disposed close to tool joint 104 . Elevator 10 may be attached to tubular member 100 when the tubular member is vertical, horizontal, or at any angle in between. Once tubular member 100 is received in elevator 10 , locking pin 20 is moved through slot 30 such that door 16 rotates to capture the tubular member.
[0026] Once in the closed position, as shown in FIGS. 8 and 9 , angled surface of top ring 18 engages the tapered shoulder of tool joint 102 . Door 16 holds tubular member 100 in close engagement with top ring 18 and bottom ring 14 . Thus, tubular member 100 is securely fastened within elevator 10 and ready to be lifted up. Once the handling of tubular member 100 is completed, door 16 is rotated back to the open position of FIG. 7 and elevator 10 can be removed from the tubular member.
[0027] As can be seen in FIG. 8 , the relationship between top ring 18 , door 16 , and bottom ring 14 and tubular member 100 is critical to the performance of elevator 10 . As the diameter and type of tubular member changes, one or more of bottom ring 14 , door 16 , and top ring 18 may have to be changed so as to properly engage pipes with different diameters or tool joint shoulders. Many of the other components of elevator 10 , such as body 12 and locking pin 20 may be used for a wide range of pipe sizes without replacement. Thus, elevator 10 may be designed to allow for simple assembly and disassembly.
[0028] Referring back to FIGS. 2 and 3 , elevator 10 can be disassembled by first removing snap ring 32 , allowing top ring 18 to be removed from body. Door 16 can then be lifted up through body 12 . As door 16 is lifted locking pin 20 will slide out of the T-shaped slot in the door, thus allowing the locking pin to be removed from slot 30 . After door 16 is removed, bottom ring 14 can then be removed from body 12 .
[0029] In the above described embodiments, locking pin 20 is used to manually open and close elevator 10 . In other embodiments, the door could have gear teeth cut on its outside surface and the locking pin could be replace by pinion and hydraulic motor which would rotate the door. The hydraulically actuated elevator may find particular usefulness in allowing for remote control of the elevator and for larger elevator sizes where manual operation would be difficult.
[0030] 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 scope 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. For example, elevators capable of handling a wide array of sizes and tubular members can be constructed in accordance with the embodiments discussed herein. 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. | An elevator comprising a body having a longitudinal axis therethrough. The body is operable to at least partially surround and support a tubular member aligned with the longitudinal axis. The body also has a longitudinal opening that is sized so as to allow the tubular member to pass therethrough. A door is rotatable about the longitudinal axis of the body and has a closed position wherein the tubular member is retained within the body and an opened position wherein the tubular member can pass through the longitudinal opening. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
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 to a new hinge for furniture products. More particularly, the present invention relates to a compact hinge that is used primarily for mounting doors onto a cabinet.
[0004] Furniture hinges have evolved in the last thirty years to become smaller in size, easier to install and adjust, and with increased functionality such as providing a self-closing force to a door, or quick disconnection between a door and a cabinet. One of the types of hinges that has become very popular in this regard is termed a “compact” hinge for the reason that it relatively moderate in size, but also because it can be installed between a door and a cabinet in a way that is very unobtrusive.
[0005] Compact hinges of the type discussed herein, are typified by a cup portion that mounts into a recess cut into a door, and an arm portion that is pivotably connected to the cup portion and is also mounted to a portion of the cabinet. Examples of compact hinges may be seen, for example, in U.S. Pat. No. 5,617,612 to Ferrari, in U.S. Pat. No. 5,604,956 to Grass, and in U.S. Pat. No. RE 34,995 which is a re-exam patent (U.S. Pat. No. 5,175,908) to Domenig.
[0006] The compact hinges continue to evolve in ways to provide easier operation and adjustment, more efficient construction, and other features that make them very desirable as components of furniture and other products.
SUMMARY OF THE INVENTION
[0007] A compact hinge of the present invention comprises a cup portion and a hinge portion, where the hinge portion is pivotably connected to the cup portion. The hinge portion is comprised of an arm that extends from an arm end that engages a hinge pin within the cup portion and bracket end that is mountable onto a cabinet frame. The hinge assembly also includes a biasing spring that works on the arm end to bias the hinge portion towards a closed or open position.
[0008] The compact hinge of the present invention includes a biasing spring that is mounted outside the hinge cup.
[0009] The compact hinge of the present invention includes a biasing spring that can be set for a desired tension.
[0010] The compact hinge of the present invention also includes a more efficient design than the prior art with fewer components and components with less working.
[0011] These and other attributes and features of the present invention will be disclosed in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a perspective view of the compact hinge of the present invention
[0013] FIG. 2 shows an exploded perspective view of a compact hinge of the present invention.
[0014] FIG. 3 shows a top view of a compact hinge of the present invention.
[0015] FIG. 4 is a side elevational view of a compact hinge of the present invention.
[0016] FIG. 5 is a rear elevational view of a compact hinge of the present invention.
[0017] FIG. 6 is a side elevational view of the arm portion of a compact hinge of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] A compact hinge 10 in accordance with the present invention is shown generally in FIG. 1 with hinge cup 12 , hinge arm 14 , cup apron 16 and cup flanges 18 . In this portrayal, the hinge is shown in the closed position which is achieved through a biased action that will be described further below.
[0019] The components of the hinge are seen in more detail in FIG. 2 , where surprisingly few such components are needed to complete the invention. As shown, the hinge 10 is also comprised of the spring 20 which includes the spring coils 22 , the intermediate spring portion 24 , the spring arm(s) 26 and the spring end(s) 28 . The assembly also includes the hinge pin 30 , with pin end 32 and pinhead 34 .
[0020] Turning now to the hinge cup 12 , the hinge pin hole(s) 40 are shown as are phantom hinge pin hole(s) 40 ( a ) which will be explained in more detail below. In addition, the access hole(s) 42 , the hinge cup flange 44 , the hinge cup interior 46 , the mounting flanges 48 , fastener 50 and plug 52 are all disclosed.
[0021] The last component of the hinge is the hinge arm 14 which includes the bracket 60 , the mounting hole 62 , the angled stops 64 , the straight stops 66 , the intermediate arm 68 , and the arm end 70 with the cam surfaces 72 .
[0022] FIGS. 3, 4 and 5 , all show the compact hinge of the present invention in different views, with the hinge cup floor 80 , the spring cowl 82 and the cowl sides 84 now visible.
[0023] FIG. 6 shows the hinge arm 14 in isolation, with the through hole 86 and the mounting surface 88 .
[0024] In use, the compact hinge is mounted onto a door by first having a recess routed out in the door itself This recess is compatibly sized to accept the hinge cup with the hinge cup flanges and the mounting flanges resting on top of the door surface. The installation of the hinge cup may be completed by insertion of the plugs into predrilled holes located for that purpose, and then tightening same down by insertion and threading of the fasteners into the plugs, expanding them into the receiving holes. As may be appreciated, this occurs on the inside surface of the typical cabinet door and in locations roughly adjacent to the cabinet front where the corresponding hinge arm part may then be fitted onto the edge of a cabinet face or frame. This method of mounting is typical for compact hinges and as such is not part of the present invention per se.
[0025] The hinge operates between an open and a closed position where the hinge arm is free to rotate about the hinge pin as may be understood and seen as between FIGS. 1 and 3 (closed and open positions respectively). The spring, through the spring arms and spring ends, provides the biasing action onto the cam surfaces of the hinge arm. When the door is brought within a distance to an open or a closed position, the bias is generated by the action of the spring arm and spring end on the cam surface, resulting in the case of the present invention, coordinated closing force or opening force. Again, the usage of the spring arms and spring ends in this fashion is somewhat similar to applications shown in the prior art, however, as will be noted below, the tension generated on the spring arms and the spring ends can be selected in the present invention which is substantially different from the prior art designs.
[0026] Continuing, the hinge arm is mounted onto a front frame edge of a cabinet in the typical application, where the mounting surface sits directly on the frame edge and the position of the hinge arm is made vertically adjustable by means of the mounting hole. The bracket portion of the hinge arm is guided somewhat by the angled stops and the straight stops which help to plant the bracket squarely onto the surface of the frame edge. The angled stops serve the purpose of handling non-uniform thicknesses in the frame itself thus allowing the stops to work even when the material making up the frame is slightly oversized.
[0027] Of interest in the present invention is the usage of a single hinge pin. The hinge pin is installed into the hinge pin holes and is rotatably fixed by heading the pin end after the hinge pin has been threaded through arm end by means of the through hole. The spring on the other hand, does not require a hinge pin in the present invention. The phantom hinge pinholes 40 ( a ) as shown in FIG. 2 represent the position where a second hinge pin would normally be installed in the prior art hinges. The placement of the spring, substantially outboard of the hinge cup, obviates the need for this second hinge pin and simplifies the assembly process tremendously. As shown, the intermediate portion of the spring and the spring coils reside under the spring cowl and the cowl sides respectively. While not shown, the intermediate portion of the spring is typically fastened to the hinge cup by means of a tab turned up from the rear wall of the hinge cup. This will retain the spring in place.
[0028] The spring arms project along the sidewalls of the hinge cup and enter the access holes. The spring arms are installed to contact the cam surfaces of the hinge arm and when they do so, there is a small amount of tension exerted (if nothing more than the weight of the spring arms) onto the cam surfaces which increases as the cam action progresses to a maximum and then back to a minimum as the door is correspondingly opened (or closed). At this point, the present invention achieves a novel result in that the spring arms have spring coil tensioning without resort to using the interference effect of the underside of a cowl side as is shown in the prior art. The importance of this lies in the variability of the effect desired, since without more, the number of coils can be changed to alter the tensioning. Spring coil tensioning is preferred since it is essentially linear over a large part of the tension curve. If only interference is used to bias a spring arm it is non-linear and may result in undesirable fluctuations of “feel” as the hinge is progressed through open and closed positions.
[0029] The tensioning on the spring arms can also be augmented by the access holes. The amount of vertical clearance given to the spring arm travel, upwardly and downwardly, can supply a pre-set interference tension to the spring arms. Unlike prior art devices which use the underside of the cowl sides to perform this task; the access holes provide a way to alter the amount of tension for given applications. For instance, it would be possible to produce a hinge with stronger tensioning, hence bias, if the access hole is shortened vertically. In doing this, the spring arms will contact the top of the access hole sooner (or later in the opposite scenario) which will provide immediate resistance to the travel of the spring arm, decreasing the length of the lever arm between the spring and the cam surfaces. The amount of biasing forces then increases dramatically under this condition resulting in a multi-staged effect when the spring ends work on the cam surfaces, with the biasing force remaining constant during the time that tensioning remains linear (spring coils) and rising and falling in non-linear fashion as contact is made or released with the top of the access holes. Changes in the non-linear biasing force can be achieved easily by changing the punch that makes the access hole, as compared to the alteration of the height of the cowl sides which would require a complete new set of tooling.
[0030] The present invention allows for the usage of one type of spring and one set of tools for the production of hinges that can be matched to given applications. This surprising result increases the efficiency in manufacturing and handling of the present invention, which is further enhanced by the reduction of the second hinge pin. Taken as a whole, substantially less components are needed for the compact hinge taught herein yet it provides at least the equivalent functionality as compared to those in the prior art and yet it can also be adjusted to provide multi-staged tensioning for differing loads and applications.
[0031] The compact hinge of the present invention may be varied without departing from the teachings herein. For instance, the usage of the second hinge pin, although redundant, could still be considered in conjunction with the variable tensioning afforded by the combination of the spring coils and the access holes. The hinge arm could be varied in ways to modify the bracket or the arm end without departing from the spirit and scope of the teachings herein. The usage of the spring coils separately, without the effect of a second stage, non-linear effect being contributed from the contact with the access holes would also be a desirable variation, resulting in a compact hinge that only had a single stage effect while retaining the economical design described above.
[0032] Although it is understood that the bulk of the construction of the present invention is preferably fabricated from metal components, where desired, plastic components could be used where it is a matter of compatible selection by one skilled in the art. | A hinge for use in securing a door to a cabinet, includes a hinge cup portion for installation onto a door, a hinge arm portion for installation onto a cabinet, a spring for rotatable connection between said hinge arm portion and said hinge cup portion, where the spring is capable of exerting a first biasing force for urging the door to a fully closed or fully open position, and a second biasing force for exerting non-linear tension on the spring at a predetermined position during the progression of the door between an open and a closed position. |
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BACKGROUND OF THE INVENTION
[0001] a) Field of the Invention
[0002] The present invention relates to an unequal-torque coil spring and a spring motor thereof, and more particularly to an unequal-torque coil spring that is applied to a curtain set which can automatically fold a curtain and used to provide a feedback torque thereto, thereby achieving objective of providing a feedback force corresponding to an actual requirement from different stages of a curtain-folding working process.
[0003] b) Description of the Prior Art
[0004] For the purpose of safely using curtains, designs of curtain sets without exposed pull cords have been tirelessly developed in the industry. As shown in FIG. 1 , a curtain set 1 uses a spring motor 2 to produce a feedback force; after a lower beam 14 is pulled downwards and becomes lowered, a downward pulling force from a pull cord 12 is transmitted and stored in an equal-torque coil spring 20 inside of a spring motor 2 via a first reel drum 21 and a second reel drum 22 . When a curtain 15 is folded back, the force stored in the spring motor 2 can be fed back and output to the lower beam 14 , so that a safe design in which the curtain 15 can be folded back by a self-generated force without a pull cord may be applied.
[0005] Further, the spring motor 2 employs an elastic reaction force of approximately equal torque from a strip of equal-torque coil spring 20 to drive the first reel drum 21 and the second reel drum 22 at two sides, so as to reversely reel back the pull cord 12 at both sides and pull up the lower beam 14 by using the force stored in the equal-torque coil spring 20 , thereby achieving the objective of folding back the curtain 15 . To lower the curtain 15 , a user pulls the lower beam 14 downwards, and an action force is transmitted to the first reel drum 21 and the second reel drum 22 via the linkage of the pull cord 12 and the turning of a turning component 13 , and then the force is reversely output to the equal-torque coil spring 20 for storage via the first reel drum 21 and the second reel drum 22 , so that the force can be used to fold back the curtain 15 later.
[0006] The equal-torque coil spring 20 is of a spiral shape, and generates an effective torque curve that is close to being horizontal, which is difficult to match the gravity force of unequal masses accumulated from setting the curtain 15 to different heights. Therefore, it is often necessary to add weights that are hung from the curtain and repeatedly adjust a torque value of a single curtain set 1 during production, in order to achieve a steady folding speed.
[0007] Referring to FIGS. 2 and 3 , the spring motor 2 comprises a housing 201 assembled and provided with an axle 23 being combined with a chainring 230 , and a coiling axle 24 being combined with a linking chainring 240 ; the chainring 230 and the linking chainring 240 are engaged with each other, and have the first reel drum 21 and the second reel drum 22 pivoted and disposed longitudinally at a front end and a rear end, respectively; the first reel drum 21 and the second reel drum 22 are respectively provided with a first chainring 210 and a second chainring 220 , which are respectively engaged with the chainring 230 and the linking chainring 240 . A detachable bearing 231 is sleeved outside of a cylindrical surface of the axle 23 , and a cylindrical surface of the detachable bearing 231 allows a spiral inner circle of the equal-torque coil spring 20 to sleeve on; a release end of the equal-torque coil spring 20 is a joining end 200 which is joined to a radial cylindrical surface of the coiling axle 24 .
[0008] Referring back to FIG. 1 , when the lower beam 14 is pulled downwards, the generated force is released from the axle 23 to the coiling axle 24 as the equal-torque coil spring 20 is coiled around by the coiling axle 24 , and the affected equal-torque coil spring 20 will generate a recovery coiling force (feedback force), when the lower beam 14 is pushed upwards, the feedback force from the equal-torque coil spring 20 is activated and released to reverse the equal-torque coil spring 20 back to the position of the axle 23 . The reverse process happens as follows: the linking chainring 240 of the coiling axle 24 drives the second reel drum 22 via the second chainring 220 and then drives the first reel drum 21 via the chainring 230 , so that the pull cord 12 at both sides are reeled back by linking the first reel drum 21 and the second reel drum 22 .
[0009] In the aforesaid process, a coiling speed of the equal-torque coil spring 20 is different from that of the chainring 230 due to the presence of the detachable bearing 231 , the chainring 230 solely serves the purpose of shifting the force in this case, and shifts a force resulted from the first reel drum 21 being pulled by the pull cord 12 and transfers the force to the linking chainring 240 of the coiling axle 24 . Similarly, when the second reel drum 22 at the right is pulled by the pull cord 12 , the second chainring 220 can also transfer the force to the coiling axle 24 , so that the coiling axle 24 can pull and coil the equal-torque coil spring 20 , and the equal-torque coil spring 20 sequentially releases the force and turns around a center of a diameter thereof when it is pulled and coiled around by the coiling axle 24 .
[0010] Referring to FIG. 4 , which shows the curtain 15 that has been folded upwards completely. When the disposed lower beam 14 is pulled by the pull cord 12 and moved upwards, each curtain piece 150 is sequentially accumulated on an upper surface of the lower beam 14 ; consequently, a plurality of curtain pieces 150 are accumulated and form a total mass W of the stacked curtain pieces, which results in a maximum pulling force from the pull cord 12 at this moment. In comparison, the pull cord 12 also withstands the maximum pulling force at this moment, and holds the lower beam 14 to keep it from falling downwards.
[0011] When the curtain piece 15 is completely lowered, the lower beam 14 is at a lowest position which is a fifth height H 5 , and the pulling force withstood by the pull cord 12 is the minimum at this moment as it only needs to support the mass of the lower beam 14 now. Therefore, within the range of a total lift height H 0 , as the lower beam 14 has the curtain pieces 150 accumulated on top of it one by one from the bottom, the weight load of the curtain pieces 150 gradually increases as a result, and the weight load reaches maximum when the lower beam 14 reaches the top, and becomes minimum when the lower beam 14 is at the bottom.
[0012] In addition, when it reaches a third height H 3 defined in the curtain folding process, the spring motor 2 needs to produce a balancing pulling force against the lower beam 14 when it is located at the third height H 3 , so as to prevent the lower beam 14 from falling downwards, while the spring motor 2 also needs to avoid producing excessive pulling force that pulls the lower beam 14 upwards.
[0013] When the lower beam 14 is located at the lowest position which is the fifth height H 5 , and being pulled upwards to a first height H 1 , an upward momentum is generated from the combined factor between a mass of the lower beam 14 and a pulling speed of the pull cord 12 . Therefore, it would be ideal to have the pulling force from the pull cord 12 lessened when the lower beam 14 reaches a second height H 2 , so as to achieve a buffering effect, and then have the spring motor 2 output a smaller torque again in order to slowly pull up the lower beam 14 located at the second height H 2 to the first height H 1 , so as to prevent the momentum from the lower beam 14 to impact on a lower part of an upper beam 11 .
[0014] Referring to FIG. 5 , two sides of each of the curtain pieces 150 are respectively combined with ladder strings 120 at two sides, and two ladder strings 120 form a top-to-bottom linkage between a pitch P to support the curtain pieces 150 . Consequently, each of the curtain pieces 150 are linked from top to bottom, and topmost ends of the ladder strings 120 are combined with the upper beam 11 . As shown in the figure, when the lower beam 14 is located at a half-height position Hn, the weight of the total mass W of the stacked curtain pieces is withstood by the upper surface of the lower beam 14 ; when the pull cord 12 is pulling upwards or supporting the curtain in a fixed position, the ladder strings 120 help support the total weight of all curtain pieces 150 interspaced by the pitch P.
[0015] As the lower beam 14 is lowered, the feedback torque stored in the spring motor 2 is needed for fixing the lower beam 14 at the half-height Hn position, while the upper surface of the lower beam 14 is supporting the total mass W of the stacked curtain pieces at Hn at the same time. Thus as the lower beam 14 moves upwards, greater balancing torque is needed from the spring motor 2 . In contrast, as the lower beam 14 moves downwards, the torque needed from the spring motor 2 declines proportionately. Subsequently, the required working torque curve from the spring motor 2 turns from steep to flat.
[0016] To allow the spring motor 2 of the curtain set 1 to produce the torque needed for folding back the curtain 15 during the curtain folding process, as disclosed in U.S. Pat. No. 6,283,192 B1; the main technical feature is related to the longitudinal area of a strip of spring, and a method of boring holes to form weak points is utilized to distribute bore holes of unequal sizes and distances, so that the strip of spring can have different elastic actions at a front end and a back end. For producing feedback torque output for actual system requirements based on simulations, and another U.S. Pat. No. 5,482,100, a strip of spring is formed with different thicknesses or widths at a front end and a back end in order to produce elastic reactions that result in varied torque to meet the actual requirements for torque. But the method of boring holes leads to weaknesses in the strip of spring, which results in the problems of mechanical damage and difficulty in processing. Further, because the strip of spring is a very thin metal slice that needs to have different thicknesses and widths at a front end and a rear end, the processing control for making increasing or decreasing thicknesses and widths needs to be extremely precise, which makes the production of the spring difficult and time-consuming.
SUMMARY OF THE INVENTION
[0017] A primary objective of the present invention is to provide an unequal-torque coil spring and a spring motor thereof, which provides feedback torque from the unequal-torque coil spring in response to requirements for different forces in different stages of a curtain-folding working process; multiple levels of torque are allocated for horizontally folding back a curtain in a curtain set. When the curtain is folded back, the torque is used to meet the requirements for the curtain-folding process and fixing the curtain at any heights when the curtain is lowered. The unequal-torque coil spring is fabricated in separate processes by simple procedures, so as to allow the unequal-torque coil spring to have different torque reactions at multiple sections.
[0018] A second objective of the present invention is to sequentially make various curvatures in different sections of a reed strip longitudinally, so as to fabricate an unequal-torque coil spring having unequal feedback torque.
[0019] A third objective of the present invention is to have different curvatures distributed in the unequal-torque coil spring; the curvatures are distributed from one end of the reed strip having a joining end to another end at different levels.
[0020] A fourth objective of the present invention is to allow the unequal-torque coil spring to generate usable feedback torque values with a ratio between 4:1.
[0021] A fifth objective of the present invention is to have the unequal-torque coil spring assembled in a housing of a spring motor, and indirectly drives a first reel drum and a second reel drum disposed at two sides of the spring motor, so that the first reel drum and the second reel drum simultaneously generate corresponding torque for pulling a pull cord coiled thereto.
[0022] To enable a further understanding of the said objectives and the technological methods of the invention herein, the brief description of the drawings below is followed by the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a front structural view of an assembly of a curtain set according to the prior art.
[0024] FIG. 2 is a three-dimensional structural view of a spring motor according to the prior art.
[0025] FIG. 3 is an assembled structural top view of the spring motor according to the prior art.
[0026] FIG. 4 is a schematic view showing the requirement of force for the curtain-folding process of a curtain set.
[0027] FIG. 5 is a lateral status view showing a lower beam of a curtain set located at the middle of a full lift height.
[0028] FIG. 6 . is a three-dimensional schematic view showing a reed strip of the present invention being bent into a first curvature.
[0029] FIG. 7 . is a three-dimensional schematic view showing the reed strip of the present invention being bent into a second curvature.
[0030] FIG. 8 . is a three-dimensional schematic view showing the reed strip of the present invention being bent into a third curvature and a fourth curvature.
[0031] FIG. 9 . is a schematic view showing the reed strip of the present invention being bent into unequal curvatures at a front end and a rear end.
[0032] FIG. 10 . is a top view of the reed strip of the present invention being bent into an unequal-torque coil spring.
[0033] FIG. 11 is a top view of an assembled system where the present invention is applied to a spring motor.
[0034] FIG. 12 is a correspondence view of the feedback torque curve of the present invention that corresponds to the requirements for the curtain-folding process in a curtain set.
[0035] FIG. 13 is another preferred embodiment showing the torque curve implemented by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The present invention provides an unequal-torque coil spring and a spring motor thereof, which uses a simple method for disposing different curvatures in multiple front and rear sections of a reed strip, so as to provide a feedback force as multiple levels of torque in response to actual working requirements from a curtain system loading end capable of arranging a curtain at different heights, and having dynamic and static friction forces between working pieces of the system, so that the curtain can be folded back and a lower beam can be fixed at any positions.
[0037] Referring to FIGS. 6-8 (with reference to FIG. 9 ), the present invention provides a strip of a reed strip 3 having different curvatures disposed as different levels, with an initial curvature A 0 , a first curvature A 1 , a second curvature A 2 , a third curvature A 3 and a fourth curvature A 4 . Each of the unequal curvatures is made by bending the strip toward an identical inner circle. Each of the different curvatures are disposed in the same reed strip 3 , and because the electronic spatial structures of different sections of the strip are modified by bending, the resulted elastic reactions of the different sections are different, which gives rise to unequal elastic forces (torque) output from different sections of the strip.
[0038] Referring to FIG. 9 again, the reed strip 3 of the present invention has an initial curvature A 0 disposed in a section starting from a joining end 300 to a first length L 1 , and a torque generated therefrom is an increasing torque TC that increases suddenly; a first curvature A 1 disposed in a section starting from the first length L 1 to a second length L 2 , and the first curvature A 1 generates a first torque T 1 which is of a slowly increasing arc when viewed on the curvature graph; a second curvature A 2 disposed in a section starting from the second length L 2 to a third length L 3 to form a second torque T 2 , and the second torque T 2 is a constant torque which is of a curve extending from a highest torque output of the first torque T 1 when viewed on the curvature graph; a third curvature A 3 disposed in a section starting from the third length L 3 to a fourth length L 4 , and the curvature of the third curvature A 3 decreases to form a third torque T 3 ; a fourth curvature A 4 disposed in a section starting from the fourth length L 4 to a fifth length L 5 , and the curvature of the fourth curvature A 4 can be made less to form a smaller fourth torque T 4 (points connecting the above-described torque curves are not changed suddenly, but have lines preceding and following the points slowly changing, the description about the points is omitted for the purpose of simplification).
[0039] For the purpose of meeting the requirement of forces corresponding to the actual curtain-folding working process, as well as easy fabrication, the reed strip 3 is fabricated by bending several sections separately to allow for the generation of several different torque forces, wherein the second torque T 2 is the maximum, and the third torque T 3 following the second torque T 2 decreases by sloping downwards; the torque forces after the fifth length L 5 are not included for consideration.
[0040] Referring to FIG. 10 , in which a structure of the formed unequal-torque coil spring 30 can be simplified into 3 layers overall; a curvature of an inner spiral layer C 3 gradually becomes less than that of an outer spiral layer C 1 , and a curvature of a mid spiral layer C 2 is also less than that of the outer spiral layer C 1 . Under a stationary condition, the unequal-torque coil spring 30 can form a self-binding force toward a center thereof to maintain a circular shape.
[0041] A ratio between the above-described torque forces can be set between 4:1, and the reed strip 3 is formed into an unequal-torque coil spring 30 by coiling, and comprises the outer spiral layer C 1 , the mid spiral layer C 2 , the inner spiral layer C 3 and a joining end 300 disposed at an exposed end of the reed strip 3 .
[0042] Referring to FIG. 11 , the unequal-torque coil spring 30 of the present invention is implemented in a housing 201 of a spring motor 2 , the unequal-torque coil spring 30 is sleeved outside of a cylindrical surface of an axle 23 around an identical center, but is not linked to the axle 23 ; the joining end 300 disposed at a free end of the reed strip 3 is joined to a cylindrical surface of a coiling axle 24 and linked thereto; an end of the coiling axle 24 is linked to a linking chainring 240 , and when driven by a chainring 220 of a second reel drum 22 or a chainring 210 of a first reel drum 21 , the linking chainring 240 drives the unequal-torque coil spring 30 to coil toward the direction of the coiling axle 24 . Under a stationary condition, the outer spiral layer C 1 of the unequal-torque coil spring 30 has the maximum torque and is the first to be coiled into the outer circle of the coiling axle 24 ; when outputting a feedback torque, the outer spiral layer C 1 is the last to be output.
[0043] Referring to FIG. 12 , the spring motor 2 is applied in a curtain set 1 for folding back a curtain 15 . Torque required for curtain-folding is different between a first height H 1 , a second height H 2 , a third height H 3 , a fourth height H 4 and a fifth height H 5 . If a lower beam 14 is folded to a position between the third height H 3 and the second height H 2 , the spring motor 2 withstands a maximum torque that is the second torque T 2 ; the distance between the second height H 2 and the first height H 1 is the last folding step and is the shortest, and the remaining momentum from the second torque T 2 generated for the curtain-folding process is sufficient for uploading a total mass W of the stacked curtain pieces. Therefore, the first torque T 1 is only used for pulling and supporting an overall weight resulted from accumulating the total mass W of all stacked curtain pieces 150 and preventing the curtain 15 from falling downward, so the torque of the first torque T 1 can be gradually decreased as it approaches the position of the first length L 1 . In other words, the torque from the first length L 1 is able to withstand the total mass W of the stacked curtain pieces.
[0044] The second torque T 2 generated from the longitudinal section of the reed strip 3 from the second length L 2 to the third length L 3 is a constant torque that corresponds to the curtain-folding process from the third height H 3 to the second height H 2 in the curtain set 1 ; when the curtain 15 is folded upwards, the torque T 2 provides the maximum torque for the lower beam 14 to withstand the loading weight of curtain pieces sequentially accumulated on a top surface thereof, and for pulling the lower beam 14 to the second height H 2 . Subsequently, the first torque T 1 is used to return the lower beam 14 to the first height H 1 . The purpose of having the first torque T 1 less than the second torque T 2 is to ease a momentum generated from the mass of the curtain 15 and the rising speed before the curtain 15 is folded back to destination (the first height H 1 ), so that a buffering effect can be achieved before the curtain-folding completes, thereby ensuring safe use.
[0045] The third torque T 3 generated from the section of the reed strip 3 from the third length L 3 to the fourth length L 4 is a decreasing torque, and the fourth torque T 4 generated from the section from the fourth length L 4 to the fifth length L 5 is less than the third torque T 3 ; the load of the fourth torque T 4 is the smallest.
[0046] During the folding of curtain, the lower beam 14 is pulled upwards from the fifth height H 5 and starts to sequentially accumulate each of the curtain pieces 150 arranged above, and then the third torque T 3 takes over as more force is needed for folding when the lower beam 14 reaches the fourth height H 4 , and the third torque T 3 rapidly generates a higher torque to relay the folding process to the second torque T 2 .
[0047] Each of the described levels of torque is able to generate a stopping and fixing force according to any needs when the lower beam 14 is located at any positions within a total lift height H 0 , so as to prevent the lower beam 14 at a particular height to fall downwards or rise upwards.
[0048] In this embodiment, the reed strip 3 corresponds to a measurement of the total lift height H 0 , and the torque distribution is as follows: the first torque T 1 is generated from the section between the first length L 1 and the second length L 2 , the second torque T 2 is generated from the section between the second length L 2 and the third length L 3 , the third torque T 3 is generated from the section between the third length L 3 and the fourth length L 4 , and the fourth torque T 4 is generated from the section between the fourth length L 4 and the fifth length L 5 .
[0049] The curve graph shows the second torque T 2 as one that needs to withstand a greater torque, and the third torque T 3 and the fourth torque T 4 can both be decreasing. This method of implementation can achieve a very steady speed for folding the curtain 15 . In a most ideal system of mechanics, the most precise curve lines are distributed in a sloping torque curve based on geometric coordinates. But for the purpose of easily manufacturing the unequal-torque coil spring and providing forces required for folding the curtain 15 , the torque distribution of the present invention is implemented according to the requirements of force for folding the curtain in the curtain set 1 .
[0050] In another simple embodiment (refer to FIG. 13 and complemented by FIG. 12 ), the torque curve T 0 of the present invention starts from zero and reaches the first length L 1 at a great angle of elevation, and achieves a force of 0.5 Kg that is the first torque T 1 , for instance. The first torque T 1 is generated from a level between the first length L 1 and the second length L 2 , and the torque curve of the first torque T 1 can be a sloping line or an arc. The second torque T 2 generated from the section between the second length L 2 and the third length L 3 is the maximum constant torque; the third torque T 3 generated from the section between the third length L 3 and the fourth length L 4 decreases at a great downward sloping rate or as an arc; the fourth torque T 4 generated from the section between the fourth length L 4 and the fifth length L 5 is constant.
[0051] The above described second torque T 2 and fourth torque T 4 are both constant, and can satisfy the requirements of force for folding the curtain in the curtain set 1 . In the process of fabricating the unequal-torque coil spring, the fabrication process is mainly focused on the second torque T 2 and the fourth torque T 4 , so that the fabrication procedures can be made easier and the making of the torque curve T 0 is more convenient.
[0052] The present invention provides different feedback torque in a reed strip by implementing different curvatures in each of the sections thereof; the distribution of different torque is well suited for providing feedback forces corresponding to different torque requirements of the curtain-folding process in the curtain set 1 . Accordingly, a new patent application is proposed herein.
[0053] It is of course to be understood that the embodiments described herein is merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | An unequal-torque coil spring and a spring motor thereof which is adapted for a curtain set that can automatically fold back a curtain; the same provides a feedback torque that responds to different stages of a curtain-folding working process and generates various corresponding torque in response, as each of the different stages requires a different force. Consequently, the curtain can be folded back at a steady speed, and positionally fixed at any height when the curtain is lowered. |