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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application claims the benefit of U.S. Provisional Application No. 60/119,691, filed Feb. 11, 1999.
BACKGROUND OF THE INVENTION
This invention relates to traffic barricades and more particularly to a traffic barricades of the sawhorse variety.
Roads, highways, sidewalks and other areas of vehicular and foot traffic are frequently subject to maintenance and reconstruction activities. Typically, such maintenance interrupts the traffic pattern and requires a detour from normal traffic flow. The principal highway warning device in a construction zone is the traffic barricade. This device typically comprises a horizontal reflective member which has a large face or surface structure to provide immediate visual recognition during both daylight and nighttime hours. This horizontal member is typically supported by two pairs of legs which are attached to form a type of sawhorse configuration.
Originally, such sawhorse traffic delineators were constructed of wood. A horizontal board was mounted to vertically inclined boards in the referenced sawhorse configuration using nuts and bolts. This construction requires a host of parts and labor to assemble the traffic delineator. Such barricades were heavy, costly and difficult to stack. Further these barricades were prone to damaging any vehicle that struck the barricade.
There are a variety of other constructions of sawhorse traffic barricades, all with certain advantages and disadvantages. What is needed then is a durable, lightweight sawhorse barricade of simple construction that can be easily constructed and stored.
SUMMARY OF THE INVENTION
The preferred embodiment of the invention is a traffic barricade comprised of substantially identical legs forming traffic barricade supports that are used to make the traffic barricade. The traffic barricade supports are rotatably joined together at one end of each leg to allow them to pivot. The traffic barricade supports are themselves joined together with one or more rectangular panels and reflective sheeting is applied to the panels, forming the traffic barricade.
Thus, the invention requires only one type of leg, a pivot mechanism and one or more panels to form the traffic barricade.
In the preferred embodiment two identical legs are pivotally attached at one end to form a traffic barricade support. Two or more traffic barricade supports are attached to one side of a rectangular panel to create a traffic barricade. Although in the preferred embodiment the panel is rectangular, any shape presenting a substantially planar surface to the two or more traffic barricade supports may be used as a panel.
The leg has a triangular cross section with a narrow side, a wide side oriented substantially normal to the narrow side and a hypotenuse side. There is a void or hole formed at a first end of the leg to create a bore through the wide side and the hypotenuse side through which a pivot may be fitted. The second end of the leg is designed to contact the surface supporting the traffic barricade support.
In the preferred embodiment the legs are hollow and made of blow-molded plastic for durability, economy and lightness. In an alternative construction, for example, the legs may be made of roto-molded plastic, metal, and they may be solid or hollow.
The pivot may be a bolt, a cylinder or other suitable member to allow two legs to be pivotally hat attached so that they may rotate between a closed position, with the legs substantially parallel, to an open position where the legs are relatively oriented at an angle. In the preferred embodiment a zinc-plated steel cylinder is used.
The two identical legs of a traffic barricade support are pivotally attached at their first ends in relatively opposite orientation, so that the hypotenuse sides of the two legs face each other. In this manner one leg may nest inside the other in the closed position and the traffic barrier support more compactly folds together.
The maximum angle that the two legs of a traffic barricade support can be opened in the open position is limited by a stop extending outwardly from the first end of the narrow side of each leg. Each stop has a contact surface that, when a first leg is pivotally attached to a second leg, engage to prevent further opening of the traffic barricade support at a predetermined maximum angle. The second end of the leg is beveled so that when the predetermined maximum angle of the traffic barrier support has been reached, the second end is substantially parallel to the ground or other supporting surface. Additionally, the triangular cross section of each leg allows a greater sectional modulus because the area of the cross section of the leg is maximized.
In order to facilitate the stacking of traffic barricades, in the preferred embodiment the narrow side of each leg is formed to have a convexly curved surface first portion and a second portion that is a concavely curved surface. The concavely curved surface and the convexly curved surface are complementary in size and shape.
The convex and concave portions formed on the narrow side of the leg allow traffic barricades made from such legs to be securely stacked. The traffic barricades are stacked in alternating opposite orientations so that the convex portions of the legs of one traffic barrier will fit closely within the concave portions of another traffic barrier. In this manner traffic barriers formed from these legs stack securely and will be less likely to shift or slide in a stack of traffic barriers.
Although these two portions may be of any suitable shape, they are preferably rectangular in shape and formed on opposite ends of the narrow side of the leg. Reflective sheeting may be applied to the panel to make the traffic barricade more visible to drivers.
Additional aspects and advantages of the present invention are set forth in the following description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a traffic barricade.
FIGS. 2 a , 2 b , 2 c and 2 d are four side views of the leg of the traffic barricade.
FIG. 3 is an exploded view of the two legs of a traffic barricade support and their pivoting mechanism.
FIGS. 4 a and 4 b are detail views of the cylinder pivot, FIG. 4 b is a side cutaway view.
FIG. 5 is a side view of a traffic barricade support with the legs in the closed position,
FIG. 5 a is a bottom view of 5 .
FIG. 6 is a side view of a traffic barricade support with the legs shown in a partially open position.
FIG. 7 is a side view of a traffic barricade support with the legs shown in the open position.
FIG. 8 is a bottom perspective view of a traffic barricade support in a partially open position.
FIG. 9 is a top view of a traffic barricade support in the closed position.
FIG. 10 is a top view of a traffic barricade support in the open position.
FIG. 11 is side view of stacked traffic barricades.
FIG. 12 is a perspective view of a traffic barricade.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a traffic barricade 1 made of two sets of legs 10 and 12 joined together with panels 9 . Each set of two legs with a pivot is collectively referred herein to as a traffic barricade support. The legs of each traffic barricade support are joined by a pivoting mechanism 14 , hereinafter termed a pivot, and in the preferred embodiment the pivot is a cylinder made of steel. The pivot 14 may be made of metal and or other materials, such as plastic or composite materials. Both legs 10 and 12 are of the same construction, therefore only a single leg design is needed for all the legs of the traffic barricade, with the same design of leg being used for each of the four legs. Other embodiments of the invention may have different but substantially identical leg designs from the preferred embodiment.
FIGS. 2 a - 2 d shows an individual leg from four side views. FIG. 2 a shows the leg from the hypotenuse side 34 . The end of the leg 15 is beveled to allow it to stand parallel or flush to a supporting surface when it is functioning as leg of a traffic barrier. Recesses 50 are shown which allow a screw to recede when it is used to affix a panel. In this view, the recesses 50 are shown with the walls 51 between the flat surface 32 of the recess and the narrow leg side 30 (shown at 2 d ). There is a panel hole 31 that corresponds to the center of recess flat surface 32 through which a panel mounting screw is fitted. Stop 22 is shown that forms a stop contact surface 23 . The stop contact surface 23 forms an angle theta with the major axis 24 of each leg. The face of the contact surface 23 can be seen in FIG. 2 b . FIGS. 2 a and 2 c show hole 13 that creates a bore from hypotenuse side 34 through wide side 32 . FIGS. 2 a , 2 c and 2 d show convexly curved surface 60 at the first end of the leg and concavely curved surface 62 at the second end. When the legs are assembled into the traffic barricade of FIG. 1, a plurality of traffic barricades may be securely stacked because the convexly curved surface 60 fits into the concavely curved surface 62 , as shown in FIG. 11 .
Any suitable plastic may be used to manufacture the legs. In a preferred embodiment of the invention, the plastic is high density polyethylene with a density of 0.96. Blow molding is the preferred method of manufacturing the both because it produces a strong barricade leg and also because it is more economical to use this method.
FIG. 3 is an exploded view showing the pivot mechanism 14 of the preferred embodiment as it fits into legs 10 and 12 to make a traffic barricade support. Pivot mechanism 14 is comprised of a cylinder 18 having a flange 16 , an end cap 19 and bolt 20 , and a nut 52 that is used in conjunction with the bolt 20 shown in the end cap washer 54 .
When the pivot is assembled, the cylinder 18 extends through the holes 13 of legs 10 and 12 . At the end of the cylinder distal the flange, there is a narrowing or constriction 17 , also shown in the cutaway side view 4 b, formed to retain end cap 19 within the cylinder. The end cap washer 54 has an inner surface that is disposed against the constriction 17 and the outside surface of leg 10 around hole 13 and the bolt 20 is affixed to nut 52 and is disposed against the outside surface of the end cap washer. Nut 52 is disposed against the inside surface of the end cap 19 within the cylinder. This configuration is preferred but not essential, the nut and bolt could be installed in the opposite direction with the bolt disposed against the inside surface of the end cap.
When assembled, the flange and the washer maintain the two legs and the distance between the flange 16 and washer 54 is such that the legs 10 and 12 can freely pivot.
FIGS. 4 a and 4 b show the detail of the pivot mechanism, also termed the pivot. Pivot 14 is shown with a flange 16 radially extending from a proximate end of a cylinder 18 . At the end of the cylinder distal the flange, there is a narrowing or constriction 17 , shown in the cutaway side view 4 b , formed to retain end cap 19 within the cylinder. The cylinder 18 extends from the flange 16 and through the top first ends of the legs 10 and 12 (not shown). The bolt 20 is mounted through the end cap of the mechanism and extends distally from the flange 16 . The end cap 19 of the cylinder 18 is shown to the left and the flange 16 of the cylinder 18 is shown to the right. Note that the end cap 19 and the flange 16 are located at opposite ends of the cylinder 18 . Other embodiments of the invention may have other ways of attaching the flange and the end cap to the cylinder or the parts may be unitary. Other embodiments of the invention may have other pivots also.
Now referring to FIG. 5, the two legs 10 and 12 are shown in the closed position nesting together. FIG. 5 a is a bottom view of the invention in this position. As shown each leg has an approximately triangular cross section. It is to understood that the use of the terms triangular and hypotenuse in this patent are not to be strictly construed as a hypotenuse of a true right triangle, this is simply the closest geometric shape that is useful to describe the structure of the present invention. For example, as FIG. 5 a shows the cross section of a leg is not a true triangle, but of general triangular shape. What is essential that the cross section of a leg includes a diagonal side, herein referred to as the hypotenuse, so that the hypotenuse sides of two legs will engage in the closed position and thereby nest together. In the preferred embodiment, for example, each leg includes a narrow trim side 25 sized to increase the overall width of a leg to allow sufficient mass of plastic to be used to support a particular traffic barricade and to form a hole of sufficient depth to support the flange. The appropriate additional width of the leg accorded by the trim side is a function of the material used to construct the leg and will be apparent to one of ordinary skill in the art.
In the preferred embodiment the surface of the leg that actually contacts the supporting surface is formed with an irregular surface, such as small bumps 27 to increase the traction of the leg on the surface.
The perimeter of the leg cross section of 5 a also has two sides, narrow side 30 and wide side 32 oriented at a right angle relative to each other. The narrow side 30 is narrower than wide side 32 . The perimeter of the leg cross section also has a hypotenuse 34 extending between the two sides 30 and 32 , in the preferred embodiment connected by trim side 25 .
When the legs 10 and 12 are closed, as shown, the hypotenuses 34 of each legs align and engage, thus nesting the legs.
Now referring to FIG. 6, the legs 10 and 12 are shown in a partially open position. The legs 10 and 12 have partially opened up in a direction 38 and 40 , respectively. The directions 38 and 40 are mutually opposing, shown by arrows, and the directions are also normal to the narrow side 30 of the respective leg.
Attachment of a panel to the legs is straightforward. In this view, the recesses 50 are shown with the walls 51 between the flat surface of the recess and the narrow leg side 30 . The panel 9 is affixed, for example, with panel mounting screws or bolts 9 ′ that extend through panel hole 31 that corresponds to the center of recess flat surface 32 through which a panel mounting screw is fitted. Screws or bolts 9 ′ used to mount the panels remain sufficiently in the recess such that they do not to interfere with the nesting of the legs in the closed position.
The legs 10 and 12 of FIG. 7 are shown in the open position. At the top first ends of the legs 10 and 12 are stops 22 . The stops 22 have contact surfaces 23 which are shown engaged in mutual contact. Notice that the stops 22 have reinforcing construction 26 in order to improve the strength of the device.
FIG. 8 shows the legs 10 and 12 fully opened and the view is looking up from the bottom of the legs towards the pivoting point. The interior, hypotenuse side 34 of the legs are shown with recesses 50 . The recesses 50 are arranged to accommodate a screw, bolt or other attaching device that is used to mount a panel to the legs. The recess 50 has a flat surface 32 that opposes the narrow leg side 30 and a bolt extends through the wall between the recess flat surface and the narrow leg side. The narrow leg side 30 has a panel hole 31 that corresponds to the center of the recess flat surface 32 through which a panel mounting screw is fitted.
FIG. 9 shows the legs 10 and 12 looking down from the top while the legs are in a closed position. As shown the stops 22 are not in contact because the legs are in the closed position, the contact surfaces 23 of the stops are exposed.
Now referring to FIG. 10, legs 10 and 12 are shown in a top view in an open position. Note that the contact surfaces 23 of the two stops 22 extending from the top of the legs are now in contact.
FIG. 11 shows the assembled barricades stacked together. The individual traffic barricades stack secure because the convexly curved surface 60 of one leg stacks neatly into the concavely curved surface 62 of the legs of the traffic barrier stacked on top of it and underneath it. They may stacked one atop another in alternating orientation with the convex portion of one leg fitting in the complementary concave surface portion another traffic barricade.
FIG. 12 shows the use of a batten 37 to ballast a traffic barricade. Slits 39 may be cut in the legs of two hollow traffic barrier supports forming a traffic barricade to receive a batten, which may be a length of plastic. A sandbag 41 or other available ballasting object may then be placed on the batten to ballast the traffic barricade from being moved by the force of wind or rain. FIG. 12 also shows the use of reflective sheeting 43 applied to the exterior face of panels 9 to increase the visibility of the traffic barricade.
It will be appreciated that the invention has been described hereabove with reference to certain examples or preferred embodiments as shown in the drawings. Various additions, deletions, changes and alterations may be made to the above-described embodiments and examples without departing from the intended spirit and scope of this invention. Accordingly, it is intended that all such additions, deletions, changes and alterations be included within the scope of the following claims. | A sawhorse type of traffic barricade constructed from identical leg units. The legs are equipped with a stop to prevent them from opening beyond a predetermined point. The legs have the cross section of a right triangle, allowing the hypotenuse sides of the legs to nest within each other. The legs may be equipped with complementary convex and concave portions to allow the barricades to be stacked securely atop one another by fitting the portions together. |
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This is a continuation of application Ser. No. 703,360 filed Feb. 20, 1985 and now abandoned.
BACKGROUND OF THE INVENTION
Double locking combination locks have been proposed in which a combination padlock is also capable of being opened by key. The use of steel balls to engage and lock shackles of combination locks has been proposed in prior patents (see U.S. Pat. Nos. 2,931,204 and 3,855,824). Arrangements for upsetting a permutation wheel during closing and locking a padlock has been proposed.
None of the prior proposals or uses has provided a satisfactory lock with the strength, security and reliability of the present invention.
SUMMARY OF THE INVENTION
Broadly, the invention comprises a double locking combination lock in which a plurality of steel balls in a lock body cavity are controlled by movement of a cam plate associated with the housing to lock the shackle with two of the balls or with the unlocked shackle withdrawn from the body to hold the cam plate means in the open position.
The cam plate means is also controllable by a key lock with a rotatable cylinder which connects to the cam plate through a key cam and slide plate.
It is a feature of the invention that the shackle carries an upset spring to cause the discs to be upset when the shackle is moved downwardly into a locked position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view as seen from the front of the lock;
FIG. 2 is an exploded perspective view as seen from the back of the lock;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 4;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3;
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. 3;
FIG. 7 is similar to the sectional view of FIG. 3 in which the lock is shown in its unlocked condition;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7;
FIG. 9 is an elevational view partially broken away to show the key lock operation;
FIG. 10 is a sectional view taken along line 10--10 of FIG. 9;
FIG. 11 is a sectional view taken along line 11--11 of FIG. 10;
FIG. 12 is a partial elevational view showing the upset mechanism clearing a disc in upward shackle movement; and
FIG. 13 is a view similar to FIG. 12 showing the upset mechanism operation in downward shackle movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, lock 10 includes a dial knob 11 carrying front combination disc 12, a main body housing 13, a shackle 14, a steel ball cam member 17, a cam member return spring 18, three (3) steel balls 21, 22, 23, a center ball spring 24, a drive lever 26, a main lock body 27, a key cylinder follower 28, a key control plate 31, a key lock body 32, an upset spring 33, an upset spring mount plate 34, middle combination disc 36, rearward combination disc 37, disc support plate 38, and housing ring 39.
Turning more broadly to FIGS. 1-8, main lock body 27 includes a steel ball chamber 41 in which steel balls 21, 22 and 23 together with control cam member 17, are housed and controlled. Chamber 41 is sized and shaped to permit cam member 17 to reciprocate partially therein, with spring 18 urging cam member 17 normally to the right as viewed in FIGS. 1 and 6. Cam member 17 can be moved to the left against spring 18 by counterclockwise movement of dial knob 11 provided the drive lever 26 has been engaged with discs 12, 36 and 37 as explained hereinafter. Cam member 17 includes vertical plate 42, plate ridge 42a, plate hole 43, ball cam piece 44 and spring mount extension 46.
Driver lever 26 includes lever body piece 48, tubular extension 49, cam member boss 51 and bar extension 52. Tubular extension 49 ridges in lock body slot 49a while bar extension 52 rides in lock body opening 52a.
Driver lever 26 is rotatable about tubular extension boss 51 which bears in plate hole 43 and therefore driver lever 26 translates back and form together with the side-to-side movement of cam member 17. Driver lever 26 is biased by spring 25 urging extension 52 downwardly against discs 12, 36 and 37. Shackle 14 includes long shackle leg 53 and short shackle leg 54. Shackle leg 53 is held locked by ball 23 in leg notch 56 and leg 54 is held locked by ball 21 in notch 57 (see FIG. 6).
Operation of the lock to free shackle 53, 54 from balls 21 and 23 requires translating cam member 17 to the left (FIGS. 1 and 6) to permit center ball 22 to be urged by its spring 24 into cam piece opening 44a. As ball 22 moves into opening 44a, outer balls 21 and 23 move out of notches 56, 57 as upward movement of the shackle legs 53 and 54 begins to permit full release of the shackle legs.
Cam member 17 can be moved to the left (FIGS. 1 and 6) only by movement of driver lever 26 which in turn can be moved to the left (1) upon entry of bar extension 52 in grooves 12a, 36a and 37a of discs 12, 36 and 37 and subsequent turning of dial knob 11, or (2) by operation of the key system as described below. When the combination is dialed, disc grooves 12a, 36a and 37a are aligned to receive bar extension 52, rotation of dial knob 11 counterclockwise causes driver lever 26 to move to the left carrying with it cam member 17. The shackle legs 53, 54 become freed and the lock can be opened by pulling out the legs 53, 54.
Turning now to FIGS. 9-11 and the operation of key lock arrangement, key lock body 32 which fits in body cavity 27a of lock body 27 (see FIG. 2) has a key-operated cylinder 64 in its interior and a slot 32a (FIG. 2) which permits key cam projection 28a to engage the cylinder 64. When the key 64a (FIG. 10) turns cylinder 64 clockwise as viewed in FIG. 9, key cylinder follower 28 is moved to the right (all as viewed in FIGS. 2, 5 and 9). Rear key follower boss 67 engages in vertical slot 68 of plate 31 to cause plate 31 together with front key follower boss 65, riding in lock body archway groove 66 to move to the right (see FIGS. 5 and 9). As plate 31 moves rightward it carries tubular extension 49 captured in slot 69 of plate 31. Movement of tubular extension 49 in turn translates cam member 17 to open the lock position.
Turning finally to FIGS. 12 and 13, during the upward movement of long shackle leg 53, upset spring plate 34 is moved upwardly due to its engagement with pin 70 positioned in notch 55 on leg 53 and bearing in housing groove 61. Plate 34 is guided by pin 58 riding in groove 59 of disc plate 38 (see FIG. 2). Spring 33 which is mounted on plate 34, deflects to pass detent 72 of rearward disc 37 (see FIG. 12). When shackle 53 is pushed downwardly to the lock position, ball 23 moves into shackle notch 56 releasing cam member 17 to move to its lock position. As cam member 17 moves its bar extension 52 ridges out of disc notches (including notch 37a; see FIG. 13). As shackle leg 53 nears its locking position, extension 52 leaves notch 37a and spring 33 engages detent 72 commencing its upset rotation of disc 37 (see FIG. 13). Shackle leg 53 continues its further movement downwardly with pin 70 bottom out in housing groove 61 and as spring 33 disengages from detent 72 rotation of disc 37 is completed. | A combination lock having both dial and key locking mechanisms and having long and short shackle legs which lock has a body containing a reciprocal cam plate for moving steel balls into and out of engagement with the shackles from lock to unlock position. An extending arm mounted on the cam plate engages the dial and key control means having a second extending arm is also engageable with the cam plate. The lock includes a spring upset arrangement. |
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This application is a continuation-in-part of U.S. Pat. Application Ser. No. 359,994, filed June 1, 1989, now U.S. Pat. No. 4,953,236 which is a continuation of U.S. Pat. Application Ser. No. 244,135, filed Sep. 14, 1988, now U.S. Pat. No. 4,886,207.
BACKGROUND OF THE INVENTION
The present invention relates to a service water tap or faucet which automatically controls operation and discharge of a water supply.
More specifically, the invention relates to an automatic service water tap or faucet which comprises a detecting sensor, compact faucet body or spout. The sensor and an aerator are installed in a nozzle cover mounted on the outlet end of the faucet body. To prevent inadvertent operation of the faucet by reflected light, the sensor is mounted at an angular position of from 0° to 20° from the vertical, with the optimum position being 10°.
The water controller, an electronic circuit (hybrid IC), and a hot and cold mixing valve are installed compactly inside the faucet body, while the check valve assembly, the battery case and the filter assemblies are mounted separately on a lower part of the faucet body. The filter assemblies are connected between the water supply pipe and the flexible connector (or tube); the check-valve assembly is connected to the base of the lower part of the faucet body by a coupling; and the battery case is coupled with the check valve assembly.
PRIOR ART
Heretofore, there have been service water taps intended to be controlled automatically with an ON/OFF operation of a water supply valve by utilizing a detecting sensor. One such system is disclosed in U.S. Pat. No. 4,741,363. However, in such previously proposed devices the components are arranged independently and then connected to each other so that they could not be made small-sized and lightweight by integrating every component as an article. Therefore, the desired effects were not obtained because establishing operation of the device was not easy and the external appearance was unsatisfactory.
Moreover, in certain conventional automatic faucets, as shown for example in FIG. 7, a solenoid coil -0 is magnetized as soon as a sensor perceives the presence of a physical object; at the same time a diaphragm 12 is opened to pass water rapidly. If the object is removed from the detecting range of the sensor, electric power supplied to the solenoid coil will be cut off. As a result, the diaphragm is suddenly closed, stopping water flow. Because of the resulting high water pressure difference a water hammer shock occurs. Whenever the valve opens and closes, this water hammer shock rattles the water supply pipes. If such shocks last long enough they can loosen or rupture the coupling parts of the pipe making a water leak.
By the present invention water hammer shock in automatic faucets is minimized. The invention lengthens the operating time for the opening and closing action of the valve as compared to a conventional water supply valve, and prevents sudden opening and closing of the valve. Instead of a diaphragm which performs the opening and closing action in a conventional valve, a valve piston of special structure is used. A pilot valve in the valve controller which controls opening and closing of the valve piston discharges water to reduce water pressure in a second chamber, with the valve piston being designed to open the water passageway in response to water pressure in a first chamber. Water hammer shock is minimized by lengthening the water discharging time in the second chamber and the operating time of the piston.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide an automatic faucet whose operation is completely automized.
It is another object of the invention to provide an automatic faucet in which all of the operative components are located within the body of the faucet, so that it can be of compact, small-size and of good appearance.
Another object of the invention is to provide an automatic faucet which can be easily installed in place of an existing faucet.
Yet another object is to minimize water hammer shock and damage to water supply pipes in an automatic faucet.
A further object of the invention is to avoid malfunctions and inadvertent operation of the automatic faucet caused by reflected light.
A still further object of the invention is to reduce operating costs by reducing breakdowns or leaking caused by heavy use of the faucet.
Yet another object of the present invention is to provide an automatic service water tap which can be substituted for an existing conventional service water tap while keeping all of the other remaining facilities (i.e., plumbing lines) as they were without any damage.
A further object of the invention is to provide an automatic service water tap which can be easily installed without providing new electric power lines so that the construction cost will be greatly decreased and so that the device can be utilized semi-permanently.
A still further object of the present invention is to provide an automatic service water tap which has an energy saving and economical effect, by allowing the automatic service water tap to be changed easily without any difficulties in existing buildings.
It is another object of the present invention to provide an automatic water supply valve which has a unique shape designed to minimize water hammer shock.
Another object of the invention is to provide an automatic water supply valve which has an automatic cutoff function.
Yet another object of the present invention is to provide an automatic water supply valve which has a semi-automatic function.
SUMMARY OF THE INVENTION
In accordance with an aspect of the present invention, an automatic faucet is provided in which the opening and closing operation of a water supply valve is controlled automatically by a signal received at the sensor. When a signal emitted from the emitting element of the sensor reflects from a physical object, it will be received by the photo detector of the sensor. This detecting signal inputs to the electronic control circuits of the device through an amplifier. The processed signal from the amplifier controls the water supply valve through a valve controller so that water flows out of, or stops flowing through, the automatic faucet.
Opening and closing of the water supply valve is performed by a valve piston. To minimize water hammer shock, the valve piston is driven by a valve driving motor and a pilot valve in a valve controller to prevent sudden opening and closing of the valve, and to make the operation of the valve more smooth.
A hot and cold water mixing valve may be provided which comprises a control screw and knob to set the desired water temperature. A temperature sensor maintains the set water temperature by sensing temperature change in the water. That sensor is installed to maintain the temperature of the water which flows out of the automatic faucet. The amount of water which flows out from the faucet may also be controlled.
When hands or physical objects are placed in the detecting range of the sensor after the temperature control knob to set the desired temperature and the water flow control knob adjusted to set the amount of water appropriately, water of desired temperature and amount will flow out automatically. Additionally, according to another feature of the invention, water flow will stop automatically after a preset time (30-60 seconds), in case gum or paper is attached on the surface of the sensor or if an object is placed within the detecting range of the sensor.
The automatic faucet of the present invention can be used for more than three years with a small battery, because the power consumption of the water supply valve and the sensor is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view, partially in section of an automatic faucet according to the present invention;
FIG. 1a is an enlarged sectional view of the phantom circled portion of FIG. 1.
FIG. 2 is a partial cross-sectional view from the left side, taken along line 2--2 of FIG. 1;
FIG. 3 is a side view from the right side, with parts broken away, of the automatic faucet of FIG. 1;
FIG. 4 is a rear view of the automatic faucet of FIG. 1, with parts broken away to illustrate the battery mounting;
FIG. 5 is a partially schematic view similar to FIG. 2, illustrating the installing position and angle of the sensor;
FIG. 6 is a cross-sectional view of the automatic water supply valve, taken along line 6--6 of FIG. 2;
FIG. 6a is a side view of the water supply valve of FIG. 6, taken along line 6a-6a with parts broken away;
FIG. 6b is a schematic cross-sectional view illustrating the closed condition of the automatic water supply valve of FIG. 6;
FIG. 6c is a view similar to FIG. 6b illustrating the opened condition of the automatic water supply valve of FIG. 6;
FIG. 7 is a schematic cross-sectional view of an existing automatic water supply valve;
FIGS. 8a and 8b are schematic diagrams illustrating the operating condition of the motor and the cam which control the pilot valve;
FIG. 9 is a block diagram illustrating the operation of the automatic water supply valve according to the present invention;
FIG. 10 is a time chart illustrating the signals of the electronic circuit of the automatic faucet;
FIG. 11 is a cross-sectional view of the mixing valve of the automatic faucet;
FIG. 11a is a cross-sectional view similar to FIG. 11 of another embodiment of mixing valve;
FIG. 12 is a top plan view of another shape of the automatic faucet;
FIG. 12a is a view similar to FIG. 12 showing the use of a digital temperature read out;
FIG. 13 is a schematic side sectional view showing a drainage control feature of the invention; and
FIG. 14 is a side sectional view of a faucet constructed according to the invention illustrating operating of the drainage control.
FIG. 14a is an enlarged sectional view of the portion of FIG. 14 boxed in dotted lines.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and initially to FIGS. 1, 2, 3 and 4, an automatic faucet "T" according to the present invention is illustrated which includes a water supply valve 100, a valve controller 101, (FIG. 2) electronic circuits (hybrid IC), and a hot and cold water mixing valve 2 all assembled as a unit compactly into faucet body I. An aerator 4 and sensor 5 are installed as a unit in a nozzle cover la in the discharge end of the faucet with sensor 5 positioned at a suitable angle of 0°-20° to the vertical. The nozzle cover 1a is coupled with the nozzle end of the faucet body 1 by screws 1b. A check valve assembly 8, battery case 9 and filter assemblies 10 are installed on the lower part of the faucet body 1.
Hot and cold water is supplied to the faucet through water supply pipes (not shown) connected to the bottoms of cut-off valves 11 of conventional construction which are, in turn, connected to the lower ends of filter assemblies 10. The latter are connected by flexible tubes 11 to the check valve assembly 8 through the hot water inlet port 8a and the cold water inlet port 8b.
Net-like tubes 10a", 10b" are located within chambers 10a' and 10b' of check valve assembly 8 and surround check valves 18, 19, respectively. The nets serve to filter the hot and cold water received from inlets 8a and 8b. Check valves 18, 19 include sliding pistons 18b, 19b having sealing gasket 18a, 19a secured on the faces thereof facing passages 10a and 10b defined in the ends of chambers 10a' and 10b'. Coil springs 18d, 19d bias the sliding pistons 18b, 19b toward valve seats 18f, 19f to normally close passage 10a and 10b. The resilient force of the springs is adjusted by adjusting screws 18e, 19e which are inserted into threaded holes 17' of screw sleeves 17. The latter are threadedly inserted into the threaded holes 20' of valve body fixing screw sleeves 20 of the check valve assembly 8. The latter include a neck portion 8' including outlet ports 8a', 8b' from chambers 1Oa, 10b and is threadedly coupled to the valve body 2b of the hot and cold water mixing valve 2. Thus, check valves 18, 19 are positioned to control passage of hot and cold water to the mixing valve. When the tap is operated pressure upstream of the valve is less than the line pressure so valves 18, 19 open and water is supplied to the tap.
A battery container 9 having a negative plate 9a (FIG. 4), including a contact spring 9' is mounted by screws 9" (FIG. 2) to the rear of check valve assembly 8. The plate 9a is removably secured to battery container 9 which also includes a positive plate 9b defining with plate 9a a battery chamber dimensioned to accept appropriately sized batteries to power the unit as described hereinafter.
As noted, hot and cold water from chambers 1Oa, 10b are supplied to the mixing valve 2. This valve may be of any convenient construction. For example, the valve, as schematically illustrated in FIGS. 1-3 and 6 may be of the same general construction as the water mixing valve described with respect to FIGS. 14-15 of U.S. Pat. No. 4,886,207 the disclosure of which is incorporated herein by reference. Preferably, however, the mixing valve has the construction illustrated in FIG. 11. As seen therein, when water flows from tubes 8a, 8b to valve 2 it first confronts the piston 16 of the mixing valve 2. The cylindrical piston 16 has opposed ports 16a, 16b formed therein for respectively receiving water from tubes 8a, 8b and discharging the water combined within the piston to the supply valve 100 thereabove. The ends of piston 16 have ports 16c, 16d formed therein so that the water in the piston is also passed to the chambers 16', 16" on either side thereof. A temperature sensor 13 is coupled with the piston 16 in the chamber 16'. This temperature sensor 13 is of known construction, as generally described hereinafter, and its sensitivity is adjusted by a control knob 26 engaged by a worm screw arrangement 14 to contract or expand the sensor, thereby to set the desired temperature. If the water temperature detected by the sensor 13 is lower than the set temperature determined by the temperature setting knob 26, piston 16 will slide to the left under the influence of spring 16b' by contraction of the sensor 13, thereby to close the inlet hole of cold water 10b, and at the same time to open the inlet hole of hot water 10a much wider. As the amount of hot water influx is larger than that of cold water influx, the water temperature inside the mixing valve 2 rises to the set temperature.
On the other hand, if the water temperature in the mixing valve 2 is higher than the set temperature, the plunger will be pushed out by expansion of the temperature sensor 13. This movement slides piston 16 to the right and blocks the hot water inlet hole 10a at the same time the inlet hole of cold water 10b opens wider, the amount of cold water influx is going to be greater than that of hot water influx. Therefore, the water temperature in the mixing valve 2 falls to keep the set temperature.
Volume control is effected by the control knob 26a connected by worm screw arrangement 14a to piston 16. This adjusts the radial position of port 16b to outlet 2a and thereby controls the volume of water exiting the mixing valve.
As shown in FIGS. 1 and 6a-6c, a water supply valve 100 is provided which receives the mixed water from mixing valve 2. Valve 100 includes a valve body 102 which contains a piston 106 slidably mounted in the body and having a flexible sealing ring 106' which divides the interior of the valve body into a first chamber 108 and a second chamber 107. The water supply valve is controlled by a valve controller 101, which comprises a pilot valve 103, valve driver gear 104a and a valve driving motor 104.
Valve body 102 includes an inlet hole 102a (FIG. 6a) coupled in any convenient manner to the outlet hole 2a (FIG. 11) of the hot and cold water mixing valve 2. The outlet hole 102b of the valve body 102 (FIG. 6) is coupled with the hose 7 which is connected to aerator 4.
As mixed water in the hot and cold water mixing valve 2 enters the first chamber 108 (FIG. 6a) through the outlet hole 2a of the water mixing valve 2 and inlet hole 102a of water supply valve 100, the water also enters the second chamber 107 through a small inlet hole 106a on the valve piston 106 (FIG. 6b). Therefore, water pressure in the first chamber 108 is initially the same as that of the second chamber 107 and the valve remains closed.
If the detecting sensor senses the presence of a physical object at this time, it will send a detecting signal to the valve driving motor 104 through electronic circuits (hybrid IC) 5'. By that pulse signal, power (electricity supplied from the battery or from a transformer) is supplied to the valve driving motor to drive the motor 104. As the motor 104 is driven it drives gear 10a, which in turn drives cam gear 114a in which a cam 114 is mounted. As described hereinafter, this rotates cam 114 through 180°. As a result of this rotation, the concave face of cam. 114 is brought into position opposite the plunger 110 which rides on the cam (FIG. 6b). This plunger also engages the diaphragm 111 which, as seen in FIGS. 1, 6 and 6b is also subject, on its opposite face, to water pressure in second chamber 107. As a result, the diaphragm moves away from its seat (FIGS. 6 and 6c) and water in the second chamber 107 drains to the outlet hole 102b on the water supply valve 100 through the water passageway 109a. As the water pressure in the second chamber 107 is lowered, the valve piston 106 is pushed downwardly by the relatively high water pressure in the first chamber. As a gap between the valve piston 106 and the main seat 109 is opened, the water passes directly from inlet 102a through the outlet hole 102b of the water supply valve 100 to the nozzle (FIG. 6c). When there is a physical object within the detecting range of the sensor 5 (i.e., when the sensor detects an object), power consumption does not occur because the motor 104 remains stationary.
When an object within the detecting range of the sensor 5 is removed, a pulse signal from the electronic circuit 5' will be transmitted to the valve controller 101. The motor 104 is then driven by the pulse signal as power is supplied again to the motor 104. As the cam gear 114a coupled with the motor gear 104a rotates again through 180°, the convex part of the cam 114 pushes the plunger 110 and thus the diaphragm 111 closes pilot valve 113. When pilot valve 113 closes, water in the second chamber 107 will fill the chamber 107 because there is no place to drain. Therefore, the water pressure in the second chamber 107 becomes identical to that in the first chamber 108. As a result, the valve piston 106 returns to the original closed position under the restoring power of the spring 106b. Thus, the valve piston 106 and the main seat 109 engage each other, close the water passage and thereby block the flow of water.
As seen in FIGS. 8a and 8b, in order to stop the rotation of motor 104 after turning the cam through 180°, a hole 114a' is formed in the cam gear 114a, and two sensors are installed in the valve body 180° symmetrically on the arc of the passage of the hole 114a. When the cam gear 114a rotates, the sensors 5 detect the hole 114a' at the point of 180° and send the detecting signal to the valve driver control circuit 104a. The circuit thus produces a signal to activate or deactivate the motor. As a result, at the moment of detecting the object by the sensor 5, the motor 104 rotates the cam gear 114a 180°. The motor then remains stationary at that point, while detecting the object. As the object disappears from the detecting range of the sensor 5, the motor drives again, and stops after rotating the cam gear 180°.
Referring now to the function of the electronic circuit (hybrid IC) 5', that will be described with reference to the block diagram FIG. 9 and the time chart FIG. 10. The circuit includes an oscillator which comprises a low power C-MOS Gate IC, and generates the basic signal during performing the emitting and detecting function. The pulse signal generated from the oscillator enters into the time base A and time base B.
In time base B, the rise of pulse signal received from the oscillator delays for fixed time, and the pulse signal of narrow pulse width is generated and is transmitted as the input signal to the synchronizer of a one-shot circuit and the detecting part of the emitting part. The pulse rise of the output signal from the one-shot circuit is generated by synchronizing of the pulse rise of the time base B. The pulse width of the output pulse of the one-shot circuit is set off narrower than that of time base B, and the output pulse of the one-shot circuit is going to become a driving signal of the infrared emitter. In time base A, the pulse signal with narrow pulse width is generated by synchronizing of the pulse signal rise received from the oscillator, and transmits to the amplifier of the detecting part, and the output pulse signal from time base A is designed to synchronize to the fall of the time base B.
The output pulse signal from the time base A acts as an electric current supplying signal of the amplifier circuit in the detecting part, and amplifies the input signal received from the detecting part only when the pulse signal of the time base A is transmitted to the amplifier. All input signals from the detecting part are not amplified continuously, but are cut off by the pulse signal from time base A, thereby minimizing consumption of power. In other words, the current supplied to the amplifier is restricted by the time of pulse width of time base A.
When an amplified signal from the amplifier is received by the synchronizer, the signal which is transmitted to the synchronizer from the time base A and the signal which is synchronized are transmitted to the next step, the retriggerable one-shot circuits. That is, it transmits only the synchronized signal which drives the analog switch by the pulse of time base B. The retriggerable one-shot circuit performs the action of keeping the input pulse of narrow pulse width longer.
In other words, the output pulse of the one-shot circuit is the driving power of the infrared emitter. At this time, the infrared emitter transmits the infrared ray, and this ray is reflected by the reflector. The reflected signal becomes the input signal of the photo detector, the faint signal which enters into the photo detector is amplified by the amplifier.
Among the output signal of amplifier, except the photo signal, the noise which caused by the cutoff of the supplying electric current from the time base A is included In order to remove this noise, the existence of a reflector can be determined by synchronizing to the pulse width of time base B which is narrower than that of the time base A. When there is a reflector in the detecting range, the synchronized pulse becomes a trigger pulse of the retriggerable one-shot, and maintains the pulse output of the retriggerable one-shot high. And, this is inverted again by the inventor, and performs the OFF function of the valve. The signal which is not inverted acts as a trigger signal of the one-shot timer A and the inverted signal acts as a trigger signal of the one-shot timer B, and this again becomes a driving signal to the valve drive motor.
The time constant of the one-shot timer A and B can be changed by the organization of mechanism of the valve control system, and this is to prevent electric discharge of the battery by malfunction of the motor driving system. When there is no pulse from photo interrupter, in other words, when there is malfunction in the system, it performs the function of preventing the flow of electric current to the motor for more than the determined time of 30 seconds.
The signal from the one-shot timer A rises by the synchronization to the pulse rise in the delay off timer, and falls by triggering to the pulse rise of the photo interrupter A. The photo interrupter A is an apparatus to make the high level signal from one-shot timer A, low level, and it is installed in the ON state of the valve. It also rises by triggering of the pulse rise of the invertor and falls by triggering of the pulse rise of the photo interrupter B. The photo interrupter B is an apparatus to make high level signal low level, and it is installed in the OFF state of the valve.
The delay off timer which also worked as a safety device of the detector serves to restrict the continuation of the opening of the valve more than a determined time (e.g , 30-60 seconds). Thus, it provides the automatic water cutoff function The delay off timer can be set for a predetermined time (30-60 seconds) to prevent continuing flow of water when a physical object (i.e., a reflector) is accidently placed in the detecting range of the sensor or when tape, paper, gum, etc. is adhered to the surface of the sensor. Thus, the water flow is automatically stopped after that time even if the sensor is disturbed.
In accordance with another feature of the invention, a switch 27a may be placed on the drainage control rod for the sink drain (see FIGS. 13 and 14) which is used to open and close the drain hole of the sink. The switch is arranged such that when the rod 27b is pulled up, the drain hole is closed same time the switch is turned to ON to send a signal (see FIG. 9) to the delay off timer. The delay off timer then generates its signal to permit water flow for a determined time. After that time, the water flow is stopped automatically. After the user has washed in the sink, pushing down on the drainage rod will open the drain hole and at the same time the switch becomes OFF. When this signal is sent to the delay off timer, the detecting function of the sensor is restored. After that, the automatic faucet returns to the function of automatic water flow. At this time, there is no inconvenience of closing the hole and turning the knob to receive the water because when the drain hole is closed, the water flows automatically. Because the set time is determined by the required time to fill the appropriate amount of water to the wash basin, there is no danger of overflow, and the water supply time is determined by the side of the sink. The valve drive motor which performs the ON/OFF function of the valve directly sets the two operating points. By driving the motor only at the moment of reaching those points, thereby the power requirement can be minimized to operate the ON/OFF motion of the valve.
FIGS. 11a and 12a illustrate another embodiment of the invention in which the hot and cold water mixing valve 2 comprises a mixing valve body 2b, a piston 16, which is coupled with a temperature sensor 13, in turn engaged with a temperature control handle 26b. The opposite side of the piston is engaged by spring 16b and faces a conical outlet port 200. The flow volume is controlled by handle 26a which adjusts the position of the conical plug 201 relative to port 200. The temperature sensor 13 is filled with the temperature sensitive materials such as wax, liquid, or others, or is made of bimetal. By expansion or contraction of this temperature sensor 13, the cylindrical piston 16 will slide from side to side within the chamber 16", thereby varying the amount of water that flows out of supply tubes 8a and 8b. As seen in FIG. 11a, water from tube 8a enters the interior of piston 16 through ports 16a on one end wall and water from tube 8b enters the piston over its open end 16d. Thus, water is mixed in the piston and temperature is transmitted by plunger 17 to sensor 13 to adjust the position of the piston The mixed water flows through port 200 for discharge through port 2a to control valve 100.
If the temperature of water flows into the piston 16 as hot water and cold water through the inlet holes 1Oa, 10b in the hot and cold water mixing valve 2 is lower than the set temperature, it will be detected by the temperature sensor which then contracts. As the piston 16 slides to the left under the influence of the spring 16b, the inlet hole for cold water, 1Ob, is closed while at the same time the inlet hole for hot water, 10a, is opened. Because the amount of cold water influx is larger than that of hot water influx, the water temperature in the mixing valve rises.
On the other hand, when the water temperature in mixing valve 2 is higher than the set temperature, plunger 16 slides the piston to the right by the expansion of temperature sensor 13. The inlet hole for hot water, 10a, is then closed at the same time the cold water inlet hole 10b is opened. By that, the amount of cold water influx becomes larger than that of hot water influx, the water temperature in the mixing valve 2 becomes lower, thereby the set temperature is maintained.
In this manner, water is mixed in mixing valve 2 to the appropriate set temperature and flows into the water supply valve 100 through the inlet hole 100a of that valve.
If desired, a separate temperature sensor 210 can be provided in any convenient manner to create a digital read out on an LCD display unit 212 (FIG. 12a).
While the present invention has been particularly described with reference to a preferred embodiment, it will be appreciated by those skilled in the art that various changes and modifications may be made therein without departing from the scope or spirit of the invention. | An electronic water faucet including an infra-red sensor to detect the presence of an object near the faucet outlet. When an object is sensed an electric motor via a transmission operates a pilot valve to control a main water faucet valve of the piston type to allow water delivery. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This continuation in part patent application claims priority to the non-provisional patent application having Ser. No. 11/089,865, which was filed on Mar. 25, 2005.
BACKGROUND OF THE INVENTION
[0002] The bracket assembly for lifting and supporting a foundation relates to L shaped foundation brackets in general and more specifically to improvements in the connections of the bracket to a pile or deep foundation pile or deep foundation pier for supporting a lightweight structure or foundation element. A unique aspect of the present bracket assembly is an adjustable U-shaped bolt and mechanism that secures the bracket against rotation and translation relative to a pile or deep foundation pile or deep foundation pier. The U-shaped bolt also permits access from the side and a sleeve that allows the assembly to move upon a pile or deep foundation pile or deep foundation pier.
[0003] Generally the top of a pile or pier is defined as top and the bracket assembly rests upon the top. Perpendicular to the top is the side and it generally flanks the pile or pier. Briefly in use, the side access to the U bolt allows a contractor to reach into a shallow excavation and to draw the U bolt upon the pile or pier by turning wrenches from the ground surface. In other brackets, a contractor has to reach below the bracket, generally opposite the top, to turn wrenches inside a deeper and wider excavation.
[0004] A structure supported on a shallow foundation or lightweight structure or foundation element may become unstable and settle as a result of soil conditions or flaws in the original foundation design. In time, foundation settlement results in a structure becoming out of level and eventually structural damage. Without a stable foundation to rest upon, a structure will become unsafe and require additional foundation reinforcement to stabilize the structure. The present invention or bracket assembly transfers the weight, or vertical load, supported by a foundation or lightweight structure or foundation element, to a heavier foundation or pile or deep foundation pile or deep foundation pier. The pile or deep foundation pile or deep foundation pier bears on a load bearing stratum below the elevation of the lightweight structure or foundation element. The bracket assembly commonly cradles an edge of a lightweight structure or foundation element, such as a porch or patio, then transfers the load to a pile or deep foundation pile or deep foundation pier that bears on compacted earth, bedrock or other load bearing strata beneath the lightweight structure or foundation element. The main concept of this invention is to support a settling but lightweight foundation with a high strength to weight ratio bracket assembly, including a lifting mechanism used to stabilize and to raise a lightweight structure or foundation element, foundation, or structure and to secure same in a stable final position.
[0005] Prior art designs have previously supported failed or shallow lightweight structures or foundations utilizing a variety of methods. Piles or deep foundation piles or deep foundation piers made of concrete, reinforced concrete, timber, steel pipe, steel tubing, and solid steel bar bent into a helix have seen use at many sites to remedy failing lightweight structures or foundation elements with varying success. Typically, piles or deep foundation piles or deep foundation piers have been placed directly under a lightweight structure or foundation element and the piles or deep foundation piles or deep foundation piers then bear on adequate strata. The adequate transfer of the load from the lightweight structure or foundation element to the pile or deep foundation pile or deep foundation pier concerns contractors, engineers, and owners alike. However, placement of these piles or deep foundation piers beneath an existing structure, foundation or lightweight structure or foundation element can be difficult, often requiring deep excavations to provide the needed clearances. Commonly, contractors place piles or deep foundation piers below a lightweight structure or foundation element by excavating next to the lightweight structure or foundation element. Piles or deep foundation piers directly below a lightweight structure or foundation element become impractical because of excavation costs and narrow clearances between lightweight structure or foundation elements and adjacent structures. To minimize risk of damaging the lightweight structure or foundation element, contractors excavate wider and deeper access holes, lest piles or deep foundation piers become too short. Short piles or deep foundation piers have proven cumbersome and time consuming for contractors and result in a pile or deep foundation pier of questionable flexural rigidity.
[0006] The present art overcomes the limitations of the prior art where a need exists for a lightweight bracket to adequately transfer the lightweight structure or foundation element load to a pile or deep foundation pier located adjacent to a lightweight structure or foundation element. The present invention allows for placement of a pile or deep foundation pier adjacent to a structure eliminating the need for deep excavations. Because the load or weight of a structure is offset from the longitudinal axis of the pile or deep foundation pier, the transfer of the load results in a rotational force, or moment, being imparted into the bracket. That is, the art of the present invention, a bracket assembly for lifting and supporting a lightweight structure or foundation element, fixes a lightweight bracket to a pile or deep foundation pier with minimal moment and rotation of the bracket when under a load. The bracket assembly reduces the distance between the pile or deep foundation pier and the lightweight structure or foundation element to minimize the moment induced into the top of a pile or deep foundation pier by an eccentric load from the lightweight structure or foundation element. The moment imparts bending upon the pile or deep foundation pier where the pile or deep foundation pier has the least lateral support from adjacent soil and tends to rotate a bracket away from the corner of the lightweight structure or foundation element. The rotation reduces the effective bearing area between the bracket and the lightweight structure or foundation element. As a key feature, the present invention has a U-shaped bolt and mechanism that secures the bracket assembly to a pile or deep foundation pier and minimizes the moment upon the present invention and the pile or deep foundation pier.
[0007] The difficulty in providing a bracket assembly is shown by prior art bracket designs that transferred a foundation load to a particular style of pile or deep foundation pier. In U.S. Pat. No. 5,120,163 to Holdeman et al., to U.S. Pat. No. 5,171,107 to Hamilton et al., and U.S. Pat. No. 5,246,311 to West et al., each describes a bracket for a specific style or size of a pile or deep foundation pier. Some prior bracket designs state a feature to accommodate different sizes and styles of piles or deep foundation piers but, only provide for partial front to rear engagement between the installed pile or deep foundation pier and a bracket. Typically, an installed pile or deep foundation pier has a clearance between the lower portions of the bracket and the front edge of a pile or deep foundation pier toward the foundation.
[0008] In U.S. Pat. No. 6,079,905 to Ruiz et al. for example, the adjustable brackets only engage the upper portion of the bracket and the back edge of an installed pile or deep foundation pier farthest from the foundation. The prior art brackets provide little means of contact between the lower portion of the bracket and the front edge of a pile or deep foundation pier towards a foundation. Under typical loads without contact at both the lower front and the upper rear edges of the pile or deep foundation pier, the prior art brackets rotate about an axis perpendicular to the length of a pile or deep foundation pier. Rotation causes the foundation support portion of a bracket to disengage from a foundation opening a gap, thus reducing the effective load capacity of a bracket. Contractors and owners alike desire a bracket assembly adaptable for various shapes and sizes of piles or deep foundation piers and adjustable to prevent rotation and to reduce moment between a bracket and a pile or deep foundation pier.
[0009] Prior art designs utilized brackets for transferring loads from a foundation or lightweight structure or foundation element to a pile or deep foundation pier, however, the current invention is an improvement related to both speed of use and safety of the installation crew. The prior art has a bracket which has an anti-rotation bolt located at the lower end of the bracket and a stop at the upper end. The anti-rotation bolt is threaded and when tightened it engages the pile or deep foundation pier and in turn biases the top of the pile or deep foundation pier against the upper bracket stop support thus securing the bracket against moment, rotation and translation relative to the pile or deep foundation pier. However, the location and orientation of the lower bracket adjustment bolt requires contractors to reach under the foundation to adjust the bracket, possibly causing an unsafe working condition.
[0010] In contrast to the prior art, the present invention improves working conditions with a threaded U-shaped bolt and mechanism. The U-shaped bolt provides adjustment and fixity at the lower end of the weldment of the present invention. And, the U-shaped bolt is oriented with the threaded stems facing away from the lightweight structure or foundation element which allows adjustments from the side and not beneath the lightweight structure or foundation element. As described above, the side refers to away from the pier, flanking the pier, and generally perpendicular to the top of the pier.
[0011] Prior art designs also have a support and lifting bracket made of an elongated pipe sleeve that slides over and upon the upper end of a pile or deep foundation pier. The pipe sleeve provides the fixity required to limit rotation of the bracket but no adjustments are possible upon the pipe sleeve. The prior art pipe sleeve requires precise or exact positioning of the pile or deep foundation pier shaft during installation. The present invention though provides a pile or deep foundation pier guide or sleeve and a spaced apart threadably adjustable U-shaped bolt that bolt fit over the pile or deep foundation pier shaft yet allow the present invention to slide. Adjustment of the U-shaped bolt compensates for misalignment of the pile or deep foundation pier and allows for exact positioning of the weldment against the lightweight structure or foundation element while limiting rotation, translation, and moment induced upon the weldment when under load. Then the prior art pipe sleeve called for an applied force to straighten a misaligned pile or deep foundation pier shaft. The pile or deep foundation pier is then held straight by the pipe sleeve and an integral bracket secured to a lightweight structure or foundation element or foundation with wedge anchors. The wedge anchors may induce a horizontal load upon the pipe sleeve that could eventually cause failure of the wedge anchors or disengagement of the pipe sleeve from the lightweight structure or foundation element. The present invention on the other hand permits adjustment to straighten a misaligned pile or deep foundation pier without inducing loads that might cause the weldment to disengage from the foundation. The present invention does not use wedge anchors but rather a U-shaped bolt and a sleeve.
[0012] Therefore, a need exists for a bracket assembly to lift and support a failing foundation or lightweight structure or foundation element in cooperation with a pile or deep foundation pier. A bracket assembly must be secured against rotation when under load and permit adjustment to compensate for misaligned piles or deep foundation piers. Thus, the present invention has the ability to fully support the foundation, or a lightweight structure or foundation element, upon the bracket, to maintain such, and to prevent slippage between the bracket and the supported foundation or lightweight structure or foundation element.
SUMMARY OF THE INVENTION
[0013] Accordingly, the present invention modifies existing brackets so that the bracket adjusts readily to piles or deep foundation piers of various sizes ranging from about one inch to about two inches in diameter and various shapes such as round, square, and polygonal. The present invention uses a U-shaped bolt to minimize moment, rotation, and translation of a weldment. The U-shaped bolt is easily and safely adjusted to fix the weldment upon a pile or deep foundation pier and position the weldment against a foundation or lightweight structure or foundation element. By fixing the weldment against rotation and translation from the lightweight structure or foundation element, an effective bearing area is maintained between the lightweight structure or foundation element and the weldment. Further, the present invention has a sleeve to guide the pile or deep foundation pier which in cooperation with the U-shaped bolt compensates for misalignment of the pile or deep foundation pier.
[0014] A U-shaped bolt and sleeve allows a contractor to install the bracket beneath the lightweight structure or foundation element after placement of a pile or deep foundation pier. The location of the U-shaped bolt allows a contractor to adjust the bolt from the side rather than beneath the present invention. This location of the bolt reduces excavation and labor costs. The present invention also allows a contractor to use multiple systems for placement of a pile or deep foundation pier such as rotational torque drive and direct resistance drive among others. The present invention maintains placement and orientation of a pile or deep foundation pier to resist rotation and slippage. Further, the present invention permits locating installation tools and components over the center of a pile or deep foundation pier to reduce induced bending moment at the junction of a pile or deep foundation pier and a bracket, particularly where the lightweight structure or foundation element rests thereon.
[0015] A bracket assembly has a weldment of a bearing member, two parallel gussets, a guide member, an adjustable bolt, a sleeve, a cap plate, and two threaded support rods. This configuration allows the bracket assembly to slide over a pile or deep foundation pier and fixes to the pile or deep foundation pier located adjacent to a failing or settling lightweight structure or foundation element in need of repair. The pile or deep foundation pier is installed into the soil to a depth which provides adequate bearing along the length of the pile or deep foundation pier to resist the vertical loads imposed by the weight of the foundation or lightweight structure or foundation element. Additionally, the pile is installed in a manner that prevents movement of the pile or deep foundation pier, relative to the ground surface, when under axial compressive loads, generally from the foundation or lightweight structure or foundation element.
[0016] In the present invention, the components of the weldment support the lightweight structure or foundation element and operate upon the pile or deep foundation pier. The bearing member supports and lifts the lightweight structure or foundation element relative to the pile or deep foundation pier which is located adjacent to a lightweight structure or foundation element. The gussets extend from the bearing member away from the lightweight structure or foundation element on both sides of a pile or deep foundation pier. Between the gussets, the guide member has a sleeve in a hole through the guide member. A pile or deep foundation pier passes through the sleeve. Opposite the sleeve, the guide member has holes through which a U-shaped bolt connects. The base of the U-shaped bolt is placed around the pile or deep foundation pier towards the lightweight structure or foundation element and the two stems of the U-shaped bolt pass through the holes in the guide member for securing by nuts or the like. The guide member then has two aligned and spaced apart holes flanking the sleeve. The threaded rods are placed through those holes and oriented parallel to the pile or deep foundation pier. Opposite the guide member, a cap plate is placed upon the pile or deep foundation pier and the threaded rods pass through holes in the cap plate also aligning with the holes in the guide member. Nuts upon the threaded rods secure the cap plate upon the pile or deep foundation pier and the weldment to the threaded rods. Turning the nuts upon the cap plate pulls the threaded rods upwards along with the lightweight structure or foundation element. Generally the weldment moves upwards upon the fixed pile or deep foundation pier immobile relative to the surrounding soil. When the lightweight structure or foundation element reaches a desired position, generally level, the weldment is secured to the pile or deep foundation pier. In one manner of securement, the pile or deep foundation pier and U-shaped bolt are welded to the sleeve. And in another method, the nuts are welded to the rods and the bracket assembly is backfilled. And, in yet another method, nuts are doubled without welding.
[0017] Therefore, it is an object of the invention to provide a bracket capable of supporting loads less than twenty five thousand pounds and typically no more than five thousand pounds.
[0018] It is another object of the invention to minimize the depth of excavation adjacent to a lightweight structure or foundation element.
[0019] It is another object of the invention to provide adequate adjustment to compensate for a misaligned pile or deep foundation pier.
[0020] It is another object of the invention to allow adjustment of the bracket from the side opposite the lightweight structure or foundation element when placed upon a pile or deep foundation pier thus not requiring a workmen or tool to reach beneath the lightweight structure or foundation element.
[0021] It is another object of the invention to provide a bracket that weighs less than two hundred fifty pounds and typically no more than twenty five pounds.
[0022] It is another object of the invention to contact and direct vertical load transfer of a foundation to a bracket and then to a pile or deep foundation pier installed adjacent to the foundation.
[0023] It is another object of the invention to provide a bracket that accepts piles or deep foundation piers of various shapes and sizes.
[0024] It is a further object of the present invention to prevent shifting and rotation of the bracket with respect to a pile or deep foundation pier particularly when subjected to the weight of the lightweight structure or foundation element.
[0025] It is a still further object of the present invention to accommodate movement of a bracket away from a lightweight structure or foundation element.
[0026] It is an even still further object of the present invention to prevent rotation of the bracket or weldment relative to an installed pile or deep foundation pier under axial compressive loads and thus maintaining engagement between the bracket and the foundation or lightweight structure or foundation element.
[0027] These and other objects may become more apparent to those skilled in the art upon review of the invention as described herein, and upon undertaking a study of the description of its preferred embodiment, when viewed in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows an isometric front view of the preferred embodiment constructed in accordance with the present invention;
[0029] FIG. 2 shows an isometric rear view of the present invention showing the U-shaped bolt and sleeve securing the present invention upon a pile or deep foundation pier;
[0030] FIG. 3 describes placement of the present invention upon a pile or deep foundation pier;
[0031] FIG. 4 describes securing the guide member to a pile or deep foundation pier using the U-shaped bolt;
[0032] FIG. 5 shows the U-shaped bolt tight against the pile or deep foundation pier;
[0033] FIG. 6 shows the installation of threaded rods and cap plate upon the weldment;
[0034] FIG. 7 shows a bottom view of the cap plate;
[0035] FIG. 8 illustrates the present invention lifting a lightweight structure or foundation element; and,
[0036] FIG. 9 describes an alternate embodiment of the guide member.
[0037] The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] The present art overcomes the prior art limitations by providing a bracket assembly 1 that lifts and supports a lightweight structure or foundation element 2 with adjustable lifting and pile or deep foundation pier positioning hardware, that transfers lightweight structure or foundation element loads to piles or deep foundation piers 3 of various shapes and sizes, and that does not induce rotation of the bracket upon a pile or deep foundation pier. The present invention is installed upon a pile or deep foundation pier 3 adjacent to a foundation or lightweight structure or foundation element 2 , and has limited rotation upon the pile or deep foundation pier due to the securing action of a U-shaped bolt 9 . The U-shaped bolt 9 is oriented with threadably adjustable nuts upon stems facing away from the foundation 2 thus allowing an installer to make adjustments to the present invention safely without reaching beneath a supported structure or lightweight structure or foundation element.
[0039] Generally, soil settles in the vicinity of a lightweight structure or foundation element as it endures weather and loads. A lightweight structure or foundation element sees loads from people walking or equipment moving upon a lightweight structure or foundation element. Further, a lightweight structure or foundation element 2 as part of a porch protects soil beneath the lightweight structure or foundation element and in time, the soil pulls away from the lightweight structure or foundation element causing it to fall. After enough settlement, a lightweight structure or foundation element will move out of alignment and likely crack. To remedy a distressed or settling lightweight structure or foundation element, building owners and contractors have turned to light duty piles or deep foundation piers. A pile or deep foundation pier 3 extends down into the soil beside a lightweight structure or foundation element 2 a sufficient length of embedment to resist lightweight structure or foundation element loads. The pile or deep foundation pier has a generally linear shape with a shank. The shank may have a helical portion to increase load capacity. Piles or deep foundation piers have a variety of cross sections ranging from square to polygonal in both hollow and solid forms. In the prior art, the pile or deep foundation pier is located at an angle away from the lightweight structure or foundation element to permit installation. Generally, the piles or deep foundation piers will be earth driven anchors.
[0040] In FIGS. 1-9 , the pile or deep foundation pier 3 has a round corner square (RCSQ) or squared cross section though the present invention 1 will accommodate other shapes. Also in FIGS. 1-9 , front refers to the direction towards and the location nearest the lightweight structure or foundation element 2 and upper or top refers to the direction and the location above a pile or deep foundation pier 3 .
[0041] When used, the bracket assembly 1 withstands a portion of the lightweight structure or foundation element load and the corresponding reaction force. As the lightweight structure or foundation element load and the reaction force are spaced apart, the lightweight structure or foundation element load and the reaction force cause a moment upon the bracket assembly 1 . The moment tends to rotate the bracket assembly 1 away from the underside of the lightweight structure or foundation element 2 . An adjusting bolt 9 and a sleeve 8 cooperate to minimize moment applied to the top of the pile or deep foundation pier 3 and rotation or pivot of the bracket assembly 1 .
[0042] The preferred embodiment of the bracket assembly 1 appears in FIG. 1 . The bracket assembly 1 begins with a weldment 4 . The weldment has a bearing member 5 that engages and rests beneath a lightweight structure or foundation element 2 . The bearing member has a generally L shaped cross section with two legs 5 a intersecting along the spine of the bearing member. In the preferred embodiment, the bearing member 5 is a structural steel angle and has a first leg and a second leg of different lengths. The first leg has a longer length than the second leg and the first leg engages the lightweight structure or foundation element 2 . The second leg is perpendicular to the first leg and generally within 50 of parallel to the longitudinal axis of a pile or deep foundation pier when installed. Two gussets 7 join to the second leg. The gussets 7 are spaced apart and mutually parallel. In the preferred embodiment, the gussets 7 have a generally triangular shape with an included angle of about 95° abutting the second leg opposite the intersection of the two legs. The gussets 7 extend above the first leg of the bearing member 5 to contact the edge of a lightweight structure or foundation element 2 .
[0043] Joined to the gussets 7 , a guide member 6 joins along the second leg of the bearing member 5 . The guide member 6 has a generally L shape of two legs 6 a with a first leg and a second leg of different lengths. In the preferred embodiment, the guide member is a formed steel angle. The first leg of the guide member is below and parallel 5° to the first leg of the bearing member 5 . The first leg has a central hole that admits a sleeve 8 . The sleeve has a hollow round shape and a length at least twice the thickness of the first leg of the guide member. A pile or deep foundation pier then fits through the sleeve when the bracket assembly is used. Then the second leg of the guide member is below, behind, and attains a 5° angle between guide and bearing members to the second leg of the bearing member. The second leg has two centered and spaced apart holes and a U-shaped bolt 9 has two stems 9 a joining and extending from a base 9 b . The two stems 9 a cooperate with the holes to secure a pile or deep foundation pier 3 to the second leg of the guide member 6 . As shown in FIG. 1 , the base 9 b of the U-shaped bolt is away from the second leg and the stems 9 a of the bolt extend through the holes in the second leg where they are secured with nuts.
[0044] Along with the weldment, the present invention has a cap plate 10 positioned opposite the weldment 4 . The cap plate 10 has a generally rectangular shape with two lateral edges, two longitudinal edges, a top surface, and an opposite bottom surface. The longitudinal edges 10 a are reinforced to withstand bending below the bottom surface. Upon the bottom surface, the cap plate has two parallel spaced apart locating members 10 b as later shown in FIG. 7 . In the preferred embodiment, the cap plate 10 is a structural steel C-shaped channel. The locating members and the reinforcement form a space that contains the top of the pile or deep foundation pier 3 . Through the top surface, the cap plate has two centered and spaced apart holes generally outside the locating members. These holes in the cap plate align with those in the guide member.
[0045] The present invention is assembled into that shown in FIGS. 1, 2 by threading nuts onto two rods 11 a . The rods serve as a means to lift 11 the lightweight structure or foundation element. Alternatively, the lifting means 11 can be at least one jack, such as a hydraulic jack, pneumatic cylinder, or compressed air bladder. This is used in combination with a separate lifting frame (not shown). Additionally, a come-along or an electric winch can be used to draw the pieces together. In the preferred embodiment, the rods 11 a have sufficient diameter and steel strength to resist lightweight structure or foundation element loads later shown in FIG. 6 . With nuts 11 b upon one end of the rods 11 a , the rods are located through the holes in the first leg of the guide member 6 . Then the guide member and the remainder of the weldment 4 are placed over the pile or deep foundation pier as the pile or deep foundation pier 3 then passes through the sleeve 8 . Then the cap plate is positioned upon the top of the pile or deep foundation pier. The two rods are then advanced through the holes in the cap plate 10 . At least two nuts 11 b are turned onto the rods until snug against the top surface of the cap plate.
[0046] As described above, the pile or deep foundation pier passes through the sleeve 8 and the base 9 b of the U-shaped bolt wraps about the pile or deep foundation pier as now shown in FIG. 2 . The base of the U-shaped bolt enwraps the pile or deep foundation pier on the perimeter towards the lightweight structure or foundation element as shown in FIG. 3 and the stems 9 a of the U-shaped bolt extend through the holes in the second leg of the guide member. Nuts are placed upon the stems outside of the second leg as shown in FIG. 4 and turning of the nuts draws the U-shaped bolt 9 and the weldment 4 closer together upon the pile or deep foundation pier. When the nuts are tight, the weldment attains the same orientation as the pile or deep foundation pier as shown in FIG. 5 . The U-shaped bolt 9 and sleeve 8 cooperate in keeping the weldment tight upon the pile or deep foundation pier. The two points of contact by the U-shaped bolt and the sleeve allow the invention 1 to support a lightweight structure or foundation element 2 while resisting moment and rotation.
[0047] To utilize the present art, a contractor inspects a lightweight structure or foundation element 2 , often seen as a sinking porch, and determines lifting points. At a lifting point, the contractor installs a pile or deep foundation pier 3 near the low edge of a lightweight structure or foundation element 2 as later shown in FIG. 8 . The contractor then excavates about a foot beneath the lightweight structure or foundation element around the pile or deep foundation pier 3 . Grasping the weldment 4 , the contractor puts the stems 9 a of the U-shaped bolt into the holes in the guide member 6 and the threaded rods 11 through the other holes in the guide member. The U-shaped bolt remains loose. The contractor then places the weldment over the pile or deep foundation pier and then the pile or deep foundation pier 3 through the U-shaped bolt 9 and the sleeve 8 . The pile or deep foundation pier is located between the stems of the U-shaped bolt. The contractor turns the weldment as needed to fit past the lightweight structure or foundation element. When the bearing member nears the bottom edge of the lightweight structure or foundation element, the contractor rotates the weldment to position the bearing member 5 beneath the lightweight structure or foundation element 2 . The contractor then reaches into the excavation and tightens the nuts on the stems 9 a as shown in FIGS. 4, 5 . The contractor does this from the side of the weldment, as opposed to beneath, as done in the prior art. Tightening the nuts on the stems secures the weldment against rotation upon the pile or deep foundation pier and induces friction between the pile or deep foundation pier and the weldment. The friction holds the weldment in position as the contractor installs further parts of the invention.
[0048] Next, the contractor applies the cap plate 10 to the top of the pile or deep foundation pier 3 in FIG. 6 . The cap plate is centered on the pile or deep foundation pier within the locating members 10 b and the rods 11 a extend through the holes in the cap plate. The contractor then finger tightens the nuts 11 b upon the rods 11 a to remove the slack in the present invention. The contractor provides final tightening to the nuts on the stems of the U bolt. The base of the U-shaped bolt now tightly grasps the pile or deep foundation pier. Advancing towards the goal of a level lightweight structure or foundation element, the contractor turns the nuts 11 b on the rods 11 a upon the cap plate. As the pile or deep foundation pier is presumed immobile, the screw action of the nuts upon the rods draws the guide member towards the cap plate. Turning those nuts pulls the rods upwards along with the weldment as shown in FIG. 8 .
[0049] Alternatively, hydraulic jacks, pneumatic cylinders, or compressed air bladders are placed on top of the cap plate and coupled to the end of the threaded rods. Upon activating the jacks, cylinders, or bladders, the rods rise and pull the weldment upwards.
[0050] And when the lightweight structure or foundation element reaches the desired elevation or becomes level, the weldment is secured to the pile or deep foundation pier by conventional means such as welding the sleeve and U-shaped bolt to the pile or deep foundation pier, doubling nuts upon the rods, encapsulation in concrete, adhesives, and the like. With the weldment secure, the rods and cap plate can be removed and the invention and the pile or deep foundation pier can be back filled. If not welded into place, the rods and cap plate remain.
[0051] An alternate embodiment of the bracket assembly 1 appears in FIG. 9 . The bracket assembly 1 begins with a guide member 6 that has a generally L shape of two legs with a first leg 6 a and a second leg 6 b of different lengths. In the preferred embodiment, the guide member is a rolled steel angle. The first leg 6 a is generally the longer leg and is also where the foundation rests upon this assembly.
[0052] The first leg 6 a has a central hole that admits a sleeve 8 and two flanking holes 11 c that admit the threaded rods 11 . The sleeve has a hollow round shape and a length at least twice the thickness of the first leg, and extends perpendicular from the first leg generally opposite the second leg 6 b . The sleeve and flanking holes are more located towards the union of the first and second legs. A pile or deep foundation pier then fits through the sleeve 8 and the threaded rods 11 fit through the flanking holes 11 c when this alternate bracket assembly is used in the previously describe manner.
[0053] Then the second leg 6 b of the guide member is generally perpendicular to and below the first leg 6 a . The second leg has two centered and spaced apart holes and a U-shaped bolt 9 has two stems 9 a joining and extending from a base 9 b . The two stems 9 a cooperate with the holes to secure a pile or deep foundation pier 3 to the second leg of the guide member 6 . As shown here in FIG. 9 , the base 9 b of the U-shaped bolt is away from the second leg and the stems 9 a of the bolt extend through the holes in the second leg where they are secured with nuts.
[0054] To withstand the foundation loads applied to the alternate embodiment, the guide member is strengthened by two braces 7 a . The braces 7 a are mutually parallel and span at an angle from the second leg to the first leg. The braces join to the first leg and the second leg opposite the union of the two legs. From a side view, the first leg, the second leg, and a brace for a generally triangular shape. In this alternate embodiment, the braces are round tubular members welded to the first leg and the second leg.
[0055] From the aforementioned description, a bracket assembly for lifting and supporting a lightweight structure or foundation element has been described. The bracket assembly is uniquely capable of decreasing moment, translation, and rotation upon a bracket with a U-shaped adjusting bolt and sleeve. The bracket assembly and its various components may be manufactured from many materials including but not limited to structural steel sections, welded steel plates, polymers, high density polyethylene, polypropylene, polyvinyl chloride, nylon, ferrous and non-ferrous metals, their alloys, and composites. | A bracket assembly rests upon a pile or deep foundation pier set adjacent to a lightweight structure or foundation element such as a porch. The bracket slides upon a pile or deep foundation pier and adjusts from the side of the pile or deep foundation pier. The bracket assembly has a weldment with bearing and guide members. The bearing member supports the lightweight structure or foundation element while the guide member raises the bearing member on the pile or deep foundation pier. The guide member has a sleeve and U-shaped bolt to grasp the pile or deep foundation pier. A cap plate atop the pile or deep foundation pier connects to the guide member through rods. Turning nuts on the upper end of the rods pulls them and thus the lightweight structure or foundation element upwards. The bracket assembly is lightweight and supports approximately five thousand pounds. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to furniture and millwork; and more particularly to a frame and panel or panels assembly which can be easily assembled or disassembled.
2. Description of the Prior Art
It is well known that one segment of the furniture and woodworking industry is concerned with what is generically known as "knock-down"--hereinafter "KD"--products, which is furniture and other woodwork items which can be easily assembled and disassembled so that the work can be shipped in a knock-down or disassembled condition and can be easily assembled by a lay person with limited mechanical ability. KD products for retail sale are usually referred to as "Ready to Assemble"--hereinafter RTA.
RTA furniture uses a wide variety of mechanically based fasteners. These vary in their machining, strength, construction and suitability for a given project. Some are fully exposed to view, some partially.
There are several basic categories of mechanical fasteners for joints needed to make a frame or other type of wood product requiring the joining of two pieces. Five types of fasteners are: a screw, a bolt, a cam, a wedge, and a nail or staple.
Bracket based corner joints have also been used, but these are ordinarily exposed to view and have limited application.
Most KD/RTA hardware after installation and project assembly would be exposed in a greater or lesser degree to view, unsightly and therefore unacceptable for this invention.
Some KD/RTA hardware cannot be disassembled.
In addition to the hardware previously discussed, there is a vast array of KD hardware available to the woodworking industry. Additional types of hardware which might be considered for assembly for this invention are as follows:
1. Hafele/bed fitting cat #271.53.000 single "keyhole" or #273.56.010 double "keyhole"--This product requires that a pocket be machined behind it to accommodate the head of a screw. This screw is the locking member for the horizontal part of the frame which butts to the vertical part of the frame holding the bed fitting. The screw used with the bed fitting does not have a positive stop for depth as does the collard screw used with the "Modular Connecting Fitting". Selby (#1093 & #1094) and Lamp/Sugatsune (S & W) make similar fittings.
2. Selby/bed rail fastener cat #74. Conceptually this product can work; however, as an off the shelf item, it is too long and would therefore not work for narrow rails (horizontal frame member) as the hardware would protrude beyond the width of the rail itself. For larger scale products it would be suitable. Also for high production runs this product could economically be scaled down. The hardware consists of a rectangular plate with two knockouts which receive the hooks mounted at right angles to a second plate. Pockets would have to be cut behind the plate with the knockouts to receive the hooks. A positive stop is integral to the design of the hardware. Lamp/Sugatsune makes a piece of hardware that is conceptually the same (BF-842-S & BF-842-W)
3. Hafele/nylon KD fitting ("dowel fastening") cat#039.40.707--Product consists of a male and female element; both made of nylon. Each section is inserted into a hole drilled into the section of the frame receiving it. It is possible with this hardware to use as many pairs as are needed to join a particular section. Because of the diameter of the hole to be drilled it would be necessary to use this on larger scaled frames making it impractical for a more standard thickness frame of 11/4" or less (for 11/4" thick frame the groove would be 1/2" as would be the tongue; thereby leaving no material for the hardware to be threaded into on the tongue). Selby (#630, 631, 632) and Lamp/Sugatsune (#CF-235) make similar products. This is one of the least desirable options.
4. Hafele/Haas fastener cat #262.48.000 --Comprised of two identical aluminum press-fit components with harpoon-type barbs. Each piece must be glued into position in addition to being press fitted. The hardware has a positive stop.
Joint strength with KD hardware fasteners appears to be somewhat higher than glued joints over time and the members are easily assembled and disassembled.
Prior art frames and panels have also been glued together with the disadvantage that as time passes the glue joint fails and becomes loose.
Prior art, such as that disclosed in U.S. Pat. No. 3,788,378 discloses a modular divider system which utilizes metal frame members which are joined together by top and bottom horizontal frames with interconnecting members mounted on an end surface of each vertical member so that a series of frames forming flush panels can be joined together to form a modular room divider for a modular office system. While this patent does disclose the addition of a fabric by removable means of a complimentary pin and slot device on the faces of the vertical members the fabric is applied as a sleeve to the exterior of the vertical support members. This type of assembly would be completely unsuitable for use in a decorative screen or for any frame assembly requiring the encapsulation of a panel by a surrounding frame. This prior art does not accomplish the goal of having an aesthetically pleasing product consisting of a panel surrounded by a decorative frame. Not only is the frame of this prior art industrial, unfinished metal; most importantly it was meant to be hidden from view and therefore not intended to embody any generally accepted or traditional aesthetic qualities.
When using frame and panel construction there have been two methods of proceeding. One is to glue, clean up and apply a finish to the frame separately and then secure the panel at the back with applied molding which is usually nailed in place. The second method is to completely assemble i.e. glue up, sand and apply a finish to the frame and panel as assembled. In this method the molding is integral on both sides and therefore retains the panel after the frame is glued up.
The use of molding or trim both for decorative purposes and for the utilitarian purpose of retaining panels is commonly used in frame and panel work. The machining and installation of these moldings can become quite problematic, most especially when there are deviations from the straight line. It is well known that frames may have design variations from a rectangular format. For these frames, for example the top rail may have a concave arc formation on the interior of the frame (or other e.g. curved pattern variation, which may be an interior and exterior arc). Ordinarily rabbets would be machined on the back of the frame and would receive the panels after frame assembly and finishing. This method is especially needed when one is using a panel insert which is other than wood (e.g. glass or fabric) and therefore needs to be installed after the frame is finished to keep it from being damaged.
The second method is usually used in higher production work. The frames, having integral molding, and the panels are assembled and joined prior to finishing. The frame with its integral panel is then finished as one piece. This makes things very difficult when using non-wood materials for panels.
There are other considerations. Some problems in manufacturing procedures can arise. One being that the groove or rabbet plowed to receive the panel would usually be machined parallel to i.e. in conformance with, the edge of the curvilinear shape. It would require that the panel insert also be machined to mirror that shape; creating additional machining as opposed to simply cutting a square or rectangular panel shape. To avoid this problem and decrease labor costs the groove plowed for such design configurations could be plowed straight across and therefore would run perpendicular to the other panel receiving element e.g. groove, situated in the stiles. This would only be possible on designs which had top rails wide enough to allow this deep cut. Top rails which were curvilinear on both the outside and inside edges would have to have a panel receiving element e.g. groove, plowed parallel to the inside curve and the panel receiving element e.g. groove would maintain the same depth end for end; therefore the panel receiving element e.g. groove, would be curvilinear instead of straight across. The choice in machining of this top rail groove is a cost and machining set-up consideration.
SUMMARY OF THE INVENTION
It is an object of this invention to produce a completely finished, high quality product of frame and panel construction allowing for separate finishing of the frame and panel; further to have integral molding on both faces of frame regardless of frame design and for both faces of frame to be of equal design and quality and to allow for finishing of frame with no damage to especially non-wood panels such as fabric.
It is further the object of this invention to allow for the possibility for especially small custom shops to economically yaw the size of the frame based on the dimensions of the panel insert to be inserted and to quickly assemble and ship varying size orders without the currently extremely labor intensive and therefore prohibitive methods available to such shops.
A still further object of this invention to provide for an assembly for use in joining two adjacent members which can be easily assembled and disassembled.
Another object of the invention is to provide for an assembly for use in connection with KD/RTA furniture and general woodwork.
Another object of this invention is the provision of an assembly for use in joining two adjacent members so that the two adjacent members will be free of any exposure of hardware whereby no distinction is drawn between an obverse and a reverse side.
Yet another object of the invention is to provide for a method and system for KD/RTA furniture, readily usable in connection with few tools, if any and to provide for furniture which can be readily assembled and disassembled.
In its broadened aspect, the invention is concerned with a fully machined frame--decorative or functional--which can be assembled without the necessity of tools. More specifically, the frame according to the invention can be readily assembled and does not require the addition of separately applied molding strips to retain a panel insert as might be required for a traditionally conceived and machined piece. This alone eliminates assembly and machining procedures which are costly and time consuming.
The most important aspects of the invention are the use of KD hardware along with the use of fully machined, and in most uses, pre-finished frame parts. This permits convenient shipping of frames which heretofore would have required full assembly and therefore the shipment of a much larger article to the end user. This is an issue that greatly impacts shipping costs. It also permits the convenient use of a frame or folding screen in commercial displays so that the screen can be readily assembled without the use of tools at a display site. It permits the convenient changing of panel inserts as display materials change or need to be upgraded. Beyond the convenience offered in shipping and assembly; and alteration potential offered by this invention, it has the added benefit of permitting a frame member to be assembled with all of its decorative molding as integral to the rails and stiles; and not applied after joining of frame parts as is traditionally done. This is most especially useful for curved members. It eliminates the necessity of making separate curved small molded parts which are labor intensive and costly and difficult to produce. It further eliminates the necessity of the use of brads, air nails or screws to secure separate molding and the need to putty same for a fine finish. This feature of integral molding, as opposed to applied, most especially makes this invention useful to the RTA market.
Another feature of the invention is to overcome the problems inherent in some design configurations of frames, which have the concave arc formation i.e. the problems of design, cost and machining associated with this formation.
Another feature of the invention is to overcome the problems inherent in having, especially, a non-wood panel insert e.g. fabric which can be inserted after all wood parts have had their finish applied.
The KD (knock down) hardware used heretofore, to join the frame is a product as shown in the "Hafele" cabinet catalogue (cat #262.47.049 Standard Modular, or 262.47.058 Semi-Permanent Modular, or 262.47.012 Permanent Modular i.e. cannot be disassembled). It is called "modular connecting fitting" and is used in conjunction with a Hospa collared screw. The KD hardware is secured with screws (factory mounted) to the bottom of the panel receiving element e.g. groove machined on the inside edges of the frame. This hardware is placed at the point of the joint i.e. where the horizontal member butts the vertical member of the frame. On the stiles (verticals) are mounted a female portion of the hardware; consisting of a formed strip of metal with a keyhole slot to receive the head of the collared screw. On the ends of the rails (horizontals) are mounted a male KD hardware piece consisting of a screw with a protruding head and integral flange (collared screw).
With the installation of the KD hardware, according to the invention, on the stiles and rails the frame can be assembled by the end user without the use of glue, nails, screws, clamps, screwdrivers, wrenches or pliers. The assembled product appears to the viewer as a traditionally joined decorative frame, and what is important is that the frame presents a finished appearance regardless of whether it is viewed from the obverse or the reverse.
It is therefore another object of the invention to provide a furniture assembly consisting of a frame and panel which can be easily assembled and disassembled without the use of glue.
The invention in its broadest aspects, comprises at least two (side) vertical (stile) frame members and at least two (top and bottom) horizontal (rail) members. Along all interior edges, a panel receiving element e.g. groove is plowed to receive both the connecting hardware and the panel insert; therefore, the exterior rails and stiles forming the perimeter of the frame would have a groove plowed on one side only (the one facing the interior of the frame). The center vertical and horizontal members would have a groove plowed on both edges (since both edges face the interior of the frame).
The frame and panel assembly in accordance with this invention is easily assembled and/or disassembled and can be readily used with fabric, art work, or numerous types of other materials for assemblies of frames and panels. To form a set of two or more frames; with pictures, designs or carvings, for example as panel inserts, the frames are often hinged--but not necessarily so. This configuration is most often used as folding room screens for decorative use. In some instances disassembly may be more difficult depending on the configuration of the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood and readily carried into effect, the same will now be described and explained in connection with the accompanying drawings, in which:
FIG. 1 is a front perspective view of an assembled individual frame having rails and stiles adapted to receive an insert prior to assembly and easily disassembled to change or remove inserts held by the rails and stiles and illustrating one center rail connected between the two vertical stiles.
FIG. 2 is a longitudinal sectional view taken along line 2--2 of FIG. 1 or line 2--2 of FIG. 5 illustrating the rails in section spaced from each and appropriately spaced to hold inserts shown in dot-dashed outline;
FIG. 3 is a transverse sectional view taken along line 3--3 of FIG. 1 showing a pair of spaced stiles with the inserts shown in dot-dashed outline;
FIG. 4 is a view showing the frame of FIG. 1 disassembled with the horizontal rails and the vertical stiles spaced from each other and illustrating the connectors on the parts to be joined;
FIG. 5 is another frame embodiment according to the invention which is a modification to the frame of FIG. 1 and includes a pair of rails--top and bottom, and center mullions (interior members of a frame separating the panels from each other) both vertical and horizontal. A variation of FIG. 5 would be to have both top and bottom rails run through or to have the center mullion run through;
FIG. 6 is a transverse section taken along line 6--6 of FIG. 5 and illustrating the common center mullion spaced between the two outer stiles with inserts shown in dot-dashed outline;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 4 and showing a stile and rail spaced from each other which are to be connected together.
FIG. 8 is a vertical sectional view taken along line 8--8 of FIG. 7 of a center rail (mullion) and a stile separated from each other and illustrating the connecting elements in their disconnected condition;
FIG. 9 is a vertical sectional view similar to that of FIG. 8 showing a stile and a center rail (mullion) connected to each other and taken along line 9--9 of FIG. 10;
FIG. 10 is a sectional view taken along line 10--10 of FIG. 9 or a sectional view taken along line 10--10 of FIG. 1,5,12 or 13 illustrating another view of the stile and rail as connected to each other;
FIG. 11 is a perspective view of the prior art connecting elements in their spaced disassembled condition;
FIG. 12 is a front view of another embodiment of the frame which includes two outer vertical stiles and a center mullion with a bottom rail extending across and below the center mullion and joined to the two outer stiles at their inside edges, the center mullion being joined to the bottom rail, and two upper curved rails joined to the two outer stiles at their inside edges and connected with the center mullion. A variation of FIG. 12 would be for the top curved rail to run through end for end and for the center mullion to butt to it underneath and;
FIG. 13 is another modification of a frame in which there is a single curved upper rail, two outer stiles and a center mullion spaced between the two outer stiles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to the drawings, and in particular to FIGS. 1 to 4 of the accompanying drawings; frame assembly 10 generally includes a pair of oppositely disposed vertical side stiles 12, 14 and two horizontal rails 16, 18 and a center divider or mullion 20.
Each of the rails and stiles is provided with a panel receiving portion e.g. groove 22 to receive a panel 24 shown in dashed outline. The outer portions of each panel receiving portion e.g. groove is provided with arcuate surface (this design varies) portions 26, 28 and form corners 30 which are coped and therefore provide a uniformly merging overlap and an outer flush surface 32, excepting the chamfer recess at the joinder of the rails and stiles along the faces 34, 36.
In the FIGS. 1-4 embodiments, one starts with two stiles 12 and 14 and the three horizontal rails although only two horizontal rails are required, but for purposes of discussion, horizontal rails 16, 18 and 20 will be discussed. Each of the stiles and rails include a panel receiving element, e.g. a groove 22, and the central rail (mullion) includes two panel receiving elements, e.g. grooves 22 in order to receive an insert or panel 24 on each side thereof. Reference is now made to FIGS. 7-11 in order to explain the connector. As shown in FIGS. 7-10, each connector assembly 40 as shown in FIG. 11 includes a first element 42 and a second element 44. Element 42 is receivable within panel receiving portion, e.g. groove 22 and includes a pair of tabs 46, 48 having screw openings 50 for connection to the bottom or flat surface 22B of panel receiving portion e.g. groove, 22 and each of the tabs 46, and 48 includes a flat surface 46F and 48F which is placed against flat surface 22B and screwed into the stile by means of screws 52 which pass through the openings 50 and provide a tight connection with the surface material beneath the base of 22B. Connection element 44 includes a threaded screw member 54 having a screw head 56 and a collar 58 which rests against the base member 22TB of the rail.
Connector element 40 in addition to the tabs 46 and 48 includes a substantially U-shaped member 60 having a base portion 62 and arms 64 and 66 joined and formed continuously with tabs 46, and 48. Tab 46 of base member 62, includes an opening 460 which has an opening wide enough to receive screw head 56 but insufficiently wide to receive collar 58.
Tab 64 has the opening 640 which is connected with opening 460 and extends along U-shaped arm 64 and connects with opening 620 in the base 62 of U-shaped member 60. Opening 620 has a diameter which is wide enough to receive screw head 56 with shaft 70 between screw head 56 and collar 58 slidable within opening 620. Collar 58 acts as a stop so that when screw 44 is secured into its position in the rail it allows the dimension between the underside of collar 58 and the underside of screw head 56 to remain constant. This allows the manufacturer to calibrate and set other dimensions so as to establish and set up an appropriate tension to hold the rail and stile in a given position against one another. In addition, the thickness surrounding the opening of 620 increases from the portion near entry point 62A to the bottom i.e. far end 62B so that by the time shaft 70 moves down to the base at 62C, there is a tight fit between base 62 and screw head 56 caused by a wedging action. It is the tension between the back of screw head 56 and the underside of 64, in conjunction with correct machining of frame members that holds the pieces of the frame in position one against the other. The connection can be made either by the use of hand force or a rubber mallet to tap one member into the other member.
As best seen in FIG. 10, an example of connector assembly 40 is shown with second connector element 44 joined with rail 20 and first connector element 42 joined with stile 12. As best seen in FIG. 7, stile 12 and rail 20 are disconnected from each other.
Referring now to FIGS. 7-9, connector assembly 40 is secured within the panel receiving element e.g. groove 22, and panel receiving element e.g. groove 22 includes upstanding sides or legs 22L each having a leading end 22LB. Rail 20 which is machined (i.e. coped) to compliment the machining (i.e. molding pattern) of stile 12 will fit with and onto the outer section of legs 22L. The end of rail 20 includes a trapezoidal configuration formed by the slope of the inner sides of legs 22TS. The substantial U-shaped inner trapezoidal configuration receives the legs 22L of 22 with the leading end 22LB of the legs 22L being held against the base 22TB when connectors 42 and 44 are connected together. The spacing between screw head 56 and collar 58 is longer than the thickness 62B. The locking engagement is maintained by the molding pattern of 22L being firmly held against the opposite, but complimentary molding pattern of 22TS, when the connectors 42 and 44 are engaged and by the tension created by the wedging action created by the back of screw head 58 pulling behind surface 62 of connector element 40. The surface portion of trapezoidal sides 22TS and the outer surface portion of 22L are always complementary to each other and could be any pattern chosen.
While in the present discussion of an explanation of various embodiments, the stiles have been shown with first connector element or locking element 42 and the rails with second connector or locking element 44, it will be evident from the further explanation of other embodiments that these connectors can be interchanged between placement on rail and stile.
Reference is now made to FIGS. 5 and 6 which show another embodiment of a frame according to the invention and this frame includes four panels 24 with stiles 12 and 14, rails 16 and 118. A center mullion 112 (a mullion is a linear member separating the panels and within the perimeter created by the rails and stiles) is provided which includes two panel receiving portions, e.g. grooves (one per edge) and two short rails (or mullions) 20 which overlies two additional panels 24. It will be evident that the frame can be increased by increasing any set of given members.
Stile 12 is connected to rail 16 at connection junction 12-16 by means of connector assembly 40 as discussed in FIGS. 7-11. In a similar manner, connector assembly 40 joins rail 16 to mullion 112 at both connections on both sides on mullion 112. The connection at the other end between rail 16 and stile 14 is the same type of connection. With respect to rails 20 and the joinder to mullion 112, the connection at connectors 112-20 are the same as that shown in FIGS. 7-11 and, the connection at rail 16 and rail 20 is also of the same type. The center mullion 112 is held in place by means of rails 16 and 20 which in turn are held in place by outer stiles 12 and 14. The upper rail 118 joins mullion 112 by 112 sliding into position by means of hardware connector assembly 40. The connection between stile 12 and top rail 118 and stile 14 and top rail 118 is also the same as that shown in FIGS. 7-11. The order of assembly is thus: 112 is joined to top rail 118, 12 and 14 are joined to 118, two panels 24 are slid into position, rails 20 are slid into position, two more panels 24 are positioned and finally rails 16 are slid into position locking all members into position. This completes the frame with four panels divided by mullions at the interior.
Reference is now made to FIGS. 12-13 which show two different types of embodiments for arranging rails and stiles. These figures clearly demonstrate that vertical stiles and horizontal rails can have curvature imparted thereto or can be non-linear depending on the configuration desired, and while the stiles are shown as straight in these figures, it is possible to have curved rails and curved stiles, with the proviso that the panels must be insertable into the rails and stiles so that an appropriate and ultimately locking outer frame is achieved.
In FIG. 12, stiles 12, 14 and mullion 112a are shown as straight. The upper rails 118a are shown curved. In the FIG. 12 embodiment, the lower rail 16a is first connected with the stiles 12, 14 and mullion 112a. Then the panel inserts are placed into the individual areas and upper rails 118a are connected at the side with stiles 12 and 14 and mullion 112a.
Referring now to FIG. 13 which shows another modification and shows upper rail 118b as a single curved rail connected with stiles 12 and 14. This configuration uses a center mullion 112b which is connected to the top rail 118b with a dowel only. The bottom rail 16b is connected by its ends to stiles 12 and 14 and is joined to the mullion 112b with hardware connector assembly 40. The order of assembly is thus, bottom rail 16b is connected to side stiles 12 and 14, slide mullion 112b into place, slip panels 24 into openings created for them by frame, slide top rail 118b into place on stiles 12 and 14 with hardware connector assembly 40 at each end while positioning hole in top rail 118b onto dowel positioned in top of mullion 112b. This dowel holds the mullion in place and prevents lateral movement when top rail 118b is moved into position it locks entire assembly together.
DESCRIPTION OF OPERATION AND UTILITY
Strips of wood or other materials which are to be utilized to form an individual frame or any configuration thereof, be it single or multiple in formation can be used to carry out the invention. A typical use would be in the configuration of a folding room screen, finished on both sides as assembled, a picture frame ready for hanging, a trade show display which is similar to a folding room screen, a frame and panel assembly for case goods sides, etc., and a frame and panel wainscot or full room paneling. These uses are especially useful in RTA marketing where amateurs and home users do not have the professional equipment or expertise to join and clamp such configurations. Each section, or independent unit is formed by the joining of members, rails (horizontal members), and stiles (vertical members) usually at ninety degrees to one another to form a square or rectangle. Upon assembly, be the style traditional or contemporary, no means of assembly are visible. The method of assembly is by sliding one male hardware member into an opposite female hardware member by pressure only. No tools, such as screw drivers or wrenches, are required. (This is assuming factory mounting of the hardware.) A hammer or mallet may be required to tap the joints flush if the members are machined to very tight tolerances. In high production it would be possible to machine to careful tolerances which would probably make the use of a mallet unnecessary. The vertical side members or stiles which are the same size, most often run the length of the frame (as opposed to stopping atop the bottom rail or under the top rail). The top, bottom and center cross-pieces or rails are of the same length; but may vary in height (i.e. the short dimension); and as is traditional in most layouts, butt to the stiles at their inside edge. All inside edges of both rails and stiles are plowed with a panel receiving portion e.g. groove, running the length of the member. It is inside this panel receiving portion e.g. groove that the hardware is secured for assembly of the frame. Again, as is traditional, the inside edges of both faces are molded with a sticking pattern. The rails are coped (machined so as to configure the abutting molding profile) to the stiles on both faces i.e. front and back. A panel of any material, such as wood, fabric or glass is inserted into the plowed groove as the frame is being assembled, and the insert is locked in place when the fourth or last member forming the square or rectangular opening for the insert is pressed into position. The integral molding on both sides of the frame is what retains the panel. Depending upon the joining hardware chosen, it is possible to disassemble the frame so as to change the panel insert. This is possible when particular KD hardware used for assembly also allows disassembly of the joint. Some KD hardware as noted heretofore, cannot be disassembled, and it is a feature of the invention to provide for ease of assembly as well as disassembly.
In addition to those technical issues already discussed there is another which needs to be considered. This involves the natural shrinkage and expansion of wood. When one joins two pieces of wood together by gluing them, this natural movement is minimized as they relate to each other; however, it is not the intention of this invention to use glue. Therefore the natural and probably uneven movement of wood pieces placed one next to the other could create troublesome and aesthetically unacceptable problems for a finished product. To alleviate this issue a chamfer would be machined on the ends of the faces of the rails where they join the stiles. The use of the chamfer would eliminate this problem and become integral to the design.
Further a length of wood being joined at each end by the same connector assembly 40 can be secured to the bottom of the frame to act as a foot or glide for the frame assembly.
While there has been shown what is considered to be the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention. | A frame assembly of the knock-down type in which the component parts can be shipped or transported in a knock-down condition and readily constructed with a minimum of tools or no tools, and disassembled when desired. The frame assembly includes at least one pair of spaced vertical stiles and at least one pair of horizontal rails substantially orthogonal thereto, and associated connecting elements for connecting the stiles and rails, one of the connecting elements being joined with a stile at a corner connection thereof and another of the connecting elements being joined with a rail at a corner connection thereof so that a pair of the associated connecting elements joins one of the stiles to one of the rails, and all of the stiles and rails as appropriate are joined to each other. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a rain gutter system for a house, building, or other structure, which facilitates cleaning of the gutters, and more particularly to a gutter system having an actuator which is utilized to rotate the gutter from a collecting position to a cleaning position and from a cleaning position to a collecting position.
2. Description of the Prior Art
Gutters are employed to catch water run off from roofs of building structures, particularly roofs of houses, to prevent erosion of the soil adjacent to the structure and to prevent damage to the foundation of the structure. However, the accumulation of debris, such as leaves, often clogs the gutter, and the water, which normally flows through the gutter, overflows down the side of the structure causing damage. Further, weather conditions often pile up ice and snow in the gutter so that water run-off is impeded resulting in leakage through the roof to the interior, and gradual rotting of the roof material and inner structure. In addition, the weight of the ice often damages the gutter itself, and seriously weakens its attachment to the structure.
Removal of accumulated debris restores proper drainage and protects the roof and structure. Although cleaning of the gutter may be accomplished manually by an individual on a ladder, this may be dangerous, particularly to an inexperienced homeowner.
In the prior art, there are rotatable gutter systems. However, these prior art gutter systems involve the use of complex mechanical devices such as pulleys, rods, gears, hand cranks, electric motors, etc. These complex electrical/mechanical prior art gutter systems are difficult to maintain, difficult to install and prohibitively expensive. In addition, the prior art gutter systems are exposed to natural elements causing failure thereof.
Many of these problems were solved by the invention disclosed in U.S. Pat. No. 5,526,611. This invention teaches the use of a gutter tilt actuator affixed to the gutter. A pole or cable is used to rotate the gutter via the gutter tilt actuator from a water collecting position to a cleaning position and from a cleaning position to a water collecting position. Therefore, the high maintenance, complex mechanical devices such as pulleys, rods, gears, hand cranks, electric motors, etc. were not required to rotate the gutter. However, the weather resistant materials (e.g. PVC) used in U.S. Pat. No. 5,526,611 expand and contract as the temperature changes. This places pressure on the slotted supports, and eventually the gutter tilt actuator embedded in the gutter may tear away from the gutter or the support may become dislodged.
SUMMARY OF THE INVENTION
A gutter system is provided which includes at least one gutter and at least one associated gutter tilt actuator for each gutter. Each gutter is configured as an open channel having a bottom and sides. Each side terminates in an upper edge which defines the opening to the channel there between. The bottom and sides have an exterior surface which preferably has a substantially uniformly shaped cross section in the longitudinal direction. A gutter tilt actuator displaces the gutter between a collecting position and a cleaning position. The gutter tilt actuator has a gutter tilt actuator lever and a gutter engaging portion configured to selectively grip the gutter. The gutter engaging portion preferably encircles the gutter complementing the shape of the exterior surface of the gutter and also spans the gutter channel. The gutter engaging portion grips the gutter for rotating the gutter between a collecting position and a cleaning position. However, the gutter engaging portion permits longitudinal displacement with respect to the gutter.
At least one gutter mounting bracket is provided to receive the gutter. The gutter mounting bracket includes a structure attaching portion for attachment to a building and a cantilevered support projecting from the structure attaching portion for supporting the gutter. The cantilevered support is configured to complement the gutter tilt actuator for rotational displacement and preferably includes a slot through which the gutter tilt actuator lever projects wherein the slot defines the limits of rotational displacement of the gutter tilt actuator and, accordingly, the gutter. The slot maintains the longitudinal position of the gutter tilt actuator within the mounting bracket which is affixed to the building structure. Since the gutter tilt actuator is not affixed to the gutter, the gutter may freely expand and contract longitudinally as the temperature changes without damaging the gutter tilt actuator or mounting bracket.
An operator rotates the gutter preferably utilizing a pole with a hook which grasps the gutter tilt actuator lever. Applying a downward force on the gutter tilt actuator lever using the pole, the gutter is rotated from the normal collecting position to the cleaning position. After cleaning, the gutter is rotated from the cleaning position to the collecting position. The gutter tilt actuator may be locked in a collecting position or a cleaning position by rotating the gutter tilt actuator into a securing slot.
In one embodiment, one of the edges of the gutter is configured with a projecting lip for directing water into the open channel of the gutter and inhibiting the collection of debris between the gutter and the structure on which the gutter is mounted. The gutter engaging portion of the gutter tilt actuator preferably has a lip receiving portion for receiving the projecting lip. The projecting lip is preferably beveled proximate the mounting area of the gutter so that the gutter tilt actuator can be received about the gutter without creating a gap between the projecting lip and the structure.
It is an object of the present invention to provide a novel gutter system with an improved gutter tilt actuator.
Another object for the present invention is to provide a gutter tilt actuator for a gutter system, which is simple and economically manufactured, easy to install, easy to maintain and easy to operate.
The above-mentioned and other objects and features of the present invention will become more apparent from the following description when read in conjunction with the accompanying drawings, in which like referenced characters designate the same or similar parts throughout the figures thereof. However, the drawings and descriptions are merely illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art gutter, gutter tilt actuator and mounting bracket.
FIG. 2 is a perspective view of a gutter tilt actuator made in accordance with a first embodiment of the present invention.
FIG. 3 is a perspective view of the gutter tilt actuator of the first embodiment of the present invention in a mounting bracket, wherein the gutter is in the water collecting position.
FIG. 4 is a perspective view of the gutter tilt actuator of the first embodiment of the present invention in the mounting bracket, wherein the gutter is in the cleaning position.
FIG. 5 is a perspective view of the second embodiment of the gutter tilt actuator.
FIG. 6 is a perspective view of the second embodiment of the gutter tilt actuator in a mounting bracket, wherein the gutter is in the water collecting position.
FIG. 7 is a perspective view of the second embodiment of the gutter tilt actuator in the mounting bracket, wherein the gutter is in the cleaning position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a prior gutter system as disclosed in U.S. Pat. No. 5,526,611. The gutter system includes a gutter tilt actuator in a slot of a mounting bracket 3 and affixed to a gutter 5. This arrangement inhibits the longitudinal displacement of the gutter 5, which expands and contracts as the temperature changes. The gutter tilt actuator 1 may eventually tear away from the gutter 5 or the mounting bracket 3 may become dislodged.
FIG. 2 is a perspective view of a first embodiment of a gutter tilt actuator 10. The gutter tilt actuator 10 includes a gutter engaging portion 12 and a gutter tilt actuator lever 14, which projects from the gutter engaging portion 12. FIG. 3 is a perspective view of the gutter tilt actuator 10 in the mounting bracket 20, which is preferably attached under a roof ledge of a structure 30 using anchors, nails, screws, etc. (not shown). The mounting bracket 20 receives a gutter 40 having an open channel between the edges. The mounting bracket 20 includes a structure attaching portion 22 and a cantilevered support 24. Preferably the gutter tilt actuator 10 encircles the gutter 40 and is slid along the outside of the gutter 40. Then, the gutter tilt actuator lever 14 is inserted in the slot of the cantilevered support 24. The gutter engaging portion 12 selectively grips the gutter 40 for rotational displacement. The gutter tilt actuator 10 may also be first placed in the mounting bracket 20 and the gutter 40 slides through the gutter engaging portion 12 of the gutter tilt actuator 10.
The gutter tilt actuator 10, mounting bracket 20 and gutter 40 are preferably manufactured from PVC plastic or any other weather resistant material. Further, it is preferable that a gutter tilt actuator 10 and a mounting bracket 20 be installed for approximately every ten feet of gutter 40.
An operator standing on the ground connects a hook (not shown) to the gutter tilt actuator lever 14 of the gutter tilt actuator 10. Normally, the gutter 40 is in a first position or collecting position (FIG. 3). When the operator wishes to clean the gutter 40, the operator standing on the ground connects the hook (not shown) to gutter tilt actuator lever 14 of the gutter tilt actuator 10, and rotates the gutter 40 to the second position or cleaning position (FIG. 4). After the gutter 40 is cleaned, the operator uses the hook to rotate the gutter 40 into the water collecting position and preferably locks the gutter tilt actuator lever 14 of the gutter tilt actuator 10 in a securing slot 50 of the cantilevered support 24. Although the gutter tilt actuator lever 14 of the gutter tilt actuator 10 is locked and therefore prevents the gutter 40 from rotating, the gutter 40 freely expands and contracts in a longitudinal direction as temperature changes. There may be a second securing slot (not shown) in the cantilevered support 24 so that the gutter tilt actuator lever 14 of the gutter tilt actuator 10 may be locked into the cleaning position.
FIG. 5 shows a second embodiment of the gutter tilt actuator 110 of the present invention. The gutter tilt actuator 110 includes a gutter engaging portion 112 and a gutter tilt actuator lever 114 which projects from the gutter engaging portion 112. The gutter engaging portion 112 includes a lip receiving portion 116.
FIG. 6 is a perspective view of the gutter tilt actuator 110 in the mounting bracket 120, which is preferably attached under a roof of a building structure 130 using anchors, nails, screws, etc. (not shown). The mounting bracket includes a structure attaching portion 122 and a cantilevered support 124. The mounting bracket 120 receives a gutter 140 having an open channel between the edges. One of the edges of the gutter 140 is configured with a projecting lip 145 on the side of the gutter intended to be mounted adjacent the structure 130 to facilitate water collection and inhibit the collection of debris between the gutter and the structure 130. The projecting lip 145 is preferably beveled for a selected distance, approximately 1-4 inches, on either side of an intended initial location of the gutter tilt actuator 110 so that the gutter tilt actuator 110 can be received in the cantilevered support 124 without pushing the projecting lip 145 away from the structure 130. The gutter tilt actuator 110 preferably is slid along the outside of the gutter 140, and inserted in the slot of the cantilevered support 124. The gutter engaging portion 112 selectively grips the gutter 140 for rotational displacement. The gutter tilt actuator 110 may also be first inserted in the mounting bracket 120 and the gutter 140 then slid through the gutter engaging portion 112 of the gutter tilt actuator 110. Although the beveled indentation 146 in the gutter lip 145 is desirable to maintain the lip 145 substantially flush with the structure, the tilt actuator 110 is capable of sliding onto the unbeveled portion of the gutter lip 145 to avoid damage to the mounted bracket 120.
The gutter tilt actuator 110, mounting bracket 120 and gutter 140 are preferably manufactured from PVC plastic, nylon or any other weather resistant material. Further, it is preferable that a gutter tilt actuator 110 and a mounting bracket 120 be installed for approximately every ten feet of gutter 140.
An operator standing on the ground connects a hook (not shown) to the gutter tilt actuator lever 114 of the gutter tilt actuator 110. Normally, the gutter 140 is in a first position or water collecting position (FIG. 6). When the operator wishes to clean the gutter 140, the operator standing on the ground connects a hook on a pole (not shown) to the gutter tilt actuator lever 114 of the gutter tilt actuator 110, and rotates the gutter 140 to the second position or cleaning position (FIG. 7). After the gutter 140 is cleaned, the operator uses the hook to rotate the gutter 140 into a water collecting position and preferably locks the gutter tilt actuator lever 114 of the gutter tilt actuator 110 in a securing slot 150 of the cantilevered support 120. There may be a second securing slot (not shown) in the cantilevered support 120 so that the gutter tilt actuator 110 may be locked into the cleaning position. Although the gutter tilt actuator lever 114 of the gutter tilt actuator 110 is locked and therefore prevents the gutter 140 from rotating, the gutter 140 freely expands and contracts in a longitudinal direction as temperature changes.
Although the invention has been described by making detailed reference to certain specific embodiments, such detail is intended to be instructive rather than restrictive. It will be appreciated by those skilled in the art that many variations may be made in a structure and mode of operation without departing from the spirit and scope of the invention as disclosed in the teachings herein. | The present invention relates generally to a gutter tilt actuator for a rain gutter system for a house, building, structure, etc., which facilitates cleaning of a gutter, and more particularly to a gutter tilt actuator, which is utilized to rotate the gutter from a water collecting position to a cleaning position and from a cleaning position to a water collecting position. |
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SUMMARY OF THE INVENTION
Cat owners find that it is a nuisance to continually let the cat in and out of the house and frequently provide a door for the cat so the cat can come and go at will. Frequently such doors take the form of a series of triangular flexible members arranged to form an iris. A cat can easily push its way through the center of such an iris and it will spring back to keep out the weather.
One difficulty with such cat doors is that stray cats will frequently follow the owner's cat into the house. Accordingly, it would be highly desirable to provide a device which would allow the owner's cat to come and go but which would prevent stray cats from entering the house.
In accordance with the present invention, a very simple and inexpensive device is provided wherein the owner's cat can come and go at will, while stray cats are kept out. This is achieved by the use of a novel magnetically actuated door and wherein the cat wears a small magnet. It is obviously suitable for other pets.
Various additional features and objects of the invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partly in section, of a novel cat door embodying the present invention.
FIG. 2 is a section through the center of the door.
FIG. 3 is an enlarged detailed view showing the manner of fastening the reed switch to one of the iris sections.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings by reference characters, the structure of the present invention includes a box-like member generally designated 5 adapted to be inserted in the wall 7 of a dwelling. The box-like member has a front wall 9 and a back wall 11. The front wall 9 is provided with a circular opening 13 into which is fitted an iris generally designated 15. The iris 15 is composed of a plurality of triangular shaped panels 17 of a flexible material such as a plastic. Such iris structures are well known to those skilled in the art and they are sufficiently pliable so that a cat or similar animal can push the segments aside and enter and the iris will then spring back to form a closure to keep out the weather. In the present instance, the bottom segment 17 is provided with a magnetic reed switch 19. The switch 19 is of the normally open type and will close in the presence of a magnet. Reed switch 19 is enclosed in a tube 21 and is located within the tube so that the switch is relatively close to the front wall of the tube and is separated by some distance from the iris.
In the back wall 11 is a swinging door 23; gravity normally holds the door in the position shown in solid lines in FIG. 2. Under the door is located a solenoid 25 having a catch 27 thereon. Catch 27 has a caming surface 29 at the rear of the door and a flat surface 31 toward the front of the door. The armature of the solenoid is normally biased in the up position by means of spring 33 so that if the current is not on, the solenoid remains in the position shown in dash lines of FIG. 2. When the solenoid 25 is energized, the catch 27 is drawn downwardly into the position shown in solid lines of FIG. 2. A suitable battery 35 is provided and the battery, solenoid 25 and switch 19 are wired in series. The owner's cat 37 is provided with a magnet 39. The magnet 39 is shown as a medallion hanging from a collar but it obviously can take various forms including the use of a collar of a ferrite-impregnated plastic which is magnetic.
At the start of a cycle, the door 23 is in the position shown in dash lines at 23A and is held in this position against the pull of gravity by catch 27. As the cat starts to enter the door as is shown in FIG. 2, magnet 39 causes switch 19 to close momentarily closing the circuit of the solenoid and pulling the catch 27 down. This permits the door 23 to move downwardly under the pull of gravity to the position shown in solid lines. Since the door is now free, the cat can push the door aside to the position shown in 23B or beyond to get into the house. As the cat leaves the box, the door 23 will be raised so high that gravity will swing it back through its center, depressing the catch 27 as it goes by and causing it to be caught in the position shown at 23A. In this position, the door is again locked so that a stray cat could not get in. On the other hand, if the cat desires to go out, the door can swing freely to the position shown at 23C so that the cat can leave. Of course, as the door swings back, it can only swing to the position shown in 23A so that another cat cannot get into the house.
As was pointed out previously, the magnetic reed switch 19 is located near the front of the tube 21 and spaced forward of the flap 17. Thus, the magnetic reed switch will not be actuated as the cat leaves, obviating the possibility that the door 23 might have swung to the position shown at 23A and then be released as the cat leaves. Holders of other shapes may be employed.
Preferably the back wall 11 has side extensions 41 at each side thereof. The reason for this is that cats have a tendency to go out the side of the door and it might be possible for the cat to get out of the door 23 without opening it sufficiently for gravity to cause it to swing back and actuate catch 27 and relock the door. By using the extensions or "blinders" at the opening, the cat is forced to go straight out for a sufficient distance to insure that the door 23 will swing far enough off center to swing back and catch.
Various departures can be made in the exact structure shown without departing from the spirit of this invention. For instance, the door 23 has been shown to be positioned by gravity, but a weak spring could be used to hold the door 23 against the catch 27 so that the door would be slightly opened when released by the catch, and then when it opened fully, gravity would cause it to overcome the force of the spring, allowing the door to recatch. Further, it is not necessary that the front door be an iris but any form of door capable of accomodating a magnetic switch could be employed. Although not shown, a clean-out drawer or tray can be provided at the bottom of the box for cleaning debris from the box. Obviously the doors must be spaced some distance apart for proper operation. | A magnetically actuated cat door is provided wherein the owner's cat can wear a magnet and go freely in and out of the door while other cats are effectively barred from entering. |
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BACKGROUND OF THE INVENTION
This invention relates generally to improvements in portable warning markers of the type used to divert motor vehicle traffic through and/or around construction sites, areas where painting and/or clean up work is in progress and the like.
Portable warning markers, particularly those of the plastic cone shaped type, have long been known and used in the prior art. Because of their shape, such cone shaped markers, take up a great deal of space during transport and storage, even when stacked one upon the other in groups of six or eight markers per stack. For this reason, there have been a number of attempts made to render cone shaped markers collapsible and foldable as a space saving measure in the storage and transport thereof. See, for example, U.S. Pat. No. 4,466,376 issued to H. D. Wells on Aug. 21, 1984; U.S. Pat. No. 4,256,050 issued to B. G. Barnard on Mar. 17, 1981; U.S. Pat. No. 2,954,005 issued to L. A. Cioffi, et al. on Sep. 27, 1960; and U.S. No. 2,762,327 issued to M. O. Weig on Sep. 11, 1956.
The Wells patent discloses a fan shaped panel of cardboard stock having four triangular faces joined together along adjacent sides by fold lines. The fan shaped panel is formed into a four sided polygon or pyramid, the base of which is attached to a base panel which has portions foldable to form a rectangular wall around the base of the pyramid. While the reference structure is, indeed, foldable, it is foldable only to assemble the structure, not to disassemble it for transport and storage purposes. The cardboard stock from which the marker is made is not very resistant to wet weather, and the base and pyramid components must be disassembled in order to unfold the unit for storage, thus resulting in two distinct broad, flat panels.
The Baker patent discloses a collapsible cone formed from a continuously extended plastic strip wound in a roll upon a base plate. A central handle permits lifting of the inner most turn of the roll which, in turn, lifts successive turns until the strip forms a vertically extending cone shaped helix. Spaced apart projections along the strip prevent the innermost turn from being pulled up so far from the base that successive turns of the helix separate from one another.
An earlier version of a collapsible traffic cone is shown in the Cioffi et al. patent wherein separate cone shaped rings of varying diameter which fit within one another can be pulled up from a relatively flat package to form a cone shaped marker.
The patent to Weig discloses an inflatable cone shaped marker that can be deflated to form a flat package for storage and transport purposes. But this device is dependent upon the integrity of its air valve which is used to inflate and deflate the device, which could be susceptible to slow air leakage over the many months of time that such devices are often used on a highway construction job site. Also, puncture of the casing of this device, as by means of flying gravel, glass or other projectiles caused by passing traffic is a constant threat to its integrity.
Moreover, none of these collapsible, foldable or inflatable markers is adapted for pick-up from a job site for placement on a truck by means of a suitable long handled tool operated by a worker from the truck bed. These prior art devices require that a worker walk along beside a truck, pick up each marker by hand, and either place it onto the truck bed himself, or hand it to another worker stationed on the truck bed. It would be advantageous if such devices were adapted for pick up by a worker stationed on the truck bed using a suitable long handled tool having a single hooked or forked end.
Another difficulty encountered with prior art portable traffic markers is the fact that their bright colored reflective surfaces tend to become dulled by oil, grease, tar and other impurities which build up thereon over a period of time when exposed to motor vehicle traffic and construction around highway job sites where such markers are routinely employed. Many state highway departments, such as in my state of Kentucky, for example, require such dulled markers to be retired from service when their bright surfaces reach a certain level of dullness and/or lack of reflectivity. It has been my experience that the conventional plastic cone shaped markers used around highway construction projects often have a useful in-service life of no more than about six months, and sometimes even less. These markers are relatively expensive to replace so often, especially when used in great volumes over long stretches of interstate highway, often extending for many miles as, for example, between successive access ramps which are often spaced many miles apart in rural areas.
By means of my invention, these and other difficulties encountered when using portable warning markers of the prior art are substantially overcome.
SUMMARY OF THE INVENTION
It is an object of my invention to provide a novel foldable portable warning marker.
It is another object of my invention to provide a novel foldable portable warning marker which has the appearance at a distance similar to the usual prior art plastic cone shaped marker whose shape is highly familiar to present day motorists.
It is yet another object of my invention to provide a portable warning marker having means by which it can be lifted by a person using a simple long handled tool while located on the load bed of a moving truck.
It is a further object of my invention to provide a transparent cover to protect the color and reflectivity of the viewable surface of a portable warning marker.
It is also an object of my invention to provide a readily replaceable non-transparent, bright colored cover for a portable warning marker which will extend the useful life of the latter.
Briefly, in accordance with my invention, there is provided a portable warning marker which includes a base member having a broad, flat upper surface, and a relatively flat plate member pivotally attached to the upper surface so as to be tiltable between an operative upright position and a downfolded storage position essentially parallel to the upper surface. A pair of relatively flat wing members are also provided which are pivotally attached to said plate member so that each wing member is tiltable between an operative position perpendicular to said plate member and folded storage position against a different one of the broad sides of the plate member. Means is also provided for releasably securing the wing members to the base member when the wing and plate members are in their operative positions.
These and other objects, features and advantages of my invention will become apparent to those skilled in the art from the following detailed description and attached drawings upon which, by way of example, only the preferred embodiments of my invention are described and illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a foldable warning marker assembly when in its unfolded, operative condition, thus illustrating one preferred embodiment of my invention.
FIG. 2 shows a top plan view of the marker assembly of FIG. 1.
FIG. 3 shows an exploded perspective view of the marker assembly of FIGS. 1-2.
FIG. 4 shows a perspective view of the marker assembly of FIGS. 1-3 in a partially folded condition.
FIG. 5 shows a perspective view of the marker assembly of FIGS. 1-4 in a fully folded condition.
FIG. 6 shows an exploded perspective view of a portion of the marker assembly of FIGS. 1-5 and a transparent protective cover for such portion.
FIG. 7 shows an exploded perspective view of a conventional cone shaped warning marker and a transparent cone shaped protective cover for protecting the viewable surface of such marker.
FIG. 8-11 show fragments of upper end portions of otherwise conventional cone shaped warning markers, each of which portions include a different means for permitting the corresponding marker to be picked up with a long handled tool having a forked end.
FIG. 12 shows a side elevation view of an alternative upper portion for a foldable warning marker which is otherwise of the type shown in FIGS. 1-5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing figures and, specifically, to FIGS. 1-5, there is shown, in a preferred embodiment of my invention, a foldable warning marker, generally designated 10. The marker 10 includes a relatively flat plate member 12, generally in the shape of an isosceles triangle (See particularly FIG. 3), which is pivotally attached along its base to a relatively broad, flat base plate 14. Also included is a pair of relatively flat wing members 16, 18 which are tiltable, independently of one another relative to the plate member 12. The wing members 16, 18 are each generally in the shape of a right triangle and are sized so that the assembly 10 appears to have four identical right triangularly shaped wings 12a, 12b (See FIGS. 1-2 and 4-5 wherein wings 12a and 12b are actually portions of the plate generally designated 12 in FIG. 3), 16 and 18 which are rotationally displaced ninety degrees apart from adjacent ones thereof, along a vertical axis of the assembly 10 when the latter is in its operative condition at best seen in FIGS. 2-3. As such, the assembly 10, when in its operative condition, simulates a conventional cone shaped warning marker of the type often seen near construction sites along the roadways of this country. This simulation is deemed advantageous since the highway traveling public is, for the most part, very familiar with conventional cone shaped markers.
One advantage of my marker over the conventional cone shaped marker is that my marker 10 is foldable into a relatively flat package for convenient shipping and storage purposes in the manner as shown in FIGS. 4-5. To illustrate this important feature, note first that the plate 12 is attached along its base edge to an elongated rod 20, opposing end portions of which project outwardly beyond the base edge and which are journaled in a pair of bearing blocks 22 affixed to opposite sides of the upper surface of the base plate 14. Each of the wing members 16, 18 have an elongated rod 24 affixed to a vertical edge thereof. The rod 24 of the wing member 16, for example, extends vertically between a semi-cylindrically shaped cam block 26 attached to a central side portion of the rod 20 and a corresponding side of a cylindrically shaped cam block 28 affixed to an upper edge of the plate member 12. End portions of the rod 24 of the wing member 16 are journaled in apertures 30 (See FIG. 3) formed in opposing surface portions of the blocks 26 and 28 immediately next to the plate 12 and rod 20. A central portion of the rod 24 snap fits into a cylindrical channel 31 in a bracket 32 attached to a central portion of the plate 12, whereby the subject rod 24 is pivotal, horizontally, about its longitudinal axis with its end portions being journaled in the apertures 30 and its central portion being slidably disposed, both vertically and rotationally, in the bracket 32. The rod 24 of the wing member 18 is pivotally attached on the opposite side of the plate 12 from the rod 24 of the wing member 16 in the same manner as the rod 24 of the wing member 16.
The wing members 16 and 18 are thus tiltable, independently of one another, between their operative positions as shown in FIGS. 1-3 and their folded positions lying against opposite faces of the plate member 12 as shown in FIG. 4. A tab 34 is attached on an outer bottom edge of each of the wing members 16 and 18 which projects downwardly into a detent 36 in an upper surface portion of the base plate 14 when each of the wing members 16 and 18 is disposed in its operative position as shown in FIGS. 1-2. The detents 36 need be just deep enough to positively fix the wing members 16 and 18 in their operative positions. In the present example, each of the members 16 and 18 can be lifted by hand against the cam block 28 to produce a slight bowing or bending of the rods 24 and corresponding wing members 16 and 18 so as to permit removal of a tab 34 from its corresponding detent 36, preparatory to pivoting one or both of the wing members 16, 18 against the plate 12. The upper surface of the cam block 26 and the lower surface of the cam block 28 each contain a groove 38 in which lower and upper edges, respectively, of the wing members 16 and 18 rest to further fix the wing members in their operative positions.
The wing members 16 and 18 should be in a slightly vertically compressed state in the opposing grooves 38 of the blocks 26 and 28 when in their operative positions as shown in FIGS. 1-2. Then, when the tab 34 of either one of the wing members 16 or 18 is lifted out of its corresponding detent, thus slightly bowing the wing member, preparatory to folding the same against the plate 12, the opposing cam surfaces of the blocks 26 and 28 will facilitate the folding action. That is because, as a given wing member 16, 18 is pivoted toward its storage position flush against the plate 12, the diagonally cammed surfaces of the blocks 26 and 28 continuously relieve the compression force on the subject wing member as it is so pivoted. And because these cam surfaces present the least compression force against the wing members 16, 18 when the latter are placed in their storage positions, the cam surfaces tend to urge the folded wing members 16, 18 to remain in their folded states. In other words, the cam surfaces of the blocks 26 and 28 tend to maintain the members 16, 18 in their folded states against the plate 12 when the wing members 16, 18 are placed in that condition.
The semi-cylindrical cam blocks 26 attached to opposite central side portions of the rod 20, form a generally circularly shaped outer edge between the two of them. A somewhat larger diameter circular opening 40 is formed in the base plate 14, directly above which, the two semi-cylindrically shaped portions of the cam block 26 are disposed when the plate 12 is operatively upright relative to the base plate 14 as shown in FIG. 1. The circular opening 40 thus permits one or the other of the semi-cylindrical portions of the cam block 26 to tilt downwardly therein as the plate 12 is tilted one way or the other from its operative position toward its storage position against the base plate 14. Without the opening 40, one or the other of the other portions of the block 26 would tilt into and bind against the base plate 14 as the plate member 12 is tilted, thus preventing the plate member 12 from being folded fully flush against the base plate 14.
It will be appreciated that the same arrangement of foldable wings and plate as illustrated in the present example, may be used to form a simulated barrel type warning marker assembly. In such an arrangement, the plate and wings will be of rectangular shape to simulate a barrel marker rather than of triangular shapes as shown in FIGS. 1-5. Otherwise, the construction and operation of such a simulated foldable barrel assembly will be the same as previously described.
I recommend the use of four flexible suction cups 42 which may be attached to the underside of the base plate 14 as shown, although this is not essential. The cups 42 may be connected in any suitable manner as, for example, by means of conventional threaded fasteners. This will inhibit, to at least some extent, the tendency of the base plate 14 to slide as the result of wind blowing against the plate and wing members 12, 16 and 18 when the base plate 14 stands on a wet or otherwise slippery pavement. Slots 44 are formed in the plate and wing members 12, 16 and 18 near their mutual intersections to allow air to pass through to help prevent wind from blowing the assembly 10 over or out of its intended position.
Another feature of the present example of my invention is a pick-up element generally designated 46 which is attached to the upper cam block 28. The element 46 includes a disc shaped cap 48 attached on one broad surface to a ball housing 50. The bottom end of the housing 50 is open so as to snap fit over a ball bearings 52 which is mounted on top of the cam block 28 (See particularly FIG. 3). The element 46 allows pickup of the assembly 10 by means of a long handled tool having a forked end whose two tines are adapted to fit on opposite sides of the ball housing 50 under the cap 48. Thus, when pick up of a long string of such devices from a road way is required, a worker located in the load bay of a pickup truck or the like can use such a tool to pick up one after another in a series of warning markers such as the marker 10 and swing them over onto the truck load bed without the necessity of leaving the truck. The time and effort saved by not having to repeatedly leave and return to the truck or by not having to walk along side the truck to manually pick up each of a series of markers and place them on the truck bed or hand them to other workers on the truck bed will be substantial. The pick-up element 46 shown in FIGS. 1-5 of the present example, can also be advantageously employed on the upper end of a conventional cone shaped marker as well as on other types of portable markers.
Referring now to FIGS. 8-11, there is shown four additional examples of pick-up elements 51, 52, 54 and 56 for use with portable warning markers. These devices are shown, for illustrative purposes, as being attached to or formed on the upper end portions of four conventional cone shaped markers 57, 58, 60 and 62, respectively. In FIG. 8 the pick-up element 51 comprises an aperture formed through an upper end portion of an otherwise conventional cone shaped marker 57. Thus a long handled tool with a hooked end can be used to pick up the marker 57 by inserting the hooked end through the aperture 51. In FIG. 9, an annular groove 64 is formed around an upper end portion of a marker 58. The groove 64 thus defines a generally disc shaped cap 66 above it. The tines of a forked tool can thus be inserted into opposite sides of the groove 64 from any direction to bear upwardly against the underside of the cap 66 to lift the marker 58. In FIG. 10, a strap loop 68 is attached on opposite ends thereof to opposite sides of an upper end portion of a cone shaped marker 60. A long handled tool containing a hook or the tines of a fork on one end can be used to lift the marker 60 by lifting the strap 68. In FIG. 11, the pick-up element 56 includes a disc shaped cap 70 attached to a post 72 which is, in turn, connected to an inverted cup 74. The cup 74 is sized to fit on and around an upper truncated end portion of a cone shaped marker 62 in relatively close fitting relationship so that it may be glued in place as shown. Pick up of the marker 62 by means of the pick up element 56 can be accomplished in the same manner as with the pick-up element 66 of FIGS. 1-5 and as with the groove 64 and cap 66 of the marker 52 shown in FIG. 9.
Another important feature of my invention is a transparent plastic cover to protect the viewing surfaces of portable warning markers from becoming covered with grease, road grime, oil, rock dust, road dust and the like. Referring to FIG. 6, there is shown a wing member 76 of the same type as used in the assembly 10 of FIGS. 1-5. A transparent plastic cover 78 of closely conforming size and shape may be slipped over the member 76 to cover its viewable surfaces and protect them from becoming dulled by dirt, grime, oil, grease, tar and the like. In this way, four such covers 78 can be used to cover the viewing surfaces of the plate and wing members 12, 16 and 18 of the assembly 10 of FIGS. 1-5.
Referring now to FIG. 7, a conventional plastic traffic cone 80 of well known type is shown which includes a truncated cone 82 forming a warning surface and a base 84. A similarly sized cone shaped transparent plastic cover 86 is applied over the top of the cone 80 to protect its viewing surface from becoming dulled by grease, oil, tar, rock dust, road dust and the like. Note that the cone shaped cover 86 can also be used to protect the viewing surfaces of the foldable marker assembly 10 of FIGS. 1-5, as a substitute for the four covers 78 of FIG. 6.
By using relatively inexpensive transparent protective covers such as cover 78 of FIG. 6, the cone shaped cover of FIG. 7 and the like, relatively more expensive warning markers will have their useful life extended indefinitely. These relatively less expensive covers can be readily removed from their markers when they become dulled by contaminates and can be replaced with new ones, thus avoiding the rapid rate of replacement of portable markers that has previously been necessary in order to meet various state highway department safety standards which require a high level of brightness of their viewable surfaces.
Alternatively, the covers of FIGS. 6-7 can be constructed of a bright colored non-transparent plastic for use with markers which have otherwise become too dull and dirty for further use due to past service in contaminated environments. Such alternative covers may, for example, be constructed to have the same familiar bright orange appearance that state highway department regulations often require for warning markers themselves. In this way, used warning markers destined for retirement from service can be saved and reused indefinitely.
With reference to my foldable warning marker 10 as exemplified in FIGS. 1-5, it will be appreciated that its various component parts, as for example, the plate 12 and wings 16 and 18 are interchangeable with corresponding component parts of other similar markers. Thus, where a foldable marker is damaged, those of its component parts which are not damaged can be reused as replacement parts for other damaged markers. Where such a marker receives damage to certain of its components, but not all of them, only the damaged components need be replaced, thus avoiding the need to discard the entire assembly and purchase a new one to replace it as is ordinarily necessary when a prior art warning marker such as the cone 80 of FIG. 7 is damaged.
Referring now to FIG. 12, an alternative arrangement for the upper end portion 88 of the foldable warning marker of my invention is shown. A circular disc 90 is fixedly connected by a pin 92 to the upper end of a plate 94. A pair of foldable wings 96 and 98 are attached to elongated rods 100 and 102, respectively, which rods are, in turn, rotatably attached to the plate 94. The plate 94 and wings 96, 98 contain slots in the upper central surfaces thereof which form a recess 104 in which a coiled spring 106 is disposed. A pair of pins 108 and 110 extend out of the upper ends of the rods 100 and 102 up through the spring 106 and slots in the disc 90 to retain the spring 106 in the recess 104. The plate 94 and wings 96 and 98 thus connect together and function in the same manner as the wings 12a and 12b and plate 16 of the example shown in FIGS. 1-5. The plate 94 is tiltably mounted on a base in the same manner as the corresponding components shown in those figures. Finally, a cap similar to the cap 48 of FIGS. 1-5 or other liftable element may be attached, as at 112, to the disc 90.
Now, instead of having to lift the wings 96 and 98 against the underside of a cam surface in order to cause a slight bowing of the wings, preparatory to folding them against the plate 94 in the manner as required in the example of FIGS. 1-5, the wings 96 and 98 can simply be lifted to compress the spring 106 until they are sufficiently clear of their base so as to be folded. Otherwise, when the plate 94 and wings 96 and 98 of the present example are disposed in their operative positions as shown, the spring 106 is in a slightly compressed state so as to cause the wings 96 and 98 to bear down upon their base to maintain those wings in their operative positions as, for example, by causing tabs on the outward lower edges to bear down into slots in their base, the same as the tabs 34 and slots 36 of the previous example as best shown in FIGS. 1-2.
Although the present invention has been described and shown with respect to specific details of certain preferred embodiments thereof, it is not intended that such details limit the scope of this patent other than as specifically set forth in the following claims. | An improved portable warning marker of the type used to divert and/or guide motor vehicle traffic through or around roadway construction sites is disclosed. The warning marker may be of a foldable type including a plate member is pivotally attached to a flat base member, and a pair of wing members pivotally attached on opposite sides of the plate member so as to be independently tiltable from operative positions perpendicular to the plate and base members to a storage position against opposite broad surfaces of the plate member. Upon placing the wing members in their storage positions, the plate member is tiltable from an operative upright position to a downfolded storage position essentially parallel to the base member. A device for permitting a portable marker to be lifted through the use of a long handled tool having a hooked or forked end, which device is attached to an upper end of the marker is also disclosed. A transparent plastic cover for the viewable surface(s) of a portable warning marker for protecting the surface(s) from becoming dulled by oil, grease, tar and other impurities is also disclosed. A replaceable, non-transparent, brightly colored cover is disclosed for use on portable traffic markers which have already become dulled through prior use in order to permit their continued use is also disclosed. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
COPYRIGHT NOTICE
[0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to storm shutters for protecting homes, buildings and other structures from wind and storm related damage, and more particularly to a light transmitting storm shutter assembly that provides sufficient resistance to hurricane force winds and impact from windborne debris while allowing light transmittance into the protected structure.
[0006] 2. Description of the Background Art
[0007] The United States has experienced 44 weather-related disasters in the past 20 years, each of which has caused in excess of $1 billion in damages. Of these 44 disasters, 38 occurred between 1988 and 1998 causing in excess of $170 billion in damage.
[0008] Population growth along the coastline of the United States has resulted in an increased risk to life and property from hurricane related damage. There are approximately 36 million permanent residents along the hurricane-prone coastline of the United States, with areas such as Texas, Florida, and the Carolinas, where hurricanes frequently strike, experiencing rapid population growth. In addition, many coastal areas experience substantial but temporary population increases from holiday, weekend, and vacation visitors during hurricane season.
[0009] Homes, buildings and other structures, suffer substantial damage when storm generated winds, and particularly windborne debris, penetrate the structures through window and door openings. Hurricane shutters have long been used as barriers to protect window and door openings from the effects of storm generated winds. Equipping homes and other buildings with hurricane protection in the form of storm shutters is one of the most prudent actions one can take to protect life and property.
[0010] Accordingly, the background art reveals a number of storm shutters designed for removable installation on homes and buildings. Conventional storm shutters typically consist of corrugated metal panels affixed to the outside of a given structure. For example, U.S. Pat. No. 2,878,536, issued to Becker, discloses a shutter structure having overlapping corrugated panels. U.S. Pat. No. 4,333,271, issued to DePaolo et al., discloses a hurricane panel system for covering windows and doors. The '271 patent discloses a plurality of corrugated metal panels arranged in overlapping relationship to provide a protective structure. U.S. Pat. No. 5,345,716, issued to Caplan, discloses a storm shutter system comprising a combination of individual, interlocking modular elements. U.S. Pat. No. 5,852,903, issued to Astrizky, discloses a hurricane shutter comprising a pair of normally open doors that are swingable to a closed position. U.S. Pat. No. 5,911,660, issued to Watson, discloses a storm panel comprising a plurality of interlocking tiles interlocked together by a plurality of dovetail joints.
[0011] A significant disadvantage with conventional storm shutter panels is that installation of the panels over all of the window openings prevents light from entering the structure. Accordingly, if power is lost, as often happens during severe storms, the occupants of the structure find themselves in total darkness. Thus, a number of references disclosed in the background art reveal attempts to provide storm shutters that provide sufficient impact resistance while allowing light to enter to building.
[0012] For example, U.S. Pat. No. 5,918,430, issued to Rowland, discloses a removable storm shield comprising convex panels. U.S. Pat. No. 5,996,292, issued to Hill et al., discloses a perforated shutter system wherein at least one panel is formed of corrugations. U.S. Pat. No. 3,358,408, issued to Cooper et al., discloses an insulated light transmitting panel construction having corrugations in the side edges thereof. U.S. Pat. No. 4,685,261, issued to Seaquist, discloses a removable translucent storm shutter consisting of a ½″ thick polycarbonate sheet in an aluminum channel frame. U.S. Pat. No. 5,595,233, issued to Gower, discloses hurricane shutters formed of transparent, double-skinned panels that are strengthened by rods extending through the end channels. The panels are mounted side-by-side to cover the expanse of a window or door being protected. U.S. Pat. No. 5,457,921, issued to Kostrzecha, discloses a storm shutter in the form of a “kit”. The kit includes a plurality of corrugated shatter-resistant and transparent plastic sheets fastened to the structure using a mounting mechanism and fasteners inserted through key-way slots.
[0013] While the use of clear plastic panels, such as Polycarbonate panels, provides light transmittance, the use of plastics can substantially reduce structural integrity and impact resistance as plastics are generally not as strong as the metal alloys, such as aluminum or steel, typically used to fabricate storm panels as disclosed in the background art. Accordingly, the clear polycarbonate storm panel structures of the background art must be fabricated to a greater thickness and/or require additional bracing and hardware that complicates installation and increases cost. For example, the '921 patent discloses corrugated polycarbonate storm panels that use stiffening cross bar members. Furthermore, the '233 patent discloses panels that are strengthened by rods extending through channels. Since weather reporting agencies typically allow a mere 24 hours in which to install storm protection installation time is an important factor.
[0014] Accordingly, there exists a need for a light transmitting storm panel assembly that avoids the disadvantages present in the storm panels disclosed in the background art.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention provides a light transmitting storm shutter system for homes, buildings and the like that overcomes the disadvantages present in the background art. A storm panel system according to the present invention includes a combination of corrugated aluminum and clear polycarbonate panels arranged in alternating adjacent relation over a given window or door opening. The aluminum panels provide structural integrity while the polycarbonate panels allow light to pass through the storm shutter system.
[0016] More specifically, the storm panel system comprises a combination of full width corrugated aluminum panels with half width corrugated polycarbonate panels installed therebetween in partially overlapping relation. The combination of full width aluminum panels and half width polycarbonate panels provides a storm shutter system that is substantially stronger and more resistant to impact deflection than the light transmitting storm shutters disclosed in the background art, and eliminates the need for additional hardware, supports, bracing etc.
[0017] Accordingly, it is an object of the present invention to provide an improved storm shutter assembly for protecting building openings from windborne debris.
[0018] Still another object of the present invention is to provide a light transmitting storm panel that has substantial impact resistance.
[0019] Yet another object of the present invention is to provide a light transmitting storm panel assembly for protecting building openings from windborne debris in compliance with the latest and strictest building codes.
[0020] Still another object of the present invention is to provide a light transmitting storm shutter assembly that achieves a high level of impact resistance without requiring the use of additional stiffeners or cumbersome cross-bracing.
[0021] Yet another object of the present invention is to provide a light transmitting panel system capable of being used in an awning or overhang configuration.
[0022] In accordance with these and other objects that will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] [0023]FIG. 1 is a cross-sectional view of a corrugated full-width metal panel according to the present invention;
[0024] [0024]FIG. 1A is a perspective view thereof;
[0025] [0025]FIG. 2 is a cross-sectional view of a corrugated half-width clear polycarbonate panel according to the present invention;
[0026] [0026]FIG. 2A is a perspective view thereof;
[0027] [0027]FIG. 3 is an exploded end view showing the panels in relative position for installation;
[0028] [0028]FIG. 4 is an assembled end view thereof;
[0029] [0029]FIG. 5 is an exploded perspective view of the panels prior to installation over a window opening;
[0030] [0030]FIG. 6 is a perspective view of the panels installed over a window opening.
DETAILED DESCRIPTION OF THE INVENTION
[0031] With reference now to the drawings, the present invention provides an improved light transmitting storm shutter assembly comprising an alternating series of individual metal (e.g. aluminum or steel) and polycarbonate panels installed in partially overlapping relation. FIGS. 1 and 1A depict a preferred embodiment of a corrugated metal panel, referenced as 10 , according to the present invention. Metal panel 10 preferably comprises a corrugated aluminum panel having a nominal thickness of approximately 0.040″ to 0.063″ (or 18 gauge to 24 gauge if fabricated from steel), and includes corrugated portions resulting in an overall depth of approximately 2.0″. Each panel defines a plurality of apertures 12 , spaced 6.0″ apart and aligned along the width of the panel, for receiving suitable fasteners as more fully disclosed hereinbelow. Metal panel 10 further includes obliquely projecting wing portions 14 formed on opposing sides thereof. The metal panel depicted in FIG. 1 may have an overall width of approximately 15.125″ which width provides a nominal 12.0″ of coverage. For purposes of description herein panel 10 may be referred to as a “full-panel”. Furthermore, the term metal encompasses various metallic materials such as aluminum, and/or suitable gauge steel, or titanium.
[0032] [0032]FIGS. 2 and 2A depict a preferred embodiment of a corrugated half width panel, referenced as 20 , according to the present invention. Panel 20 preferably comprises a corrugated polycarbonate panel having a nominal thickness of approximately 0.075″, and includes corrugated portions resulting in an overall depth of approximately 2.0″. Each polycarbonate panel 20 defines a plurality of apertures 22 , spaced 6.0″ apart, as seen in FIG. 2, and suitably spaced and aligned along the length of the panel, for receiving suitable fasteners as more fully disclosed hereinbelow. Polycarbonate panel 20 further includes angularly projecting wing portions 24 on opposing ends thereof. As depicted in FIG. 2, panel 20 has an overall width of approximately 8.0″ and provides a nominal 6.0″ of coverage. For purposes of description herein panel 10 may be referred to as a “half-panel”, e.g. a panel width that is approximately one-half the width of a full panel.
[0033] [0033]FIGS. 3 and 4 illustrate the relative positions of metal panels 10 and polycarbonate panels 20 to form a storm shutter assembly with panels arranged in adjacent, partially overlapping relation to cover an opening. The panel assembly is preferably secured to the structure by fasteners 30 . As best seen in FIG. 3, a nominal 30 ″ opening may be covered by installation of two full-width metal panels, referenced as 10 A and 10 B, and one half-width polycarbonate panel 20 in adjacent partially overlapping relation. It is important that the polycarbonate panel(s) be positioned on the outer facing side of the metal panels (e.g. metal panels disposed between polycarbonate panels and structure) as the present invention specifically relies on this configuration for providing an assembly that has the greatest strength and impact resistance. More particularly, impact resistance is maximized in the disclosed configuration as the polycarbonate panel(s) 20 is supported from the structure side (e.g. back) by the metal panels 10 , and particularly by the projecting wing portions 14 of each adjacent metal panel. In a preferred embodiment, wing portions 14 are approximately 1.75″ in length. It has been found that wing portions of shorter lengths do not provide sufficient support for the overlapping polycarbonate panel thereby degrading impact resistance of the assembly. The structure disclosed herein has been subjected to impact testing wherein it was unexpectedly found that objects impacting the polycarbonate panel sections result in a certain amount of deflection in the metal panels, and particularly deflection of the wing portions, such that the wing portions each temporarily deflect to a position that is more parallel (e.g. less angled) relative to the wall of the structure. The geometry is such that the deflection causes the wing portions 14 to extend toward the center of the polycarbonate panel 20 during the deflection, thereby directly supporting a larger portion of the polycarbonate panel from the rear. The gap existing between the metal panels 10 A and 10 B, is thus narrowed by deflection of wings 14 A and 14 B. Impact testing confirms that deflection of metal wings 14 provides additional structural support to the inherently weaker polycarbonate panels thereby increasing impact resistance. Conversely, if the wing portions 14 were eliminated or if the polycarbonate panels were positioned on the opposite side of the metal panels impact resistance would be significantly decreased.
[0034] Panels 10 and 20 may be mounted using additional mounting hardware, such as an aluminum header, or other suitable hardware, such as known track devices (e.g. “F” Tracks, “C” Tracks, “E” Tracks and the like), anchored to the structure surrounding the opening to be covered. As best seen in FIGS. 3 - 6 , fasteners 30 are preferably used to anchor the panels to the structure and/or to fasten the panels in overlapping configuration. As best depicted in FIGS. 5 and 6, a light transmitting, impact resistant storm shutter assembly is formed by anchoring a sufficient number of metal panels 10 and clear polycarbonate panels 20 to cover an opening of any given width. FIG. 6 depicts a storm shutter assembly according to the present invention installed on a building in covering relation with a window opening.
[0035] As should be apparent, the use of light transmitting (e.g. transparent and/or translucent) plastic half panels allows available ambient light to pass through the installed storm shutter assembly into the protected structure thereby avoiding a significant disadvantage present with conventional all Aluminum and/or Steel storm shutters. Furthermore, the use of half width polycarbonate panels disposed between full width Aluminum and/or Steel panels provides a barrier that is sufficiently resistant to impact so as to comply with even the most stringent codes. In addition, the assembly disclosed herein allows for the use of thinner/less expensive polycarbonate panels thereby providing a light transmitting storm shutter assembly that offers impact resistance at a lower cost than an all polycarbonate assembly.
[0036] The storm shutter assembly disclosed herein has been tested in accordance with the 1999 Standard Building Code, SSTD 12-99, a test standard for determining impact resistance from windborne debris. The panels disclosed herein are also suitable for use in connection with roof openings (e.g. skylights). In addition, the panels may be configured for use as an awning. Finally, since polycarbonate is more costly than aluminum or steel, the alternating Aluminum and polycarbonate panel configuration provides a light transmitting storm shutter that is far less costly than the all polycarbonate storm shutters disclosed in the background art.
[0037] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious structural and/or functional modifications will occur to a person skilled in the art. | A light transmitting storm shutter system for homes, buildings and the like includes a combination of full width corrugated aluminum and half width clear polycarbonate panels arranged in alternating adjacent and partially overlapping relation over a given window or door opening. The aluminum panels provide structural integrity while the polycarbonate panels provide light transmittance. The combination of full width aluminum panels and half width polycarbonate panels provides a storm shutter system that is substantially stronger and more resistant to impact deflection than the light transmitting storm shutters disclosed in the background art, and eliminates the need for additional hardware, supports, and bracing. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/240,804 entitled SAFETY MARKER WITH INTEGRAL BATTERY OPERATED CONVECTION FAN filed Sep. 9, 2009.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to safety devices and, more particularly, to a safety marker with a convection fan for marking areas to be avoided while concurrently producing a convection effect upon all surrounding floor areas so as to enhance the evaporation of liquids thereon.
[0005] 2. Description of the Related Art
[0006] Safety markers specifically suited for use on floors or in other prescribed interior or exterior areas have been in use for years. Typically, safety markers are objects used for marking off areas to be temporarily avoided. Currently known safety markers come in various sizes and shapes ranging from small cones to large traffic safety barrels.
[0007] Three basic types of safety markers are typical for use within and around buildings and other pedestrian based facilities. These include collapsible safety markers which are made of fabric and are collapsible to allow for storage within flat or tubular containers, foldable safety markers which are typically of plastic construction and foldable upon a top mounted hinge to allow for flat storage against a wall, and stackable safety markers which are typically of plastic or rubber construction and are tapered like a cone to enable stacking for efficient storage of multiple markers.
[0008] Safety markers are typically of a bright color to enhance their visibility. Some have provisions for connecting a sign or a battery operated flashing light to enhance their visibility further. In addition to having a shape and color conducive to drawing attention, most safety markers include written warnings or visual depictions of danger printed on their external surfaces. Such warnings act to communicate the dangers inherent to the area that a safety marker is marking to be avoided. Apart from safety markers used for highway safety applications, safety markers used within and around pedestrian based facilities are most often used for applications involving wet surfaces to be avoided by the public. Wet surfaces (primarily floors) are commonly marked by safety markers in restaurants, grocery stores, factories, shopping malls, and other areas where foot traffic is prevalent and spills may occur. Their purpose is generally to prevent people from coming into contact with the wet surface so as to prevent tracking of the wetness throughout the facility and, more importantly, slips and falls due to the slippery surface caused by the wetness. Accordingly, by reducing the possibility of slips and falls in a facility, the proprietor of such facility will typically reduce their liabilities associated with wet floors and the slips and falls they may cause.
[0009] One deficiency with conventional safety markers is that they typically do nothing to improve the condition of the area over which they are being used to mark as dangerous. They merely mark or cover the area. In the case of a wetted area being marked, the area will remain wet until evaporation removes the wetness. In this regard, the marker itself does not contribute to the evaporation process in any way.
[0010] Accordingly, there is a need in the art for a safety marker configured to alert pedestrians of nearby hazards, while at the same time introducing forced convection for drying a wetted area of the underlying surface. These and other advantages attendant to the present invention will be described in more detail below.
BRIEF SUMMARY OF THE INVENTION
[0011] In accordance with the present invention, there is provided a safety marker with a convection fan for marking areas/hazards to be avoided while concurrently producing a convection effect upon the adjacent surfaces (e.g., floors) so as to enhance evaporation of liquids/moisture thereon. Along these lines, the safety marker will not only mitigate risks by allowing for the marking of an area to be avoided, but also, uniquely, by accelerating the elimination of what is most often the root cause of the risk, i.e., wetness on the floor.
[0012] According to one implementation, the safety marker includes a portable housing having a fluid intake and a fluid exhaust, wherein the housing is configured to be disposable on a surface having a hazard and/or a wetted area. A convection fan is disposable within the housing and is configured to direct fluid radially outward to dry the wetted surface.
[0013] The portable housing may include an upper body and a lower body selectively engageable with the upper body. The lower body may include a base and a plurality of inlet fins extending from the base, wherein the inlet fins are sized and configured to align the upper body with the lower body and to frictionally engage with the upper body. The fluid intake may be formed by a space between the upper body and the lower body base, while the fluid exhaust may be formed by a space between the base and the underlying support surface. A plurality of exhaust fins may be disposed between the base and the support surface to facilitate a more even air distribution across the support surface.
[0014] The fan may be powered by a rechargeable battery. The battery may be disposed within a battery receptacle coupled to the upper body and electrically connectable with the fan via an internal wire. When the power within the battery is drained, the battery may be recharged by a battery charger having the wiring and transformer needed for converting AC power from a conventional wall outlet to the DC power generally required to charge the battery.
[0015] Another implementation of the present invention is directed toward a drying unit configured for use with a conventional safety marker. The drying unit includes a base and a fan connected to the base to create a fluid flow. The drying unit is configured to engage with and support a conventional safety marker to perform the dual functionality of alerting nearby pedestrians of potential hazards while concurrently drying an adjacent wetted area to mitigate risk of a slip and fall injury.
[0016] The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These, as well as other features of the present invention, will become more apparent upon reference to the drawings wherein:
[0018] FIG. 1 is a top perspective view of a portable safety marker and drying device for marking a hazard and drying a liquid disposed on a surface;
[0019] FIG. 2 is an exploded top perspective view of the portable safety marker and drying device depicted in FIG. 1 ;
[0020] FIG. 3 is an enlarged view of an upper portion of the portable safety marker and drying device depicting a battery receptacle and removable battery engageable therewith;
[0021] FIG. 4 is a top perspective view of the battery shown in FIG. 3 and a corresponding battery charger;
[0022] FIG. 5 is a top perspective view of a second embodiment of a portable safety marker and drying device including a plurality of casters to facilitate movement of the marker;
[0023] FIG. 6 is a top perspective, partial cutaway view of a third embodiment of a portable safety marker and drying device including a battery connectable directly to a fan;
[0024] FIG. 7 is a top perspective, partial cutaway view of a fourth embodiment of a portable safety marker and drying device including a single housing body;
[0025] FIG. 8 is a top perspective view of a sixth embodiment of a portable safety marker and drying device;
[0026] FIG. 9 is an exploded top perspective view of the portable safety marker and drying device depicted in FIG. 8 ;
[0027] FIG. 10 is a top perspective view of a fifth embodiment of a portable safety marker and drying device including a portion formed from a collapsible and breathable material; and
[0028] FIG. 11 is an exploded top perspective view of the portable safety marker and drying device depicted in FIG. 10 .
[0029] Common reference numerals are used throughout the drawings and detailed description to indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Referring now to the drawings, wherein the showings are for purposes of illustrating preferred embodiments of the present invention, and not for purposes of limiting the same, there is shown in FIGS. 1 and 2 a portable safety marker drying device 10 for marking the location of a hazard on a surface 11 , such as a wet surface 11 , wherein the safety marker drying device 10 is additionally configured to dry the surface 11 to reduce the likelihood of injury which may be caused by the wet surface 11 , i.e., a slip and fall. The safety marker drying device 10 is believed to be more desirable than conventional markers because the device 10 is configured to create a fluid flow to dry the wet surface 11 via convection. Therefore, the device 10 may be placed on the wet surface 11 to not only alert pedestrians of the presence of liquid on the surface 11 , but also to direct air over the surface 11 to more quickly dry the wet surface 11 .
[0031] Referring now specifically to FIGS. 1-3 , there is depicted a first embodiment of the safety marker drying device 10 including a portable housing 12 comprised of an upper body 14 and a lower body 16 . The device 10 further includes a fan 18 disposable within the portable housing 12 to generate the drying force. In this regard, the housing 12 defines a fluid flow path where air is supplied to the fan 18 and is then exhausted from the housing 12 over the surface 11 to dry liquid disposed thereon. In this regard, air is exhausted from the housing 12 in a plane substantially parallel to the surface 11 .
[0032] The upper body 14 may be configured to define a variety of shapes and sizes; however, in the embodiment shown in FIGS. 1-3 , the upper body 14 has a generally frusto-conical shape defining and thus disposed about an upper axis 15 (see FIG. 2 ). The upper body 14 includes a first end portion 20 and an opposing second end portion 22 , and also defines a hollow interior chamber 23 (see FIG. 2 ) extending between the first end portion 20 and the second end portion 22 . The diameter of the upper body increases from the first end portion 20 toward the second end portion 22 , with the second end portion 22 including a cylindrical collar 25 that is of substantially uniform diameter. The device 10 is configured to be disposable on the surface 11 to assume an upright configuration wherein the first end portion 20 is disposed further from the surface 11 than the second end portion 22 .
[0033] The upper body 14 may be configured to alert nearby pedestrians of hazards present on the surface 11 . In this regard, the upper body 14 may be of a bright color (orange/yellow) or include wording (i.e., “CAUTION” or “WET SURFACE”), symbols, or other indicia displayed on an exterior surface thereof to denote nearby hazards.
[0034] According to one implementation, the upper body 14 is configured to be removably engageable with the lower body 16 . The lower body 16 includes a base 24 defining and thus disposed about a lower axis 27 (see FIG. 2 ). The lower body 16 also defines a first end portion 26 and an opposing second end portion 28 , as well as a hollow interior chamber 30 extending between the first end portion 26 and the second end portion 28 . The base 24 defines an arcuate (e.g., concave) surface which circumvents the lower axis 27 and extends between the first end portion 26 and the second end portion 28 , wherein the arcuate surface has an outer diameter which increases from the first end portion 26 toward the second end portion 28 . The outer diameter of the first end portion 26 of the lower body 16 is preferably smaller than the outer diameter of the second end portion 22 of the upper body 14 to allow a portion of the lower body 16 to be received into the upper body 14 . Along these lines, the outer diameter of the second end portion 28 of the lower body 16 is preferably larger than the outer diameter of the upper body 14 to provide stable support for the upper body 14 .
[0035] The housing 12 defines a fluid intake 32 and a fluid exhaust 34 to create a fluid flow for drying the liquid disposed on the underlying surface 11 . Air is drawn into the housing 12 through the fluid intake 32 and is expelled from the housing 12 through the fluid exhaust 34 to dry the surface 11 . In the embodiment shown in FIGS. 1-2 , the fluid intake 32 is defined by a gap between the base 24 and the upper body 14 . Disposed within this gap is a plurality of inlet fins 36 which extend from the arcuate surface of the base 24 in a direction generally parallel to the lower axis 27 . The inlet fins 36 are disposed in spaced relation to each other (preferably at equidistant intervals) and frictionally engage with the upper body 14 to align and secure the upper body 14 to the lower body 16 . As is best depicted in FIG. 2 , the inlet fins 36 preferably extend above an upper edge 38 of the base 24 to collectively define a containment area for the fan 18 , as described in more detail below.
[0036] The fluid exhaust 34 is in fluid communication with the fluid intake 32 via the hollow interior 30 of the base 24 , and is defined by a gap or space between the base 24 and the surface 11 upon which the device 10 is positioned. Disposed within such gap is a plurality of exhaust fins 40 which protrude from a lower surface of the base 24 . Like the fins 36 , the fins 40 extend from the base 24 in a direction generally parallel to the lower axis 27 . The fins 40 are disposed in spaced relation to each other (preferably at equidistant intervals) and are sized and arranged to be rested directly upon the surface 11 to support the base 24 in spaced relation to such surface 11 . In this regard, the fins 40 preferably each include a distal edge or surface, such distal surfaces residing on a common plane. The fins 40 additionally facilitate a more even air distribution over the underlying surface 11 when the device 10 is in operation.
[0037] In an exemplary embodiment, the upper body 14 and lower body 16 have a combined height of approximately 24-36 inches, although those of ordinary skill in the art will appreciate that the upper and lower bodies 14 , 16 may be of other sizes without departing from the spirit and scope of the present invention. Furthermore, the upper body 14 and lower body 16 are preferably formed from an injection molded plastic; however, other materials may be used without departing from the spirit and scope of the present invention. In addition, the upper body 14 and/or the lower body 16 may be configured to enable stacking of a plurality of upper bodies 14 of identical or approximate shape.
[0038] The fan 18 of the device 10 is disposed within the containment area defined by the plurality of inlet fins 36 . As such, as viewed from the perspective shown in FIG. 2 , the fan 18 resides on top of the base 24 . The fan 18 has an outer diameter smaller than the diameter of the second end portion 28 of the base 24 , the outer ends of the fins 40 terminating at and being substantially flush with the second end portion 28 . In this respect, the outer diameter of the fan 18 is preferably substantially equal to the outer diameter of the base 24 at the upper edge 38 such that when the fan 18 is disposed within the containment area, the outer surface of the fan is substantially flush with the upper end portion 26 of the base 24 . A screen or wire mesh 42 may extend across the upper end portion 26 to cover one end of the hollow interior 30 to support the fan 18 and to prevent external objects from making contact with the outlet side of the fan 18 . The fan 18 may be connected to the housing 12 via mechanical fasteners such as screws, rivets, and the like.
[0039] The fan 18 is configured to create the above-described fluid flow through the housing 12 . In this regard, when the fan 18 is on, fluid (air) is drawn into the housing 12 though the fluid intake 32 . The fan 18 pulls air into the hollow interior 23 of the upper body 14 and forces the air out through the hollow interior 30 of the lower body 16 where it exits through the fluid exhaust 34 . The fan 18 may be operable at different speeds to create convection forces at different magnitudes.
[0040] According to one implementation, the fan 18 is powered by battery to allow for remote positioning of the device 10 (i.e., the fan 18 does not need to be plugged into a wall outlet; although it is contemplated that other embodiments of the fan 18 may include a power cord that is pluggable into a wall outlet to receive power). Therefore, the device 10 includes a battery receptacle 44 electrically connectable with the fan 18 and engageable with a rechargeable battery 46 . The battery receptacle 44 includes a neck 49 configured to extend partially into the hollow interior 23 of the upper body 14 to secure the battery receptacle 44 adjacent the first end portion 20 thereof. The battery receptacle 44 defines a cavity 47 which is sized to receive and engage with a complimentary stem 49 formed on the rechargeable battery 46 . The cavity 47 includes internal electrical contacts which mate with external electrical contacts on the stem 49 when the battery 46 is connected to the battery receptacle 44 . The battery 46 may include a finger actuated, spring-loaded retainer 43 to secure the battery 46 to the receptacle 44 . Actuating the retainer 43 disengages the battery 46 from the receptacle 44 allowing a user to remove the battery 46 from the receptacle 44 .
[0041] The battery 46 may be configured to supply power to the fan 18 upon engagement with the battery receptacle 44 . In this regard, the battery 46 may continuously supply power to fan 18 until the power is completely drained from the battery 46 or until the battery 46 is disengaged from the receptacle 44 . Alternatively, the battery receptacle 44 may include an ON/OFF switch for controlling the operation of the fan 18 . Additionally, the battery receptacle 44 may be equipped with a variable speed control switch allowing for the creation of convection forces of different magnitudes via the fan 18 . A wire 50 extends internally between the battery receptacle 44 and the fan 18 to communicate power from the battery receptacle 44 to the fan 18 .
[0042] Referring now specifically to FIGS. 3 and 4 , the battery receptacle 44 preferably includes one or more battery charge indicator LED lights 48 to provide a visual indication as to the power level or strength of the battery 46 . When the power level is low, the battery 46 may be disengaged from the battery receptacle 44 and connected with a power charger 51 to recharge the battery 46 , as described in more detail below. The power charger 51 includes a cavity 53 sized to receive and engage with the stem 49 to recharge the battery 46 , as well as a cord 55 to plug the charger 51 into a wall outlet to receive power therefrom. The charger 51 incorporates the wiring and transformer needed for converting AC power from a wall outlet to DC power required to charge the battery 46 . Charger indicator lights 57 indicate the power level of the battery 46 as it is getting charged. When the battery 46 is completely charged, it may be removed from the charger 51 and replaced on the battery receptacle 44 . While the battery 46 is being charged by the power charger 51 , a battery backup may be connected to the receptacle 44 to provide power to the fan 18 .
[0043] According to one embodiment, the device 10 may include a timer in operative communication with the LED lights 48 to illuminate the LEDs 48 for a specified period of time. For instance, if a particular floor (i.e., a bathroom floor) is routinely cleaned or mopped, the cleaning staff may know that it takes a certain period of time for that floor to dry (i.e., fifteen minutes). Therefore, the timer may be set for fifteen minutes to illuminate the LEDs 48 for alerting nearby pedestrians that the floor is wet. The timer may be powered by the battery 46 when the battery is coupled to the battery receptacle 44 .
[0044] Referring now to FIG. 6 , it is also contemplated that the battery receptacle 44 may be integrated directly into the fan 18 to eliminate the need of an external cord extending between the battery 46 and the fan 18 . Furthermore, this configuration may advantageously conceal the battery 46 if there is a concern that the battery 46 may be tampered with.
[0045] Referring now back to FIG. 5 , it is contemplated that the safety marker drying device 10 may include structural features intended to facilitate the movement of the device 10 . It is contemplated that the weight of the device is small enough to allow a single person to lift and carry the device; however, the size and shape of the device 10 may make it difficult to complete such a task. Therefore, certain embodiments may include structural features to facilitate movement of the device 10 without carrying the device. For instance, the device 10 may include one or more wheels or castors 60 connected to the housing 12 to allow a user to roll the device 10 along a surface. The castors 60 may be of the swivel construction type and coupled to the underside of the outer diameter of the second end portion 28 of the lower body 16 , and in particular the base 24 thereof. While the use of a plurality of casters 60 allows for movement of the device 10 across the surface 11 , the use of casters 60 having a predetermined resistance to rotation or having a locking mechanism integral to their design may be included to maintain the device 10 in a desired position. Alternatively, a separate braking device that is not integrated to the casters 60 may be included to maintain the device 10 in a desired position. As seen in FIG. 5 , the device 10 may additionally include a handle 52 to provide a location where a user may easily grip the device 10 for movement thereof. As depicted in the drawings, the handle 52 is connected to the battery 46 ; however, it is understood that the handle 52 may be connected to other portions of the device 10 , such as the upper body 14 or the battery receptacle 44 , without departing from the spirit and scope of the present invention.
[0046] Referring now to FIG. 7 , there is depicted another embodiment of the safety marker drying device 110 including a single, unitary housing 112 . In this regard, the primary distinction between the device 110 , and the device 10 discussed above, is that the device 10 includes a housing 12 having an upper body 14 and a separate lower body 16 , whereas the device 110 is comprised of only the housing 112 . The housing 112 includes an upper end portion 115 and an opposing lower end portion 117 . A flange 119 may be disposed about the lower end portion 117 to provide stability and support. The housing 112 defines both a fluid intake 116 and a fluid exhaust 118 in fluid communication with the fluid intake 116 to facilitate fluid flow through the device 110 . The fluid intake 116 is formed by a series of slots extending through the housing 112 into fluid communication with the hollow interior thereof. The fluid exhaust 118 is defined by a space or gap disposed between the housing 112 and the surface upon which the housing 112 is positioned. A plurality of exhaust fins 120 having structural and functional characteristics mirroring those of the fins 40 described above in relation to the device 10 may be coupled to the housing 112 to dispose the housing 112 in spaced relation to the underlying support surface to define the fluid exhaust 118 .
[0047] A fan 114 is disposed within the interior of the housing 112 , and in the intended path of fluid flow therethrough, such that the fluid intake 116 is disposed upstream of the fan 114 and the fluid exhaust 118 is disposed downstream of the fan 114 . The housing 112 may include tabs, a flange, a shelf, etc., against which the fan 114 may be coupled. The fan 114 may be battery operated, similar to the fan 18 discussed above.
[0048] Referring now to FIGS. 8-9 , there is shown a further embodiment of the safety marker drying device 210 which is specifically configured to integrate a conventional safety marker 212 therein. In this regard, the device 210 includes a drying unit 214 upon which a conventional safety marker 212 may be placed. The drying unit 214 includes a base 216 and a plurality of inlet fins 218 configured to engage with the conventional safety marker 212 to dispose the safety marker 212 in spaced relation to the base 216 . In this regard, the inlet fins 218 collectively define a surface configured to support the safety marker 212 . The space or gap between the safety marker 212 and the base 216 defines a fluid intake 215 . The drying unit 214 is configured to dispose the base 216 in spaced relation to the underlying support surface to define a fluid exhaust 217 . The drying unit 214 may include one or more casters 222 or fins like the above-described fins 40 to maintain the base 216 in spaced relation to the underlying support surface. The casters 222 may facilitate movement of the device 210 . The fluid intake 215 and fluid exhaust 217 are in fluid communication with each other. In this regard, the base 216 may include an opening to facilitate such fluid communication.
[0049] A fan 220 is connected to the base 216 to draw air through the fluid intake 215 and to force air through the fluid exhaust 217 upon the engagement of the safety marker 212 to the base 216 . However, it is understood that the fan 220 and base 216 are able to draw air through the unobstructed fluid intake zone 219 above the fan 215 and to force air through the fluid exhaust 217 even without engagement of the safety marker 212 to the base 216 , thus allowing for the drying unit 214 to be similarly integrated to other items such as a mop bucket or cart. The inlet fins 218 may define a containment area within which the fan 220 may be placed. The fan 220 may be battery powered, as described in detail above.
[0050] The base 216 may include one or more LED battery indicator lights 225 to indicate the power level of the battery. As such, when the battery is connected to the fan 220 , the battery is additionally placed in electrical communication with the base 216 to allow the base 216 to provide a visual indication of the power level of the battery.
[0051] Referring now to FIGS. 10 and 11 , there is depicted an additional embodiment of the safety marker drying device 310 including a breathable safety marker 312 and a drying unit 314 . The breathable marker 312 is formed from a breathable fabric shell 316 (i.e., nylon) and a spring-loaded, collapsible, spiraling conical wire frame 318 . In this regard, the breathable marker 312 may be disposed in a deployed position (as shown in FIGS. 10 and 11 ) as well as a collapsed position to facilitate storage or transport thereof. The drying unit 314 includes a base 320 having a fan 322 connected thereto. The drying unit 314 is similar to the drying unit 214 discussed above. The fan 322 is configured to draw air through the breathable fabric shell 316 and force air through an exhaust 325 disposed between the base 320 and the surface upon which the base 320 is supported. A plurality of fins 324 are connected to the base 320 and define a containment area within which the fan 322 is positioned. The fins 324 may also be configured to facilitate the frictional engagement with the breathable marker 312 . A plurality of castors 326 may be connected to a base 320 to facilitate movement thereof.
[0052] This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by this exemplary embodiment. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure. | In accordance with the present invention, there is provided is a safety marker with an on-board convection fan for marking areas/hazards to be avoided while concurrently producing a convection effect upon the adjacent, surrounding surfaces so as to enhance evaporation of liquids/moisture thereon. Along these lines, the safety marker will not only mitigate risks by allowing for the marking of an area to be avoided, but also, uniquely, by accelerating the elimination of what is most often the root cause of the risk; wetness on the floor. |
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TECHNICAL FIELD OF INVENTION
[0001] This invention relates to an improved window covering. More particularly, this invention relates to an improved window covering having the ability to tilt, raise or lower the slats of the window covering by operation of its bottom rail.
BACKGROUND OF THE INVENTION
[0002] Venetian blinds are a type of window covering comprising horizontal slats, one above another. The slats are typically suspended between an upper rail and a bottom rail by cords. One cord, the ladder cord, is used to control the rotation of the blinds. The other cord, the raising cord, is used to raise and lower the slats. The ladder cord allows the slats to rotate or tilt approximately 180 degrees in either direction. At one extreme the slats are rotated such that they overlap with one side of the slats facing inward and the other sides of the slats facing outward. At the other extreme, the opposite sides of the slats face inward and outward. When the lift cord is pulled, the bottom rail moves towards the upper rail, causing the slats to be stacked one on top of the other.
[0003] In most prior art Venetian blinds, an external tilting wand is used to control an operating mechanism that causes the rotation of the slats and an external lift cord is used to control the height of the bottom rail. These components are visible and not aesthetically pleasing. Moreover, the cords pose a choking or strangulation hazard for children. While some prior art Venetian blinds have removed the external tilting wand or lift cord, no such prior art devices have eliminated the needs of the external tilting wand, as well as the external lift cord without severely limiting the function of the blind. Therefore, it is desirable to provide an aesthetically pleasing and safe window blind that does not include either an external tilting wand or an external lift cord.
[0004] Therefore, there is a need for an actuator mechanism for controlling the movement of a window covering, such as a Venetian blind, that overcomes the foregoing problems.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a cordless actuator mechanism that is suitable for use with a window covering that does not require the use of conventional pull cords to raise or lower the window covering. The present invention is particularly suitable for use with a Venetian blind which includes a head rail, a plurality of slats, a raising cord, and a bottom member suspended from the raising cord to impart vertical adjustments thereto by a user. Other possible window coverings are cellular shades that include adjustable vanes within the cells.
[0006] With a Venetian blind a ladder extending from the head rail is provided, which is attached to and supports the plurality of slats for tilting movement thereof. A stop arrangement adapted to limit vertical movement of the ladder cord and the slats suspended therewith, a rotatable drive axle disposed within the head rail having a winding drum member mounted therewith, and a raising cord upper end portion secured with the winding drum member whereby vertical adjustment of the raising cord cooperates with the drive unit for rotation of the winding drum member and the drive axle are also provided. The stop arrangement can take various forms as will be discussed in greater detail below.
[0007] A tilting member is rotationally fixed with the drive axle, while an upper portion of the ladder is secured to the tilting member such that rotation of the tilting member applies a tilting force to the ladder to cause the ladder to tilt the slats. A clutch arrangement is provided between the drive axle and the tilting member, which is responsive to the stop arrangement arresting vertical movement of the ladder cord, to disengage the rotational or tilting force from the drive axle from being applied to the ladder.
[0008] In one embodiment, the tilting member comprises an outer drum about which the ladder cord is attached. The actuator mechanism further comprises an inner drum member circumferentially mounted about and rotationally fixed to the drive axle, and a collar member, such as a coil spring, comprising the clutch arrangement. The coil spring is circumferentially mounted about the inner drum and has a tightened state whereby the coil spring is engaged with the inner drum, and an expanded state whereby the coil spring is disengaged from the inner drum.
[0009] The outer drum is circumferentially mounted about the coil spring. The coil spring is biased toward the engaged condition. The coil spring is moved to the engaged condition by rotation of the winding drum member and the drive axle in response to vertical adjustment of the raising cord, by upward or downward manipulation of the bottom member, which enables a force to be transmitted from the drive axle to the coil spring.
[0010] In a second embodiment, the tilting member includes a winding pulley having a hub located between a pair of pulley sidewalls to define a generally V-shaped recess for confining a loop of the ladder cord as the ladder cord is wound about the hub. The pulley sidewalls are responsive to the stop member engaging at least one of the slats to stop tilting movement thereof so as to increase force on the ladder cord loop, causing the ladder cord loop to engage the pulley sidewalls, moving the ladder cord away from the hub so as to disengage the tilting force applied to the ladder cord. In a related embodiment, the hub comprises a plurality of ribs to provide increased engagement with the ladder cord.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a Venetian blind shown in an open configuration, and including an actuator mechanism according to a preferred embodiment of the present invention;
[0012] FIG. 2 is an exploded perspective view of part of a tilt control mechanism of the actuator mechanism shown in FIG. 1 ;
[0013] FIG. 3 is a perspective view of a coil spring of the tilt control mechanism shown in FIG. 2 ;
[0014] FIG. 4 is a perspective view of the tilt control mechanism shown in FIG. 2 ;
[0015] FIG. 5 is a top view of an actuator mechanism of the embodiment shown in FIG. 1 ;
[0016] FIG. 6 is a perspective view of the actuator mechanism of the embodiment shown in FIG. 5 ;
[0017] FIG. 7 is a cross-sectional view of the Venetian blind shown in FIG. 1 , taken along line 7 - 7 and shown in a fully retracted configuration;
[0018] FIG. 8 is a cross-sectional view similar to FIG. 7 , but shown in a first closed configuration;
[0019] FIG. 9 is a cross-sectional view similar to FIG. 7 , but shown in an open configuration;
[0020] FIG. 10 is a cross-sectional view similar to FIG. 7 , but shown in a second closed configuration;
[0021] FIG. 11 is a perspective view of a second embodiment of an actuator mechanism according to the present invention;
[0022] FIG. 12 is an exploded perspective view of the actuator mechanism shown in FIG. 11 ;
[0023] FIG. 13 is a fragmentary perspective view of the actuator mechanism shown in FIG. 11 ;
[0024] FIG. 14 is a perspective view of the actuator mechanism shown in FIG. 11 ;
[0025] FIG. 14A is a cross-sectional view of the actuator mechanism shown in FIG. 11 ;
[0026] FIG. 15 is a side elevational view of the winding drum assembly of FIG. 6 , shown partly in cross-section;
[0027] FIG. 16 is a fragmentary side elevational view of an actuator mechanism with an alternative tilt winding pulley;
[0028] FIG. 17 is a perspective view thereof;
[0029] FIG. 18 is a front elevational view of the tilt winding pulley;
[0030] FIG. 19 is a side elevational view thereof;
[0031] FIG. 20 is a fragmentary side elevational view of an actuator mechanism with another tilt winding pulley;
[0032] FIG. 21 is a perspective view thereof;
[0033] FIG. 22 is a front elevational view of the tilt winding pulley;
[0034] FIG. 23 is a side elevational view thereof;
[0035] FIG. 24 is a fragmentary side elevational view of an operating mechanism with an actuator mechanism with an alternative clutching arrangement;
[0036] FIG. 25 is an exploded view of the actuator mechanism of FIG. 24 ; and
[0037] FIG. 26 is a perspective view of the actuator mechanism of FIG. 24 .
DETAILED DESCRIPTION OF THE INVENTION
[0038] The invention disclosed herein is, of course, susceptible of embodiment in many different forms. Shown in the drawings and described herein below in detail are preferred embodiments of the invention. It is understood, however, that the present disclosure is an exemplification of the principles of the invention and does not limit the invention to the illustrated embodiments.
[0039] For ease of description, actuator mechanisms for Venetian blinds embodying the present invention and utilizing a novel drive clutch arrangement, embodied as either a coil spring or a pulley wheel, is described herein below in their usual assembled position as shown in the accompanying drawings, and terms such as upper, lower, horizontal, longitudinal, etc., may be used herein with reference to this usual position. However, the actuator mechanisms may be manufactured, transported, sold, or used in orientations other than and described and shown herein.
[0040] A preferred embodiment of the present invention is shown in FIGS. 1 through 10 . Referring to FIG. 1 , Venetian blind 10 is shown in a fully extended position with its slats opened. The blind 10 includes head rail 12 , bottom rail 16 , a plurality of slats 70 and actuator mechanisms 20 and 21 . Head rail 12 has a rectangular plinth-like shape and includes a bottom side 15 and a substantially open top side 13 . The inside of head rail 12 forms a substantially hollow channel 14 . As shown in FIGS. 7-10 , bottom side 15 of the head rail 12 includes a stop member or first bottom edge 11 (see FIGS. 8 and 10 ) and a second bottom edge 19 (see FIG. 7 ). Head rail 12 may be secured to a window or similar surface by means known in the art. It may also include decorative facing without departing from the spirit of the invention.
[0041] Referring again to FIG. 1 , bottom rail 16 includes top side 17 and bottom side 18 . Preferably, the area of top side 17 is substantially equal to the longitudinal area of each individual slat 72 , although this is not required. The shape of the bottom rail may vary without departing from the spirit of the invention.
[0042] The slat array or plurality of slats 70 comprises a plurality of individual slats 72 . Each slat 72 includes a top portion 73 and a bottom portion 74 . Top portion 73 and bottom portion 74 are connected together by border 75 . Border 75 includes a first edge 76 , a second edge 77 , a third edge 78 and a fourth edge 79 , the third and fourth edge 78 and 79 extending along the width of each slat 72 . In the preferred embodiment, the cross-sectional shape of each slat 72 is substantially rectangular. Other shapes may be utilized, however. The number of slats included is determined based on the size of the slats and the desired length, or vertical extent, of the blind.
[0043] A tilt control mechanism 30 for tilting the plurality of slats 70 is provided, and is shown in greater detail in FIGS. 2-6 . The tilt control mechanism 30 includes an inner drum 40 , a clutch arrangement that includes a coupling member, such as coil spring 50 , and a tilting member 60 that, in this embodiment, is an outer drum. As shown, the inner drum 40 , coil spring 50 and tilting member 60 are comprised of individual components, although other combinations of parts is possible. Inner drum 40 is preferably provided as a monolithic plastic molding and includes an outer surface portion 44 that is generally cylindrical. First and second flange portions 42 and 46 respectively protrude from the outer surface 44 of the inner drum 40 at two axially opposite sides thereof. Through hole 48 is defined by inner drum 40 . Through hole 48 is configured to accept insertion of drive axle 24 such that the inner drum 40 is tightly mounted on the drive axle 24 and also rotationally fixed relative to the drive axle. The inner drum 40 can also define a slit 45 cut through the second flange 46 and a portion of the outer surface 44 proximate to the second flange 46 . Slit 45 can add some resiliency to the end portion of the inner drum 40 for facilitating its assembly through the tilting member 60 .
[0044] The tilting member 60 is hollow and generally cylindrical in shape. The tilting member 60 includes an outer surface 61 , and defines a recess 63 having an inner surface 68 . The inner surface 68 of recess 63 further defines a slot 62 . Formed axially on the outer surface 61 is a groove 64 . Groove 64 is sized to receive retainer segment 66 that includes clipping tabs 65 and 67 for securely fixing end portions of ladder cord sections 22 a and 22 b ( FIG. 5 ), which are front and rear ladder cord sections, to tilting member 60 . In this embodiment, the retainer segment 66 and the tilting member 60 are separate components. In other embodiments, retainer segment 66 may also be integrally formed on the tilting member 60 . Retainer segment 66 can be shaped to match the radius of curvature of the tilting member 60 .
[0045] As more clearly shown in FIG. 3 , coil spring 50 comprises end portions or prongs 52 , which extend in a substantially radial outward direction. The coil spring 50 can have two states, referred to herein as tightened and expanded states. Coil spring 50 is configured such that in a tightened state, it is firmly mounted by way of friction on the outer surface portion 44 of the inner drum 40 between the first and second flange portions 42 and 46 . Provided with the coil spring 50 , the inner drum 40 can be inserted into recess 63 of the tilting member 60 with the prongs 52 being lodged in the slot 62 thereof. When the coil spring 50 is in the tightened state, the coil spring 50 tightly presses around the outer surface 44 of the inner drum 40 so that the inner drum 40 , coil spring 50 and tilting member 60 rotate in unison. When the coil spring 50 is in the expanded state, the coil spring 50 expands so that it no longer tightly grips on the outer surface 44 of the inner drum 40 . The inner drum 40 is thus' able to rotate along with the drive axle 24 independent of the coil spring 50 and tilting member 60 .
[0046] Referring to FIGS. 2-6 , the tilt control mechanism 30 includes the coil spring 50 mounted around the inner drum 40 . Inner drum 40 and coil spring 50 are mounted within recess 63 of the tilting member 60 with the prongs 52 of the coil spring 50 placed within the slot 62 . The height of the first and second flange portions 42 and 46 is preferably sized so as to prevent axial shifting of the coil spring 50 or the tilting member 60 from the inner drum 40 . To drive the tilt control mechanism 30 , the drive axle 24 is mounted through the hole 48 of the inner drum 40 .
[0047] With reference to FIGS. 1 , 5 and 6 , two ladder cord sections 22 a and 22 b are engaged with the clipping tabs 65 and 67 on the retainer segment 66 . It will be understood by skilled practitioners that one ladder cord section 22 a can extend at the front of the Venetian blind 10 and connect with one side edge of the plurality of slats 70 (e.g., fourth edge portion 79 ), whereas the other ladder cord section 22 b can extend at the rear of the Venetian blind 10 and connect with an opposite side edge of the plurality of slats 70 (e.g., third edge portion 78 ). Each of the ladder cord sections 22 a and 22 b has an upper end secured with the tilt control mechanism 30 , and a lower end secured with the bottom rail 16 . Ladder cord sections 43 are secured at one end to another tilt control mechanism 31 and at the other end, to bottom rail 16 in a manner similar to ladder cord sections 22 a and 22 b . The plurality of slats 70 can be thereby suspended from ladder cord sections 22 a , 22 b and 43 . Raising cord 25 extends from the winding drum assembly 29 of the actuator mechanism 20 , through an aperture in head rail 12 , through the plurality of slats 70 , and is fixed at a lower end to bottom rail 16 . Raising cord 26 similarly extends from the winding drum assembly of another actuator mechanism 21 similar to the actuator mechanism 20 , through an aperture on head rail 12 , through the plurality of slats 70 and is secured with bottom rail 16 . As will be seen, the bottom rail 16 may be pulled or pushed by a user to impart vertical adjustments to the raising cord and adjust the inclination of, i.e., tilt, the plurality of slats 70 .
[0048] Referring to FIGS. 5 and 6 , the actuator mechanism 20 includes the winding drum assembly 29 and tilt control mechanism 30 . The winding drum assembly 29 and tilt control mechanism 30 is mounted with the drive axle 24 . In the same manner, actuator mechanism 21 is also mounted on the drive axle 24 and includes a winding assembly and tilt control mechanism similar to those of actuator mechanism 20 . The use of a common drive axle 24 to connect multiple actuator mechanisms also provides for a simple and reliable means for synchronization and balancing of the actuator mechanisms to promote even lifting and tilting of the blind. In the embodiment disclosed, two actuator mechanisms are mounted on the drive axle 24 . The number of actuator mechanisms utilized depends on the weight and width of the blind, and may vary as needed.
[0049] FIG. 15 is a cross-sectional view illustrating one embodiment of the winding drum assembly 29 used for operating the raising cord 25 (for clarity, the tilt control mechanism has been omitted in FIG. 15 ). As shown, the winding drum assembly 29 includes a support structure, such as housing 138 . Positioned within the housing 138 are a winding drum 140 and a motor spring 142 (shown in cross section) axially spaced apart from each other. In this embodiment, the winding drum 140 includes a spindle 144 that is integrally formed with the winding drum 140 . The drive axle 24 , which defines a longitudinal axis 48 , is inserted through and secured with the spindle 144 such that the winding drum 140 and drive axle 24 rotate together. It is preferred that the winding drum 140 , spindle 144 and motor spring 142 are coaxial with one another. More specifically, the motor spring 142 can be a spiral spring having a first end fixedly secured on the housing 138 and a second end fixedly secured on the spindle 144 . The motor spring 142 exerts a rotational force, i.e., torque, on the drive axle 24 and the winding drum 140 in a direction that winds the raising cord 25 around the winding drum 140 . Preferably, the motor spring 142 is a constant force spring that provides a constant amount of force or torque throughout the range of extension of the spring. As each winding drum assembly is mounted on the same drive axle 24 , additional winding drum assemblies may be incorporated in a simple and convenient manner for a wider window covering that requires greater lifting force.
[0050] The raising cord 25 is secured at a first end 150 to a post 152 formed on the winding drum 140 . When the bottom rail is raised, the raising cord 25 is wound around the winding drum 140 , which is rotated by the torque from the motor spring 142 . When the bottom rail 16 reaches a desired height and the pulling force thereon is removed, a counterbalancing force to the torque from the motor spring 142 enables the bottom rail and plurality of slats to remain in position. This counterbalancing force can include internal friction, and the weight load exerted by the bottom rail and slats stacked thereon on the raising cord 25 .
[0051] Reference now is made to FIGS. 7 through 10 to describe an operation of the Venetian blind 10 . Shown in FIG. 7 is the Venetian blind 10 of FIG. 1 in a fully raised position. In this configuration, the plurality of slats 70 are stacked on top of each other and rest on the top portion 17 of bottom rail 16 in a substantially horizontal position. The top slat 72 abuts the second bottom edge 19 of head rail 12 . In this configuration, coil spring 50 is in its tightened state wherein coil spring 50 tightly holds onto the inner drum 40 . Additionally, raising cord 25 is also wound up around winding assembly 29 .
[0052] FIG. 8 shows Venetian blind 10 of FIG. 1 in a lowered first closed position. In this position the plurality of slats 70 are in a substantially vertical position wherein bottom portion 74 of the individual slats 72 faces forward. When it is desired to lower the Venetian blind 10 , the bottom rail 16 is grasped and lowered from the fully raised position as shown in FIG. 7 toward the position in FIG. 8 , i.e. the bottom rail 16 is pulled away from head rail 12 . As the bottom rail 16 is pulled away from the head rail 12 , the raising cord 25 is unwound from the winding assembly 29 , which causes rotation of the winding drum 140 and the drive axle 24 (e.g., in a counterclockwise direction). Rotation of the drive axle 24 causes rotation of the inner drum 40 . The rotation of the inner drum, in this configuration is transmitted via the coil spring 50 to the tilting member 60 . As a result, one of the ladder cord sections 22 b is pulled upward while the other ladder cord section 22 a is moved downward which causes the plurality of slats 70 to tilt in a first direction until each individual slat 72 reaches a first maximum inclination, which may be stopped when fourth edge portion 79 of the top slat 72 abuts the first bottom edge 11 of head rail 12 and/or third edge portion 78 of each individual slat 72 abuts against an adjacent lower slat 72 . In one embodiment, the bottom edge 11 of the head rail 12 can thus be engageable with the top slat to act as a stop arrangement to restrict vertical movement of the ladder cord sections 22 a and 22 b and to stop tilting movement at a maximum inclination of the plurality of slats 70 . This maximum inclination may correspond to a closed position of the Venetian blind 10 where no or a minimal amount of light is allowed to pass through the plurality of slats 70 . When tilting of the plurality of slats 70 is stopped at the first maximum inclination, rotation of the tilting member 60 is blocked, and further rotation of the drive axle 24 , which is imparted directly to the inner drum 40 , causes the coil spring 52 to rotate slightly such that one of the prongs 52 of coil spring 50 presses against a sidewall of the radial slot 62 of the rotationally blocked tilting member 60 . As a result, the coil spring 50 expands to an expanded state whereby the inner drum 40 is allowed to rotate as the drive axle 24 continues to rotate, whereas the tilting member 60 , coil spring 50 and ladder cord sections 22 a and 22 b remain rotationally stationary relative to the drive axle. Because the end portions of ladder cord sections 22 a and 22 b are secured to the outside of the tilting member 60 , no frictional movement occurs between the ladder cord sections 22 a and 22 b and the tilting member 60 , thereby preventing wear damage to the ladder cord sections 22 a and 22 b . The configuration of the components also allows the drive axle 24 to continue to rotate, thereby allowing the raising cord 25 to be unwound from winding drum assembly 29 and allowing the plurality of slats 70 to be deployed. As a result of the construction of Venetian blind 10 , the plurality of slats 70 tilt in one direction and travel downward during this stage of operation.
[0053] Shown in FIG. 9 is Venetian blind 10 adjusted to an open and lowered position. In this position, the plurality of slats 70 is in a substantially horizontal position. To reconfigure window blind 10 from the lowered closed position as shown in FIG. 8 to the lowered open position in FIG. 9 , bottom rail 16 is slightly lifted towards head rail 12 . As this occurs, drive axle 24 rotates clockwise, and prong 52 of the coil spring 50 previously pressed against the corresponding sidewall of the radial slot 62 is no longer urged against thereto. As a result, the coil spring 50 recovers its tightened state on the inner drum 40 , such that clockwise rotation of the drive axle 24 again causes the rotational force on the inner drum 40 to be transmitted via the coil spring 50 to the tilting member 60 . Accordingly, rotation of the tilting member 60 pulls upward one of the ladder cord sections 22 a and extends downward the other ladder cord section 22 b . This action causes the plurality of slats 70 to tilt in a second direction. When the desired amount of tilt is achieved, upward lifting of the bottom rail 16 can be discontinued, and the slats come to rest as shown in FIG. 9 .
[0054] FIG. 10 illustrates an operation for raising the Venetian blind 10 of FIGS. 7-9 . When the bottom rail 16 is raised, the drive axle 24 and winding drum assembly 29 are driven in (e.g., clockwise) rotation by action of the motor spring 142 , which winds the raising cord 25 around the winding drum assembly 29 . The clockwise rotation of the drive axle 24 is imparted to the inner drum 40 and transmitted via the coil spring 50 to the tilting member 60 . As a result, the ladder cord sections 22 a and 22 b raise and lower, respectively, and cause the plurality of slats 70 to rotate or tilt in a second direction opposite to the first direction until a second maximum inclination of the plurality of slats 70 is reached. The second maximum inclination of the plurality of slats can occur when the slats 72 contact with one another or the third portion edge 78 of the top slat 72 abuts against the first bottom edge 11 of head rail 12 . Once the second maximum inclination of the plurality of slats 70 is reached, rotation of the tilting member 60 is blocked. As the bottom rail 16 continues to rise, which causes continued rotation of the drive axle 24 , another one of the prongs 52 of the coil spring 50 presses against a corresponding sidewall of the radial slot 62 of the rotationally blocked tilting member 60 . As this occurs, the coil spring 50 again expands, thereby allowing rotation of the inner drum 40 with the drive axle 24 relative to the tilting member 60 and the coil spring 50 , which will remain substantially rotationally stationary as the drive axle 24 and inner drum 40 continue to rotate. As the drive axle 24 continues to rotate, the raising cord 25 is wound around the winding drum assembly 29 so that the plurality of blinds slats 70 may be progressively raised and stacked on the bottom rail 16 . With this construction of Venetian blind 10 , the plurality of slats 70 can thus tilt in one direction and slide upward at the same time.
[0055] Certain variations in the above are to be understood as being within the scope of the present invention. For example, the directions of rotation of components within the header rail described above may be reversed. Also, the above description of FIGS. 7-10 specifically refer to actuator mechanism 20 , however, the description is equally applicable to actuator mechanism 21 as actuator mechanisms 20 and 21 are identical and operate simultaneously because they are both connected to drive axle 24 . As will be appreciated, coil spring 50 functions as a clutch arrangement between the drive axle 54 and the tilting member 60 , responsive to a stop arrangement which in this embodiment is the bottom wall of the head rail body, engaging the top slat to stop tilting movement of the slats, causing the coil spring to loosen, discontinuing the tilting force applied to the ladder cord sections.
[0056] Although the clutching arrangement used to transmit torque between the inner drum 40 and tilting member 60 is preferably embodied as the coil spring 50 , the clutching arrangement may comprise other types of known mechanisms wherein the inner drum and the tilting member rotate together and, with sufficient force, is allowed to rotate relative to the tilting member.
[0057] For example, the clutching arrangement may be a sleeve that is rotationally secured with tilting member, and thereby frictionally engaged with the inner drum. Upon application of sufficient torque from the drive axle, the static coefficient of friction between the inner portion of the sleeve and the outer surface of the inner drum may be overcome, thereby allowing for relative rotational movement between the tilting member and inner drum. When the torque is discontinued, the static friction again causes the tilting member and inner drum to rotate in conjunction with each other.
[0058] As yet another alternative, referring to FIGS. 24-26 , the outer surface portion 320 of inner drum 302 may fit snugly within an inner portion 306 of the tilting member 304 such that the inner drum 302 is frictionally engaged with the tilting member 304 . In such a configuration, no separate intermediate member between the inner drum 302 and the tilting member 304 is necessary. Rather, the static friction between the inner drum 302 and the tilting member 304 are sufficient to enable the inner drum 302 and the tilting member 304 to rotate together. When the static friction is overcome by sufficient force from the drive axle 24 the inner drum 302 may be rotated independent of the tilting member 304 .
[0059] Another embodiment of the present invention is shown in FIGS. 11-14A . Actuator mechanism 80 includes a winding drum 100 , inner drum 109 , coil spring 110 having out-turned ends or prongs 112 , tilting control mechanism 90 , ladder cord sections 84 and raising cord 86 . Actuator mechanism 80 is mounted in the head rail 81 with the drive axle 82 . Actuator mechanism 80 may replace the actuator mechanism described previously in reference to FIGS. 1-10 . As such, actuator mechanism 80 is used to raise, lower and tilt a plurality of blind slats.
[0060] Shown in FIG. 12 is a portion of actuator mechanism 80 wherein the parts are unassembled. In this embodiment, winding drum 100 includes a substantially hollow cylindrical body 104 having a cord-winding barrel 108 , and a shaft sleeve 109 extending at one side of the cord-winding barrel 108 and having a diameter smaller than the cord-winding barrel 108 . The shaft sleeve 109 has a substantially cylindrical shape and is adapted to mount around the drive axle 82 . An inner surface of the cord-winding barrel 108 also includes a radial slot 106 adapted to engage with the prongs 112 of the coil spring 110 .
[0061] In this embodiment, the tilting control mechanism 90 includes a pulley 98 , and a sleeve portion 94 adjoined at one side of the pulley 98 . Pulley 98 includes radial ribs 92 for increased gripping of each ladder cord section 84 by the tilting control mechanism 90 , which facilitates displacement of the ladder cord sections 84 for tilting the slats.
[0062] In conjunction with FIGS. 11 and 12 , FIG. 13 is an enlarged view of the tilting control mechanism 90 assembled with the winding drum 100 FIG. 14 is a perspective view of the actuator mechanism 80 , and FIG. 14A is a cross-sectional view of the actuator mechanism 80 shown in FIG. 14 (for clarity, the drive axle and cord elements are not shown in FIG. 14A ). As shown, the coil spring 110 is tightly mounted around the sleeve portion 94 of the tilting control mechanism 90 . The shaft sleeve 109 of the winding drum 100 is then mounted through the sleeve portion 94 of the tilting control mechanism 90 provided with the coil spring 110 , and the prongs 112 of the coil spring 110 are engaged with the slot 106 . As with the previous embodiment, the coil spring 110 has two states. In its tightened state, the coil spring 50 tightly fits around the sleeve portion 94 , so that the winding drum 100 , coil spring 110 and tilting member 90 can rotate together. In its expanded state, the coil spring 110 expands so that the coil spring 110 loosens its grip on the tilting control mechanism 90 . When the coil spring 110 is in the expanded state, as the winding drum 100 is rotated by the drive axle 82 , the tilting control mechanism 90 and coil spring 110 remain rotationally stationary relative to the drive axle 82 . In this manner, the coil spring 110 acts as a clutch arrangement for coupling and uncoupling rotational movements of the winding drum 100 and tilting control mechanism 90 .
[0063] Each ladder cord section 84 is engaged with one side of the plurality of blind slats (e.g., one ladder cord section at the front side, and another one at the rear side), and has an upper portion secured about pulley 98 . The end portions of the two ladder cord sections 84 are secured together by clip 85 at a location between the ribs 92 of the pulley 98 . As shown in FIGS. 14 and 14A , the actuator mechanism 80 can be mounted in a casing 88 having a first compartment 88 A, a second compartment 88 B, and a third compartment 88 C between the first and second compartment 88 A and 88 B. The first compartment 88 A of the casing 88 can house a motor spring 130 used for sustaining the bottom rail 16 in equilibrium at a desired height. In one embodiment, the motor spring 130 includes a constant force spiral spring having a first end secured with the drive axle 82 via an adapter sleeve 132 , and a second end secured with the casing 88 . The second compartment 88 B houses the winding drum 100 coupled with the raising cord 86 . In turn, the third compartment 88 C houses the tilting member 90 coupled with the ladder cord sections 84 , at a position between the cord-winding barrel 108 and the motor spring 130 . The drive axle 82 is assembled through the interior of the casing 88 , and passes respectively through the winding drum 100 , the tilting member 90 , and the motor spring 130 . With this construction, the actuator mechanism 80 can be assembled in a compact and modular manner, which can be easily mounted with the drive axle 82 .
[0064] The actuator mechanism 80 may replace the actuator mechanism 20 previously in connection with FIGS. 1-10 for operating the Venetian blind. During operation, the motor spring 130 exerts a force on the drive axle 82 , which is converted into an upward force via the winding drum 100 and raising cord 86 for sustaining the weight of the bottom rail 16 and any slats 72 stacked thereon.
[0065] When a user wants to tilt the plurality of slats 70 in a first direction, he or she pulls down slightly on the bottom rail 16 within a limited range of displacement. The raising cord 86 is then pulled downward causing rotation of the winding drum 100 , which causes the coil spring 110 in its tightened state and the winding drum 100 to rotate. As a result, the tilting member 90 moves the two ladder cord sections 84 in opposite directions to tilt the plurality of slats 70 in the first direction. The plurality of slats 70 continue to rotate and tilt in the first direction as the bottom rail 16 moves downward. Once the plurality of slats 70 reach the desired inclination, the user releases the bottom rail 16 . The sum of all the forces applied on the raising cord 86 (including the lifting force generated by the motor spring 130 , the weight of the bottom rail 16 and slats stacked thereon, and internal friction force) acts to keep the bottom rail 16 and plurality of slats 70 in equilibrium at the desired inclination.
[0066] If the user wants to tilt the plurality of slats 70 in a second direction opposite to the first direction, he or she applies an upward force on the bottom rail 16 , which causes rotation of the drive axle 82 and winding drum 100 driven by the motor spring 130 . This motion of the winding drum 100 is imparted to the tilting member 90 via the coil spring 110 being in a tightening state. As a result, the tilting member 90 moves the two ladder cord sections 84 in opposite directions to tilt the plurality of slats 70 in the second direction. The plurality of slats 70 continuously tilts in the second direction as the bottom rail 16 rises. Once the plurality of slats 70 reach the desired inclination, the user can release the bottom rail 16 .
[0067] When a user wants to lower the Venetian blind and deploy the plurality of slats 70 (as shown in FIG. 8 ), the bottom rail 16 is grasped and lowered away from the head rail 12 . As the bottom rail 16 is pulled away from head rail 12 , the raising cord 86 is pulled downward, which causes rotation of the winding drum 100 and drive axle 82 (e.g., in a counterclockwise direction). Rotation of the winding drum 100 is transmitted to the tilting member 90 via the coil spring 110 such that one of the ladder cord sections 84 is pulled upward while the other ladder cord section 84 is extended downward, which causes the plurality of slats 70 to tilt in the first direction until they reach a first maximum inclination in the first direction. Tilting of the plurality of slats is stopped when fourth edge portion 79 of the top slat 72 abuts the first bottom edge 11 of head rail 12 and/or third edge portion 78 of each individual slat 72 abuts against an adjacent lower slat 72 ( FIG. 1 ). When the plurality of slats 70 are stopped at the first maximum inclination, further rotation of the tilting member 60 is blocked, and further rotation of the winding drum 100 causes one of the prongs 112 of the coil spring 110 to press against one sidewall of the radial slot 106 and cause the coil spring 110 to move to an expanded state. As a result, the coil spring 110 and winding drum 100 are permitted to rotate as the bottom rail 16 is lowered and the raising cord 86 unwinds, whereas the tilting member 90 and the ladder cord sections 84 held thereon are kept stationary at the first maximum inclination of the slats 70 .
[0068] When a user wants to raise the Venetian blind and retract the plurality of slats 70 (as shown in FIG. 10 ), a slight upward force (e.g., less than the weight load on the raising cord 86 ) can be applied on the bottom rail 16 . As a result, the motor spring 130 acts to rotate the drive axle 82 and winding drum 100 (e.g., in a clockwise direction) to wind the raising cord 86 and raise the bottom rail 16 . Rotation of the winding drum 100 is imparted to the tilting member 90 via the coil spring 110 . As a result, the ladder cord sections 84 causes the plurality of slats 70 to tilt in the second direction opposite the first direction until they reach a second maximum inclination, which may be stopped when the third edge portion 78 of the top slat 72 abuts the first bottom edge 11 of the head rail 12 and/or fourth edge portion 79 of each individual slat 72 abuts against an adjacent lower slat 72 ( FIG. 1 ). When the plurality of slats 70 are stopped at the second maximum inclination, rotation of the tilting member 60 is blocked, and further rotation of the winding drum 100 causes one of the prongs 112 of the coil spring 110 to press against one sidewall of the radial slot 106 and force the coil spring 110 to loosen its grip on the blocked tilting member 60 . As a result, the coil spring 110 and winding drum 100 continue to rotate as the bottom rail 16 rises and the raising cord 86 winds around the winding drum 100 driven by the motor spring 130 , whereas the tilting member 90 and the ladder cord sections 84 held thereon are kept stationary at the second maximum inclination of the slats 70 . The bottom rail 16 can be thereby raised until it reaches a desired height.
[0069] Because the ladder cord sections 84 move along with the tilting member 90 , no frictional movement occurs between the ladder cord sections 84 and the tilting member 90 . When the bottom rail 16 is lowered to deploy the plurality of slats 70 , the stationary position of the tilting member 90 and ladder cord sections 84 can eliminate conventional wear damage to the ladder cord sections 84 .
[0070] Turning now to FIGS. 16-19 , an alternative actuator mechanism 200 is shown. Actuator mechanism 200 includes a tilt control mechanism embodied as tilt winding pulley 204 made of molded plastic or other suitable material. Tilt winding pulley 204 has a central opening through which drive shaft 24 is passed for rotationally coupling the winding pulley 204 with the drive shaft 24 . As shown in FIG. 18 , tilt winding pulley 204 includes a tilting cylinder or central hub 207 (see FIG. 18 ) and sidewalls 206 that define an internal V-shaped recess 210 , that narrows toward the center of the tilt winding pulley 204 . Referring to FIG. 16 , the upper end of ladder cord sections 22 is formed in a closed loop, and is inserted within recess 210 so as to contact the surfaces of tilt winding pulley 204 that define recess 210 . When the bottom rail is moved upward or downward for tilting the slats, the drive axle 54 can accordingly rotate to drive rotation of the tilt winding pulley 204 . Because the loop of ladder cord sections 22 is tightly fitted within the recess 210 , rotation of the tilt winding pulley 204 also causes displacement of the ladder cord sections 22 for tilting the slats. When the slats reach the maximum inclination and the drive axle 54 continues to rotate, the ladder cord sections 22 cannot move further and start to slip relative to the tilt winding pulley 204 rotating in unison with the drive axle 54 .
[0071] FIGS. 20-23 show another alternative tilt control mechanism 220 , which includes a tilting member embodied as tilt winding pulley 224 made of molded plastic or other suitable material. Tilt winding pulley 224 is substantially identical to tilt winding pulley 204 in construction and function, except for the addition of radially directed drive ribs 234 that extend from the central hub 235 to provide enhanced engagement with the ladder cord sections.
[0072] Tilt winding pulley 224 has a central opening through which drive shaft 24 is passed. As shown in FIG. 22 , tilt winding pulley 224 includes side walls 206 that define an internal V-shaped recess 230 that narrows toward the center of the pulley 224 . Referring to FIG. 20 , the upper ends of ladder cord sections 22 are joined to form a closed loop, and are tightly fitted within recess 230 so as to contact the inner surfaces of tilt winding pulley 204 that define recess 230 . When the bottom rail is displaced upward or downward for tilting the slats, the drive axle 54 can accordingly rotate to drive rotation of the tilt winding pulley 224 . Because the loop of ladder cord sections 22 is tightly fitted within the recess 230 , rotation of the tilt winding pulley 224 also causes displacement of the ladder cord sections 22 for tilting the slats. When the slats reach the maximum inclination and the drive axle 54 continues to rotate, the ladder cord sections 22 cannot move further and start to slip relative to the tilt winding pulley 224 rotating in unison with the drive axle 54 . With this construction, a separate clutch arrangement is not required, but is instead integrated into the tilt control mechanism.
[0073] The stop arrangement for limiting vertical movement of the ladder cord sections has been described as an engagement between and edge of a topmost slat with the head rail, or contact between adjacent slats tilted to their maximum inclination. However, the stop assembly may also take other forms. For example, another alternative stop arrangement is the inclusion of protrusions or other detent arrangements on the tilting drum that will engage a fixed catch structure within the head rail.
[0074] In addition to the clutching arrangements described above, other clutching arrangements may be suitable. For example, the winding drum and the tilt control mechanism may be engaged to one another by way of static friction, such as being positioned in an abutting coaxial arrangement. When sufficient force is exerted on the winding drum and rotation of the tilt control mechanism is stopped by the stop arrangement, the static friction could be overcome and the winding drum allowed to rotate independent of the tilt control mechanism. An adjustable spring can be incorporated to adjust or otherwise vary the amount of static friction between the winding drum and the tilt control mechanism. Yet another possible clutching arrangement would be similar to the embodiment shown in FIGS. 16-19 , wherein the winding drum and the tilt control mechanism are an integral unit having a winding portion connected to the raising cord and a tilting portion connected to the ladder cord.
[0075] The foregoing descriptions and the accompanying drawings are illustrative of the present invention. Still other variations and arrangements of parts are possible without departing from the spirit and scope of this invention. | An actuator mechanism for window coverings, such as, Venetian blinds that eliminates the use of pull cords and tilting wands is provided. The actuator mechanism includes a stop member engageable with at least one of the slats to stop tilting movement thereof and a clutch arrangement between a drive axle and a tilt control mechanism, responsive to the stop member engaging at least one of the slats, to disengage the tilting force applied to a ladder cord supporting the slats. |
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TECHNICAL FIELD OF INVENTION
[0001] The invention relates to the infrastructure field, more specifically to sewage technologies. Even more particularly, the invention relates to providing a manhole for desert environments where temperatures can be very high and environmental conditions such as erosion exert different challenges on sewage infrastructure.
BACKGROUND
[0002] Urbanisation requires sewage systems, and to accommodate this need, various technologies related to manholes have been devised.
[0003] A traditional manhole used in Finland is shown in FIG. 1 in accordance with the prior art. FIG. 1 shows the top view at the top of the page and side view at the bottom of the page. Traditionally the parts of concrete manholes below ground surface are in size 80 cm or 1 m for the diameter and are made of concrete cones 100 , typically of height 50 cm or 75 cm. Traditionally a manhole is built of several parts: bottom ring 110 , cone 100 and several adjusting rings 140 , 141 and 142 . The outlet pipe 120 leads the water to the rest of the sewage system.
[0004] For adjusting the height of the manhole separate adjusting rings 140 , 141 and 142 on the top of the concrete cone 100 have been used. In most cases there has been a need for several adjusting rings, as is also shown in FIG. 1 where three adjusting rings 140 , 141 and 142 are exhibited. The height of the adjusting rings typically varies between 5 cm and 25 cm, and the number of rings used varies also. Typically sealing tape is used between the adjusting rings. Occasionally elastomeric sealing rings are also used. The manhole cover 130 is typically a cast iron solid cover, which also acts as a rainwater cover.
[0005] The concrete cone 100 is typically of 80 cm or 60 cm or 1 m diameter. The height of the cone 100 is typically 50 cm or 75 cm. The concrete bottom ring 110 typically has a diameter of 80 cm-1 m. The concrete in both the cone 100 and the bottom ring 110 is made of sulfate resistant cement.
[0006] One problem with the traditional solution of adjusting rings is that the joint between the adjusting rings 140 , 141 , 142 , or an adjusting ring 140 and the cone 100 is occasionally not water and soil proof. Further the adjusting rings may get easily broken during the building of manholes, and over operational lifetime of the manhole. In many cases there has been a need for replacing broken adjusting rings 140 , 141 and 142 during yearly repairs of the concrete manholes.
[0007] FIG. 2 shows another manhole in accordance with the prior art. FIG. 2 shows the top view at the top of the page and side view at the bottom of the page. In one alternative way of building a manhole, traditional concrete cone 100 is replaced with a concrete cone 200 and a telescope pipe 250 . The telescope pipe 250 is made of PEH (High density polyethylene). Clear opening of the telescope pipe 250 and cast iron cover 230 is about 60 cm, i.e. the same as in traditional concrete cone 100 of FIG. 1 . Benefits of using the telescope pipe 250 are variable height adjustment and tightness against leaking water from the ground and soil.
[0008] Further, in Finland roads are not paved with asphalt directly after installing water pipes and manholes. The heights of the manholes need to be adjusted during the building of the pavement, and telescope makes it easier and faster to adjust the height. Building of manhole with several parts i.e. a bottom ring 110 , cone 100 and several adjusting rings 140 , 141 and 142 is slower than with telescope cone 250 . In many cases there has been a need for replacing broken adjusting rings 140 , 141 , 142 during yearly repairs of concrete manholes 10 . Telescope 250 and concrete cone 200 reduces also the amount of repairs needed. Lifting the heavy concrete cone 200 has also been made safer with lifting wire instead of traditional lifting grabs.
[0009] The concrete cone 200 is typically 80 cm or 60 cm or 1 m in diameter and has a matching PEH-pipe telescope and two circular ring seals 260 and 261 .
[0010] The telescope 250 is used to set the cover 230 so that it matches the final ground level. The concrete in both the cone 200 and the bottom ring 210 is made of sulfate resistant cement. The outlet pipe 220 leads the water to the rest of the sewage system.
[0011] FIG. 3 demonstrates a typical concrete manhole 30 in Arabia, from the United Arab Emirates. In the UEA manholes are casted on worksite. This is in contrast to Europe where most of the manholes are casted in concrete mills and are then transported to worksites for assembling. A typical problem with manholes in the UAE is that the soil sinks around manhole and the manhole becomes too high. The cover 330 , which is typically a ductile iron inlet frame and crate, is then elevated and the concrete sides 300 of the manhole are exposed. A concrete slab 370 has been sometimes placed under the manhole to try and stabilize it. The outlet 330 and the inlet 331 connect the manhole to the rest of the sewage system.
[0012] In the Middle East cities of millions of people are being built on sandy deserts, and in the United States many states such as Texas and Arizona are experiencing rapid growth in urbanisation. These areas are so hot that the PEH with a melting point of 120 Celsius is suboptimal for sewage applications, because PEH at a temperature of 40-50 Celsius degrees begins to be closer to the physical parameters where it behaves like a fluid, which of course is harmful in these sewage applications.
[0013] Building sewage systems in these areas is challenging because temperature variations can be quite high and the ground is not always of a stable composition, i.e. many times the ground is composed of sand that can be quite mobile over long time periods.
[0014] It is also known in the prior art that manholes have been protected against earthquakes, e.g. in JP2000291034A which is cited here as reference.
[0015] Clearly what is needed is a manhole solution that can be casted on work site and the on-site casted manhole should still be resistant to environmental change such as erosion and temperature changes over long time periods in a desert environment.
SUMMARY
[0016] The invention under study is directed towards a system and a method for effectively providing a manhole for very hot desert conditions that can be casted on site and has an extended, long stable operational lifetime in a desert environment.
[0017] A further object of the invention is to present a manhole that is cheap to construct and easy to maintain in desert conditions.
[0018] One aspect of the invention involves a manhole with a metal telescopic pipe arranged into a concrete cone, which is attached to a concrete manhole that has a concrete slab of large area underneath it. Inlets and outlets are connected to the concrete manhole. The concrete cone, manhole and slab can all be casted on the worksite, or only some of them may be cased on the worksite. The metal telescopic pipe has a diameter that matches the diameter of the concrete cone, and the interface between the concrete cone and the metal pipe telescope is sealed with heat resistant sealing rings. The metal telescopic pipe can be moved within the concrete cone so that the position of the cover of the manhole is matched to the ground level.
[0019] Therefore, whenever a sand storm, desert wind or other form of erosion causes a change in the ground level, a maintenance engineer can quite simply adjust the manhole so that the cover does not protrude or fall short from the ground, but matches the ground level.
[0020] Further, in desert environments the ground is more fluid, as the ground is more sand based than in those regions where it is rock based. Therefore in one aspect of the invention the soil sinks around the manhole just because the sand moves, e.g. underneath the concrete or asphalt that surrounds the manhole. This causes the manhole to protrude and create torsion or shear into the asphalt or concrete surrounding the manhole, as the asphalt or concrete is going down due to the escape of sand underneath and gravity, and the manhole cover is going up relatively, as the concrete cone is unaffected by the movement of the sand. In these situations, the inventive manhole can be easily realigned to have the cover of the manhole match the (now lowered) surface level of the ground in accordance with the invention by moving the telescopic pipe.
[0021] A manhole in accordance with the invention comprises a telescope and a cover, wherein the telescope is arranged to adjust the height of the manhole cover from the ground and is characterized in that,
said telescope is a metal pipe within a concrete cone with at least one seal arranged to seal the interface between the pipe and the concrete cone, said concrete cone is arranged to be attached to the manhole, and said metal pipe telescope is arranged to be moved within said concrete cone vertically to adjust the cover position to ground level.
[0025] A method of constructing a manhole is in accordance with the invention and the said manhole comprises a telescope and a cover, wherein the telescope adjusts the height of the manhole cover from the ground and is characterized by the following steps,
said telescope is a metal pipe and is placed within a concrete cone with at least one seal, sealing the interface between the pipe and the concrete cone, said concrete cone is attached to the manhole, and said metal pipe telescope is moved within said concrete cone vertically to adjust the cover position to ground level.
[0029] If the inventive manhole has a very wide diameter, e.g. larger than 1 m or the manhole is very low in height or shallow in depth, the concrete cone is removed and the telescope is attached to the manhole directly.
[0030] The inventive manhole has numerous advantages over the prior art. The inventive manhole is very resistant to environmental changes such as erosion and temperature changes over long time periods, thereby providing a good return on infrastructure investment by providing sewage service to populations in these environmentally challenged locations. The inventive manhole can be constructed on site from the elements, i.e. its parts can be casted on the worksite, and it can be maintained very easily on its site. If the ground level changes, it will take just five minutes for a maintenance engineer to fix the manhole to match the current ground level by simply moving the telescopic pipe in the manhole.
[0031] In addition and with reference to the aforementioned advantage accruing embodiments, the best mode of the invention is considered to be a steel pipe telescope matched to two circular heat resistant sealing rings in a concrete cone. The concrete cone is attached to a concrete manhole with a heat resistant seal. The position of the concrete cone is stabilised by a large concrete slab at the bottom of the manhole. The cover of the manhole rests on the steel pipe telescope, and when the ground level changes, the steel pipe telescope can simply be repositioned within the concrete cone to match the changed ground level. There is a mechanical system for moving the telescope for example by turning a handle or a lever that makes it possible to adjust the telescope height without actually dismantling the manhole during yearly repairs. All concrete parts can be casted on-site, which means that preferably both the construction and the maintenance of the manhole happen at the installation site in the best mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the following the invention will be described in greater detail with reference to exemplary embodiments in accordance with the accompanying drawings, in which
[0033] FIG. 1 demonstrates an embodiment of a prior art traditional manhole 10 .
[0034] FIG. 2 demonstrates an embodiment of a prior art telescopic manhole 20 .
[0035] FIG. 3 demonstrates an embodiment 30 of a prior art work site casted manhole currently used in desert conditions.
[0036] FIG. 4 demonstrates an embodiment 40 of the inventive manhole.
[0037] FIG. 5 demonstrates an embodiment 50 of the inventive method of constructing the manhole of the invention in desert conditions.
[0038] FIG. 6 demonstrates an embodiment 60 of the inventive manhole where the manhole is low and/or flat or large in diameter.
[0039] Some of the embodiments are described in the dependent claims.
DETAILED DESCRIPTION OF EMBODIMENTS
[0040] FIGS. 1 , 2 and 3 that depicted prior art were already discussed in the background section.
[0041] FIG. 4 displays an inventive manhole 40 with a concrete cone 400 with a telescope pipe 450 for hot climate regions. The on worksite casted manhole 410 has both an outlet 420 and an inlet 421 in some embodiments, but may also have only one or the other of the inlet 421 or outlet 420 .
[0042] The concrete cone 400 , or any other concrete parts of the manhole 40 , may either be precasted at a concrete mill before bringing it to the worksite, or it may be casted at the worksite. When a concrete cone 400 is precasted in a concrete mill, it is faster to assemble the manhole 40 on the worksite. However, casting the concrete cone 400 at the worksite may save transportation costs substantially in some embodiments. In some embodiments the concrete may be made from polymer concrete. This is preferable especially in desert conditions where the salt content of the ground/soil is higher than in rocky ground/soil. In some embodiments polymer and cement are mixed together in different compositions to make up a polymer-cement concrete in accordance with the invention.
[0043] The concrete cone 400 is arranged to host a telescope pipe 450 made of metal, preferably steel in some embodiments of the invention. The concrete cone 400 with the steel telescope 450 is surprisingly suitable for hot climate regions, and is designed to solve the problem of flexible height adjustment on demand for the manhole, in case ground level sinks or rises. The manholes typically become too high while the soil sinks around them. The main benefit of concrete cone 400 with the telescope 450 is that the height of the manhole can be made to follow the ground level, if ground sinks around the manhole.
[0044] During repairs a technician will simply just move the telescope 450 to a new position in the concrete cone 400 to provide a different height for the telescope 450 and the cover 430 . The movement of the telescope 450 can take place preferably vertically with the telescope 450 in the concrete cone 400 . Even with this relative movement of the ground and the manhole, the inventive manhole stays still tightly sealed and does not leak. In some embodiments where the concrete cone is detached or not yet mounted onto the manhole, the movement can of course take place in any direction, depending on how the concrete cone 400 is positioned at that time.
[0045] In the inventive concrete cone 400 the telescope 450 material is chosen for the hot climate, and also the joining of the concrete cone 400 to the on worksite casted manhole 410 is different, and in some embodiments utilizes a heat resistant seal 462 , which is e.g. circumferential along the entire interface of the concrete cone 400 and the on worksite casted manhole 410 . Also, in some embodiments it is preferable to have the bottom slabs of the manholes, i.e. the concrete slab 470 casted on the worksite in accordance with the invention, which saves transportation effort and cost. In other embodiments of the invention the concrete slab 470 may be precasted at a concrete mill for quick installation at the worksite.
[0046] The concrete cones 400 with steel telescopes 450 can be manufactured in concrete mills in some embodiments, but also on the worksite in other embodiments. The cover 430 is typically made of solid iron, and is a rainwater cover, in some embodiments of the invention. The concrete cone 400 is interfaced to the metal telescope 450 with two O-ring seals 460 , 461 which are preferably heat resistant in accordance with the invention in some embodiments. Other types of seals may also be used in accordance with the invention.
[0047] The telescope 450 is used to match the cover 430 level to the ground level and thereby establish the goals of the invention. In one preferred embodiment there is a mechanical system 480 for adjusting the position of the metal pipe telescope 450 within the concrete cone 400 , for example by turning a lever or handle mechanically. This way the technician can adjust the position of the metal pipe telescope and the cover anytime he wants, simply by using the mechanical system 480 , and there is no need to dismantle any part of the manhole or use complicated tools to move the metal pipe telescope 450 . For example, a chain and a lever and/or a gearwheel, gear, cogwheel and/or a cog with a lever or handle can be utilized to transmit the mechanical energy provided by the technician to move the metal pipe telescope in some embodiments of the invention. For example in one embodiment, the technician rotates a handle, which rotates a gearwheel, which pulls or pushes a chain or a rope or a structure on the metal pipe telescope 450 , thereby moving the telescope 450 within the concrete cone 400 up or down.
[0048] In some embodiments of the invention the metal pipe telescope 450 is coupled to the surrounding tarmac, asphalt, or other surface material surrounding the manhole cover. As the soil sinks, the surface material will also start to sink, thereby moving the metal pipe telescope 450 , which is coupled to the surface material. This way, there is no need to adjust the metal pipe telescope 450 by a repair technician, because the metal pipe telescope 450 dynamically adjusts its position to the demands of the environment.
[0049] Naturally all aspects of the described manhole system 40 can be combined with the method 50 of constructing the inventive manhole in accordance with the invention.
[0050] Quite clearly any feature or phase of the embodiment 40 may be readily combined with any feature or phase of any of the subsequent embodiments 50 and 60.
[0051] FIG. 5 shows the method of constructing the inventive manhole as a flow diagram. The concrete parts needed in the construction, for example the concrete cone 400 , or any other concrete parts of the manhole 40 , may either be precasted at a concrete mill before bringing it to the worksite, or it may be casted at the worksite. When a concrete cone 400 is precasted in a concrete mill, it is faster to assemble the manhole 40 on the worksite. However, casting the concrete cone 400 at the worksite may save transportation costs substantially in some embodiments. In some embodiments the concrete may be made from polymer concrete. This is preferable especially in desert conditions where the salt content of the ground/soil is higher than in rocky ground/soil. In some embodiments polymer and cement are mixed together in different compositions to make up a polymer-cement concrete in accordance with the invention.
[0052] In phase 500 the metal pipe telescope 450 is placed into the concrete cone 400 that forms the throat of the manhole. The sealing between the concrete cone 400 and the metal pipe telescope is made tight enough that the metal pipe does not move unless considerable external force is applied to it, (e.g. a man pushing on it very hard.) This is to make sure that the pipe does not mechanically drift due to gravity over long time periods. The heat resistant seals 460 , 461 are applied and adjusted so that the interface between the concrete cone and the metal pipe is established in this way in phase 500 .
[0053] In phase 510 the concrete cone 400 is attached to the manhole 410 . If the concrete cone is precasted, it is simply placed over the manhole, mason over the manhole, or attached with the sealing element 462 , which is designed to make the interface between the concrete cone 400 and the manhole 410 water- and soil-proof.
[0054] In phase 520 the metal pipe telescope position is adjusted so that the cover of the manhole is at the same level to the ground. This is achieved by just mechanically moving the metal pipe telescope to a new position. In some embodiments of the invention the metal pipe telescope 450 is attached with screws and/or bolts to the concrete cone 400 or some other adhesive structure or method that is easy to dismantle or detach during the time of repairs when the telescope needs to be moved.
[0055] In some embodiments of the invention in phase 520 the metal pipe telescope 450 is coupled to the surrounding tarmac, asphalt, or other surface material surrounding the manhole cover. As the soil sinks, the surface material will also start to sink, thereby moving the metal pipe telescope 450 , which is coupled to the surface material. This way, there is no need to adjust the metal pipe telescope 450 by a repair technician, because the metal pipe telescope 450 dynamically adjusts its position to the demands of the environment.
[0056] Quite clearly any feature or phase of the embodiment 50 may be readily combined with any feature or phase of any of the other embodiments 40 and 60.
[0057] FIG. 6 shows an embodiment 60 of a low or a wide manhole, where there is no need for a concrete cone. This embodiment is typically used in situations where the diameter of the manhole is more than one meter, or the manhole is so low that the concrete cone does not fit into the manhole. The telescope pipe 650 is attached to a manhole 610 as shown in FIG. 6 . The telescope pipe 650 is preferably a metal pipe telescope, for example a steel pipe telescope. The seals 661 , 662 are typically O-ring seals, and are also arranged to lubricate and/or reduce friction similarly to ball bearings between the manhole 610 and the telescope pipe 650 when the telescope pipe is being moved. The seal 660 is typically a slightly larger seal, for example 2 cm*2 cm in size. The purpose of the seal 660 is specifically to block the entry of soil or water into the manhole 610 .
[0058] Quite clearly any feature or phase of the embodiment 50 may be readily combined with any feature or phase of any of the other embodiments 40 and 60.
[0059] The invention has been explained above with reference to the aforementioned embodiments and several commercial and industrial advantages have been demonstrated. The methods and arrangements of the invention allow the manhole to be very resistant to environmental changes such as erosion and temperature changes over long time periods, thereby providing a good return on infrastructure investment by providing sewage service to populations in environmentally challenged locations, such as desert locations. The inventive manhole can be constructed on site from the elements, i.e. its parts can be casted on the worksite, and it can be maintained very easily on its site. If the ground level changes, it will take just five minutes for a maintenance engineer to fix the manhole to match the current ground level by simply moving the telescopic metal pipe in the manhole, preferably with the mechanical system 480 , thus avoiding the need to dismantle any part from the manhole.
[0060] Naturally all aspects of the described method 50 of constructing the inventive manhole can be combined with the inventive manhole 40 in accordance with the invention.
[0061] The invention has been explained above with reference to the aforementioned embodiments. However, it is clear that the invention is not only restricted to these embodiments, but comprises all possible embodiments within the spirit and scope of the inventive thought and the following patent claims.
REFERENCES
[0000]
JP2000291034A, Ishikawa Takashi, NIPPON MANHOOLE KOGYO KK, 2000 | A manhole ( 40 ) for desert environments where temperatures can be very high and environmental conditions such as erosion exert different challenges on sewage infrastructure, the manhole including a steel pipe telescope ( 450 ) matched to two circular heat resistant sealing rings ( 460, 461 ) in a concrete cone ( 400 ). The concrete cone is attached to a concrete manhole ( 410 ) with a heat resistant seal ( 462 ). The position of the concrete cone is stabilised by a large concrete slab ( 470 ) at the bottom of the manhole. The cover ( 430 ) of the manhole rests on the steel pipe telescope ( 450 ), and when the ground level changes, the steel pipe telescope can simply be repositioned within the concrete cone to match the changed ground level. All concrete parts ( 400, 410, 470 ) can be casted on-site, which means that preferably both the construction and the maintenance of the manhole happen at the installation site. |
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TECHNICAL FIELD
[0001] The present invention is related to devices for the spacing of structural elements for reinforcing concrete, of the type with disc form where the structural element is located inside and throughout the central axis of the device, and in special, to one of such devices in which the insertion of the structural element is made by a radial opening that goes from the center of the device to one of its ends, with elements to hold and close of the two parts once the structural element in the central axis has been inserted, so that it forms an element or closed circular device, that maintains the steel of reinforcement centered.
BACKGROUND OF THE INVENTION
[0002] In the prior art, devices are described that have functions of separation between constructive elements or between them and some limiting surface. A special case is that to which the present invention goes, where a device serves to distance to a structural element of the walls or surfaces of containment the concrete. Some examples of the developments that are at the moment in the prior art, are described briefly next and must be taken as reference.
[0003] Gavin, in U.S. Pat. No. 5,347,787 (Gavin, 1994) describes a device molded in rigid plastic, as a single piece, essentially circular formed, used in concrete constructions as spacer element in the reinforcement bar; it consists of two sections connected in one end to a hinge, and held by a pawl in the other end. The bar subjects in the center of the wheel by means of a pair of seats, located one in each section of the wheel. A column together with one of the sections between the seats and the hinge avoids that the bar slipping.
[0004] In U.S. Pat. No. 5,542,785 (Cloud, 1996) it is described a spacer mounted on a lateral bar of a reinforcing cage the spacer includes a pair of wheel members adjustable between themselves—in a rotatable relation, mounted on one of the cage's bars to form the spacer. As the reinforcement cage is coupled and turns along the lateral wall of the well. Coupling with the wall of the drilled well, centers the cage in the drilled well and maintains it in centered position while the well is poured.
[0005] In U.S. Pat. No. 6,385,938 (Gavin, 2002) it is described how a pair of curved arms are attached to a body to form an annular seat to support a first diameter of a bar; there is a slit trough the external diameter of the body, which forms a radial entrance path towards the seat; the seat offers a spring movement towards the bar.
[0006] In other fields, specifically in that of the elongated elements supports, some documents are found describing interesting developments in the way to fasten circular cross-section elements.
[0007] In U.S. Pat. No. 5,118,215 (Freier, 1992) it is described a fastener for tube or duct which includes a plated formed base, a pair of arched segments, two rotatable supports connecting the two segments with the base in an intermediate point in respect of the ends, to divide the segments of a belt in one peripheral internal part and one peripheral external part; serrated tongues coupling between themselves to close with the peripheral ends of the belt, to fit them around the duct or tube. The closing tongues in the external peripheral part of one of the segments, cover a plurality of external teeth and the closing tongues in the external peripheral part of the other segment cover a plurality of internal teeth, in a way that when the closing tongues fit around the duct or tube, the belts are symmetrical with the tube or duct axis supported.
[0008] In U.S. Pat. No. 4,214,351 (Wenk, 1980) it is described a staple which securely supports an object to another, as for support a tubing or similar elements with a flexible strap; includes an annular strap with an open end having a pair of members attachable one to another and opposite, located in the open ends. One of the attachable members generally includes a teethed jaw and an internal arm radially spaced defining a entrance. There are a pair of supporting arms located radially between the arms at the end of the jaw and opposite to the entrance.
[0009] Application and use of the elements as described in the prior art patents, and subject matter of this invention, date back long time ago, once traditionally this type of circular spacers for foundation piles or walls, or for certain types of walls, are used to be made in one piece, pouring concrete or some melted plastic materials in olds designed ad hoc and habilitated in situ.
[0010] Function of this type of accessories has been always to place one of them in one of the circular bars or “brace support”, perpendicular to the bars that constitute the main steel and located longitudinally in the cage or reinforced steel, in a way for the disc rotate when the structure is introduced into the perforation or form, and it can couple with the external wall of the excavated well, in order to the spacer disc center the cage within the excavated well and maintain it in such centered position while the well is poured.
BRIEF DESCRIPTION OF THE INVENTION
[0011] The device subject matter of this invention is an spacer or separator element essentially in a disc form, with a hole or central axis that when it is closed forms a ring or open cylinder whose walls conforms to the geometry of an structural elongated member passing through it; preferably with circular cross-section although it can have any other geometry.
[0012] Function of the device of the invention is to separate the structural element in a determined distance to achieve a cover or concrete layer equal to the radial distance between the central axis and the surface of the external ring of the device, or from any other object such as the surface or wall of the perforation or form.
[0013] Different to other devices in the prior art, the device of the invention is made in one single piece, injection molded from a plastic resin such as but not limited to high density polyethylene (HDP), and it is formed by two semicircles joined in one of their common ends taking advantage of the properties of the raw material, by means of a flexible integration that interacts similar to a hinge; this one-piece design offers a higher stability and strength as well as an easier installation, with savings on labor and costs because it has up to 20% less raw materials, permits the separation and closing of the opposite ends of the semicircles, which have reception elements that permit their fixation or embrace the structural element when it is introduced through said opening to locate on the central axis of the device, on the reception elements preferably formed as to the structural element profile and located en the central zone of the device; both semicircles are closed forming a ring or shaft pillow on the structural element and they are fixed in position by means of attachment complementary elements disposed on both straight sides of the slit, producing the final disc shaped form to the device. The device of the invention has as a important feature that when it is closed, at the central axis, cylinder or shaft pillow, it does not fasten the steel, but it can rotate around the structural element as an axis; this freedom to rotate permits to the device to displace along the walls of any type of direct perforations in the soil, some of them without even walls or surfaces, so when the pile or wall is being introduced in the perforation or form, it maintains the metallic structure centered within the perforation, correctly locating the structure and assuring a minimal required concrete coating.
SUMMARY OF THE INVENTION
[0014] Regarding the problems found in this technical field, it is necessary to achieve a development with the following objectives:
[0015] It is an object of this invention to provide a device for spacing of a elongated element such as a reinforcement bar or structural element, from a reference surface such as the surface of a perforation or that of the form, or that of the adjacent wall designated to retain concrete; said device being made in one-piece, preferably configured with disc or ring shape, wherein the structural element is located inside a elongated ring or interior shaft pillow at the center of the device, and the distance to the reference surface is determined by the radial distance from the center towards the external surface of an external disc or ring.
[0016] It is another object of this invention that the spacer device contains a series of elements to coupling of the two sections that conform it, that provide high stability to the device once it is closed, avoiding deformation and sliding of the coupling sections, assuring uniformity in the longitude of the distance between the structural element and the surface of reference when the device is in use.
[0017] It is yet another object of this invention that the spacer device is easy to integrate to a reinforcement structure, when said device is incorporated on the structural element, passing it through a radial opening to the device and closing the device around the structural element; as well as to center or locate the whole structure when it is installed or introduced in the perforation to attain predetermined concrete coatings on said structural element.
[0018] It is a additional objective of this invention that the spacer device has a plurality of holes between an interior support ring for the structural element and an exterior ring, permitting the pass of concrete and aggregates through said holes.
[0019] It is another further object of this invention to provide a spacer device for structural element with respect to a reference surface, with an incremented resistance with respect to other devices on the art, because the gradual increment of width of the device from the external ring towards the internal ring, where it reaches the maximum width.
[0020] Other objects and advantages will be evident for a person skilled in the art, in view of the description and illustrative drawings following.
BRIEF DESCRIPTION OF FIGURES
[0021] In order to have a better comprehension of the description of this invention, it must be read jointly with the figures annexed, which illustrates a preferred embodiment on the invention and where similar elements maintain the same numerical reference in all of them.
[0022] FIG. 1 is a upper plain view of a first embodiment of the disc of the invention, in a closed or use position, showing its constitutive elements,
[0023] FIG. 2 is a simple perspective view of the first embodiment of the disc of the invention in its position on no-use or open,
[0024] FIG. 3 is a simple perspective view of the first embodiment of the disc of the invention in its position of use or closed,
[0025] FIG. 4 is a upper plain view of a second embodiment of the disc of the invention, in position of no-use or open, showing its constitutive elements,
[0026] FIG. 5 is a lateral view of the second embodiment of the disc of the invention in its no-use or open position, from the entrance entrance
[0027] FIG. 6 is a lateral view of the second embodiment of the disc of the invention in its no-use or open position, taken from the opposite side to the entrance, i. e. from the union flexible zone,
[0028] FIG. 7 is a simple perspective view of the second embodiment of the disc of the invention in its no-use or open position,
[0029] FIG. 8 is a upper plane view of a third embodiment of the disc of the invention, with external protrusions diminishing the contact points,
[0030] FIG. 9 is a perspective view of the device of the invention, in its use position.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Following is a more detailed description of the invention, taking as reference the annexed figures which pretend to be illustrative of the features of the invention, and which must no to be considered limitative of the different modifications that can be obvious to a person skilled in the art, in view of this description.
[0032] Referring the FIG. 1 , showing a first embodiment of a device incorporating the features of this invention, it is view that the device ( 100 ) is constituted by an external ring ( 110 ) essentially shaped as a right cylinder, an internal ring ( 120 ) essentially shaped as a right cylinder too, located concentrically with respect to the external ring ( 110 ) and it is maintained in this concentric relation by means of a plurality of union elements ( 180 ) being essentially fasteners harpoon shaped, which trap between them, with constant width, going from the external face of the internal ring ( 120 ) to the internal face of the external ring ( 110 ).
[0033] The set of external ring ( 110 ), internal ring ( 120 ) and the plurality of union elements, determine a set of holes ( 160 ) whose geometric configuration is determined basically by the walls of the union elements ( 180 ), the external face of the internal ring ( 120 ) and the internal face of the external ring ( 110 ), but it can be altered adding a reinforcement surface ( 190 ), plain and transversal to the semicircles.
[0034] The set ( 100 ) is divided into two sections essentially semicircular by a diametrical sectional line ( 130 ) dividing the internal ring ( 120 ) totally, the external ring ( 110 ) exclusively in one end of the diameter and the reinforcement surface ( 190 ) on said diameter, maintaining both semicircular sections joined together by an area of uncut material in the external ring ( 110 ), a flexible zone ( 170 ) that functions as a hinge to permit the opening and closing of said semicircular sections, as shown in FIG. 2 , where it can be observed that the edges of the diametrical sectional line ( 130 ) form a entrance or opening towards the internal ring ( 120 ). Hereinafter the numeral ( 130 ) will be used to refer to the sectional line ( 130 ) as well as the entrance determined by it.
[0035] It is observed from the FIGS. 1 to 3 that the interior FACE of the external ring ( 110 ) defining the flexible zone ( 170 ) lacks of a reinforcing surface ( 160 ) to guarantee precisely the flexibility of such zone.
[0036] Device ( 100 ) is then designed to an elongated structural element such as a metallic rod or similar reinforcement element, preferably with but not limited to circular cross-section, can pass through the entrance ( 130 ) when the device is in open or not-use position, up to the hollow space defined by the internal ring ( 120 ); once the elongated element is in its site, the device is closed by blending the flexible zone ( 170 ) as for the opposite ends of the entrance ( 130 ) are proximal.
[0037] Once the device is in its site, it is evident that the structural element occupy just the center of that, and said structural element will be always a distance at least equal to the longitude between its external surface and that of the external ring ( 110 ), with respect to any surface of reference in contact with said external face of the external ring ( 110 ). Because it is not necessary that the elongated element has a diametrical measure such that fits in the internal ring ( 120 ), the device maintains a rotate relation around its own axis, that coincide with the longitudinal axis of the elongated element inside; this feature is very useful even when, i. e. a metallic structure made by a plurality of structural elements disposed like a mesh must slide in a perforation such as a well drilled directly in the soil, wherein a plurality of devices as that of the invention, are distributed in the rebar cage or reinforcement cage or metal reinforcement structure in such a way that they function as casters to facilitate the displacement of the set, and once this is in its final position, guarantee that the structural elements associated are at a predefined distance from the walls of said well.
[0038] To assure that the device is maintained in its position with respect to the elongated element or rod located in its center, the device has a plurality of coupling and fastening means, said coupling means being constituted by a first hook engage able to a second hook (receptor) located preferably in the following way:
1. two of the first hooks ( 150 ) are formed from the same material as the device, as prolongations of the ends of the semicircle that will form the internal ring ( 120 ), being located proximal to one of the most external edges of the cylinder defined by said internal ring ( 120 ), and being opposite between them (front to front); 2. two of the second hooks ( 151 ) (receptors) are formed from the same material as the device, as prolongations of the ends of the semicircle that will form the internal ring ( 120 ), located in the ends of the semicircular section opposite to the first hooks, and in a operable relation with those; coupling means ( 150 ) and ( 151 ) occupy just the most external portion proximal to the edges of the cylinder defined by the internal ring ( 120 ), and it is apparent from FIGS. 1 to 3 in symmetrical relation; the receptor hooks ( 151 ) are limited towards the mean part of the external surface of the cylinder determined by the internal ring ( 120 ), by the body of the union elements ( 180 ) corresponding to the position of said receptor hooks ( 151 ) as for said union elements ( 180 ) determine a stop for the respective union elements ( 180 ). Similarly, in the other face of the device are distinguished: 3. two of the first hooks ( 150 ) are formed from the same material as the device, as prolongations of the ends of the semicircle that will form the internal ring ( 120 ), being located proximal to one of the most external edges of the cylinder defined by said internal ring ( 120 ), and being opposite between them (front to front); 4. two of the second hooks ( 151 ) (receptors) are formed from the same material as the device, as prolongations of the ends of the semicircle that will form the internal ring ( 120 ), located in the ends of the semicircular section opposite to the first hooks, and in a operable relation with those; it is apparent from FIGS. 1 to 3 that the hooks ( 150 ) of the second face are located in the same semicircular section that the receptor hooks ( 151 ) of the first face and vice versa. In such a way, not any of the pairs of hooks ( 150 ), ( 151 ) conforming the coupling means, can make a displacement in the longitudinal direction relative to the rotation axis of the device in any direction; moreover, because the symmetric disposition in two planes, practically it is impossible that the coupling means are unnoticeable detached and they just can be detached applying a force with magnitude and direction appropriate on the four pairs of hooks simultaneously. All of this offers the set a superior stability in its configuration with respect to devices known in the art.
[0043] In a second embodiment, shown in FIGS. 4 to 7 , it is observed that the device ( 200 ) is made in the same way that in the first embodiment illustrated in FIGS. 1 to 3 , with an external ring ( 210 ) essentially right-cylinder shaped, an internal ring ( 220 ) essentially right-cylinder shaped too, located concentrically in relation to the external ring ( 210 ), maintained in such concentric relation by means of a plurality of union elements ( 280 ) essentially formed by constant width strips going from the external face of the internal ring ( 220 ) towards the internal face of the external ring ( 210 ). However, in this embodiment, the width of the union elements ( 280 ) increases from the external ring ( 210 ) up to its maximum in the contact line with the internal ring ( 220 ); this increment in width in the vicinity of the elongated element increase the stability of the device in the structure once it is coupled to said elongated element.
[0044] The set of external ring ( 210 ), internal ring ( 220 ) and the plurality of union elements, determine a set of holes ( 260 ), whose final geometrical configuration is basically determined by the walls of the union elements ( 280 ), the external face of the internal ring ( 220 ) and the internal face of the external ring ( 210 ), but it can be altered by adding a reinforcement surface ( 290 ), as described before in relation to the first embodiment. In the illustrated example said holes ( 260 ) are preferably circular, except those respective to the opening or entrance ( 230 ). In the illustrated embodiment, a parallel rib is added to the section ( 290 ) or, in the same direction that semicircles, obtaining higher rigidity for superior diameter models.
[0045] The external ring has a flexible zone ( 270 ) too, permitting a hinged movement for both semicircular sections, which when the device is in use position, close around the elongated element to the device operates as spacer.
[0046] It is appreciated in FIGS. 4 to 7 that the internal face of the external ring ( 210 ) defining the flexible zone ( 270 ), lacks a reinforcement surface ( 260 ) to guarantee precisely the flexibility in that zone.
[0047] Similarly to the first illustrated embodiment, the device of the second embodiment incorporates a plurality of coupling elements ( 250 ), ( 251 ), cooperative one to another and symmetrically disposed in the ends of the semicircles of the internal ring ( 220 ), diametrically as well as with respect to medium plane passing through the device. Coupling elements ( 240 ), ( 241 ) are present too in the opposite ends of the entrance ( 230 ). It must be noted that the symmetry with respect to the medium plane of the device is better shown in FIG. 7 , with respect to the coupling means ( 240 ), ( 241 ) in the external ring ( 210 ) and ( 250 ) and ( 251 ) in the internal ring ( 220 ).
[0048] In FIG. 8 it is illustrated a third embodiment ( 300 ) of the device subject matter of this invention. In the figure, the external surface of the external ring ( 310 ) is covered by a plurality of protrusions towards the exterior of the device ( 300 ), equidistant between them, so as to the contact with the surface of reference is limited to the end of such protrusions. This is useful in those cases in which the concrete finished surface requires a minimal evidence of the spacer's material. Protrusions can have practically any form but they are preferred those profiles in which the contact area with the reference surface be a minimum, i. e. truncated triangles (trapezoids) or rectangular or oblong protrusions.
[0049] Finally, in FIG. 9 it is show a scheme on how to dispose the device of this invention in its use position, illustrating on the base of the first embodiment of this invention, in which just a few elements are numerically referred as in the previous figures, it seems clearly in the figure that the elongated structural element is located in the central ring hole, without touching its walls in a tight mode, so the device can freely rotate around said elongated structural element, maintaining a distance with the external wall of the external ring, practically constant, further permitting that a complete structure can slide on the walls of, i. e. a form or the walls of a well, using the spacers of the invention as casters, ensuring the final position of said structure at a predetermined distance from the surface of reference.
[0050] Even that the qualities and advantages of this invention have been described on the basis of the illustrations of three preferred embodiments, it should be understood that those modifications a person skilled in the art could realize in the illustrated embodiments, will be within the scope of the invention that must be understood in view of the following claims. | The invention relates to a device for maintaining structural elements at a distance from one another for the purpose of reinforcing concrete, said device taking the form of a disk which is formed from a single piece, preferably by means of injection moulding, using a plastic resin such as high-density polyethylene. According to the invention, the structural element is positioned along the central axis of the device and the element is inserted through a reinforced radial hole which extends from the centre of the device to one of the ends thereof, said two parts being fixed with corresponding fixing elements following the insertion of the structural element. The inventive device enables greater concrete continuity, with a larger available space for the concrete, thereby reducing the interface coefficient. The design of the central ring confers increased strength and stability in order to maintain the structural reinforcement inside same and, consequently, ensure a good performance, by reducing the mechanical advantage of the perimeter against the central axis. In addition, savings are made in terms of resources since the installation and reinforcement time is reduced |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] 1. Technical Field
[0004] The present invention generally relates to concrete structures and the methods for forming the same. More particularly, the present invention relates to concrete structures and forming methods that enhance the replenishment of underground water in aquifers.
[0005] 2. Description of Related Art
[0006] As is generally understood, a common source of fresh water for irrigation, human consumption, and other uses is groundwater. Usable groundwater is contained in aquifers, which are subterranean layers of permeable material such as sand and gravel that channel the flow of the groundwater. Other forms of groundwater include soil moisture, frozen soil, immobile water in low permeability bedrock, and deep geothermal water. Among the methods utilized to extract groundwater include drilling wells down to the water table, as well as removing it from springs where an aquifer intersects with the curvature of the surface of the earth.
[0007] While groundwater extraction methods are well known, much consideration has not been given to the replenishment thereof. It is not surprising that many aquifers are being overexploited, significantly depleting the supply. The most typical method of aquifer replenishment is through natural means, where precipitation on the land surface is absorbed into the soil and filtered through the earth before reaching the aquifer. However, in arid and semi-arid regions, the supply cannot be renewed as rapidly as it is being withdrawn because the natural process takes years, even centuries, to complete. It is well understood that in its equilibrium state, groundwater in aquifers support some of the weight of the overlying sediments. When aquifers are depressurized or depleted, the overall capacity is decreased, and subsidence may occur. In fact, such subsidence that occurs because of depleted aquifers is partially the reason why some cities, such as New Orleans in the state of Louisiana in the United States, are below sea level. It is well recognized that such low-lying and subsided areas have many attendant public safety and welfare problems, particularly when flooding or other like natural disasters occur.
[0008] The problem of rapid depletion is particularly compounded in developed areas such as cities and towns, where roads, buildings, and other man-made structures block the natural absorption of precipitation through permeable soil. Generally, building and paving materials such as concrete and asphalt are not porous, in that water cannot move through the material and be absorbed into the soil. In fact, porous material would be unsuitable for construction of buildings, where internal moisture is desirably kept to a minimum. Thus, these developed areas are typically engineered with storm drainage systems whereby precipitation is channeled to a central location, marginally cleaned of debris, bacteria, and other elements harmful to the environment which were picked up along the drainage path, and carried out to the sea. Instead of allowing precipitation to absorb into the ground, modern developed areas transport almost all surface water elsewhere.
[0009] One of the methods for replenishing aquifers is described in U.S. Pat. No. 6,811,353 to Madison, which teaches a valve assembly for attachment to aquifer replenishment pipes. However, the use of such replenishment systems required frequent human intervention. Furthermore, in order for the water in the aquifer to remain clean, existing clean water had to be pumped in. Additionally, the volume of water that was able to be carried to these re-charging locations was limited, thus limiting the replenishment capacity.
[0010] Changes to paving materials have also been considered. As is well known in the art, concrete is a composite material made from aggregate and a cement binder, the most common form of concrete being Portland cement concrete. The mixture is fluid in form before curing, and after pouring, the cement begins to hydrate and gluing the other components together, resulting in a relatively impermeable stone-like material. By eliminating the aggregate of gravel and sand, the concrete formed miniature holes upon curing, resulting in porous concrete. This form of concrete, while allowing limited amounts of water to pass through, was unsuitable for paving purposes because of its reduced strength. Additionally, the aforementioned drainage systems were still required because the porous concrete was unable to handle all of the water in a typical rainfall. Structures designed to increase the strength while maintaining porosity have been attempted, whereby reinforcement in the form of rods, rebar, and/or fibers were incorporated into the structure. Nevertheless, the strength of the structure was insufficient because of the reduced internal bonding force of the concrete due to the lack of an aggregate.
[0011] Therefore, there is a need in the art for an aquifer replenishment system for collecting precipitation and absorbing the same into the pavement and the soil in the immediate vicinity. There is also a need for aquifer replenishment system that are capable of withstanding environmental stresses such as changes in temperature, as well as structural stresses such as those associated with vehicle travel. Furthermore, there is a need for an aquifer replenishment system that can be retrofitted into existing pavement structures.
BRIEF SUMMARY
[0012] In light of the foregoing problems and limitations, the present invention was conceived. In accordance with one embodiment of the present invention, an aquifer replenishing pavement is provided, which lies above soil having a sand lens above an aquifer, and a clay layer above the sand lens. The structure is comprised of: an aggregate leach field abutting the subgrade (typically comprised of clay); and a layer of suitable surface paving material such as reinforced concrete or asphalt, abutting the aggregate leach field. Additionally, one or more surface drains extend through the concrete layer, and one or more aggregate drains extend from the aggregate leach field to the sand lens. The surface drains have a higher porosity than the paving layer, and is filled with rocks. According to another aspect of the invention, leach lines having a higher porosity than the surrounding leach field are provided. The surface drains are in direct fluid communication with the leach lines, and the leach lines are in direct fluid communication with the aggregate drains.
[0013] An aquifer replenishing concrete paving method is also provided, comprising the steps of: (a) clearing and removing a top soil layer until reaching a clay layer; (b) forming one or more aggregate drains through the clay layer to a sand lens; (c) forming an aggregate leach field above the clay layer; (d) forming a pavement layer above the aggregate leach field; and (e) forming surface drains extending the entire height of the pavement layer. Additionally, forming of the aggregate leach field also includes the step of forming one or more leach lines therein.
[0014] In accordance with another embodiment of the present invention, an aquifer replenishing concrete gutter for use on a road surface with an elevated curb section is provided. The gutter is comprised of a porous concrete section having an exposed top surface in a co-planar relationship with the road surface, supported by the elevated curb section and the side surface of the road. According to another aspect of the present invention, a cut-off wall is provided to further support the porous concrete section. A bore extending from the porous concrete down to the aquifer is also provided, and is filled with rocks.
[0015] An aquifer replenishing concrete gutter formation method is provided, comprising the steps of: (a) forming a gutter section between an elevated curb section and a road surface; (b) boring a hole in the gutter section into the aquifer; (c) filling the hole with rocks; (d) filling the gutter section with porous concrete; and (e) curing the porous concrete. In accordance with another aspect of the present invention, step (a) includes removing a section of the road surface adjacent to the elevated curb section. Finally, step (a) also includes forming a cut off wall extending downwards from the road surface and offset from the elevated curb section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
[0017] FIG. 1 is a cross-sectional view of the surface of the earth;
[0018] FIG. 2 is a perspective cross-sectional view of a road surface aquifer replenishment system in accordance with an aspect of the present invention;
[0019] FIG. 3 is a cross-sectional view of a gutter aquifer replenishment system in accordance with an aspect of the present invention;
[0020] FIG. 4 is a cross-sectional view of a conventional road;
[0021] FIG. 5 is a cross-sectional view of a conventional road excavated for retrofitting an aquifer replenishment system in accordance with an aspect of the present invention;
[0022] FIG. 6 is a cross-sectional view of conventional road after excavation and formation of a cut-off wall in accordance with an aspect of the present invention; and
[0023] FIG. 7 is a cross sectional view of a road after excavating a bore reaching an aquifer and filling the same with rocks, and depicts the pouring of concrete into the gutter section in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
[0024] The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. It is to be understood, however, that the same or equivalent functions may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0025] With reference now to FIG. 1 , a cross sectional view of the earth's surface is shown. Atmosphere 30 is shown with clouds 32 releasing precipitation 34 , falling towards the ground 50 . As is well understood, ground 50 is comprised of top soil layer 52 . Underneath top soil layer 52 is clay layer 54 , and underneath that is sand lens 56 . Aquifer 60 is a layer of water, and can exist in permeable rock, permeable mixtures of gravel, and/or sand, or fractured rock 58 . Precipitation 34 falls on top soil layer 52 , and is gradually filtered of impurities by the varying layers of sand, soil, rocks, gravel, and clay as it moves through the same by gravitational force, eventually reaching aquifer 60 . In the context of the above natural features, the present invention will be described.
[0026] Referring now to FIG. 2 , a first embodiment of the present inventive concrete paving system 100 is shown. Situated above clay layer 54 is an aggregate leach field 82 comprised of sand and gravel particles. Above aggregate leach field 82 is a pavement layer 80 , which by way of example only and not of limitation, is concrete composed of Portland cement and an aggregate. Pavement layer 80 may be reinforced with any reinforcement structures known in the art such as rebar, rods and so forth for increased strength. Preferably, the reinforcement structure has the same coefficient of thermal expansion as the pavement material, for example, steel, where concrete is utilized, to prevent internal stresses in increased temperature environments. By way of example only and not of limitation, pavement layer 80 has reinforcement bars 90 . It will be appreciated by one of ordinary skill in the art that the pavement layer 80 need not be limited to architectural concrete, and asphalt and other pavement materials may be readily substituted without departing from the scope of the present invention.
[0027] Extending from the top surface to the bottom surface of pavement layer 80 are one or more surface drains 84 . Due to the fact that non-porous concrete, that is, concrete having aggregate mixed into the cement, permits little water to seep through, surface drains 84 expedite the water flow into aggregate leach field 82 . Typically, by way of example only and not of limitation, surface drains 84 are filled with rocks to prevent large debris such as leaves and trash from clogging the same.
[0028] Within aggregate leach field 82 are one or more leach lines 86 , which assist the transfer of fluids arriving through surface drains 84 . By way of example only, leach lines 86 are in direct fluid communication with surface drains 84 . Leach lines 86 have a higher porosity than the surrounding leach field 82 to enable faster transmission of fluids. Leach field 82 is also capable of absorbing water, and in fact, certain amounts are absorbed from leach lines 86 . Additional water flowing from surface drains 84 is also absorbed into leach field 82 . In this fashion, water is distributed across the entire surface area of leach field 82 , resulting in greater replenishment of the aquifer. A person of ordinary skill in the art will recognize that the leach field 82 acts as a filter by gradually removing particulates from precipitation, and resulting in cleaner water in the aquifer.
[0029] As is well understood in the art, clay has a lower porosity as compared to an aggregate of, for example, sand, gravel, or soil. In order to expedite the transmission of water into the aquifer, aggregate drains 88 extend from aggregate leach field 82 , through clay layer 54 , and into sand lens 56 . Therefore, a minimal amount of water is absorbed into the clay layer 54 , and the replenishment process is expedited.
[0030] After the water flows from leach field 82 into sand lens 56 via aggregate drains 88 , it is dispersed throughout sand lens 56 , trickling through to the aquifers in the vicinity. The water in the aquifer is thus replenished through largely natural means, namely the filtration process involved in absorbing precipitation through aggregate leach field 82 and sand lens 56 , despite the existence of a non-porous material such as concrete overlying the ground surface in the form of pavement layer 80 .
[0031] The aquifer replenishment system as described above is generally formed over previously undeveloped land, or any land that has been excavated to a clay layer 54 . Thus, surfaces that have been previously paved by other means must first be removed so that the natural water absorption mechanisms of the earth are exposed. After this has been completed, aggregate drains 88 are drilled from the exposed clay surface 54 into sand lens 56 . After filling the aggregate drains 88 with aggregate, a generally planar aggregate leach field 82 is formed. Contemporaneously, leach lines 86 are formed, and is encapsulated by the aggregate which constitutes leach field 82 . After leach field 82 is constructed, concrete reinforcements 90 are placed, and uncured concrete is poured to create pavement layer 80 .
[0032] With respect to the formation of surface drains 84 , any conventionally known methods of creating generally cylindrical openings in concrete may be employed. For example, before pouring the uncured concrete, hollow cylinders may be placed and inserted slightly into leach field 82 to prevent the concrete from flowing into the opening. Yet another example is pouring the concrete and forming a continuous layer, and drilling the concrete after curing to form surface drain 84 . It is to be understood that any method of forming surface drain 84 is contemplated as within the scope of the present invention.
[0033] With reference to FIG. 3 , a second embodiment of the aquifer replenishing system 200 is shown, including an elevated curb section 192 , a gutter section 196 , and a road pavement section 190 . Road pavement section 190 is comprised of a pavement surface 195 , which by way of example only and not of limitation, is architectural concrete, asphalt concrete, or any other paving material known in the art, and is supported by base course 194 . Base course 194 is generally comprised of larger grade aggregate, which is spread and compacted to provide a stable base. The aggregate used is typically ¾ inches in size, but can vary between ¾ inches and dust-size.
[0034] In accordance with the present invention, gutter section 196 has a porous concrete gutter 184 in which the top surface thereof is in a substantially co-planar relationship with the top surface of pavement surface 195 . Optionally, porous concrete gutter 184 is supported by base 185 which is composed of similar aggregate material as base course 194 . Furthermore, extending from optional base 185 into aquifer 60 is a rock filled bore 188 . As a person of ordinary skill in the art will recognize, a bore filled with rocks will improve the channeling of water due to its increased porosity as compared with ordinary soil. Optional base 185 and porous concrete gutter 184 is laterally reinforced by cut off walls 183 and elevated curb section 192 . The cut off walls 183 are disposed on opposing sides of the porous concrete gutter 184 and the base 185 between the elevated curve section 192 and the pavement surface 195 . It is expressly contemplated that the cut off walls 183 may be pre-cast or cast in place.
[0035] When precipitation falls upon road pavement section 190 , the water is channeled toward gutter section 196 . Porous concrete gutter 184 permits the precipitation to trickle down to aquifer 60 . When optional base 185 and rock filled bore 188 is in place, there is an additional filter effect supplementing that of the porous concrete gutter 184 . A similar result can be materialized where the water drains from the upper surface of elevated curb section 192 , or precipitation directly falls upon porous concrete gutter 184 . Please note a large surface drain may be used in lieu of the porous concrete gutter.
[0036] This embodiment is particularly beneficial where retrofitting the gutter is a more desirable solution rather than re-paving the entire road surface. In a conventional road pavement as shown in FIG. 4 , pavement surface 195 and base course 194 extend to abut elevated curb section 192 . In preparation for retrofitting gutter section 196 , a section of pavement surface 195 and base course 194 is excavated as shown in FIG. 5 , leaving a hole 197 defined by the exposed surfaces of elevated curb section 192 , base course 194 , and pavement surface 195 . This is followed by the optional step of pouring and curing a cut-off wall 183 as illustrated in FIG. 6 , which, as discussed above, serves to reinforce the gutter section 196 . One or more bores 188 are drilled down to aquifer 60 , and filled with rocks, as shown in FIG. 7 . An optional base of aggregate 185 is formed above rock filled bore 188 , and compacted by any one of well recognized techniques in the art. Finally, a volume of porous concrete mixture, that is, a concrete without sand or other aggregate material, is poured and cured, forming porous concrete gutter 184 . While recognizing the disadvantages of using porous concrete, namely, the reduced strength of the resultant structure, a person of ordinary skill in the art will also recognize that gutter section 196 sustains less stress thereupon in normal use as compared to road pavement section 190 .
[0037] The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. | A concrete structure for replenishing an aquifer and a method for constructing the same is provided. The structure is comprised of a pavement layer with surface drains that extend through the pavement layer and into an aggregate leach field. The leach field includes leach lines spanning the leach field. An aggregate drain extends from the leach field into a sand lens. Precipitation which falls upon the structure thus flows through the surface drain, absorbed into the aggregate leach field, and transported to the aggregate drains by way of aggregate leach lines. The water is then absorbed into the sand lens, ultimately replenishing the aquifer. Existing conventional pavement structures are retrofitted by the removal of a section of the pavement, and filling the same with porous concrete. |
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BACKGROUND OF INVENTION
[0001] In the process of rotary drilling a well, drilling fluid, or mud, is circulated down the rotating drill pipe, through the bit, and up the annular space between the pipe and the formation or steel casing, to the surface. The drilling fluid performs different functions such as removal of cuttings from the bottom of the hole to the surface, to suspend cuttings and weighting material when the circulation is interrupted, control subsurface pressure, isolate the fluids from the formation by providing sufficient hydrostatic pressure to prevent the ingress of formation fluids into the wellbore, cool and lubricate the drill string and bit, maximize penetration rate, etc.
[0002] The required functions can be achieved by a wide range of fluids composed of various combinations of solids, liquids and gases and classified according to the constitution of the continuous phase mainly in two groupings: aqueous drilling fluids, and oil-based drilling fluids. In drilling water-sensitive zones such as reactive shales, production formations, or where bottom hole temperature conditions are severe or where corrosion is a major problem, oil-based drilling fluids are preferred.
[0003] Oil-based drilling fluids typically contain oil-soluble surfactants that facilitate the incorporation of water-wet clay or non-clay formation minerals, and hence enable such minerals to be transported to surface equipment for removal from circulation before the fluid returns to the drill pipe and the drill bit. The largest formation particles are rock cuttings, the size typically larger than 0.1 to 0.2 mm, removed by shale-shaker screens at the surface. Smaller particles, typically larger than about 5 μm, will pass through the screens, and must be removed by centrifuge or other means.
[0004] Oil-based drilling fluids have been used for many years, and their application is expected to increase, partly owing to their several advantages over water based drilling fluids, but also owing to their ability to be re-used and recycled, so minimizing their loss and their environmental impact.
[0005] As mentioned above, during drilling, formation particles become incorporated into the drilling fluid. Unless these are removed, they eventually alter the fluid's properties, particularly the Theological parameters, out of the acceptable range. However, formation particles that are less than about 5 to 7 μm in size are more difficult to remove than larger particles. These low gravity solids can build up in a mud system, causing inefficient drilling problems such as drill pipe sticking, increased pipe torque, and other high viscosity issues.
[0006] While low gravity solids may be removed from drilling fluids using mechanical means such as a centrifuge, it has been found that longer run-times are required to remove the colloidal particles, if the low gravity solids can be removed at all. Thus, there is a need for an apparatus that can be used with traditional solids separation equipment to reduce the run-time required to remove low gravity solids. Further, it would be an improvement in the art to have an apparatus that can be utilized both on active drilling projects to facilitate solids control equipment efficiency as well as by mud plants in reclaiming and/or reconditioning mud returned from field operations.
SUMMARY
[0007] In one aspect, the claimed subject matter is generally directed to an apparatus for preparing an oil-based drilling fluid for recovery. The apparatus includes a first static mixer in which the oil-based drilling fluid and a surfactant are mixed. In a second static mixer a flocculant and a base fluid may be mixed. The flocculant mixture is added to the drilling fluid mixture and further mixing occurs through a series of additional mixers. Upon exiting the final mixer, the drilling fluid mixture is prepared to have solids separated therefrom so that the oil-based drilling fluid may be further processed for recovery. A centrifuge may be used to separate solids from the remaining effluent.
[0008] In another illustrated aspect, the claimed subject matter is directed to an apparatus for reclaiming oil-based drilling fluid and recovering valuable weighting agent. The apparatus includes an additional centrifuge to remove the weighting agent prior to the injection of polymer to the oil-based drilling fluid.
[0009] In another illustrated aspect, a method for preparing an oil-based drilling fluid for recovery is claimed. The method includes demulsifying the drilling fluid with a surfactant and preparing a flocculant mixture. The flocculant mixture is then mixed with the drilling fluid mixture. The next step includes separating solids from the drilling fluid mixture and collecting them. Effluent from the separating solids step may be collected for further processing.
[0010] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic of an apparatus for preparing an oil-based drilling fluid for recovery.
[0012] FIG. 2 is a schematic of an alternative embodiment of an apparatus for preparing an oil-based drilling fluid for recovery.
[0013] FIG. 3 is a layout of the apparatus mounted on a skid.
DETAILED DESCRIPTION
[0014] The claimed subject matter relates to an apparatus and method for preparing an oil-based drilling fluid for recovery. The oil-based drilling fluid includes oil, water, and solids in relative proportions consistent with used drilling fluid that has been subjected to preliminary processes to remove large solids from the fluid. The solids remaining in the drilling fluid typically include a percentage of high gravity solids and a percentage of low gravity solids. High gravity solids are those solids that are dense, as in barite or hematite, while low gravity solids are those solids that have a lower density than barite. The oil and water in the used drilling fluid are present in proportionate amounts, the relationship between them often being expressed as an oil-to-water ratio.
[0015] In a first embodiment, shown in FIG. 1 , the apparatus 10 includes a plurality of mixers 12 - 20 that may be mounted to a common skid 22 . Oil-based drilling fluid 24 is pumped from a mud plant 26 to the first mixer 12 . A pump 28 may be used to introduce the drilling fluid 24 to the first mixer 12 with a predetermined pressure and flow rate. A surfactant 32 is pumped into the first mixer 12 from a surfactant tank 34 . The surfactant 32 may be diluted with water 30 from water tank 38 prior to its introduction to the first mixer 12 . A dose pump 36 may be used to introduce the surfactant 32 to the mixer with a predetermined pressure and flow rate. The surfactant 32 acts on the mud solids, improving their hydrophilicity so that the polymer, which is very hydrophilic and added downstream, can flocculate the solids.
[0016] The first mixer 12 preferably is a static shear mixer including an insert (not shown) that provides shear to the fluid passing through the first mixer 12 sufficient to mix the surfactant 32 and the drilling fluid 24 . The surfactant 32 and the drilling fluid 24 are introduced to the first mixer 12 upstream from the insert and exit the mixer 12 as a surfactant treated mud 40 .
[0017] A flocculant polymer 42 is stored in a flocculant storage tank 44 and ma) be mixed with a base fluid 46 , when necessary, to form a flocculant mixture 48 . The dilution of the flocculant polymer 42 with the base fluid 46 can improve the dispersal of the polymeric droplets into the mud. The decision to do this or not is based on the type of dosing equipment, the viscosities of the mud 24 and the flocculant polymer 42 , and the strength to the mixing employed.
[0018] Dosing pumps 50 , 52 may be used to introduce the flocculant 42 and the base fluid 46 , respectively, to the second mixer 14 in predetermined relative quantities. The second mixer 14 preferably is a static shear mixer including an elongated insert to enhance the dispersion of flocculant 42 within the base fluid 46 and to provide turbulence to the flow. The turbulence created by the insert causes the flocculant 42 and the base fluid 48 to form the flocculant mixture 48 .
[0019] The flocculant mixture 48 is mixed with the surfactant treated mud 40 in a third mixer 16 . Like the first mixer 12 , the third mixer 16 preferably is a static mixer including an insert to provide shear to the passing fluids sufficient to mix the fluids together. The addition of flocculant 48 to the surfactant treated mud 40 causes solid material in the surfactant treated mud 40 to coagulate around the flocs. Creating larger solid masses aids in their later removal from the drilling fluid.
[0020] The treated mud 54 is mixed further in additional downstream mixers 18 , 20 . Preferably, a fourth mixer 18 is a dynamic mixer. In the dynamic mixer 18 , the treated mud 54 is subjected to agitation providing additional shearing to facilitate the coagulation of solids and floc. Additional mixers 20 , 21 may be included. The additional mixers 20 , 21 preferably are in-line mixers, providing additional mixing by subjecting the drilling fluid and polymer mixture 54 to shear as in the second mixer 14 discussed earlier. By including a plurality of mixers downstream from the injection of flocculant polymer 48 , the exposure of solids to the flocculant is enhanced prior to directing the treated mud 54 to a separation process.
[0021] Upon exiting the final mixer 21 , the treated mud 54 is a prepared mud mixture 56 ready for further processing to remove the solids from the fluid. The prepared mud mixture 56 may be directed to equipment outside of the skid 22 for additional processing. Such equipment may include a centrifuge 58 to which the prepared mud mixture 56 is directed. The centrifuge 58 includes a bowl that is rotated at a speed sufficient to separate the solids 60 in the prepared mud mixture 56 from the fluid, or effluent 62 . As the solids 60 are discharged from the centrifuge 58 , they may be collected in a cuttings box 64 . Effluent 62 may be released to a fluid storage area 66 , or directed to additional equipment (not shown) for further processing.
[0022] As previously stated, the equipment required to process the drilling fluid 24 prior to its being directed to the centrifuge 58 may be housed on a skid 22 . To consolidate the equipment onto a single skid 22 , attention must be given to the layout of the equipment. In a preferred embodiment, shown in FIG. 3 , water and base oil tanks 38 , 47 are positioned directly above the surfactant and polymer tanks 34 , 44 . The water and base totes 38 , 47 may be placed on rails so that they are movable to an outward position, away from the polymer and surfactant tanks 34 , 44 for refilling.
[0023] Dosing pumps 36 , 39 , 50 , 52 may be positioned on the skid 22 such that the polymer and base oil pumps are directly beside their respective tanks with one pump placed atop another to conserve space. Likewise, the surfactant and water pumps may be stacked to conserve space.
[0024] The flocculant polymer 42 or flocculant mixture 48 added to the drilling fluid enhances removal of the solids 60 by the centrifuge 58 by forming larger solid particles. The polymer droplets have to be well dispersed into the mud to be flocculated, without dissolving the polymer. The droplets remain intact and adhere the solids in the mud together, thus greatly improving the solid-liquid separation efficiency upon centrifugation. In order to derive the most benefit from the polymeric droplets as a flocculant, it is necessary that they be well mixed into the mud, and at an efficacious dose. The amount of flocculant polymer 48 added to the surfactant treated mud 40 should be that sufficient to leave the polymeric droplets homogeneously dispersed throughout the mud 24 to be flocculated.
[0025] A second embodiment of the apparatus 10 ′ is shown in FIG. 2 . In this embodiment, the drilling fluid 24 is pumped from the mud plant 26 into a first centrifuge 70 . The first centrifuge 70 is optimized to recover the weighting agent 72 , such as barite, from the drilling fluid 24 . The weighting agent 72 is discharged from the first centrifuge 70 to a cuttings box 74 or a storage tank 66 ′ to be reintroduced to the recovered drilling fluid 62 ′ discharged from the apparatus 10 ′. Effluent 76 from the first centrifuge 70 is pumped into the first mixer 12 . As previously described, surfactant 32 is injected into the first mixer 12 and the effluent 76 and surfactant 32 are subjected to static shear sufficient to distribute the surfactant through the drilling fluid to form a surfactant treated effluent 40 ′.
[0026] A polymer mixture 48 is made by mixing a flocculant 42 and a base fluid 46 in a mixer 14 , if a base fluid is needed. The polymer mixture 48 is directed to mixer 16 where it is mixed with the surfactant treated effluent 40 ′, as previously described. If a base fluid is not needed, flocculant 42 may be directed to the mixer 16 , in which it is mixed directly with the surfactant treated effluent 40 ′ to form a treated mud 54 ′.
[0027] The treated mud 54 ′ from the mixer 16 is directed through a series of additional mixers 18 , 20 , 21 to ensure there is sufficient mixing to prepare the treated mud 54 ′ for separation and further processing. As previously described, a dynamic mixer 18 and one or more inline mixers 20 , 21 are preferred to ensure sufficient mixing of the flocculant 42 within the surfactant treated effluent 40 ′.
[0028] A centrifuge 58 may be used to separate solids 60 ′ and effluent 62 ′. The recovered weighting agent 72 from the first centrifuge 70 may be added to the effluent 62 ′ as needed to reproduce drilling fluid to be used in drilling operations.
[0029] While the claimed subject matter has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the claimed subject matter as disclosed herein. Accordingly, the scope of the claimed subject matter should be limited only by the attached claims. | Oil-based drilling fluid is prepared for further processing to recover the drilling fluid by pumping the drilling fluid through a flow meter. Surfactant may be added to the drilling fluid by using a dose pump and a flow meter. The drilling fluid and surfactant are then blended by passing them through a static mixer. A flocculating polymer is transferred via dose-pumps to another static mixer where it is blended with the surfactant and drilling fluid mixture. To ensure adequate mixing and reaction, additional mixers are included through which the mixture passes. A centrifuge is used to separate solid particles from the fluid. |
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION:
The invention relates to a subterranean well tool for use in water, oil and gas subterranean wells.
2. BRIEF DESCRIPTION OF THE PRIOR ART:
Subsequent to the drilling of an oil or gas well, it is completed by running into such well a string of casing which is cemented in place. Thereafter, the casing is perforated to permit the fluid hydrocarbons to flow into the interior of the casing and subsequently to the top of the well. Such produced hydrocarbons are transmitted from the production zone of the well through a production tubing or work string which is concentrically disposed relative to the casing.
In many well completion operations, it frequently occurs that it is desirable, either during the completion, production, or workover stages of the life of the well, to have fluid communication between the annular area between the interior of the casing and the exterior of the production tubing or workstring with the interior of such production tubing or workstring for purposes of, for example, injecting chemical inhibitor, stimulants, or the like, which are introduced from the top of the well through the production tubing or workstring and to such annular area. Alternatively, it may be desirable to provide such a fluid flow passageway between the tubing/casing annulus and the interior of the production tubing so that actual production fluids may flow from the annular area to the interior of the production tubing, thence to the top of the well. Likewise, it may be desirable to circulate weighting materials or fluids, or the like, down from the top of the well in the tubing/casing annulus, thence into the interior of the production tubing for circulation to the top of the well in a "reverse circulation" pattern.
In instances as above described, it is well known in the industry to provide a well tool having a port or ports therethrough which are selectively opened and closed by means of a "sliding" sleeve element positioned interiorly of the well tool. Such sleeve typically may be manipulated between open and closed positions by means of wireline, remedial coiled tubing, electric line, or any other well known auxiliary conduit and tool means.
Typically, such ported well tools will have upper and lower threaded ends, which, in order to assure sealing integrity, must contain some sort of elastomeric or metallic sealing element disposed in concert with the threads to prevent fluid communication across the male/female components making up the threaded section or joint. A placement of such a static seal represents a possible location of a seal failure and, as such, such failure could adversely effect the sealing integrity of the entire production tubing conduit.
Additionally, in such well tool, a series of upper and lower primary seals are placed in the housing for dynamic sealing engagement relative to the exterior of a sleeve which passes across the seals during opening and closing of the port element. As with all seals, such primary sealing means also represent an area of possible loss of sealing integrity. Thus, such prior art well tools have been commercially manufactured with four possible seal areas, the integrity of which can be compromised at any time during the well life and the usage cf the tool.
During movement of the sleeve to open the port in such well tool to permit fluid communication between the interior and exterior thereof, such primary seals positioned between the interior wall of the well tool housing and the exterior wall of the shifting sleeve will first be exposed to a surge of fluid flow which can cause actual cutting of the primary seal elements as pressure is equalized before a full positive opening of the sleeve and, in some instances, during complete opening of the sleeve. In any event, any time such primary seals are exposed to flow surging, such primary seals being dynamic seals, a leak path could be formed through said primary seals.
Accordingly, the present invention provides a well tool wherein the leak paths as above described are reduced from four to two, thus greatly reducing the chances of loss of sealing integrity through the tool and the tubular conduit. Secondly, the well tool of the present invention also provides, in one form, a fluid diffuser seal element which resists flow cutting damage to the primary seal element by substantially blocking fluid flow thereacross during shifting of the sleeve element between open and closed positions.
Other objects and advantages of the incorporation of use of the present invention will be appreciated after consideration of the drawings and description which follow.
SUMMARY OF THE INVENTION
A downhole well tool is securable to tubular members for forming a section of the cylindrical fluid flow conduit within said well and for selective transmission of fluids therethrough between the interior and exterior of the tool.
The well tool comprises a housing. First and second threaded ends are provided for securing said housing between companion threaded ends of said tubular members. A fluid communication port is disposed through the housing and between the threaded ends. One of the threaded ends is positioned upstream of the port and the other threaded end is positioned downstream of the port. Primary means are interiorly positioned inside each of the tubular members and have a face in abutting relationship with the housing. One of the primary sealing means is positioned downstream of one of the threaded ends, and the other of the primary sealing means is positioned upstream of the other of the threaded ends.
The well tool also includes a sleeve which is disposed interiorly of the housing and is shiftable between first and second positions for selectively communicating and isolating the fluid communication port relative to the interior of the tool.
Each of the primary sealing means has an exterior face in circumferential sealing alignment with the housing and an interior face which is always in circumferential sealing alignment with the sleeve.
The apparatus also includes a flow diffuser ring element which is placed around the interior of the housing and downstream of the port to eliminate damage to the primary seal element downstream thereof such that there is effectively no flow across the primary seals during the shifting of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a subterranean well showing the apparatus positioned above a well packer during actual production of the well.
FIG. 2 is a longitudinally extending sectional view, partly interior and partly exterior, of the apparatus of the present invention with the port in fully closed position.
FIG. 3 is a view similar to FIG. 2 showing the apparatus with the sleeve and port in intermediate, or equalizing, position.
FIG. 4 is a view similar to that of FIGS. 2 and 3 showing the port of the well tool of the present invention being in an open condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With first reference to FIG. 1, there is schematically shown the apparatus of the present invention in a well W with a wellhead WH positioned at the top and a blowout preventor BOP positioned thereon.
It will be appreciated that the apparatus of the present invention may be incorporated on a production string during actual production of the well in which the wellhead WH will be in the position as shown. Alternatively, the apparatus of the present invention may also be included as a portion of a workstring during the completion or workover operation of the well, with the wellhead WH being removed and a workover or drilling assembly being positioned relative to the top of the well.
As shown in FIG. 1, the casing C extends from the top of the well to the bottom thereof with a cylindrical fluid flow conduit 10 being cylindrically disposed within the casing C and carrying at its lowermost end a well packer WP. The well tool 100 is shown being carried on the cylindrical fluid flow conduit 10 above the well packer WP.
Now with reference to FIG. 2, the well tool 100 is secured at its uppermost end to a first tubular member 117 forming a portion of the cylindrical fluid flow conduit 10, and at its lowermost end to a second tubular member 119 forming the lowermost end of the cylindrical fluid flow conduit 10 and extending on to the well packer WP at threads 112. Alternatively, the well tool 100 of the invention may also be provided in a form wherein members 117, 119 are actual parts of the well tool itself, with members 117, 119 and 103 forming the entire outer housing.
The well tool 100 has a cylindrical interior 101 and an exterior 102 which are permitted to be selectively communicated therebetween by means of a fluid communication port 106.
In the position in FIG. 1, it will be assumed that production fluids are to flow through the cylindrical fluid flow conduit 10 from below the well packer WP to the top of the well, but such flow could be in the opposite direction. Thus with reference to FIGS. 2, 3, and 4, the arrow 108 in the interior of the tool above of the fluid communication port 106 is defined as pointing towards the downstream flow portion relative to the port 106 and the arrow 107 below the fluid communication port 106 is defined as pointing towards the upstream area of the fluid flow, as described
The well tool 100 has a primary sealing means 109 downstream of a first threaded end 104. As shown, the sealing means 109 is comprised of a series of Chevron shaped thermoplastic compound elements, but may be in the form and include a number of well known sealing components for sliding sleeve mechanisms utilized in the well completion art.
With reference to FIG. 2, the sealing means 109 includes a lower face 109c which is in abutting engagement with the uppermost end 103a of the housing 103 which, in effect, is an abutting shoulder for receipt of the lower end of the sealing means 109.
An interior sealing face 109f sealing means 109 projects interiorly of the inner wall of the first tubular member 117 for sealing dynamic contact with a cylindrical shifting sleeve 111 concentrically positioned within the well tool 100. Likewise, the sealing means 109 also have their outer face 109a facing exteriorly and away from the sleeve 111 for sealing engagement with the inner cylindrical wall of the first tubular member 117. The sealing means 109 is thus contained within a profile 117p of the first tubular member 117.
The sleeve 111 is normally secured in position for running into the well as shown in FIG. 2, where the fluid communication port 106 is closed. In some operations, for equalization purposes, and the like, the sleeve 111 may be placed in the "open" position such that the fluid communication port 106 is in fluid communication with the interior 101 of the well tool 100 from the exterior 102 thereof. In any event, when the sleeve 111 is in the position where the fluid communication port 106 is in the "open" position, an outwardly extending flexible latch element 111a is secured within an upper companion groove 119a on the tubular member 119. A shifting neck 111b is defined at the lowermost end of the sleeve 111 for receipt of a shifting prong (not shown) of a wireline, coiled tubing, or the like, shifting tool for manipulating the sleeve 111 from one position to another position relative to the fluid communication port 106. As the shifting prong engages the shifting neck 111b, a downward load may be applied across the shifting prong through the shifting neck lllb the sleeve to move same, such as from the fully "closed" position shown in FIG. 2, to the intermediate equalizing position shown in FIG. 3, or the fully open position shown in FIG. 4. Once sleeve 111 is shifting, latch 111a will rest in snapped engagement in the intermediate groove 119b upstream of the groove 119a and, in such position, the sleeve 111 is in the equalized position. Continued downward movement will move the sleeve 111 to the fully open position, and the latch 111a will be in the groove 119c. Of course, the sleeve 111 may also be moved by appropriate connection of a shifting tool at an alternate shifting neck 111c at the top end of the sleeve 111.
The fluid flow diffuser ring 113 has an outwardly defined 45 degree angled expansion area 115 around the exterior to permit the components of the fluid flow diffuser ring 113 to expand therein as the well tool 100 encounters increased temperatures and pressures within the well W, during operations. An inner wall 113a of the fluid flow diffuser ring 113 will sealingly engage along the exterior surface of the sleeve 111 such that there is substantially no effective fluid flow across the primary sealing means 109 as the sleeve 111 is shifted to open the fluid communication port 106 relative to the interior 101 of the tool 100.
The fluid flow diffuser ring 113 may be made of any substantially hard nonelastomeric but plastic material such as Polyetheretherkeytone (PEEK), manufactured and available from Green, Tweed & Company, Kulpsville, Pennsylvania. It will be appreciated that the fluid flow diffuser ring 113 is not a conventional elastomeric seal which degrades rapidly during shifting or other "wiper" which only serves the function of wiping solid or other particulate depris from around the outer exterior of the sleeve 111 as it dynamically passes across the sealing means 109 but, rather, the fluid flow diffuser 113 acts to substantially eliminate fluid flow to prevent fluid flow damage to the primary sealing assembly, 109.
Below the fluid communication port 106 and positioned at the lowermost end of the housing 103 in the upstream direction 107 from of the second threaded end 105 is a second sealing means 110 emplaced within a profile 119p of the tubular member 119. This sealing means 110 may be of like construction and geometrical configuration as the sealing means 109, or may be varied to accomodate particular environmental conditions and operational techniques.
With reference to FIG. 2, the sealing means 110 has an upper face 110c which abutts the lowermost end 103b of housing 103 below the second threaded end 105 of housing 103. The outer face of the seals 110a is in sealing smooth engagement with the inner wall of the profile 119p of the second tubular member 119. Additionally, the interior face 110b of sealing means 110 faces inwardly for dynamic sealing engagement with the sleeve 111 positioned thereacross.
OPERATION
The well tool 100 is assembled into the cylindrical fluid flow conduit 10 for movement within the casing C by first securing the housing to the first and second tubular members 117, 119 at their respective threaded ends 104, 105. The sleeve 111 will be concentrically housed within the well tool 100 at that time with the sealing means 109, 110 in position as shown in, for example, FIG. 2.
During makeup, the seal means 109, 110, will, of course, be secured within their respective profiles 117p and 119p . Now, the first tubular member 117 and/or the second tubular member 119 are run into the well W by extension thereto into a cylindrical fluid flow conduit 10 with, in some instances, the well packer WP being secured at the lowermost end of the second tubular member 119 at, for example, threads 112. If the well tool 100 is run into the well in the closed position, the well tool 100 will be in the position as shown in FIGS. 1 and 2.
When it is desired to open the fluid communication port 106, the sleeve 111 is manipulated from the position shown in FIG. 2 to the position shown in FIG. 3, where pressure exterior of the well tool 100 and interior thereof are first equalized. It will be appreciated that the positioning and location of the sealing means 109, 110 relative to their respective threaded ends 104, 105, eliminate the necessity of a fluid tight seal being required between these threaded members, thus greatly reducing by a factor of 50 percent the number of locations for possible loss of pressure integrity within the well tool 100.
Additionally, it will also be appreciated that such positioning of the primary seals 109 in a position in the downstream direction 108 relative to the fluid flow diffuser 113 such seals from being exposed to fluid flow when the sleeve 111 is shifted from the position shown in FIG. 2, where the fluid communicaton port 106 is isolated from the interior 101 of the tool 100, to the equalizing position, shown in FIG. 3.
Subsequent to the shifting of the sleeve 111 to the equalized position, it may be opened fully to the position shown in FIG. 4. Where equalization is not deemed to be a particular problem because of comparative low pressure environments of operation, the tool may, of course, be shifted from the position shown in FIG. 2 to the position shown in FIG. 4, without any sort of time in the equalization position shown in FIG. 3.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of this disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | A downhole well tool is provided which includes a shifting sleeve for opening a flow communication port. The well tool includes first and second primary seal elements positioned upstream and downstream, respectively, of the port as well as upstream and downstream of the threaded connections between the well tool and sections of tubing forming the well flow conduit. A fluid diffuser element may be included to abate flow damage across the primary seal elements during the shifting of the sleeve. A method of selectively transmitting fluid incorporating said well tool also is disclosed. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to the injection of fluid into underground strata for various purposes with the system including an injector for effective control of injection of fluid into an underground formation by the use of pumps for injection under pressure, or gravity flow depending upon the fluid being injected, the characteristics of the underground formation into which the fluid is being injected and the function of the injection system.
2. Description of the Prior Art
It is well-known to inject fluids into underground hydrocarbon reservoirs or formations for the purpose of recovering additional hydrocarbon liquids. This technique, generally referred to as secondary or tertiary recovery, includes pumping of the fluid into an injection well at a high pressure which requires the use of a plurality and relatively long high pressure pipelines extending from a high pressure pump to a plurality of injection wells. Such techniques, while having some degree of success, have many inherent disadvantages and limitations. For example, the control of the quantity of fluid injected at each individual well has not been too successful. When choking the fluid flow in the system to direct more fluid to a particular well usually results in an increase of resistance or pressure throughout the system and this increase requires a corresponding increase in horsepower at the central pump or pumps in order to maintain volume which in turn increases the pipeline pressure resulting in pipeline failures which, of course, can cause the complete shutdown of the flooding operation. The known techniques also result in high energy consumption relative to the volume of fluid injected due to resistance to flow in the pipeline system which must be overcome by the pumps. Also, relatively poor sweep efficiency of the flooding fluids within the hydrocarbon reservoir occurs due to the limited flexibility of the system, all of which results in unacceptable total losses of hydrocarbons throughout the world. As a result of inefficiencies inherent in the present techniques and the costs involved, there have been many instances in which secondary or tertiary recovery of hydrocarbon fluids from reservoirs has been found to result in large energy and monetary losses, thereby rendering the recovery operation economically unprofitable.
In regard to other problems which are encountered throughout the world, underground water supplies have diminished or become unusable because of excessive use, depletion and the like. However, in many of these areas, at certain periods, there is an excess supply of fresh water which results from rainfall or in neighboring geographical areas, there may be an excess supply of fresh water which could be effectively utilized if supplied to a water depleted area by an economical means. In many instances, underground aquifers and other water bearing strata have been exhausted by excessive removal of underground water without regard to the depletion of the supply. Many efforts have been made to impound excessive water supply by using dams to form surface reservoirs which, of course, are used in many localities but which suffer from extreme loss due to evaporation and can become contaminated as well as utilizing substantial land areas that could be better utilized for other purposes.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an underground fluid injection system which includes an injector located at each injection well site associated with a supply of treated or filtered fluid by a gravity flow system or low pressure flow system so that extensive high pressure pipelines are eliminated with each well injector being continuously supplied with fluid to be injected by an adequately sized, low pressure, non-corrosive, non-conductive pipeline system by gravity fall from an elevated tank or by a low pressure, high volume, pressure regulated pump.
Another object of the invention is to provide an injector as set forth in the preceding object that includes a vessel which serves as a storage tank for the fluids arriving at each injector, a high speed, high pressure multi-cylinder pump assembly driven by a variable speed electric motor, final screening and filtering arrangement, individually driven, rate adjustable injector means for the injection of polymers, bactericides, detergents or other added liquids when needed, a flow meter for accurate measurement of total fluids injected, a sensing system to start up or shutdown the motors relative to fluid availability, a control unit coupled to the sensing system to control the system, an electronic interface and data transmission and receiving system to be made available where remote sensing and control are desired, manual or automatic controls of volume, pressure and rates, fluid taps for testing of fluid at the unit before injection and a shutoff system to control any overflow condition.
When using the system for fresh water injection into underground reservoirs to recharge depleted or insufficient fresh water underground strata from rainfall run off or other sources of fresh water, a series of strategically located wells can be drilled and completed to assure that water injected would enter the desired strata and only the desired strata and at each of these wells, an injection unit would be installed similar to those used in injecting fluids into a hydrocarbon reservoir with the only differences being the size and accessories involved to comply with any legal, sanitary, or health requirements. This would enable fresh water to be collected in ponds, lakes, or behind dams or run off areas which provide the least contamination possible and as soon as water becomes available in these areas, the water, after filtering, purifying, clarifying, or other processes necessary, would be conveyed by gravity fall or high volume, low pressure pumps to elevated tanks so that the water will flow by gravity fall through adequately sized, underground, non-corrosive, non-conductive pipelines to each injector unit for injection into the desired underground strata either by gravity flow or by pump depending upon the permeability of the underground strata.
When injecting fresh water into underground strata, natural underground filtering and purification will be effected by flowing water through the porous medium of the underground reservoirs. This also results in natural cooling of the water, reduction of evaporative losses, improvement in the potability of water, less risk of deliberate contamination, a balancing effect in many geographic areas where cyclic drought occurs, regulated agriculture balance to water availability without excessive evaporative losses, slightly saline underground reservoirs in some regions will become less saline and will reach potable levels and, in some instances, the gravity fall of water can be used to generate electricity for more efficient operation of the system.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view illustrating a typical installation in which injection fluid is stored in an elevated tank and supplied to a well injector by gravity flow.
FIG. 2 is a vertical sectional view of the well injector.
FIG. 3 is a plan sectional view taken substantially upon a plane passing along section line 3--3 of FIG. 2 illustrating the association of the components of the well injector.
FIG. 4 is a vertical sectional view taken substantially upon a plane passing along section line 4--4 of FIG. 2 illustrating further structural details of the water injector.
FIG. 5 is a fragmental sectional view taken substantially upon a plane passing along section line 5--5 of FIG. 2 illustrating further structural details of the supporting structure for the pump and filtering assembly.
FIG. 6 is a fragmental perspective view of the supporting structure for the pump and filter assembly.
FIG. 7 is a fragmental sectional view of the sectional standpipe or vessel illustrating the structure of the vessel and the connection between the sections.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now specifically to the drawings, FIG. 1 illustrates schematically the system of the present invention including an elevated tank 10 having a quantity of injection fluids, such as water, therein with the fluid level being indicated by numeral 12. The tank is supplied with injection fluid through a suitable supply pipe 14 connected with a gravity supply, pump supply, or other supply, of injection fluid with the level of the invention fluid in the tank 10 being maintained at any suitable point above an outlet screen 16 adjacent the lower end of the tank which is connected to a gravity flow pipeline 18 that extends to a lower elevation and connects with a well injector generally designated by the numeral 20 which discharges injection fluid into a well generally designated by numeral 22 through a suitable flexible or other conduit 24 connected to the upper end of the well casing 26 by a suitable fitting 28. While a gravity flow system has been illustrated from the tank 10 to the injector 20, in certain installations, it may be desirable to utilize a low pressure high volume pump to supply injection fluid to the well injector 20. In other instances, injection fluid, such as water, may be conveyed from a water impoundment site such as a lake, pond, river, reservoir, or the like, through the pipeline 18 to the well injector 20 with the pipeline 18 being low pressure, non-corrosive, non-conductive and not subject to evaporation or freezing due to contact with atmosphere since it is usually desirable for the pipeline to be disposed below ground as indicated by numeral 30. Thus, it will be appreciated that various installational requirements may be complied with for supplying low pressure high volume injection fluid to the well injector 20. Any filtering or other treatment of the water is accomplished prior to delivery of the water or other fluid to the well injector 20.
Referring now specifically to FIGS. 2-4, the well injector 20 includes a vessel or tank 32 of cylindrical configuration and located below ground 34 a sufficient distance to avoid freezing and to make certain that freezing of the fluid will not occur, a segmented layer of insulation 36 is placed across the top and down the sides of the vessel 32. As illustrated, the tank 32 is provided with a cylindrical baffle 38 extending from the top to bottom thereof disposed in concentric relation to the lower end of a standpipe 40 with the bottom end of the standpipe 40 having notches 42 therein where it joins with the bottom of the tank 32 and the baffle 38 includes notches 44 at the upper end thereof where it joins with the top of the vessel 32 to provide a sediment area in the tank externally of the baffle 38 since the fluid entering the standpipe 40 must initially pass over top of the baffle 38 as defined by the notches 44. The tank 32 is connected to the pipeline 18 through a coupling 46 and a valve 48 located exteriorly to the tank 32 and also positioned underground or otherwise associated with the tank 32 for enabling the supply of fluid to the vessel 32 to be controlled. The pipeline 18 will also have a valve at its juncture with the tank 10 but frequently, the pipeline 18 will serve a plurality of well injectors 20 with the valve 48 on each vessel 32 enabling individual control of the flow rate into each well injector.
The standpipe 40 includes a plurality of sections 50 each of which is provided with a flange 52 at each end for connection with adjacent sections by suitable bolts 54. The interior of the sections 50 are coated with plastic non-corrosive material 56, as illustrated in FIG. 7, with the liner or coating 56 also extending between the flanges 52 to provide continuity of the non-corrosive surface on the interior of the standpipe 40. The construction of the standpipe 40 of a plurality of sections enables the height thereof to be varied depending upon the installational requirements with the lowermost section of the standpipe 40 being integral with or welded to the vessel 32 so that the vessel 32 in effect forms a supporting pedestal for the standpipe 40, thereby effectively supporting a vertical column of injection fluid which maintains a height in the standpipe equal to the height of the injection fluid level 12 in the tank 10 as illustrated in FIG. 1. Also, the standpipe 40 is provided with an insulating covering 58 which extends along the flanged coupling as indicated by numeral 60 with this insulation being provided throughout the vertical height of the standpipe or, if desired, the heating device may be provided to maintain the temperature of the injection fluid above freezing. The upper end of the standpipe 40 is provided with a closure dome 62 and a closure plate 64 having a float valve assembly 66 associated therewith and connected with an overflow line 68 which communicates with the interior of the standpipe 40 to enable ingress and egress of air therefrom, but preclude discharge of liquid, since the float valve 66 will close when liquid approaches the plate 64.
The standpipe 40 includes a laterally extending tubular pipe 70 rigidly affixed thereto and extending horizontally therefrom in a cantilevered fashion with the outer end of the pipe 70 being externally threaded as at 72 and the inner end thereof being rigidly supported by a reinforcing partial collar 76 with the inner end of the pipe 70 extending into the interior of the standpipe 40 and projecting from the diametrically opposite side thereof through a similar reinforcing collar 78. A fitting 80 is provided in the pipe 70 within the interior of the standpipe 40 and descending from the fitting 80 is an inlet screen 82 which extends downwardly to the point adjacent to but spaced above the bottom of the vessel 32 as illustrated in FIG. 2, thereby providing communication between the interior of the vessel 32 and the pipe 70.
Mounted on the pipe 70 is an elongated tubular sleeve 84 which has its inner end abutted against the reinforcing collar and flange 76 with its outer end being engaged by a screw threaded cap 86 mounted on the externally screw threaded end 72 of the pipe 70. Rigidly supported on the sleeve 84 is a plate 87 and framework 88 which supports a pair of pumps 90 each of which is provided with an electric motor 92 drivingly connected thereto by a belt drive 94 or the like. Each of the pumps 90 is provided with an inlet conduit 96 communicated with diametrically opposite sides of the cap 86 as illustrated in FIG. 4 with suitable quick disconnect couplings provided therefor so that the conduits 96 are communicated with the pipe 70 thereby providing inlet to the pumps 90 from the vessel 32. The cap 86 is provided with lateral projections 98 which facilitate rotation thereof since the cap 98 serves to detachably retain the entire pump unit mounted on the pipe 70 in a cantilever fashion.
Supported below the plate 87 is additional framework 100 and a plate 102 supporting a pair of longitudinally extending filters 104 by suitable bracket structures 106. The pumps 90 each include a discharge conduit 108 connected to the center outer end of the respective filters 104, which extend parallel to and generally in underlying relation to the pump and motor units as illustrated in FIGS. 2 and 4. The inner ends of the filters 104 are provided with discharge pipes 110 provided with a check valve 112 with the pipes 110 being communicated with a flow meter 114 located between the filters 104 adjacent the inner ends thereof with the discharge of the flow meter 114 connected to a pipe or conduit 116 which extends forwardly between the filters 104 and is connected to the conduit 24 to the well head 28 through a valve structure 118 as illustrated in FIG. 2, thus completing the supply of injection fluid from the vessel 32 into the standpipe 40, through the screen 82, through the pipe 70 and the inlet conduits 96 into the pumps 90. From the pumps 90, injection fluid passes through the outlet conduits 108, through the filters 104, conduits 110, check valve 112 and flow meter 114 into the conduit 116, through the valve 118 and conduit 24 in through the fitting 28 into the well 22 for discharge into a desired underground strata.
The pumps in and of themselves are conventional or triplex, uniflow reciprocating pumps, such as those manufactured by Cat Pumps Corporation, 1600 Freeway Boulevard North, Minneapolis, Minnesota 55430, which was stated to be covered by one or more of the following U.S. Pat. Nos. 3,558,244, 3,652,188, 3,809,508, 3,920,356 and 3,930,756.
To protect the pumps while still enabling the motors 92 to be cooled by the atmosphere, a housing 120 is provided for the pumps 90 while the motors 92 are disposed externally of the housing 120. To provide access to the cap 86 and also the pumps 90, a portion of the housing 120 is hingedly mounted by hinge structures 122 with the top portion of the housing 120 which is hingedly mounted being designated by numeral 124 which opens somewhat in the nature of a protective housing which encloses the pumps, filters and flow meter but does not enclose the motors 92. The housing may be constructed of fiberglass, sheet metal or any other suitable material and may be supported in any suitable manner such as by being rigidly affixed to the standpipe or clamped thereto with the housing 120 being separated into two sections along flanged coupling 126 to facilitate installation of and removal of the housing 120 when desired. The housing may be anchored to longitudinal frame members 128 and separated horizontally into top and bottom sections to enable easy removal and installation thereof. The entire pump assembly along with the motors, filters, flow meter and associated piping conduits are removed as a unit from the supporting pipe 70 after the inlet conduits 96 have been detached from the cap 86 and the cap removed from the end of the pipe 70, thus facilitating removal of the pump unit for repair or replacement. This structure also enables bypass of the pump units where the underground strata is such that gravity flow flooding with the injection fluid either going directly from the pipe 70 into the filters 104 thus bypassing the pumps, or a direct connection can be made to the conduit 24, thus bypassing the pumps, filters and flow meter, although it usually is desirable to maintain control of the flow rate and also enable monitoring of the flow rate.
As illustrated in FIGS. 2, 3 and 6, the pipe 70 which extends through the fitting 80 interiorly of the standpipe 40 also includes an end portion extending through the coupling 80 which is provided with a cap 128 which forms a closure therefor and is provided to enable a chemical injection pump to be supported from a pipe attached thereto by a suitable coupling in a cantilever manner similar to the pipe 70 which supports a chemical injection pump unit (not shown) which is communicated with the interior of the standpipe in the same manner as pipe 70 and which includes a discharge conduit connected to the flow meter 114 by a suitable adapter 130, so that chemical additives may be added to the injection fluid on the downstream side of the filters 104. The use of a chemical additive injector pump is optional depending upon the installation requirements and the chemical injection pump will be a self-contained, commercially available unit powered by a suitable electric motor.
Also, the standpipe 40 is provided with a float control switch 132 having a float 134 connected thereto which will control the water level in the standpipe within certain limits with the float valve 66, of course, preventing fluid overflow of the standpipe. The discharge line 68 extends into a sterilizer 136 which enables discharge of air from the standpipe but when the fluid level in the standpipe recedes, incoming air will be sterilized, thereby preventing growth of alga or bacteria in the water in standpipe 40. Also, the standpipe 40 may serve as a supporting post for an electrical conductor 138 or the like to supply electrical energy to the pump motors and also to enable sensing and control signals to be remotely provided to the injector to enable the well injector conditions to be monitored and controlled from a remote location as desired.
When a formation in which fresh water is being stored is sufficiently permeable to provide free flow into the underground strata, the pumps can be bypassed and, of course, not operated until such time as water backs up into the standpipe to a predetermined level at which time a sensing switch will render the pumps operative. In situations where water is conveyed for relatively long distances with substantial gravity fall, hydroelectric generators may be incorporated into split lines at various locations including the terminal end of the pipeline in order to generate electricity for various purposes including providing power to the injector pumps. Such generators would be conventional and would be feasible wherever the water head or gravity fall of water is sufficient to power conventional turbine driven generators. Also, where wells take a large gravity flow of water having a substantial head, downhole water driven turbine-generator units may be provided to produce electrical energy for various purposes including the powering of control apparatuses, drive motors, and the like, of the system.
In addition to installation in association with secondary or tertiary recovery of hydrocarbons and storage of fresh water in underground strata, the well injectors are well adapted for disposal of salt water or brine in oil fields in which a smaller unit incorporating a single pump provided with a drive motor and including or omitting filtering, metering and other accessories enables injecting oil field salt brine into underground disposal strata. In such installations, a low pressure line may be connected to a single or a plurality of siphon lines or to an elevated holding tank where water will flow by gravity or pumped by a low pressure, high volume, pressure regulated pumps to the well injectors where automatic injection will be accomplished by the small vessel injector units. Also, a small injector unit may be used by ranchers, farmers, industrial users, or the like, for recharging underground water strata during wet seasons, that is, for storing fresh water for point of use rather than for use by the general population. The same general construction can be used for underground disposal of any fluids contaminated by industrial processes or the like bearing in mind that certain materials, for safety and health reasons, should not be injected underground.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A system for injecting fluid into underground formations for various purposes including the secondary and tertiary recovery of oil or other hydrocarbons from underground formations, storage of fresh water in underground formations, recharging depleted or insufficient fresh water underground strata from rainfall run off or other sources of fresh water to provide fresh water supply during low rainfall periods or the like, disposal of brine or saline solutions into underground formations where such solutions will be purified by filtering through porous media and disposal of contaminated fluids resulting from industrial, chemical processes, and the like. The system includes a unique injector capable of gravity flow injection or pressure injection by use of a pump arrangement with the gravity flow of fluids such as water enabling turbines to be utilized in the flow path at a point having the necessary water head and pressure characteristics to rotate a generator for providing electrical energy to power certain components of the equipment or for use in any manner desired. |
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RELATED APPLICATION
This is a continuation in part of application Ser. No. 08/684,004 filed Jul. 19, 1996, now abandoned and application No. 08/850,726 filed May 2, 1997.
INTRODUCTION TO THE INVENTION
This invention relates to the installation of decorative coverings. It has been shown in the present inventor's first patent U.S. Pat. No. 4,822,658 that carpets having a looped backing can be conveniently installed on a floor by the use of complementary hooked tape. One of the primary ways disclosed in that patent is attaching the tape to the floor at the perimeter and seams (hereinafter “perimeter and seam” installation). The present inventor has also developed an anchor sheet which is described in U.S. patent application Ser. No. 08/685,004 filed Jul. 19, 1996 and continuation-in-part application Ser. No. 08/850,726 filed May 2, 1997 (the specifications of which are herein incorporated by reference). Rather thin attaching the carpet directly to a hooked tape attached to the floor, an intermediate thin flexible relatively rigid anchor sheet is provided which gives rigidity and integrity and mass to the overlying pieces of carpet covering. The anchor sheet can be covered in hooks. The carpet has an underlying looped backing for attachment to the hooks. The carpet can be in pieces which overlap the anchor sheet pieces to provide rigidity and strength to the total unit.
The perimeter and seam method and the anchor sheet structure and method can both be used and will both work. However in some circumstances it may be advisable to use a combination of both methods in which a form of anchor sheet provides a stable framework into which either a cushion or a covering material or both can be inserted either attached to the floor by a hook and loop attachment method or as a “free float” within the framework. In these circumstances, the anchor sheet can be a support for a covering unit attached to the anchor sheet by hook and loop as shown in the earlier related cases. Carpet within the framework can then be installed with hook and loop or in a conventional manner, i.e., without hook and loop, by glue down or even by free floating.
In some circumstances the hook tape of a perimeter and scam installation can be the “framework” within which an anchor sheet installation can be made. In this case the anchor sheet may float within the framework created by hook tape attached to a floor. Additional methods of attaching a tape framework and a tape framework construction are disclosed as well as other methods of installing an anchor sheet as a framework, including the use of a form or jig.
BACKGROUND OF THE INVENTION
The need for flexibility in installing floor coverings is well known. Most floor coverings must be cut and fit on site and therefore must be flexible to provide for different physical limitations In addition subflooring and supporting substrates differ widely in both quality and type, even in new construction In old construction existing flooring may reman and present problems.
The background to the invention is substantially shown in the present inventor's prior issued patents U.S. Pat. No. 4,822,658 (Apr. 18, 1989, Pacione); U.S. Pat. No. 5,191,692 (Mar. 9, 1993, Pacione); U.S. Pat. No. 5,382,462 (Jan. 17, 1995, Pacione); and U.S. Pat. No. 5,479,755 (Jan. 2, 1996, Pacione). In addition attempts to make structural semi-permanent flooring and wall material incorporating a hook surface is also disclosed in the present inventor's earlier anchor board system U.S. Pat. No. 5,060,443 (Oct. 29, 1991, Pacione); U.S. Pat. No. 5,259,163 (Nov. Pat. No. 9, 1993, Pacione); and U.S. Pat. No. 5,144,786 (Sep. 8, 1992, Pacione).
SUMMARY OF THE INVENTION
A thin rigid but flexible anchor sheet has advantages to stabilize the overlying carpet to provide a relatively rigid subfloor for installation of an overlying carpet. When a resilient backing of cushioning material is attached to or supplied under such anchor sheet, the anchor sheet provides a novel subfloor which has significant advantages over existing underpads.
We have described the anchor sheet as both “flexible” and “rigid”. It is flexible in the sense that over a reasonable length it can bend and in most circumstances can even be rolled with a radius of curvature for example of perhaps 1 or 4 inches unlike for example plywood. It is rigid in the sense that if held at one end it can support itself for instance over a distance of 12-24 inches without drooping unlike a cloth or fabric tape.
It is not commonly appreciated that an underpad, while it provides resiliency, can lead to degradation in the overlying decorative textile surface. This is because the resiliency allows for the carpet to deform when walked upon or when furniture or other items are placed on the carpet. This deformation can, if it is not properly supported from below, result in crushing and eventual deterioration of the carpet structure.
The anchor sheet of this invention has a relatively rigid yet flexible thin sheet material, preferably a plastic or of a polymer material such as a polyester, polycarbonate, polypropylene or even a graphite or other advanced polymer material overlying a resilient cushion. This structure provides a surprising amount of resiliency and cushioning to the carpet. However because the overlying anchor sheet is relatively rigid, the carpet fibres are protected from crushing and therefore the life of the carpet is significantly extended while still appearing to have a sufficient degree of resiliency.
In order to provide the proper degree of resilience in the hooks and the proper degree of rigidity to the sheet, the hooks and sheets may need to be made from, for example, different plastic materials by lamination or coextrusion.
To the inventor's knowledge no person, until disclosed in this and the earlier related applications, has had the relatively unconventional idea of covering a resilient material with a thin flexible relatively rigid sheet material.
Thus the invention comprises in, one aspect, an anchor sheet subfloor comprising a laminate having an upper layer of a relatively thin and flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material.
While not as pronounced, the advantages of a relatively rigid but flexible anchor sheet to create a smooth subfloor and to tie overlying carpet pieces together into a stable mass can to some extent be achieved even without a resilient undercushioning. Thus the invention comprises in another aspect a relatively thin flexible rigid sheet material preferably of plastic or polymer which can be cut and fit on site to fit the contours of a room or other area to be covered to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be laid decorative covering pieces.
In another aspect the invention comprises a carpet and subfloor comprising a first layer of relatively resilient cushioning material overlaying the floor. A second layer of a thin flexible rigid polymer material overlaying the first layer and hooks covering at least a portion of the top surface of the second layer and a carpet having an undersurface covered in loops and detachably attached to the hooks covering the second layer to form a coherent stable carpet structure.
In another aspect, the subfloor and structure created by the first resilient layer and the second layer of anchor sheet, can be covered across its surface by perimeter and seam hooked tape so as to allow for installation of a carpet on the subfloor in accordance with the method described in U.S. Pat. No. 4,822,658. In this case the subfloor is actually not attached to the floor directly but is normally “floating” but this may be sufficient, in many installations, to stabilize the carpet.
As previously described, in some circumstances, the anchor sheet can act as g framework for either a carpet or an underpad or both, Thus, in another aspect, the invention covers an anchor sheet, carpet and an underpad combination for installing a carpet or underpad onto a floor comprising an anchor sheet installed along the perimeter of an area to be covered, describing and bounding that area, hook tape attached to the sheet along the perimeter of the upper face of the anchor sheet and a resilient underpad of a height matching the height of the anchor sheet sized to fit within the area bounded by the anchor sheet. A carpet having an underside covered in loops can then be overlaid. The anchor sheet perimeter and the resilient underpad may be either free floating or installed in a conventional manner within the anchor sheet framework.
A more complex anchor sheet framework can also be formed consisting of modular covering units made as disclosed in related application Ser. No. 08/850,726. Thus in another aspect the invention comprises a modular framework for carpet installation comprising a plurality of covering modules having decorative coverings attached to a thin flexible rigid anchor sheet so as to leave exposed overlapping areas of anchor sheet or covering for detachable attachment and interlocking relationship to an adjoining module as disclosed in related application Ser. No. 08/850,726. In this aspect of the invention, the modules are then detachably interlocked to define and enclose an area. Carpet or underpad or carpet and underpad depending upon the height of the framework created, is then cut and fit within the area defined by the covering modules,
As previously mentioned, an anchor sheet subfloor can also be installed within a perimeter bounded by hooked tape, in effect creating a hooked tape framework. In this aspect of the invention, a perimeter of hooked tape is attached to the floor. The tape may be of a form disclosed in, for instance, U.S. Pat. No. 5,382,462 or having a tape with a cushioned backing or a tape with a foundation sheet as disclosed in the present application.
In this aspect of the invention, a thin rind flexible anchor sheet having an upper surface having a plurality of hooks in which the anchor sheet or anchor sheet and cushion is substantially the same height as the tape can then be cut and fit within the area bounded by the hooked tape to provide for a surface underlayment over which a carpet or other decorative covering having a looped backing can be installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, reference being had to the accompanying drawings, wherein:
FIG. 1 shows covering modules and a jig for installation.
FIG. 2 shows the covering modules and jig in the process of installation to a floor.
FIG. 3 shows the next step in installation of the covering module and jig.
FIG. 4 shows the finished covering module framework.
FIG. 5 shows the covering module framework at the commencement of the installation of an inserted cushion or carpet.
FIG. 6 shows the completed covering.
FIG. 7 shows the anchor sheet perimeter arrangement.
FIG. 7A shows another form of anchor sheet perimeter arrangement similar to that shown in FIG. 7 .
FIG. 8 shows another form of anchor sheet perimeter arrangement in which the anchor sheet carries a decorative covering which contains a border pattern.
FIG. 8A shows a completed anchor sheet perimeter arrangement.
FIG. 9 shows a form of anchor sheet upon which is installed a perimeter and seam hook and loop tape arrangement.
FIG. 10 shows a form of tape suitable for use in a perimeter arrangement.
FIG. 11 shows a cross-section of a perimeter arrangement having a hooked tape bounding an area of anchor sheet and an overlying decorative covering.
FIG. 12 shows an arrangement of anchor sheet providing a border.
FIG. 13 shows another border arrangement with anchor sheet and cushion.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 is shown a variety of covering modules 2 and 4 . These are similar to the type of covering modules disclosed in related case Ser. No. 08/850,726. In the case of covering module 2 there is an anchor sheet 6 larger than the decorative covering piece 8 . In the case of covering module 4 there is a decorative covering piece 10 which overlaps the anchor sheet 12 .
Normally the anchor sheet areas would be substantially covered in hooks 14 as shown in only representative detail. The overlapping pieces 10 will have on their undersurface loops (not shown) for attachment to the exposed hooks 14 of anchor sheet, for instance, 6 .
A jig or pattern 16 is also shown in FIG. 1 . Its use will become apparent.
The jig at 16 has corners for instance 18 and 19 which serve to locate the corresponding comers of decorative covering piece 8 at each of the four corners of the jig. Thus the covering modules are separated and appropriately spaced in the desired location. Covering module 4 cam then be inserted along the sides of the jig abutting the jig as shown. Loops on the undersurface of covering piece 10 (not shown) will enable the covering piece to be installed in detachable attachment in a manner shown in related case Ser. No. 08/850,726 preferably by the use of a smooth slip cover as disclosed in related U.S. patent application Ser. No. 08/850,726. The slip cover can be a hard smooth piece temporarily insert. It can then be removed and the covering modules will form a framework as shown in FIG. 3, in which pieces 4 and pieces 2 have combined to create a structure. Jig 16 is then removed as shown in FIG. 4 so that the anchor sheet framework now lies upon and circumscribes an area of floor 21 and also an area of hooked anchor sheet 20 which is at a different level than the surface of decorative covering 22 .
As shown in FIG. 5 a decorative covering unit 24 can be inserted into the framework 26 . The unit may be carpet having a looped backing (not shown) in which case the carpet would be detachably attached to hooks 28 in the area shown. Normally the complete area would be covered in hooks but only representative samples are shown.
If desired the floor area 21 could be made level with the hooked area 28 by the use of an anchor sheet of suitable thickness, also covered with hooks or smooth, or by the installation of a pad. The area of floor 21 could be left empty because of the low profile of the hooked area 20 .
FIG. 6 shows the unfinished subunit which is ready to be attached by hooks 30 to other adjoining anchor sheet units or covering modules.
In FIG. 7 is shown another form of anchor sheet perimeter installation in which an anchor sheet 32 is formed having a thin rigid flexible covering 34 preferably formed of a plastic or polymer material as described in related application Ser. No. 08/850,726 preferably of a polypropylene, polycarbonate or polyester material and laminated and bonded thereto is a resilient cushion 36 of polyurehane foam or other similar carpet underpad material. Similar anchor sheet units 32 A and 32 B are placed on the floor in abutting relation and the units may be joined together by a pressure sensitive adhesive hooked tape 38 overlying the seams of the anchor sheets or by plain single-sided pressure sensitive tape. Additional hooked tape 40 is added to the perimeter of the anchor sheet installation to provide for a regular perimeter and seam installation as shown in U,S. Pat. No. 4,922,659. It would be convenient if the tape covering joins 41 line up with carpet seams but if they do not, additional tape can be installed on the anchor sheet 32 to provide for at least seam coverage.
Of course if plain tape is used, then hooked tape will normally have to be installed at the carpet seams. Such tape is normally covered prior to installation. Full coverage could also be provided either by adding more hooked tape or by providing anchor sheet 32 with a flexible sheet pre-manufactured with a complete hook covering.
In FIG. 7A is shown an additional similar form of arrangement which combines a hooked tape 42 to be described later at the perimeter of the room, an underpad or anchor sheet with underpad 44 , an additional anchor sheet with underpad 46 , conventional underpads 48 and 50 and anchor sheets 52 and 54 with resilient cushioning and then tape 56 . Thus a complete resilient underlayment is created which is partly a framework made by tape 42 and anchor sheets 44 , 46 , 52 and 54 within which are contained conventional underpads 48 and 50 . A carpet can then be installed over top of this by perimeter and seam tape using tape 42 and 56 at the perimeter and tape 53 at the seams or by the use of an additional anchor sheet (not shown) to provide for decorative surface covering pieces. As shown in FIG. 8 an additional foundation sheet 58 of a similar material to the anchor sheet can have pre-attached permanently or detachably an anchor sheet 60 having a resilient undercushion 62 . The anchor sheet 60 could be one as shown in related application Ser. No. 08/850,726 having its upper surface substantially covered in hooks 64 , Decorative cover pieces, in this case carpet units 65 , can then be installed in any pattern over the anchor sheet. In the example given in FIG. 8 they are installed in a border pattern. When fully assembled as shown in FIG. 8A such a unit can create a framework within which carpet can be installed in a conventional way, or using hook and loop or perimeter and seam or in a small enough area free floated within the area bounded by the decorative border 66 as shown in FIG. 8 A.
FIG. 9 shows an arrangement similar to FIG. 7 in which there is an anchor sheet and resilient cushion framework 68 on either side of conventional carpet pads 70 . The conventional carpet pads may be free floating or attached to the floor in a conventional manner. Normally if the anchor sheets 68 are on the perimeter of the room and abut, for instance, wall 71 on one side and wall 72 on the other side, the whole structure can be “free floating” in the sense that it is not attached to the floor. Hook tape 74 can be installed at the perimeter. Suspended tape 76 at the seams provides a form of perimeter and seam installation over top of a conventional cushion or a partial anchor sheet and conventional cushion. The carpet or other decorative surface covering has loops on its undersurface at 80 (not shown) for detachable attachment to hooks 81 on pieces 74 and 76 .
FIG. 10 shows a form of hook tape that can be used to create a perimeter for the installation of a conventional underpad 87 . This tape has a foundation layer 8 to which is attached the tape 84 having a resilient cushion layer 86 . The tape is hook tape and contains across its surface resilient hooks 88 . It normally would be supplied with a tape covering 90 . The foundation sheet 82 allows for a lip or area so that the hook tape may be stapled or nailed through the sheet 82 or through tape 84 to the floor or it ran be installed using double-sided adhesive tape 92 or by hook and loop or by a conventional method.
Another form of tape 94 is also shown having foundation sheets 96 and 98 on both sides of the tape. The tape could be stapled to a floor and within the framework bounded by the tape could be inserted an appropriate underpad which could either be installed in a conventional manner or free floating between the tape gad an overlying anchor sheet or an anchor sheet having hooked covering (not shown) could also be installed within the area bounded by the tape.
In FIG. 11 is shown a cross-section of hooked tape 100 having cushion 102 attached to the floor.
If the tape is as shown in FIG. 10 it could have foundation sheet 82 for installation. Anchor sheet 104 with (as shown) or without an attached resilient cushion can then be inserted within the area bounded by hooked tape 100 and a decorative covering 106 having an undersurface covered in loops 107 could be installed across the area created by the hooked tape and anchor sheet.
FIG. 12 shows an arrangement in which an anchor sheet 108 is provided with hooks at least over the exposed area 110 shown and also under carpet pieces 112 and border pieces 114 , 116 and 118 . Border pieces 114 , 116 and 118 may be detachably attached to anchor sheet 108 in a pattern anchor sheet and 108 with such pieces could be sold as a preassembled unit. Such piece could be attached to a floor by pressure sensitive adhesive, with hook and loop or by nailing through sheet 108 . Carpet 112 having a loop backing and a pile surface 120 could then be installed and attached to hooks on anchor sheet 110 .
FIG. 13 shows another arrangement, in which anchor sheet 122 , has a resilient cushion 124 and a carpet covering piece 126 detachably attached to the anchor sheet. A conventional cushion 128 can abut the anchor sheet and cushion and a carpet 130 having a loop backing 132 can be installed over the anchor sheet 122 and cushion 128 .
It will be recognized that within the description of this present case and the related earlier pending cases many variations and permutations and combinations are possible of anchor sheet and tape with or without cushion and with or without installation directly to the floor all of which come within the spirit of the described invention as defined in the attached claims. | An anchor sheet subfloor that includes a laminate having an upper layer of relatively thin flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. The upper sheet layer can be formed of a plastic or polymer material. In one arrangement, the sheet can be cut and fit within the boundaries of a room and the sheet has sufficient rigidity and mass to remain without distortion or buckling within the room by free floating on the existing floor without substantial attachment to the floor. It can be possible for a sheet to be cut and fit on site to fit the contours of a room to form by itself or in combination wit other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to take up devices for use in building structures and is useful in particular, but not exclusively, holdowns for reinforcing building structures against seismic vibrations and hurricane damage.
[0003] 2. Description of the Related Art
[0004] Holdowns are used in wood frame building structures in order to secure the structures to their concrete foundations. For this purpose, conventional holdowns are made of sheet metal and are secured by nails, bolts and other fasteners to the wooden components of the building structure and by anchor bolts to the concrete foundations of the buildings.
[0005] It is found, in practice, that nuts securing the holdowns to the anchor bolts tend to become loose, after a period of time, as a consequence of wood shrinkage due to drying and, also, due to vibration of the building structure caused by seismic activity.
BRIEF SUMMARY OF THE INVENTION
[0006] It is, therefore, an object of the present invention to provide a novel and improved take up device for building structures which will counteract such loosening of the securing nuts.
[0007] According to the present invention, there is provided a take up device which comprises a housing secured by fasteners to a building structure, the housing defining a cylindrical chamber containing a piston and a fluid, i.e. a liquid or a gas, with a piston rod projecting from one or both ends of the housing. One end of the piston rod is connected to a foundation anchor, and a fluid passage interconnects portions of the cylindrical chamber at opposite sides of the piston. The fluid passage is provided with a one-way valve.
[0008] In use, the one-way valve allows the housing to move in one direction, i.e. toward the anchor member, relative to the piston in order to maintain a tight connection between the housing and the anchor. This tightening movement counteracts any compression of the wooden components of the building structure. However, the one-way valve counteracts flow of the fluid in the opposite direction through the fluid passage so as to prevent loosening of this connection.
[0009] The present take up device may be used as a holdown or part of a holdown, e.g. for securing a building structure to a foundation, or as a take up device between e.g. horizontally or vertically adjacent building components.
[0010] In a preferred embodiment of the invention, the fluid passage is formed by a clearance between the piston and the wall of the cylindrical chamber, and the one-way valve comprises an annular seal between the piston and the cylinder wall.
[0011] To allow the present device to act as a dampener, e.g. for dampening seismic vibrations of the building structure, a further fluid flow passage may be provided, e.g. through the piston or bypassing the piston, to allow relaxation of the connection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will be more readily understood from the following description of preferred embodiments thereof given, by way of example, with reference to the accompanying drawings, in which:—
[0013] [0013]FIG. 1 shows an exploded view, in perspective, of a holdown according to a first embodiment of the present invention;
[0014] [0014]FIG. 2 shows a view in perspective of components of the holdown of FIG. 1;
[0015] [0015]FIG. 3 shows a view in perspective of a piston and an annular seal forming parts of the holdown of FIG. 1;
[0016] [0016]FIG. 3A shows a view taken it in cross-section through the annular seal of FIG. 3 along the line 3 A- 3 A of FIG. 3;
[0017] [0017]FIGS. 4 and 4A show views corresponding to those of FIGS. 3 and 3A, but of a modified annular seal;
[0018] [0018]FIGS. 5 and 5A show views in vertical cross-section through a housing, a piston and a one-way valve forming components of the holdown of FIG. 1;
[0019] [0019]FIGS. 6 and 7 show views corresponding to that of FIG. 5 but illustrating modifications of the holdown components of FIG. 5;
[0020] [0020]FIG. 8 shows a view in perspective of the holdown of FIG. 1 in an assembled condition;
[0021] [0021]FIGS. 9 and 9A show views corresponding to that of FIG. 8, but illustrating modifications of the holdown of FIG. 8;
[0022] [0022]FIG. 10 shows a broken-away view, in perspective, of another modification of the holdown of FIG. 1;
[0023] [0023]FIGS. 11 and 12 shows views in perspective of two further modifications of the holdown of FIG. 1, in a partly exploded condition;
[0024] [0024]FIGS. 13 and 14 show, respectively, a view in perspective of the holdown of FIG. 1 with added components and a broken-away view in side elevation of an application of that holdown;
[0025] [0025]FIGS. 15 through 22 show views corresponding to those of the FIGS. 13 and 14, but illustrating different applications of the holdown according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] As shown in FIG. 1, a holdown indicated generally by reference numeral 10 has a housing 12 provided with a housing cover 14 , which is secured to the housing 12 by screws 15 .
[0027] A piston 16 on a piston rod 18 is located in a cylindrical chamber 20 (FIG. 5) in the housing. 12 . The cylindrical chamber 20 is closed at one end by the housing cover 14 and, at its opposite end, by a wall 22 of the housing. The housing cover 14 has a cylindrical recess accommodating a bushing 24 , and the wall 22 has a cylindrical recess accommodating a bushing 26 . The piston rod 18 extends in opposite directions from the piston 16 through the bushings 24 and 26 , and has opposite threaded ends 28 and 30 .
[0028] The outer diameter of the piston 16 is less than the inner diameter of the cylindrical chamber 20 , so that a clearance 31 (FIGS. 5 and 5A) is provided between the periphery of the piston 16 and the cylindrical wall of the cylindrical chamber 20 . An annular seal 32 extends around the periphery of the piston 16 and provides a seal between the piston 16 and the wall of the cylindrical chamber 20 , as described in greater detail below. More particularly, and as shown in FIG. 3A, the annular seal 32 has a U-shaped cross-section comprising limbs 34 and 35 connected by an intermediate portion 36 . The limb 34 , which is the outermost limb, is normally in sealing contact with the cylindrical wall of the cylindrical chamber 20 , and the inner limb 35 is in sealing contact with the piston 16 .
[0029] [0029]FIGS. 4 and 4A show a modified O-ring 38 , which has first and second limbs 39 and 40 , extending toward one side of the O-ring 38 , which are in sealing contact with the cylindrical wall and the piston 16 , respectively, and third and fourth limbs 42 and 43 extending oppositely from the limbs 39 and 40 , and sealingly contacting the cylinder wall. The O-ring 38 of FIGS. 4 and 4A is used instead of the O-ring 32 on the piston 16 , as shown in FIG. 6 and described in greater detail below.
[0030] As can be seen in FIG. 5, the piston 16 has an annular intermediate surface 46 , which is cylindrical, between an annular peripheral projection 48 , forming a shoulder on the piston 16 , and a frustoconical surface 50 , which tapers convergently from the annular intermediate surface 46 . The modified annular seal 38 , as shown, in FIG. 6, extends around the annular intermediate surface 46 , with its limbs 39 and 43 in sealing contact with the annular intermediate surface 46 .
[0031] Referring again to FIG. 1 of the accompanying drawings, the holdown 10 is provided with inlet openings 52 and 54 which are provided with threaded plugs 55 and through which a fluid is introduced into the cylindrical chamber 20 at opposite sides of the piston 16 . The opening 52 is provided in the housing 12 , and communicates directly with the cylindrical chamber 20 , while the opening 54 is provided in the housing cover 14 and communicates with the cylindrical chamber 20 through an axial passage 56 in the housing cover 14 .
[0032] In operation of the holdown 10 , as it has so far been described, the piston is able to move along the cylinder 20 toward the housing cover 14 , e.g. in response to shrinkage of the wooden building components secured by the holdown 10 as described below, so that the housing 12 is able to move relative to the piston 16 toward the end 30 of the piston rod 18 . When this occurs, the pressure of the fluid in the portion of the cylindrical chamber 20 between the piston and the housing cover 14 causes some of the fluid to flow through the clearance 31 between the piston 16 and the wall of the cylindrical chamber 20 , thereby causing the annular seal 32 to be dislodged from the annular intermediate surface 46 to the frustoconical surface 50 , as shown in FIG. 5A. When this occurs, the annular seal 32 no longer provides a seal between the piston 16 and the wall of the cylindrical chamber 20 .
[0033] When, however, the piston 16 is urged in the opposite direction, i.e. toward the end wall 22 of the housing 12 , the fluid in the portion of the cylindrical chamber 20 between the piston 16 and the wall 22 of the housing presses the annular seal 32 back onto the annular intermediate surface 46 and into sealing contact with the piston 16 and the wall of the cylindrical chamber 20 . Consequently, the displacement of the piston 16 in this direction is counteracted by the pressure of the fluid between the piston 16 and the housing wall 22 .
[0034] Therefore, the annular seal 32 serves as a one-way valve, which allows the piston 16 to be displaced in one direction relative to the housing 20 but which counteracts, or even prevents, displacement of the housing 12 in the opposite direction relative to the housing 20 .
[0035] The piston 16 is also formed with a further annular peripheral projection 52 , toward which the frustoconical surface 50 tapers. This further annular peripheral projection 52 serves to retain the annular seal 32 on the piston 16 when the seal is displaced, as described above, from the annular intermediate surface 46 to the frustoconical surface 50 .
[0036] [0036]FIG. 6 shows a modification of the piston 16 , which is indicated by reference numeral 60 . The piston 60 differs from the piston 16 in that the piston 60 , which is otherwise the identical to the piston 16 , is formed with a boring 62 extending through the piston 60 , parallel to the longitudinal axis of the piston rod 18 . This boring 62 provides a further fluid flow passage interconnecting the portions of the cylindrical chamber 20 at opposite sides of the piston 16 , and allows a restricted flow of the fluid past the piston 16 . In this embodiment of the present invention, the annular seal 32 is replaced by the annular seal 38 .
[0037] By this means, the piston 16 is enabled to move gradually toward the housing wall 22 . Consequently, when this modified piston 60 is substituted for the piston 16 in the holdown 10 , the latter acts as a dampener.
[0038] [0038]FIG. 7 illustrates a further modified piston, indicated by reference numeral 64 , which is identical to the piston 60 of FIG. 6 except that the piston 64 is additionally provided with a flow control screw 66 , in the form of a grub screw, which can be screwed into a correspondingly threaded opening 68 in the piston 64 . When thus inserted into the piston 64 , the flow control screw 66 can be adjusted so as to obstruct, to a greater or lesser extent, the cross-sectional area of the boring 62 and, thus, so as to adjustably restrict the flow of fluid through this further flow passage and, thereby, to control the damping effect of the piston 64 .
[0039] [0039]FIG. 8 shows a view in perspective of the holdown 10 of FIG. 1 in an assembled condition.
[0040] [0040]FIG. 9 shows a view corresponding to that of FIG. 8 but illustrating a modification of the holdowns of FIGS. 6 and 7, indicated generally by reference numeral 10 A, in which the piston 16 is provided, i.e. the piston lacks the further flow passage formed by the boring 62 in the piston 60 or 64 , but in which the opposite sides of the piston 16 are instead interconnected by a further flow passage extending through a tube 70 at the exterior of the housing. The tube 70 is provided with a check valve 69 controlling flow through the tube 70 .
[0041] [0041]FIG. 9A shows the holdown of FIG. 9 modified by the provision of an adjustment screw 71 , which can be screwed into the check valve 69 to a greater or lesser extent in order to correspondingly adjust the flow through the tube 70 .
[0042] FIGS. 10 to 12 show further modifications 10 B, 10 C and 10 D of the holdown 10 , in which flow passages within the housings of the modified holdowns interconnect the portions of the cylindrical chambers at opposite sides of the pistons.
[0043] In FIG. 10, an auxiliary chamber 72 communicates through openings 74 and 76 with opposite sides of the piston.
[0044] In FIG. 11, a modified piston rod 16 C projects downwardly from the holdown 10 C but does not project upwardly through a cover 14 C of a housing 12 C. A spring (not shown) is provided between the piston 16 C and the housing 12 C. An auxiliary chamber 78 , corresponding to the chamber 72 of FIG. 10, interconnects opposite sides of piston 16 C.
[0045] The holdown 10 D of FIG. 12 is similar to the holdown 10 C except that, as shown in FIG. 12, the upper end 28 of the piston rod 18 projects through housing cover 14 D.
[0046] [0046]FIG. 13 shows the holdown 10 mounted on a pair of parallel elongate support blocks 100 , which are provided with through-openings 102 for receiving fasteners, for example screws (not shown). In FIG. 14, the holdown 10 of FIG. 13, together with its support blocks 100 , is shown mounted on the top of a building structure indicated generally by reference numeral 104 at the top of the building structure 105 . The fasteners (not shown) extend through the support blocks 100 so to secure the holdown 10 to the top of a plate 104 . The piston rod 18 thus extends vertically, and its lower threaded end 30 is connected through a plurality of connecting rods 106 and couplings 108 to an anchor bolt 110 , which is secured in a concrete foundation 112 .
[0047] Two further holdowns 10 are shown in FIG. 14, which are interconnected between two of the couplers 108 and plates 109 on joists 111 at intermediate floors of the building structure 105 . However, these two further holdowns 10 may be omitted if not required.
[0048] [0048]FIG. 15 shows the holdown 10 secured to one face of a vertical metal plate 112 , formed with bolt holes 113 , with a support block 114 , which is fixed to the plate 112 , underlying the housing 12 of the holdown 10 . A plurality of such holdowns 10 , each provided with a respective vertical plate 112 , can then be bolted to vertical studs 116 of building structure, as shown in FIG. 16, and connected between the uppermost holdown 10 , which is similar to that of FIG. 13, and the anchor bolt 110 .
[0049] [0049]FIG. 17 shows the holdown 10 secured to a pair of a vertical metal plates 120 . As shown in FIG. 18, these vertical plates can then be secured by nuts 122 and bolts 123 between a pair of studs 124 , with the bolts 123 extending through bolt holes 126 in the plates 120 and through the studs 124 , the holdown 10 being connected between the anchor bolt 110 and the lower end 30 of the piston rod 18 by one of the couplers 108 . The upper end 28 of the piston rod 18 is connected by a further coupler 108 and connecting rod 106 to an overlying holdown (not shown).
[0050] [0050]FIG. 19 shows the holdown 10 mounted on a conventional sheet metal holdown indicated generally by reference numeral 130 . The holdown 130 is secured to a pair of studs 132 by a pair of bolts 134 , each provided with a nut 136 and a washer 138 (FIG. 20). The holdown 10 is mounted on an intermediate portion 140 of the holdown 130 extending between opposite sidewalls 142 and is connected by coupler 108 to the anchor bolt 110 .
[0051] [0051]FIG. 21 shows a further arrangement of the holdown 10 , which in this case is mounted between a pair of identical elongate rectangular plates 150 , to which the housing 12 of the holdown 10 is attached by welding or otherwise. The plates 150 are formed with circular openings 152 , which are connected through tubes 154 welded or otherwise attached to the plates 150 .
[0052] As shown in FIG. 22, the holdown 10 together with the plates 150 are located between a pair of wooden studs 156 , with bolts 158 extending through the studs 156 and through the tubes 154 and secured by nuts 160 . The holdown 10 is again connected through coupler 108 to the anchor bolt 110 .
[0053] The fluid provided in the holdowns according to the present invention may be hydraulic fluid or any suitable inert gas.
[0054] As will be apparent to those skilled in the art, various modifications may be made in the above described invention within the scope and spirit of the accompanying claims. | A take up device for a building structure, e.g. holdown for securing the building structure to a foundation, has a housing secured by fasteners to the building structure, the housing defining a cylindrical chamber containing a piston and fluid, with a piston rod projecting from the housing. The piston rod is connected to a foundation anchor, and a fluid passage interconnects portions of the cylindrical chamber at opposite sides of the piston. The fluid passage is provided with a one-way valve, which allows the housing to move upwardly relative to the piston, to maintain the tightness of the connection to the anchor bolt, but resists opposite movement of the housing. |
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FIELD OF THE INVENTION
[0001] The present invention relates to a supervisory control system and method of supervisory control for fluid networks, and relates particularly, though not exclusively, to supervisory control systems for open conduits (channel networks) and closed conduits (pipelines).
BACKGROUND OF THE INVENTION
[0002] In our U.S. Pat. No. 7,152,001, the entirety of which is herein incorporated, there is disclosed a computer based system for predicting the fluid level in a fluid flow network. The system has been very successful as it can use past and present measurements of parameters to predict and control fluid level and flow. The system gathers data from timed fluid levels and opening positions of regulators or valves to provide a model from which fluid levels and flow can be determined in real time. An irrigation channel is an open hydraulic system that serves to convey water from a source supply to end customers. Along the channel, flows and water levels are regulated via control gates situated at discrete points. FIG. 1 of U.S. Pat. No. 7,152,001 shows a side view of a typical channel regulated by overshot gates. The stretch of channel between gates 16, 18 is referred to as a pool. Water flows under the power of gravity, from a water source along the channel to farms. In view of this, the water levels along the channel correspond to the potential energy available to produce flow of water along the channel itself, into lateral distribution systems and onto land to be irrigated. It is therefore important to maintain the water levels above the levels required to meet flow demand.
[0003] The goal of automating an irrigation channel is to improve distribution efficiency in terms of the water taken from the supply and the water delivered to end customers. This is achieved by employing advanced instrumentation and control systems of the type shown in U.S. Pat. No. 7,152,001, which provide for a closer match between the water ordered by the farmers and the volume of the water moving through or flowing into the channel system, while maintaining the water levels along the channel system within operational limits dictated by quality of service and safety concerns.
[0004] U.S. Pat. No. 7,152,001 includes sensors 24, 26, 28, 29 and actuators linked through a Supervisory Control and Data Acquisition (SCADA) communication network 44 and advanced control practices that work in conjunction with each other to achieve high distribution efficiency, reduce transmission losses and provide high level of service to the customer/farmer thereby yielding high productivity from water which is a limited resource. When a channel is fully automated, the channel control gates 16, 18 are operated in such a manner so as to meet the demand for water downstream of the control gates 16, 18 and to maintain the water level upstream of the gate or regulator in every pool. A certain level of water must be exceeded in each pool to provide the potential energy needed to propel water further downstream, into secondary channels and onto the adjacent farms. The volume of water flowing into the channel system is controlled at the upstream or top end. The volume of water flowing into the channel is increased if a drop in the water level is sensed in a given pool or is reduced if the water level rises ensuring a constant water level is maintained.
[0005] A reactive control strategy is employed to maintain the water level in pools at their set points, i.e. control action is taken only when the controlled variable (water level in a pool) deviates from its set point. This is often referred to as feedback control. Measured flow information at the downstream regulator 18 in a pool and at the lateral off takes and at the farm outlets (if available) can be exploited to augment the feedback controller and make the control system more responsive. Often referred to as feed forward control, the upstream gate 16 sends a percentage of the measured outflows immediately rather than waiting for the flows to affect the water level in the pool and the feedback controller to take action.
[0006] The reactive control architecture described above confines the propagation of transients to upstream of changes in flow load (i.e. an out flow starting or stopping). This has merit in terms of the corresponding demand driven release of water from the upstream source; i.e. water is released from the top only when there is an out flow due to an off take downstream and this is cut off when the off take stops. However, the achievable transient performance is fundamentally limited by inherent transport delays, particularly in terms of transient peaking of control gate flow commands and deviation in water levels in response to an increase in flow load and similar undesirable effects when flow load is reduced.
[0007] FIG. 1 of the drawings shows a graph of a flow peak amplification along a channel operated using U.S. Pat. No. 7,152,001 for a 55 Megalitre/day step up 20 in flow from bottom control gate in the channel. The first and main limitation of the control strategy depicted in FIG. 1 is the limited transient flow characteristic. The peaks in the transient flows commands for the control gates 16 are amplified as the effect of a load change propagates upstream. Transient behaviour as depicted in FIG. 1 can result in actuator (i.e. control gate) saturation, thereby triggering undesired behaviour. This is the second limitation of the existing strategy used in U.S. Pat. No. 7,152,001. The mechanism to counter saturation, often called anti-windup in the control industry, is designed as an afterthought in U.S. Pat. No. 7,152,001 and this may not be very effective. In the case of long pools e.g. greater than 5 km that have limited storage volume, the flow transient may result in unacceptable water level deviations that may affect service to customers/farmers or it may violate safe operational limits. This is the third limitation of the existing strategy. The third limitation means that the existing control strategy cannot be applied to open irrigation channels with very limited freeboards. This is the fourth limitation. “Freeboard” is the height of the channel bank above the highest water level anticipated.
OBJECTS OF THE INVENTION
[0008] It is an object of the present invention to provide a method and system to accurately deliver water through an irrigation network to customers.
[0009] A further object of the invention is to provide a method or system where overheads to the delivery of water through an irrigation network are reduced.
SUMMARY OF THE INVENTION
[0010] The present invention in one aspect provides a method of delivery of fluid to at least one customer through a computer controlled fluid network, said fluid network having a plurality of regulators to control the flow of fluid along said fluid network to deliver a predetermined amount of fluid to said at least one customer, said network including a first control system for opening and closing said regulators under computer control, said first control system collecting data based on timed measurements of fluid levels upstream and downstream of respective regulators and the opening positions of respective regulators, using data analysis to provide respective models for prediction of respective fluid levels between regulators, a second control system that is a supervisory layer interacting with said first control system to provide adjustments to the controlling of said regulators by said first control system based on constraint and future flow load, and a third control system interacting with said first and second control systems, said third control system processing fluid delivery requests from said at least one customer to provide a flow load delivery schedule based on the hydraulic capacity of said fluid network.
[0011] The invention also provides a delivery system for the delivery of fluid to at least one customer through a computer controlled fluid network, said fluid network having a plurality of regulators to control the flow of fluid along said fluid network to deliver a predetermined amount of fluid to said at least one customer, said network including a first control system for opening and closing said regulators under computer control, said first control system collecting data based on timed measurements of fluid levels upstream and downstream of respective regulators and the opening positions of respective regulators, said first control system adapted to use data analysis to provide respective models for prediction of respective fluid levels between regulators, a second control system that is a supervisory layer interacting with said first control system to provide adjustments to the controlling of said regulators by said first control system based on constraint and future flow load, and a third control system interacting with said first and second control systems, said third control system processing fluid delivery requests from said at least one customer to provide a flow load delivery schedule based on the hydraulic capacity of said fluid network.
[0012] In a preferred embodiment said second control system uses model predictive control to provide pre-emptive control.
[0013] Preferably data from a SCADA interface is used to calibrate and continually fine tune the computer controlled fluid network using a model of the pipe network based on system identification techniques.
[0014] The invention may also provide a method of delivery of fluid to at least one customer through a computer controlled fluid network, said fluid network having a plurality of regulators to control the flow of fluid along said fluid network to deliver a predetermined amount of fluid to said at least one customer, said network including a first control system for opening and closing said regulators under computer control, said first control system collecting data based on timed measurements of fluid levels upstream and downstream of respective regulators and the opening positions of respective regulators, using data analysis to provide respective models for prediction of respective fluid levels between regulators, and a second control system that is a supervisory layer interacting with said first control system to provide adjustments to the controlling of said regulators by said first control system based on constraint and future flow load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The structure and functional features of a preferred embodiment of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0016] FIG. 1 shows a graph of a flow peak amplification along a channel operated using the system described in U.S. Pat. No. 7,152,001 for a 55 Megalitre per day step up in flow from the bottom most regulator;
[0017] FIG. 2 is a schematic flow chart of a computer controlled fluid network in accordance with the concepts of the present invention; and
[0018] FIG. 3 is a similar view to that of FIG. 3 of U.S. Pat. No. 7,152,001 including features in accordance with the concepts of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The preferred embodiment is an enhancement of the inventions disclosed in U.S. Pat. No. 7,152,001 and Australian Patent Application No. 2011903084, now International Patent Application No. PCT/AU2012/000907 and any patent applications based on International Patent Application No. PCT/AU2012/000907. In order to reduce repetition of description, the whole contents of U.S. Pat. No. 7,152,001 and International Patent Application No. PCT/AU2012/000907 are herein incorporated into this specification.
[0020] FIG. 2 is a schematic flow chart of a computer controlled fluid network system 100 for open conduits, i.e. channel networks, especially for irrigation. The system has three (3) sub-systems, namely a first control system 102 , a second control system 104 and a third control system 106 . The first control system 102 is a fluid regulator system preferably of the type disclosed in U.S. Pat. No. 7,152,001 which is more fully disclosed and incorporated into this description from U.S. Pat. No. 7,152,001. The third control system 106 is a demand management system preferably of the type disclosed in International Patent Application No. PCT/AU2012/000907 which is more fully disclosed and incorporated into this description from International Patent Application No. PCT/AU2012/000907. The second control system 104 is a supervisory control system to be discussed shortly. The first control system 102 provides a control scheme and allows movement of a plurality of control gates (not shown) to set flow locally after a disturbance in the form of water level deviation or a measured outflow in the pool is observed. This operation is discussed in the preferred embodiment of U.S. Pat. No. 7,152,001. First control system 102 has control gate flow commands 108 for the opening of control gates (not shown). An approach to mitigating the limitations of reactive control architecture of this kind is to exploit available information about future flow demand. Allowing the control gate flow commands 108 produced by first control system 102 and the water level references 109 used in determining these commands to be adjusted by second control system 104 , provides scope for systematically exploiting both measure off-take flows and a schedule of such flows into the future. Accordingly, the second control system 104 makes adjustments 107 to the control gate flow commands 108 and/or water-level references 109 in order to improve transient performance by ensuring the satisfaction of constraints, based on measured information and a model of the automated channel, including a representation of future flow load, such as a schedule. The second control system 104 is the middle layer in a three-tier hierarchy, with the channel operating under first control system 102 at the lowest layer and the third control system 106 , the demand management system, at the highest layer. The third control system 106 processes orders 112 from customers or farmers 114 to build up a flow load schedule 116 .
[0021] A preferred embodiment of the supervisory control scheme that can achieve the objectives specified above, involves the use of a receding horizon optimal control technique often called Model Predictive Control (MPC) in the open literature for the third control system 106 . It is particularly well suited to supervisory control problems of the kind mentioned above. Specifically, the MPC technique can directly incorporate predictions or a schedule of the flow load (demand) over a future horizon, as well as constraints on how the water level and references may vary across time. These features are ideally suited to providing quality-of-service guarantees at supply points, flood-free operation and the avoidance of actuator saturation, which can lead to very undesirable dynamic behaviour. That is, the features are ideally suited to mitigating the four limitations of the existing first control system 102 i.e. the fluid regulator system disclosed in U.S. Pat. No. 7,152,001.
[0022] As can be seen in FIG. 2 , second control system 104 has knowledge of the future flow load schedule 116 and it obtains an estimate of the state of the first control system 102 , via measured water level and flow information 110 . This provides scope for taking pre-emptive control action in anticipation of future load (demand) in order to achieve improved transient performance, with quality of service guarantees via the satisfaction of constraints on water levels and flows.
[0023] The control scheme of the first control system 102 provides a degree of robustness against uncertainties such as model and instrumentation inaccuracies, transportation losses and customer/farmer non-compliance with the agreed flow load schedule via feedback based control action. The second control system 104 also employs feedback in decision making via the measured water level and flow information 110 .
[0024] The hierarchical architecture of the three control systems 102 , 104 , 106 provides scope for exploiting the advantages of both worlds; pre-emptive control via second control system 104 that is a supervisory control layer that exploits the knowledge of future flow demand schedule using the preferred control implemented via MPC, for example, and reactive control via first control system 102 . This is a first unique aspect of the solution. The additional supervisory control layer of the second control system 104 in the hierarchy will enable further exploitation of the capability of the fluid network system by the use of available storage to surcharge the network in anticipation of a future load change, via adjustment of water-level references 109 and by varying the flow commands 108 of first control system 102 .
[0025] The use of MPC techniques to implement a supervisory control layer in second control system 104 for a lower-level reactive water-level regulation controller of the first control system, with a view to exploit information regarding the load schedule agreed between the customers 114 and a demand management system in the third control system 106 so as to improve transient performance, is a second unique aspect of the solution.
[0026] As previously discussed MPC is a receding horizon optimal control technique. Within the context of FIG. 2 , this means that before each update time, the adjustment to the flow command or water-level reference 107 is determined by solving a constrained optimization problem. This occurs each time the flow commands and reference water levels 107 are to be updated. The optimization problem solved at each time step involves a model for the channel operating under the first control system 102 , which includes the effect of the schedule load over a prediction horizon into the future. The model is initialized using observer-based estimates of the state, derived via measurements of the water levels and flows along the channel. The optimization problem solved for each update time involves a cost function to steer the solution to desirable transient characteristics and constraints on water-levels and flows, which avoid the performance degrading effects of actuator saturation and which lead to quality of service and safe operation guarantees. The ability to make such guarantees is a third unique aspect of the solution.
[0027] The building blocks of the MPC are the channel models and controller models that underpin the design of the first control system as described in U.S. Pat. No. 7,152,001. The channel models are grey box (part physics based part data based) models with good predictive capabilities. The usage of grey box models is fourth unique aspect of the solution. A common practice in the automation industry is to use black box models based on a step response. All the abilities of the invention discussed in columns 8 and 9 of U.S. Pat. No. 7,152,001 are applicable to MPC as well since MPC is built using the models and controllers described in U.S. Pat. No. 7,152,001.
[0028] The preferred Model Predictive Controller of second control system 104 will seamlessly integrate with the SCADA and computer environment discussed at column 6 of U.S. Pat. No. 7,152,001. A copy of “FIG. 3” from U.S. Pat. No. 7,152,001, augmented to include an MPC implementation of the supervisory control layer of second control system 104 , is shown as FIG. 3 of the present application. The architecture of deploying MPC as a supervisory control layer as shown in FIG. 3 is a fifth unique aspect of the solution. FIG. 3 uses the identical reference numerals used in FIG. 3 of U.S. Pat. No. 7,152,001 and discussion of reference numerals 42 to 54 are fully described in U.S. Pat. No. 7,152,001 and do not require further repetition of description. As can be seen second control system 104 is linked to pool construction module 54 , LQR controller software module, the SCADA module 44 , main database 46 and third control system 106 . Similarly, third control system 106 is linked to network topology software 52 , second control system 102 , main database 46 and user interface 48 . This integration of second and third control systems provides a complete irrigation control system as opposed to the fluid regulation system of U.S. Pat. No. 7,152,001.
Glossary of Terms
[0029] “Black box model”—Model based on pure input and output behaviour of the system without any knowledge of actual physics
[0030] “Demand”—Flow load on the fluid network system
[0031] “Grey box model”—Model based on physics of the system and experimental data
[0032] “Off-take”—A channel for taking away water. An off-take can be a farmer outlet or a secondary irrigation channel taking water off the main irrigation channel
[0033] “Transient response”—behavior of a control system for a change in its load or set point
[0034] “Set point”—Desired level/band at/within which the controlled variable should be maintained
[0035] “Step response”—Step response is the time behavior, of the outputs of a system when its inputs change from zero to a non-zero value in a very short time
[0036] The invention will be understood to embrace many further modifications as will be readily apparent to persons skilled in the art and which will be deemed to reside within the broad scope and ambit of the invention, there having been set forth herein only the broad nature of the invention and certain specific embodiments by way of example. | A method of delivery of fluid through a computer controlled fluid network, the network including: regulators to control the flow of fluid to deliver a predetermined amount thereof to at least one customer; a first control system for opening and closing the regulators, which collects data based on timed measurements of fluid levels upstream and downstream of respective regulators and the opening positions of respective regulators, using data analysis to provide models for prediction of fluid levels between regulators; a second control system that is a supervisory layer interacting with the first control system to provide adjustments to the controlling of the regulators based on constraint and future flow load; and a third control system interacting with the first and second control systems, which processes fluid delivery requests from the at least one customer to provide a flow load delivery schedule based on the hydraulic capacity of the network. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally related to the field of earth boring. More specifically, the present invention is related to the field of methods and devices for cleaning tools used to bore into the earth or other solid or semi-solid matter.
2. The Background Art
Commonly ground boring tools are cleaned manually. Manual cleaning of an auger is performed by hand by a workman wearing gloves as the auger is withdrawn from the bore hole.
Bollinger et al. (U.S. Pat. No. 4,650,012) discloses an apparatus for cleaning dirt and debris from a helical earth boring tool. It has a scraper blade which is mounted on a rotating support which is driven to rotate my a motor. The apparatus is mounted to be freely movable (up and down) along a post.
Hennecke et al. (U.S. Pat. No. 3,581,833) discloses an apparatus for cleaning dirt and debris from a helical earth boring tool. It has opposed wipers which are biased by a spring to move inwardly to engage the boring tool. Both the boring apparatus and the cleaning apparatus are commonly mounted along guide mast.
Blum (U.S. Pat. No. 5,242,027) discloses an apparatus for cleaning dirt and debris from a helical earth boring tool. It has a multi-blade scraper with blades arranged radially. The boring tool and the cleaning apparatus are mutually mounted from the support structure.
Brenner (U.S. Pat. No. 3,968,846) discloses an apparatus for cleaning dirt and debris from a helical earth boring tool. It has a multi-blade scraper with blades arranged radially. Movement of the scraper is actuated by a hydraulic cylinder.
Stanley (U.S. Pat. No. 386,901) discloses a post hole digging apparatus (see FIG. 1) which has a rotary earth boring tool (drill-rod S with a bit at the bottom), and a tool cleaner structure which is fixedly mounted to the frame of the apparatus.
Chattstrom (U.S. Pat. No. 1,356,125) discloses an apparatus for cleaning dirt and debris from a helical earth boring tool. It has a scraper and a handle and it is pivotably mounted to a plate.
Gibson (U.S. Pat. No. 1,602,375) discloses an earth boring apparatus which has a cleaning brush mounted thereon to clean dirt and debris from helical boring tool.
Hermanns (U.S. Pat. No. 902,294) discloses a manual post hole digger which has integrally mounted thereon a cleaning mechanism for forcing accumulated soil from the digger.
Newman (U.S. Pat. No. 370,810) discloses a manual post hole digger which has integrally mounted thereon a cleaning mechanism for forcing accumulated soil from the digger.
Watts (U.S. Pat. No. 3,382,935) discloses an earth boring apparatus which has a helical earth boring tool, a cylindrical casing, and a movable cover member for allowing elimination of dirt from the casing as the tool rotates.
Panak et al. U.S. Pat. No. 3,817,337 discloses an apparatus for making holes in putting greens which has a spring-loaded mechanism for cleaning the soil core from the apparatus.
The conventional devices fail to solve the problem of cleaning dirt and debris from earth boring augers in an easy use and cost-effective manner. The conventional devices are mounted to the digging apparatus as an integral part thereof. Thus, the conventional solutions must be implemented at manufacture of the digging machine, or they must be retro-fitted to the digging machine.
BRIEF SUMMARY OF THE INVENTION
The auger cleaner is a tool for cleaning dirt and debris from the stem and flighting of earth boring augers. The auger cleaner is portable and so may be moved from one job site to another. The auger cleaner is readily adaptable such that it may be exchanged between different digging machines, even ones with different size augers or ones built by different manufacturers.
Most significantly, the auger cleaner makes work easier for the operator of the earth boring machine, or the operators assistants. Rather than cleaning dirt and debris from the auger by hand, the auger cleaner may be fastened about the auger and used to clean the auger with a minimum of effort.
Also of significant advantage, the auger cleaner is small and may be manufactured at a minimal cost. As the auger cleaner is not to be mounted to the earth boring machine as an integral fixture, there is no need for a costly retro-fitting.
It is an object of the present invention to provide an easy way for an operator of an earth boring auger to clean dirt and debris from the auger, which requires less physical exertion than previous methods, such as cleaning by hand.
It is another object of the present invention to provide a cost effective means for earth boring augers to be provided with a cleaning mechanism.
It is another object of the present invention to provide a cleaning tool for an earth boring auger which may be hand held and operable by one person.
It is another object of the present invention to provide a portable cleaning tool for an earth boring auger which may be moved easily from one earth boring machine to another, and thus, exchanged between earth boring machines.
It is another object of the present invention to provide a cleaning tool for an earth boring auger which may be readily modified to fit augers of different sizes and different manufacturers.
Other objects of the present invention will become clear as the invention is described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the auger cleaner device according to a preferred embodiment.
FIG. 2 shows a view of the auger cleaner according to the present invention fastened in an engaged, operating position about an earth boring auger.
FIG. 3 shows a top view of the auger cleaner device according to a preferred embodiment.
FIG. 4 shows a side view of the auger cleaner device according to a preferred embodiment.
FIG. 5 shows a detail view of one of the exchangeable blade assemblies.
DETAILED DESCRIPTION OF THE INVENTION
The auger cleaner according to the present invention is simple to use and has a "user friendly" construction. The auger cleaner 10 is a hand tool which secures 20 about an earth boring auger 30. Once the auger cleaner 10 is fastened about the stationary auger 30, the user operates the cleaner by grasping the handles and rotating the cleaner 10 around the auger 30.
The apparatus is composed of four major components: 1) the handles, 2) the hinge, 3) the latch, and 4) the blades.
The handles 12, 14 of the device 10 provide a means for the user to easily grasp the device 10 and to apply force to the device to cause it to rotate about the auger 30 being cleaned. The handles 12, 14 are configured in two separate handle portions which are hinged together. Each of the handle portions may be configured to have one or two hand holds. According to a preferred embodiment, the handles 12, 14 are configured such that each of the two handle portions has two hand holds to form a total of four hand holds 16, 18, 22, 24.
Each of the handles 12, 14 should be formed to be long enough to provide a suitable mechanical advantage to dramatically decrease the amount of effort required to rotate the auger cleaner 10 about the auger 30, as compared to cleaning by hand. As a countervailing consideration, the handles 12, 14 should not be made so long as to collide with the other equipment of the drilling rig (not shown) when the auger cleaner 30 is being used. Accordingly, the handles should have a length which is short enough to operate easily on most rigs having a retractable slide base with out restricting or modifying routine operations.
The handles 12, 14 are spaced in such a way as to be ergonomically correct for a comfortable feel. That is to say, when the auger cleaner 10 is affixed or latched onto the auger 30 to be cleaned, the handles 12, 14 are relatively spaced such that the hand holds 16, 18, 22, 24 may be easily grasped while the cleaner 10 is rotated either clockwise or counter-clockwise during the cleaning process. This allows the operator of the cleaner to easily locate one of the four hand holds 16, 18, 22, 24 (one at each end of each handle) by simply grasping the hand hold with one hand and rotating the cleaner 10 about the auger 30.
The two handles 12, 14 may advantageously be constructed of mild steel, black wall pipe. It is contemplated that schedule 40 pipe may be used for this purpose.
The second component of the device according to the present invention is the hinge 25 which is made up of two hinge plates 26, 28, outer hinge pin housings 32, a hinge pin 34 (or a simple bolt), and a hinge pin retainer pin 36 (or a nut to retain a bolt). There may be either three (shown) or four (not shown) outer hinge pin housings 32. In the case that four hinge pin housings are implemented, the first and second hinge plates 26, 28 are identically constructed to the hinge pin housings 32, and couple together rotatably to form a hinge between the two handle portions 12, 14. The hinge plates 26, 28 are fixed to the handles 12, 14, respectively.
The hinge 25 serves as one of the only two moving parts of the cleaner. The hinge also serves to maintain the proper mechanical tolerances (i.e., cleaning quality) of the device.
The third component of the device according to the present invention is the latch assembly. The latch 38 is the second of the two moving parts of the cleaner. It is simple in design and can be affixed to either of the handle portions 12, 14. Preferably, the latch 38 is disposed just inside the hand holds 18 and 24.
The latch assembly serves as a device to secure the auger cleaner 10 onto the auger 30. The latch 38 is affixed onto one handle 14 opposite the hinge 25 and employs that handle 14 as its pivot point. To prevent the latch 38 from sliding axially along the handle 14 and the handle 12, latch restraints 40 are provided, fastened to the handles 12, 14. The latch 38 is then pivoted on an axis so as to secure or latch onto the other handle 12 at the hand hold 24 opposite of the hinge 25. The latch assembly also serves as a mechanism that helps control the mechanical tolerance between the auger cleaner 10 and the auger 30, resulting in better cleaning quality.
Each end of the latch 38 is constructed with a notch in such a way as to be identical to one other. During assembly one end of the latch 38 is modified through bending so as to permanently affix the latch 38 to the handle 14 in a rotatable relationship. The bending of the end of the latch 38 may be done via cold bending or heated bending.
The auger cleaner 10 has a pair of opposedly mounted blade assemblies 50, 60, each of which is mounted from one of the handle portions 12, 14, respectively. According to a preferred embodiment, the blade assemblies 50, 60 are removably mounted onto the handles 12, 14. Each blade set along with its associated mounting hardware form a blade assembly.
A blade assembly 50 is composed of the blade holder or socket 51, the socket-to-blade connecting shaft 52, the tube blade 53 (or stem blade), the flighting blade 54, and the blade assembly retaining pin 55 (which could advantageously be a bolt & nut). A blade set is the combination of a tube blade 53 with its associated flighting blade 54.
Each blade set is constructed to be custom configured to the augers to be cleaned, taking into account the quality control tolerances of the manufacturer of the particular auger. This means that the blade set will fit an entire manufacturing line of that particular auger.
The stem and flighting blade assembly 50, 60, handles 12, 14, hinge plates 26, 28, blade assembly sockets 51, 61, blade assembly retaining pins or bolts 55, 65, and latch guide washers 40 are identical between the left and right half of the auger cleaner 10 except that one side is simply an inverted, or turned over, version of the other side. This lends to the ease of construction and quality control of the auger cleaner. This feature also allows the cleaner to clean the top and bottom of the flighting and the stem at two separate locations equally well regardless of rotation direction.
The tube and flighting blade set is removable and exchangeable between different auger cleaners or handle assemblies.
The stem or tube blades 53, 63 of the cleaner 10 are designed and constructed to peel the debris from the tube or stem, resulting in a very complete cleaning.
AN EXAMPLE
If a person is cleaning augers with an auger cleaner 10 fitted with a blade assembly for Central Mine Equipment 41/4" inside diameter hollow stem augers, the blade assembly retaining pin may be removed, and the blade assembly slid out from the blade holder socket. Then a blade assembly suitable for Mobile Drilling Company 21/4" inside diameter hollow stem augers may be installed, following the above steps in reverse order. That person is then ready to clean the Mobile auger as easily as the Central Mine Equipment augers.
A first alternate embodiment (not shown) of the present invention may be realized by making the device larger in dimensions to clean larger augers. According to this first alternate embodiment, larger diameter "heavier" wall pipe will be used to construct handles which will be identical in construction to the preferred embodiment, but will employ blades to clean hollow stem augers having inside diameters in a range of from about 41/4 inches to about 121/4 inches. The construction and appearance of the hinge assembly will be identical, for this first alternate embodiment, to that of other embodiments in all aspects other than physical size.
A second alternate embodiment (not shown) of the present invention may be realized by making the blade portions unitary with the handles. That is, the blade assemblies of the second alternate embodiment are not removable from the rest of the device.
A preferred embodiment of the invention has been described for purposes of illustration. Of course, various equivalent elements may be substituted for those described above without departing from the spirit of the invention. The embodiments described are not intended to be limiting, and the scope of the invention is limited only so far as the appended claims. | An apparatus is provided for cleaning dirt and debris from the stem and flighting of an earth boring auger. The auger cleaner apparatus has an opposed pair of blade assemblies which are brought into mechanical engagement with the stem and flighting of the auger. Once the auger cleaner is engaged about the auger, the user of the apparatus then need only rotate the auger cleaner about the auger to strip off dirt and debris. The auger cleaner has handles which provide mechanical advantage to the user for causing the device to rotate about the auger. The device may be provided with selectively exchangeable blade assemblies for adapting the auger cleaner for use on augers of different sizes and of different manufacturers. |
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BACKGROUND
1. Field of Invention
The invention is directed to gravel packs in oil and gas wells and, in particular, to downhole tools comprising screens for insertion into the gravel pack completions in wellbores.
2. Description of Art
In completing wells having production or injection zones which lie adjacent to incompetent formations formed from unconsolidated matrixes such as loose sandstone, or which lie adjacent formations that have been hydraulically-fractured and propped such as through fracturing processes, sand control problems often arise during the operational life of the well. These sand control problems are encountered when large volumes of sand and/or other particulate material such as backflow of proppants from a hydraulically-fractured formation dislodge from the formation and become entrained in the formation fluids and are produced therewith into the wellbore. These produced materials have an adverse effect on the operation of the well because they can cause erosion and plugging of the well equipment which, in turn, leads to high maintenance costs and considerable downtime of the well.
One technique for controlling sand production in a wellbore is referred to as “gravel packing” or forming a “gravel pack completion.” In general, a gravel pack completion comprises a screen, such as a fluid-permeable liner, a perforated liner, a slotted liner, a pre-packed screen, that is disposed within an open-hole or cased wellbore adjacent the incompetent or fractured zone and is surrounded by aggregate or particulate material collectively referred to as “gravel.” As known in the art, the gravel particles are sized to block or filter out the formation particulates that may become entrained in the produced fluids, while the openings in the screen are sized to block the gravel from flowing into the screen.
One method for installing a typical gravel pack completion in a wellbore involves placing the gravel in the wellbore first and then driving, rotating, or washing the screen into the gravel to form the gravel pack. To assist in installing the screen in gravel disposed in a wellbore, the liner may include one or more auger blades, referred to herein as an “auger-flighted screen.”
SUMMARY OF INVENTION
In accordance with the disclosure herein, a screen is included as part of a downhole tool designed to assist in the installation of the screen into gravel disposed in a wellbore. Broadly, the downhole tool includes the liner or screen having at least one port disposed in the screen's outer wall surface, a dynamic isolation device comprising a sealing element, and an artificial lifting device. The artificial lifting device is disposed above the dynamic isolation device which, in turn, is disposed above the screen so that the sealing element can divide the wellbore into two zones, an upper zone and a lower zone. The screen will, therefore, be disposed in the lower zone and the artificial lifting device will be disposed in the upper zone. The two zones are in fluid communication with each other through a longitudinal bore within the downhole tool.
In operation, the artificial lifting device of the downhole tool creates a negative pressure such that wellbore fluid is transported from the lower zone, through the downhole tool and into the upper zone. Due to this flow of fluid through the downhole tool, gravel disposed within the wellbore becomes sufficiently fluidized due to an increase in pressure within the lower zone. This fluidization of the gravel facilitates the screen to be inserted into the gravel form the gravel pack completion.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of one specific embodiment of a downhole tool having an auger-flighted screen disclosed herein shown in the run-in position.
FIG. 2 is cross-sectional view of the downhole tool of FIG. 1 shown in the set position.
FIG. 3 is a detailed cross-sectional view of the artificial lift device of the downhole tool of FIGS. 1 and 2 .
FIG. 4 is a perspective view of another embodiment of the downhole tool having a screen disclosed herein shown in the run-in position.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
Referring now to FIGS. 1-3 , one embodiment of downhole tool 40 is shown disposed in wellbore 20 within an earthen formation. Wellbore 20 comprises casing 30 . This embodiment of downhole tool 40 comprises screen 50 having bore 51 , and one or more sections 52 having ports 53 in fluid communication with bore 51 and the outer wall surface of screen 50 so that bore 51 can be placed in fluid communication with annulus 21 of wellbore 20 . As shown in FIGS. 1-2 , screen 50 has three sections 52 connected in series through any known device or method, for example, threads (not shown). Closed end 54 of screen 50 includes bit 56 to facilitate insertion of screen 50 into the gravel (not shown) disposed within wellbore 20 . Auger 58 is spiraled or “flighted” around the outer wall surface of screen 50 to further facilitate insertion of screen 50 into the gravel. Thus, screen 50 in this embodiment is referred to as an auger-flighted screen.
In the embodiment of FIGS. 1-3 , screen 50 is releasably secured to lower coupler 60 through any known device or method, for example, threads (not shown). Lower coupler 60 comprises bore 61 and is releasably secured to ported member or pup 62 through any known device or method, for example, threads (not shown). Ported member 62 includes bore 63 and one or more ports 64 in fluid communication with bore 63 and an outer wall surface of ported member 62 so that bore 63 can be placed in fluid communication with annulus 21 of wellbore 20 .
Ported member 62 is releasably secured to isolation device 66 through any known device or method, for example, threads (not shown). Isolation device 66 comprises bore 67 . Isolation device 66 contacts the inner wall surface of wellbore 20 when isolation device 66 is placed in the set position ( FIG. 2 ).
In the set position, isolation device 66 , separates annulus 21 of wellbore 20 into two zones, upper zone 22 disposed above isolation device 66 and lower zone 23 disposed above isolation device 66 . Isolation device 66 comprises a dynamic seal against the inner wall surface of wellbore 20 such that isolation device 66 is in sliding engagement with the inner wall surface of wellbore 20 . Accordingly, downhole tool 40 is capable of sliding downward along the inner wall surface of wellbore 20 during insertion or installation of screen 50 into the gravel disposed within wellbore 20 . Isolation device 66 is shown in the embodiment of FIGS. 1-3 as comprising two swab packer cups 68 , 70 . Such isolation devices 66 are known in the art.
Isolation device 66 is not required to form a leak-proof seal with the inner wall surface of wellbore 20 . Fluid is permitted to flow between isolation device 66 and the inner wall surface of wellbore 20 , provided that the connection between isolation device 66 and the inner wall surface of wellbore 20 is sufficient to allow wellbore fluid to be transported from the lower zone to the upper zone as discussed in greater detail below.
Isolation device 66 is releasably secured to upper coupler 72 through any known device or method, for example, threads 71 (shown in FIG. 3 ). Upper coupler 72 comprises bore 73 and is releasably secured to artificial lift device 74 through threads 71 ( FIG. 3 ) or any other known device or method. As discussed in greater detail below, artificial lift device 74 functions by lifting, transporting, of flowing fluid from lower zone 23 of annulus 21 of wellbore 20 when isolation device 66 and, thus, downhole tool 40 is in the set position within wellbore 20 . Therefore, fluid from lower zone 23 of annulus 21 of wellbore 20 can be lifted, transported, or flowed above isolation device 66 into upper zone 22 of annulus 21 of wellbore 20 so that the fluid can be lifted, transported, or flowed up and out of wellbore 20 .
Artificial lift device 74 may be any device known to persons of ordinary skill in the art. In the embodiment shown in FIGS. 1-3 , artificial lift device 74 comprises jet pump 80 . Suitable jet pumps 80 are available from Oilwell Hydraulics, Inc. of Odessa, Tex.
In the embodiment shown in FIGS. 1-3 , jet pump 80 includes valve 82 , shown as a one-way check valve having ball 83 , cavity 84 , flow path 86 , fluid injector tubing 88 , fluid accelerator 90 with fluid exhaust port 92 , chamber 94 , and outlet 96 . As shown in FIG. 3 , chamber 94 has a conical-shape to facilitate movement of fluid out from fluid exhaust port 92 and through outlet 96 .
Once assembled, longitudinal bore 76 is formed between screen 50 , lower coupler 60 , ported member 62 , isolation device 66 , and upper coupler 72 by placing bores 51 , 61 , 63 , 67 , 73 in fluid communication with each other. Longitudinal bore 76 is in fluid communication with outlet 96 of jet pump 80 through valve 82 , cavity 84 , flow path 86 , fluid exhaust port 92 , and chamber 94 .
In one particular operation of downhole tool 40 , a tubing string (not shown) is used to dispose downhole tool 40 into wellbore 20 . After disposition within wellbore 20 , isolation device 66 is activated so that annulus 21 of wellbore 20 is divided into upper zone 22 above isolation device 66 and lower zone 23 below isolation device 66 . Activation of isolation device 66 can be accomplished using known methods.
With particular reference to the arrows shown in FIG. 3 that illustrate fluid flow through downhole tool 40 , after setting isolation device 66 within wellbore 20 , fluid, such as water, is pumped down fluid injector tubing 88 through fluid accelerator 90 , and out of fluid exhaust port 92 into chamber 94 . Fluid accelerator 90 and fluid exhaust port 92 increase the pressure at which the fluid is expelled from fluid injector tubing 88 thereby creating a venturi effect. Due to the increased pressure expulsion of fluid through fluid exhaust port 92 , negative pressure is created within jet pump 80 and, thus, in upper zone 22 so that wellbore fluid located within lower zone 23 of annulus 21 below isolation device 66 is lifted, transported, or flowed through ports 64 of ported member 62 and through ports 53 in screen 50 , into longitudinal bore 76 . The wellbore fluid continues to be lifted, transported, or flowed up through longitudinal bore 76 and into jet pump 68 through valve 82 . The wellbore fluid is then lifted, transported, or flowed through flow path 86 until it mixes with the fluid being pumped down fluid injector tubing 88 , through fluid accelerator 90 , and out of fluid exhaust port 92 into chamber 94 . This mixture of wellbore fluid with the fluid being pumped down fluid injector tubing 88 then exits jet pump 80 through outlet 96 into upper zone 22 of annulus 21 of wellbore 20 so that it can travel within wellbore 20 up toward the surface of wellbore 20 .
As a result of the activation of jet pump 80 , the wellbore fluid is lifted, transported, or flowed from lower zone 23 of annulus 21 to pull hydrostatic pressure off of the upper surface of the gravel (not shown) which lessens the overburden pressure acting downward on the top of the gravel. Therefore, the gravel is fluidized sufficiently to facilitate installation of screen 50 into the gravel. In other words, as a result of fluidization of the gravel due to wellbore fluid being lifted, transported, or flowed from lower zone 23 into upper zone 22 , downhole tool 40 and/or screen 50 can be moved downward more easily so that screen 50 is inserted or installed into the gravel. In one particular embodiment, screen 50 is rotated to facilitate installation of screen 50 into gravel. In another embodiment, downhole tool 40 and, thus, screen 50 , is rotated to facilitate installation of screen 50 into gravel.
As mentioned above, the methods of installing the liner or screen into the gravel temporarily relieve an overbalance or overburden pressure acting on the top of the gravel relative to the earthen formation. This overburden pressure is relieved by decreasing the pressure above isolation device 66 and increasing the pressure below isolation device 66 so that the gravel becomes fluidized as a result of wellbore fluid being lifted, transported, or flowed from and through lower zone 23 and into upper zone 22 . This fluidization of the gravel facilitates insertion of screen 50 into the gravel.
Referring now to FIG. 4 , in another embodiment, downhole tool 140 includes screen 150 , isolation device 166 , and artificial lifting device 174 . Each of these three components is releasably connected directly to each other so that screen 150 is disposed below isolation device 166 and isolation device 166 is disposed below artificial lifting device 174 . With the exception of screen 50 comprising auger 58 in the embodiment shown in FIGS. 1-3 , each of screen 150 , isolation device 166 , and artificial lifting device 174 in the embodiment shown in FIG. 4 is identical to screen 50 , isolation device 66 , and artificial lifting device 74 in downhole tool 40 ( FIGS. 1-3 ). Additionally, downhole tool 140 operates in the same manner as described above with respect to downhole tool 40 ( FIGS. 1-3 ).
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the screen is not required to include an auger. Additionally, the artificial lift device is not required to be a jet pump. Further, the jet pump is not required to include a valve or any of the other the specific components described with respect to the jet pump shown in FIGS. 2-3 . Moreover, the isolation device can be any type of isolation device known in the art used to divide a wellbore and be in sliding engagement with the inner wall surface of the wellbore. Additionally, the upper and lower couplers are not required. Further, the inner wall surface of the wellbore may be disposed along the open hole formation, along wellbore casing (as shown in FIGS. 1-2 and 4 ), or along a tubular member, including a packer or bridge plug, disposed within the wellbore casing or open hole formation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | Downhole tools for gravel pack completion processes in wellbores comprise a screen, an isolation device comprising a sealing element disposed above the screen, and an artificial lifting device disposed above the isolation device. Upon actuation, the sealing element divides the wellbore into an upper zone and a lower zone so that the screen is disposed in the lower zone and the artificial lifting device is disposed in the upper zone. The two zones are in fluid communication with each other through a longitudinal bore within the downhole tool. In operation, the artificial lifting device of the downhole tool creates a negative pressure so wellbore fluid is transported from the lower zone into the upper zone. Due to this flow of fluid through the downhole tool, gravel disposed within the wellbore becomes sufficiently fluidized to facilitate the screen being inserted into the gravel form the gravel pack completion. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to pressure controlled well tools, and more specifically relates to methods and apparatus for selectively "locking out" or preventing operation of selected pressure controlled well tools until such time as operation is desired.
Many types of well tools are known which are responsive to pressure, either in the annulus or in the tool string, in order to operate. For example, different types of tools for performing drill stem testing operations are responsive to either tubing or annulus pressure, or to a differential therebetween. Additionally, other tools such as safety valves or drill string drain valves may be responsive to such a pressure differential.
Such well tools typically have some member, such as a piston, which moves in response to the selected pressure stimuli. Additionally, these well tools also typically have some mechanism to prevent movement of this member until a certain pressure threshold has been reached. For example, a piston may be either mechanically restrained by a mechanism such as shear pins or similar devices; whereby the pressure must exceed the shear value of the restraining shear pins for the member to move. Alternatively, a rupture disk designed to preclude fluid flow until a certain threshold pressure differential is reached may be placed in a passage between the movable member and the selected pressure source. Each of these techniques is well known to the art.
Disadvantages may be found where multiple pressure operated tools are utilized in a single tool string. Conventional methods and apparatus for operating two tools in a tool string from the same pressure source (i.e., for example, the well annulus) are to establish the tool string such that the operating pressures for the tool to be operated second are at a pressures value greater than that required to operate the first tool. In some circumstances, this can present a disadvantage in that the releasing and operating pressure for the second-operated tool may be required to be higher than would be desirable. For example, in the above-stated example, it could be undesirable to apply the degree of pressure to the well annulus which might be necessary to operate the second-operated tool.
Additionally, in some types of tools it would be desirable to have a well tool operate in response to a specific and predetermined pressure differential for use when conditions in the well have changed. For example, where a tool is to be operated in response to pressure.
Accordingly, the present invention provides a new method and apparatus whereby a pressure operated well tool may be restricted from operation, and may be selectively enabled for operation while minimizing or eliminating pressure applications required to achieve such enabling; and whereby pressure previously applied to a pressure source may be stored in a well tool and used to facilitate operation of the well tool at a desired pressure differential.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus useful with pressure responsive well tools or well apparatus which will maintain the well tool in a non-responsive condition to pressure changes or cycles at the pressure source until such time as the tool is desired to be rendered responsive to such pressure cycles.
For example, in one preferred embodiment, an apparatus in accordance with the present invention will include a movable member which will, when the tool is operable, be responsive to pressure stored in a variable fluid spring. The methods and apparatus of the present invention allow pressure increases at the pressure source to be stored in such fluid spring, thereby increasing the force of the spring, but will preclude the release of such fluid spring relative to the movable member. In such preferred embodiment, the well tool will include a releasable means, which may be, for example, a pressure differential responsive valve, such as a rupture disk. When the specified pressure is applied across this pressure differential responsive valve, such as by increasing the pressure at the pressure source and then decreasing the pressure at the pressure source, the valve will open, thereby communicating pressure of the fluid spring to the movable mandrel.
In one particularly preferred embodiment and method of implementation of the present invention, the well tool includes one or more valve members which are responsive to movement of a mandrel. In an application where the well tool is responsive to annulus pressure, the annulus pressure will be supplied through a fluid medium, such as a generally noncompressible oil, through a hydraulic lockout sub, to one side of a movable piston. Movement of the piston serves to compress a compressible gas which forms the variable fluid spring. Any increase in pressure in the well annulus will be communicated through the fluid body and hydraulic lockout sub to the fluid spring until the pressures are substantially equalized (discounting, for example, frictional losses within the tool). The hydraulic lockout sub, however, precludes the release of fluid, and therefore the release of pressure from said fluid spring, upon a decrease in fluid pressure in the well annulus. In one particularly preferred embodiment, this is accomplished through use of a one way check valve which precludes the return of fluid when there is a pressure differential in favor of the fluid spring. Pressure from the fluid spring is also precluded from being released to the movable mandrel by means of a rupture disk. This arrangement allows an essentially infinite number of cycles of pressure in the well annulus, so long as those cycles do not exceed a predetermined value. This predetermined value is the yield pressure of the rupture disk.
Once it is desired to make the well tool responsive to a pressure cycle, the pressure will be cycled to this predetermined yield pressure. This pressure will then be communicted through the body of fluid in the tool and into the fluid spring, as with previous cycles. However, once the pressure is reduced, and the yield pressure differential across the valve member (in this preferred case, a rupture disk) is achieved, the rupture disk will break, allowing application of the force stored in the fluid spring to the movable mandrel. The movable mandrel of the tool may then be manipulated according to its design criteria in response to cycles of pressure in the well annulus.
In one preferred implementation of the invention, the rupture disk yield pressure will be set at a pressure which is higher, by some safety margin, than the expected or foreseeable degree of pressurization to be achieved during pressure cycles during which the well tool is desired to remain nonresponsive. For example, in an environment where the "baseline" pressure is to be hydrostatic pressure, and where the pressure cycles which are foreseeable before the well tool of the present invention is expected to operate are expected to be approximately 500 psi. or less, the rupture disk would preferably be established at some substantial safety margin, such as, for example, 1,000 psi.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an exemplary testing string deployed relative to an offshore oil or gas well, which string includes an apparatus in accordance with the present invention in one exemplary operating environment.
FIGS. 2A-G depict an exemplary well tool, in this case a multi-mode testing tool including both a circulating valve and a well closure valve, in accordance with the present invention, illustrated partially in half vertical section.
FIGS. 3A-B depicts the selective pressure lockout sub of the apparatus of FIG. 2, in greater detail, illustrated in vertically section.
FIG. 4 depicts the check valve assembly of the apparatus of FIG. 2 in greater detail, illustrated in vertical section.
FIG. 5 schematically depicts one exemplary embodiment of a ratchet slot arranged suitable for use with the well tool of FIG. 2.
FIG. 6 schematically depicts an exemplary construction of an operating section of a well tool designed to facilitate operation of the tool at a predetermined pressure differential.
FIG. 7 schematically depicts another exemplary construction of an operating section of a well tool designed to facilitate operation of a conventional pressure operated well tool after a predetermined pressure differential has been achieved.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in more detail, and particularly to FIG. 1, therein is depicted an exemplary multi-mode testing tool 100 operable in accordance with the methods and apparatus of the present invention, in an exemplary operating environment, disposed adjacent a potential producing formation in an offshore location.
In the depicted exemplary operating environment, an offshore platform 2 is shown positioned over submerged oil or gas wellbore 4 located in the sea floor 6, with wellbore 4 penetrating a potential producing formation 8. Wellbore 4 is shown to be lined with steel casing 10, which is cemented into place. A sub sea conduit 12 extends from the deck 14 of platform 2 into a sub sea wellhead 16, which includes blowout preventer 18 therein. Platform 2 carries a derrick 20 thereon, as well a hoisting apparatus 22, and a pump 24 which communicates with the wellbore 4 by a way of a control conduit 26, which extends below blowout preventer 18.
A testing string 30 is shown disposed in wellbore 4, with blowout preventer 18 closed thereabout. Testing string 30 includes upper drill pipe string 32 which extends downward from platform 2 to wellhead 16, whereat is located hydraulically operated "test tree" 34, below which extends intermediate pipe string 36. A slip joint 38 may be included in string 36 to compensate for vertical motion imparted to platform 2 by wave action. This slip joint 38 may be similar to that disclosed in U.S. Pat. No. 3,354,950 to Hyde, or of any other appropriate type as well known to the art. Below slip joint 38, intermediate string 36 extends downwardly to the exemplary multi-mode testing tool 100 in accordance with the present invention.
Multi-mode testing tool 100 is a combination circulating and well closure valve. The structure and operation of the valve opening and closing assemblies of well tool 100 are of the type utilized in the valve known by the trade name "Omni®" valve manufactured and used by Halliburton Services. The structure and operation of the valve opening and closing assemblies are similar to those described in U.S. Pat. No. 4,633,952, issued Jan. 6, 1987, to Paul Ringgenberg and U.S. Pat. No. 4,711,305, issued Dec. 8, 1987, to Paul Ringgenberg, both patents being assigned to the assignee of the present invention. The entire disclosures including the specifications of U.S. Pat. Nos. 4,711,305 and 4,633,952 are incorporated herein by reference for all purposes.
Below multi-mode testing tool 100 is an annulus pressure-operated tester valve 50 and a lower pipe string 40, extending to tubing seal assembly 42, which stabs into packer 44. When set, packer 44 isolates upper wellbore annulus 46 from lower wellbore annulus 48. Packer 44 may be any suitable packer well known to the art, such as, for example, a Baker Oil Tool Model D Packer, an Otis Engineering Corporation type W Packer, or an Easy Drill® SV Packer. Tubing seal assembly 42 permits testing string 30 to communicate with lower wellbore 48 through perforated tailpipe 51. In this manner, formation fluids from potential producing formation 8 may enter lower wellbore 48 through perforations 54 in casing 10, and be routed into testing string 30.
After packer 44 is set in wellbore, a formation test controlling the flow of fluid from potential producing formation 8 through perforated casing 10 and through testing string 30 may be conducted using variations in pressure affected in upper annulus 46 by pump 24 and control conduit 26, with associated relief valves (not shown). Formation pressure, temperature, and recovery time may be measured during the flow test through the use of instruments incorporated in testing string 30 as known in the art, as tester valve 52 is opened and closed in a conventional manner. In this exemplary application, multi-mode testing tool 100 is capable of performing in different modes of operation as a drill string closure valve and a circulation valve, and provides the operator with the ability to displace fluids in the pipe string above the tool. Multi-mode testing tool 100 includes a ball and slot type ratchet mechanism which provides a specified sequence of opening and closing of the respective wellbore closure ball valve and circulating valve. Multi-mode testing tool also allows, in the circulation mode, the ability to circulate in either direction, so as to be able to spot chemicals or other fluids directly into the testing string bore from the surface, and to then open the well closure valve (and the well tester valve 52), to treat the formation therewith.
As will be apparent to those skilled in the art, during the conduct of the drill stem test achieved by opening and closing tester valve 52 for specified intervals for a predetermined number of cycles, it may be desirable that the multi-mode testing valve 100 not operate in any way in response to the pressure increases and decreases which serve to operate tester valve 52.
The prior art testing tool disclosed in U.S. Pat. Nos. 4,633,952 and 4,711,305 incorporated by reference earlier herein includes a series of "blind" ratchet positions whereby the tool will cycle through a predetermined number of pressure increases and decreases without initiating operation of either of the bore closure (ball) valve of the tool or the circulation valve. While this tool has performed admirably in most circumstances, such a system does present a limitation to the number of pressure cycles (and therefore valve openings and closings), which can be implemented during a drill stem test procedure. The present invention incorporates the same highly desirable feature of allowing a predetermined number of pressure increases and decreases to be cycled through before effecting a change in the opened or closed status of either the circulating valve or bore closure valve, but further facilitates preventing the operation or responsiveness of multi-mode testing tool to any such cycling pressure increases and decreases until a desired point in time when a activating pressure increase will be applied to multi-mode testing tool 100.
Referring now also to FIGS. 2A-G, therein is depicted an exemplary embodiment of a multi-mode testing tool 100 in accordance with the present invention. Tool 100 is shown primarily in half vertical section, commencing at the top of the tool with upper adaptor 101 having threads 102 secured at its upper end, whereby tool 100 is secured to drill pipe in the testing string. Upper adaptor 101 is secured to nitrogen valve housing 104 at a threaded connection 106. Nitrogen valve housing 104 includes a conventional valve assembly (not shown), such as is well known in the art for facilitating the introduction of nitrogen gas into tool 100 through a lateral bore 108 in nitrogen valve housing 104. Lateral bore 108 communicates with a downwardly extending longitudinal nitrogen charging channel 110.
Nitrogen valve housing 104 is secured by a threaded connection 112 at its lower end to tubular pressure case 114, and by threaded connection 116 at its inner lower end to gas chamber mandrel 118. Tubular pressure case 114 and gas chamber mandrel 118 define a pressurized gas chamber 120, and an upper oil chamber 122. These two chambers 120, 122 are separated by a floating annular piston 124. Tubular pressure case 114 is coupled at a lower end by thread connections 128 to hydraulic lockout housing 126. Hydraulic lockout housing 126 extends between tubular pressure case 114 and gas chamber mandrel 118. Hydraulic lockout housing 126 houses a portion of the hydraulic lockout assembly, indicated generally at 130, in accordance with the present invention. Although some components of hydraulic lockout assembly 130 are depicted in FIG. 2, these elements will be discussed in reference to FIG. 3, wherein they are depicted completely and in greater detail. Hydraulic lockout assembly 130 includes passages, as will be described in relation to FIG. 3, which selectively allow fluid communication of oil, through hydraulic lockout housing 126, between upper oil chamber 122 and an annular ratchet chamber 158.
Hydraulic lockout housing 126 is coupled by way of a threaded connection 140 to the upper end of ratchet case 142. A ratchet slot mandrel 156 sealingly engages the lower end of hydraulic lockout housing 126 to cooperatively, (along with hydraulic lockout housing 126 and ratchet case 142) define annular ratchet chamber 158. Ratchet slot mandrel 156 extends upwardly within the lower end of hydraulic lockout housing 126. The upper exterior 160 of mandrel 156 is of substantially uniform diameter, while the lower exterior 162 is of greater diameter so as to provide sufficient wall thickness for ratchet slots 164. Ratchet slots 164 may be of the configuration shown in FIG. 5. FIG. 5 depicts one preferred embodiment of ratchet slot design 164 utilized in one preferred embodiment of the invention. There are preferably two such ratchet slots 164 extending around the exterior of ratchet slot mandrel 156.
Ball sleeve assembly 166 surrounds ratchet slot mandrel 156 and comprises an upper sleeve/check valve housing 168 and a lower sleeve 174. Upper sleeve/check valve housing 168 includes seals 170 and 171 which sealingly engage the adjacent surfaces of ratchet case 142 and ratchet slot mandrel 156, respectively. Upper sleeve/check valve housing 168 also includes a plurality of check valve bores 172 opening upwardly, and a plurality of check valve bores 173 opening downwardly. One each of check valve bores 172 and 173 are are depicted in FIG. 2B; however, in one preferred embodiment, two check valves extending in each direction, generally diametrically opposite one another will be utilized. Each check valve bore 172, 173 will include a check valve 175a, 175b. Exemplary check valves for use as Check valves 175a, 175b are depicted in greater detail in FIG. 4. Upper sleeve/check valve housing 168 and lower sleeve 174 are preferably coupled together by a split ring 179 secured in place with appropriately sized C rings 176; which split ring 179 engages recesses 177 and 178 on upper sleeve/check valve housing 168 and lower sleeve 174, respectively. Coupling split ring 179 is preferably an annular member having the appropriate configuration to engage annular slots 177 and 178 which has then been cut along a diameter to yield essentially symmetrical halves. Ratchet case 142 includes an inwardly extending shoulder 183, which will serve as an actuating surface for check valve 175b. Ratchet case 142 includes an oil fill port 132 which extends from the exterior surface to the interior of ratchet case 142 and allows the introduction of oil into annular ratchet chamber 158 and connected areas. Oil fill ports 132 are closed with conventional plugs 134 which threadably engage ratchet case 142 and seal ratchet chamber 158 from the exterior of tool 100.
The lower end of lower sleeve 174 of ball sleeve assembly 166 is able to rotate relative to upper sleeve/check valve housing 168 by virtue of the connection obtained by split ring 179. Lower sleeve 174 includes at least one, and preferably two, ball seats 188, which each contain a ratchet ball 186. Ball seats 188 are preferably located on diametrically opposite sides of lower sleeve 174. Due to this structure, when ratchet balls 186 follow the path of ratchet slots 164, lower sleeve 174 rotates with respect to upper sleeve/check valve housing 168. Upper sleeve/check valve housing 168 of ball sleeve assembly 166 does not rotate, and only longitudinal movement is transmitted to ratchet mandrel 156 through ratchet balls 186. Lower extreme 180 of ratchet slot mandrel 156 includes an outwardly extending lower end 200 which is secured at a threaded connection 202 to an extension mandrel 204. Ratchet case 142 and attached piston case 206, and extension mandrel 204, cooperatively define annular lower oil chamber 210. A seal assembly 208 forms a fluid tight seal between ratchet case 142 and piston case 206. A seal 203 provides a sealing engagement between extension mandrel 204 and lower end 200 of ratchet slot mandrel 156.
An annular floating piston 212 slidingly seals the bottom of lower oil chamber 210 and divides it from well fluid chamber 214 into which pressure ports 154 open. Annular piston 212 includes a conventional sealing arrangement and also preferably includes an elastomeric wiper member 215 to help preserve the sealing engagement between annular piston 212 and extension mandrel 204. Piston case 206 includes another oil fill port 209 sealed by a plug 211. The lower end of piston case 206 is secured at threaded connection 218 to extension nipple 216. The uppermost inside end 217 again preferably includes an elastomeric wiper 219 to preserve the sealing engagement between extension nipple 216 and extension mandrel 204. Extension nipple 216 is also preferably coupled by threaded coupling 222 to circulation-displacement housing 220, and a seal 221 is established therebetween. Extension nipple 216 also preferably includes a lower wiper assembly 223 to help preserve the seal between extension nipple 216 and extension mandrel 204. Circulation/displacement housing 220 includes a plurality of circumferentially-spaced radially extending circulation ports 224, and also includes a plurality of pressure equalization ports 226. A circulation valve sleeve 228 is coupled by way of a threaded coupling 230 to the lower end of extension mandrel 204. Valve apertures 232 extend through the wall of sleeve 228 and are isolated from circulation ports 224 by an annular elastomeric seal 234 disposed in seal recess 236. Elastomeric seal 234 may have metal corners fitted therein for improved durability as it moves across circulation ports 224. Partially defined by the juncture of circulation valve sleeve 228 with displacement valve sleeve 238. Circulation valve sleeve 228 is coupled to displacement valve sleeve 238 by a threaded coupling 240.
Displacement valve sleeve 238 preferably includes a plurality of index groove sets 242, 244, and 246. Each of these index groove sets is visible through circulation ports 224 depending upon the position of displacement valve sleeve 238, and therefore of ratchet slot mandrel 156 relative to the exterior housing members, including circulation displacement housing 220. Accordingly, inspection grooves 242, 244, and 246 allow visual inspection and confirmation of the position of displacement sleeve 238 and therefore the orientation of tool 100 in its ratchet sequence. Displacement valve sleeve 238 includes a sealing arrangement 248 to provide a sealing engagement between displacement mandrel 238 and circulation-displacement housing 220. Beneath a radially outwardly extending shoulder 249 at the upper end of displacement mandrel 238 is a sleeve section 260. Sleeve section 260 extends downwardly and includes an exterior annular recess 266 which separates an elongated annular extension shoulder 268 from the remaining upper portion of displacement mandrel 238.
A collet sleeve 270, having collet fingers 272 extending upper therefrom engages extension sleeve 260 of displacement mandrel 238 through radially inwardly extending protrusions 274 which engage annular recess 266. As can be seen in FIG. 2E, protrusions 274 and the upper portions of fingers 272 are confined between the exterior of lower mandrel section 260 and the interior of circulation-displacement housing 220.
As can also be seen in FIG. 2E, lower mandrel section 260 also includes a seal 265 which seals against collet sleeve 270 at a point below the lowermost extent 267 of collet fingers 272. This assures a secure seal between lower section 260 and collet sleeve 270. Collet sleeve 270 has a lower end which includes flanged coupling, indicated generally at 276, and including flanges 278 and 280, which flanges define an exterior annular recess 282 therebetween. Flange coupling 276 receives and engages a flange coupling, indicated generally at 284, on each of two ball operating arms 292. Flange coupling 284 includes inwardly extending flanges 286 and 288, which define an interior recess 290 therebetween. Flange couplings 276 and 284 are maintained in their intermeshed engagement by their location in annular recess 296 between ball case 294 and ball housing 298. Ball case 294 is threadably coupled at 295 to circulation-displacement housing 220.
Ball housing 298 is of a substantially tubular configuration having an upper, smaller diameter portion 300 and a lower, larger diameter portion 302, which has two windows 304 cut through the wall thereof to accommodate the inward protrusion of lugs 306 from each of the two ball operating arms 292. Ball housing 298 also includes an aperture 301 extending between the interior bore and annular recess 296. This bore prevents a fluid lock from restricting movement of displacement valve sleeve 238.
On the exterior of ball housing 298, two longitudinal channels, indicated generally by arrow 308, of arcuate cross-section, and circumferentially aligned with windows 304, extend from shoulder 310 downward to shoulder 311. Ball operating arms 292 which have substantially complementary arcuate cross-sections as channels 308 and lower portion 302 of ball housing 298, lie in channels 308 and across windows 304, and are maintained in place by the interior wall 318 of ball case 294 and the exterior of ball support 340.
The interior of ball housing 298 includes an upper annular seat recess 320 within which annular seat 322 is disposed. Ball housing 298 is biased downwardly against ball 330 by ring spring 324. Surface 326 of upper seat 322 includes a metal sealing surface which provides a sliding seal with exterior 332 of ball valve 330. Valve ball 330 includes a diametrical bore 334 therethrough, which bore 334 is of substantially the same diameter as bore 328 of ball housing 298. Two lug recesses 336 extend from the exterior 332 of valve ball 330 to bore 334. The upper end 342 of ball support 340 extends into ball housing 298 and preferably carriers lower ball seat recess 344 in which a lower annular ball seat 346 is disposed. Lower annular ball seat 346 includes an arcuate metal sealing surface 348 which slidingly seals against the exterior 332 of valve ball 330. When ball housing 298 is assembled with ball support 340, upper and lower ball seats 322 and 346 are biased into sealing engagement with valve ball 330 by spring 324. Exterior annular shoulder 350 on ball support 340 is preferably contacted by the upper ends 352 of splines 354 on the exterior of ball case 294, whereby the assembly of ball housing 294, ball operating arms 292, valve ball 330, ball seats 322 and 346 and spring 324 are maintained in position inside of ball case 294. Splines 354 engage splines 356 on the exterior of ball support 340, and thus rotation of the ball support 340 and ball housing 298 within ball case 298 is prevented.
Lower adaptor 360 protrudes that its upper end 362 between ball case 298 and ball support 340, sealing therebetween, when made up of ball support 340 at threaded connection 364. The lower end of lower adaptor 360 includes exterior threads 366 for making up with portions of a test string below multi-mode testing tool 100.
As will be readily appreciated, when valve ball 330 is in its opened position, as depicted in FIG. 2F, a "full open" bore 370 extends throughout multi-mode testing tool 100, providing a path for formation fluids and/or for perforating guns, wireline instrumentation, etc.
Referring now to FIG. 3, therein is depicted hydraulic lockout assembly 130 in greater detail. As previously stated, hydraulic lockout assembly 130 includes hydraulic lockout sub 126. Hydraulic lockout sub 126 includes a first generally longitudinal passageway 382 which extends from the lower end 384 of housing 126 to proximate upper end 386. As can be seen from a comparison of FIGS. 3A and 3B, longitudinal passageway 382 will preferably be formed of two offset bores 383, 385. The upper extent of passageway 382 (i.e., bore 385), is plugged such as by a suitable metal plug 388, using any conventional technique as is well known to the art. Bore 385 intersects a lateral bore 390 which communicates passageway 382 with an annular recessed area 392 formed between the exterior of hydraulic lockout sub 126 and tubular pressure case 114. On the opposing side of radial aperture 390 from plug 388, is another lateral aperture 394 which communicates bores 383 and 385. Lateral aperture 394 contains a rupture disk plug 396 which defines a flow path which is, at an initial stage, occluded by a rupture disk 398. As will be appreciated from FIGS. 3A-B, plug 396 secures rupture disk 398 in position such that any flow through passageway 382 is prevented by rupture disk 398, until such time as a pressure differential will cause rupture disk to yield, thereby opening passageway 382. Hydraulic lockout sub 126 also includes a passageway 400 which extends from lower end 384 of sub 126 to upper end 386 of sub 126. Bore passageway 400 is preferably diametrically opposed to bore 382 in sub 126. Proximate the upper end of hydraulic lockout sub 126, the sub is secured such as by a threaded coupling 402 to an end cap 404. Hydraulic lockout sub 126 and end cap 404 include generally adjacent complementary surfaces which are each angularly disposed so as to form a generally V-shaped recess 406 therebetween. A portion of this recess is relieved in end cap 404 by an annular groove 408. Disposed in annular recess 406 is a conventional O-ring 410 which, as will be described in more detail later herein, serves as a check valve for flow between passage 400 in hydraulic lockout sub 126 and upper oil chamber 122, beneath floating annular piston 124. A small recess 412 is provided between end cap 404 and hydraulic lockout sub 126 adjacent bore 400 to assure fluid communication between bore 400 and V-shaped groove 406 beneath O-ring 410.
Referring now to FIG. 4, therein is depicted an exemplary check valve 175 as is useful for each check valve in upper sleeve/check valve housing 168 of multipurpose testing tool 100. Check valve 175 includes a body member 420 having an external threaded section 422 adapted to threadably engage the bores 172, 173 in upper sleeve/check valve housing 168. Body 420 defines a central bore 424 in which is located check valve stem 426. Stem 426 includes a central bore extending from the outermost end 428 to a position inside stem 426. First and second lateral bores 432, 434 intersect central bore 430. First and second lateral bores 432, 434 are spaced sufficiently far apart that when stem 426 is moved in its only direction of movement away from body member 420 (i.e., down as depicted in FIG. 4), lateral bores 432 and 434 will be on opposed sides of body member 420. These bores assure appropriate fluid flow through check valve 175. Stem 426 and body member 420 also include complementary sealing surfaces 436 and 438, respectively, which occlude flow when the surfaces are in engagement with one another. Check valve 175 further includes a spring member 440 which urges stem and body member seating surfaces 436 and 438 toward one another to assure a sealing relationship therebetween. Stem 426 preferably includes an elongated extension member 442 which extends through spring 440 and serves to keep spring 440 properly aligned in an operating configuration therewith.
Referring now to all of FIGS. 1-4, operation of multi-mode testing tool 100 is as follows. As tool 100 is run into the well in testing string 30, it will typically be run with the circulating valve closed and with the ball valve in its open position, as depicted in FIGS. 2A-G. As tool 100 moves downwardly within the wellbore, annulus pressure will enter through annulus pressure port 154 and urge annular floating piston 212 upwardly in annular lower oil chamber 210. The pressure will be communicated through the oil tool 100, and through passageway 400 in hydraulic lockout sub 126. As the pressure passes through passageway 100, and becomes greater than the pressure in pressurized gas chamber 120 acting on check valve O-ring 410, the pressure will urge check valve O-ring 410 outwardly, and will act upon the lower surface of floating annular piston 124. Floating annular piston 124 then will move upwardly, pressurizing the nitrogen in pressurized gas chamber 120 to be essentially equal to the annular hydrostatic pressure (discounting, for example, frictional losses within tool 100).
As is apparent from the figures, rupture disk 398 will be exposed on one side, in bore 383, to the pressure of fluid in the wellbore, and will be exposed on the other side, in bore 385, to the pressure trapped in pressurized gas chamber 120. The valve of rupture disk 398 will be set at some safety margin over the maximum pressure which is expected to be applied to operate other tools in the tool string. For example, if a pressure of 500 psi. above hydrostatic is expected to be applied to tester valve 52 in tool string 30, then the value of rupture disk 398 would preferably be set at 750 to 1,500 pounds above, and most preferably would be set at approximately 1,000 pounds. Accordingly, rupture disk 398 will not rupture until a pressure of 1,000 pounds is applied thereacross.
As will therefore be appreciated, pressure in the annulus may be raised and lowered any number of times to operate tester valve 52 as desired. The maximum pressure applied in the annulus adjacent multi-mode testing tool 100 will be applied, as described earlier herein, through hydraulic lockout assembly 380 to pressurize gas chamber 120. Thus, the pressure within pressurized gas chamber 130 will remain at the highest pressure applied to the annulus.
When it is desired to actuate multi-mode testing tool 100, the pressure will be elevated a single time to the differential above hydrostatic at which rupture disk 398 is set, preferably with an extra margin to assure reliable operation. For example, with a 1,000 pound burst disk, a pressure of at least 1,000 pounds would be applied to the annulus. When this pressure is applied adjacent multi-mode testing tool 100, it will be trapped by hydraulic lockout assembly 130. As the pressure is reduced to hydrostatic, the differential of 1,000 pounds will be applied across the rupture disk 398, and it will rupture, thereby facilitating normal operation of the tool 100, as described in U.S. Pat. No. 4,711,305, incorporated by reference earlier herein. Force from the pressure in the fluid spring established by pressurized gas chamber 120 and piston 124 will then be applied to the piston area of upper sleeve/check valve housing 168, which serves as a movable operating mandrel, through balls 186.
A subsequent increase in pressure through annulus pressure ports 154 acts against upper sleeve/check valve housing 168. The oil is prevented from bypassing housing 168 by seals 170, 171. Upper sleeve/check valve housing 168 is therefore pushed against lower end 384 of hydraulic lockout sub 126. This movement pulls lower sleeve 174, ball sleeve 180, and balls 186 upward in slots 164. In this manner, balls 186 begin to cycle through ratchet slots 164.
When upper sleeve/check valve housing 168 reaches lower end 384 of hydraulic lockout sub 126, it is restrained from additional upward movement, but check valve 175 will open, (and, in turn, due to the recruiting pressure differential a check valve 175b, it too will open), allowing fluid to pass through passages 400 and 382 into upper oil chamber 122, which equalizes the pressures on both sides upper sleeve/check valve housing 168 and stops the movement of ball sleeve assembly 156 and of balls 186 in slots 164. As annulus pressure is bled off, the pressurized nitrogen in chamber 120, now that rupture disk 398 is broken, pushes against floating piston 124, which pressure is then transmitted through upper oil chamber 122 and passageway 382 against upper sleeve/check valve housing 168, biasing it and lower sleeve 174 downwardly, causing ratchet balls 186 to further follow the paths of slots 164. After a selected number of such cycles as determined by the ratchet, the ratchet will cause balls 186 to move ratchet mandrel, 156 extension mandrel 204 and sleeve attached thereto, opening either the circulating valve or ball valve.
Referring now to FIG. 6, therein is schematically disclosed an exemplary embodiment of an operating system for a well tool 500 incorporating a hydraulic lockout method and apparatus in accordance with the present invention. Well tool 500 includes a movable mandrel 502 which represents the key operating mechanism which is being restrained from movement until after a specified pressure differential has occurred, enabling operability of tool 500.
For purposes of clarity of illustration, well tool 500 will be described in terms of an automatic drain valve for allowing fluid to drain from a drill stem testing string as it is pulled from the well. The description of tool 500 relative to such a tool is purely illustrative, however, as those skilled in the art will readily recognize that the principles of the schematically illustrated embodiment could be applied to a circulating/safety valve, or numerous other types of well tools. Well tool 500 includes, in addition to movable mandrel 502, a housing assembly 504. Housing assembly 504 and movable mandrel 502 cooperatively serve to define an upper gas chamber 506. Upper gas chamber 506 will be filled through an appropriate mechanism (not shown) with a volume of gas, preferably nitrogen, suitable to provide a desired resistance in tool 500. At the lower end of upper gas chamber 506 is a movable piston 508. Beneath movable piston 508 is an upper oil chamber 510. The opposing end of upper oil chamber 510 is defined by a delay assembly which may be either formed into an extension of housing assembly 504 or may be sealingly secured thereto. Hydraulic lockout assembly 512 sealingly engages movable mandrel 502 so as to define both an upper oil chamber 510 and intermediate oil chamber 514. Hydraulic lockout block assembly 512 includes a rupture disk assembly 516 which may be of the type previously disclosed herein which, at least initially, occludes a passageway 518 between upper and intermediate oil chambers 510 and 514, respectively. Hydraulic lockout assembly 512 also includes a second passageway 520 extending between upper and intermediate oil chambers 510 and 514, and which includes a check valve assembly 522 therein. Check valve assembly 522 serves to allow fluid flow from intermediate oil chamber 514 through passage 520 and into upper oil chamber 510 and against the lower side of piston 508, but to preclude flow in the opposing direction. The lowermost end of intermediate oil chamber 514 is defined by an annularly outwardly extending flange 524 on movable mandrel 502 which sealing engages housing assembly 504. Flange 524 also serves to define the upper extent of lower oil chamber 526. A check valve 525 in flange 524 allows the flow of oil from lower oil chamber 526 into intermediate oil chamber 514, and again, precludes flow in the opposing direction. A movable piston 528 separates lower oil chamber 526 from an annular pressure chamber 30 which communicates through a passage 532 with the well annulus exterior to tool 500. Movable mandrel 502 includes an inner drain port 534 which, in a first position as depicted in FIG. 6, is isolated on upper and lower sides by sealing assemblies 536 and 538. Well tool 500 also includes an annular drain port 540 which, when inner drain port 544 is aligned therewith, will allow the passage of fluid from the interior of tool 500 to the exterior. Pressure in annular drain port 540 is further isolated from additional extensions of movable mandrel 502 by an additional sealing assembly 542.
The operation of well tool 500 is similar to that described above with respect to the multi-mode testing tool 100 of FIGS. 1-5. As pressure is applied in the well annulus, that pressure will be applied through annulus pressure port 532 to piston 528 which will move and transmit the applied pressure through the oil and lower oil chamber 526. This pressure will then move movable mandrel 502 upwardly, and through the action of check valve 525, the applied annulus pressure will be transmitted through hydraulic lockout unit 512 to upper oil chamber 510, and thereby to the fluid spring formed by upper gas chamber 506. As previously described, due to construction of hydraulic lockout assembly 512, upon reduction of this pressure, the pressure will be trapped in upper gas chamber 506 through operation of rupture disk 516 and check valve 522.
As tool 500 is withdrawn from the well, or as the hydrostatic head of fluid proximate annulus pressure part 532 is otherwise reduced, the differential across rupture disk 516 will increase. When the differential reaches the predetermined differential at which the rupture disk will rupture, the disk will rupture, and the pressure in nitrogen chamber 506 will be applied through passage 518 to intermediate oil chamber 514 and to radial flange 524. Because the fluid and pressure may not bypass flange 524, movable mandrel 502 will be driven downwardly. In this illustrated example, such a downward movement will cause intermediate drain port 534 to align with annular drain port 540, allowing fluid in the bore of tool 500 to drain to the annulus.
Referring now to FIG. 7, therein is depicted an alternative embodiment of a well tool 600 in accordance with the present invention. Well tool 600 provides a lockout mechanism which may be coupled to any appropriate type of pressure operated well tool to prevent operation of the tool until after a predetermined pressure differential has been achieved. For example, the hydraulic lockout operating section of tool 600 could be adapted to a circulating valve, safety valve, etc. One particular use would be for use with a tool in a drill stem testing operation where hydrostatic conditions in the borehole have changed since the time the tool was placed into the borehole. For example, if heavy fluid in the tubing had been replaced with a lighter fluid, or if the fluid level in the annulus had been reduced for some reason, thereby reducing the hydrostatic head adjacent well tool 600. Well tool 600 includes components and assemblies which correspond to those described and depicted relative to well tool 500. Accordingly, such elements are numbered similarly, and the same description is applicable here.
As will be apparent from FIG. 7, housing assembly 604, proximate the lower end, includes an annulus pressure aperture 608. Moveable mandrel 602 includes a radially outwardly extending section 606 including seal assemblies 610 and 612. Assemblies 610 and 612 are initially on opposing sides of annulus pressure port 608 so as to isolate port 608. Mandrel 602 and housing 604 cooperatively define a lower pressure chamber 617 which includes a radial recess 616. The walls defining recess 616 are radially outwardly placed relative to sealing surface 614 which engages sealing assembly 610 and 612. Accordingly, if movable mandrel 602 is moved downwardly to a position where sealing assemblies 610 and 612 are adjacent recess 616, then fluid from annulus pressure port 608 may be in fluid communication with chamber 617 through recess 616. A lower sealing assembly 622 engages a lower skirt portion 624 movable mandrel 602 to isolate pressure chamber 617. Chamber 617 is coupled through a passage 618 to the annulus pressure inlet port of the specific conventional well tool to be operated.
In operation, well tool 600 will function similarly to well tool 500 described above. Once the prescribed pressure differential has been achieved across rupture disk 516, the disk will rupture and pressure will be allowed to act upon outwardly extending flange 524 to move movable mandrel 602 downwardly. In the operating situation where well tool 600 has been placed into the well with a heavy fluid in the well, tool 600 will serve to preclude the heavy hydrostatic head from operably affecting the attached well tool. It will be apparent to those skilled in the art, when such heavy fluid is then replaced in the well by a lighter fluid, the rupture disk will be exposed on one side to pressure in gas chamber 606 equal to the hydrostatic head of the heavier fluid plus any additional pressure which was applied thereto. Meanwhile, the pressure on the opposing side of rupture disk 516 will be the hydrostatic head presented as the heavier fluid is replaced with the lighter fluid. Once this pressure differential exceeds the rupture value of rupture disk 516, the disk will then rupture enabling further operation of well tool 600.
As movable mandrel 602 moves downwardly, annular pressure port 608 will be uncovered, and will communicate thorough recess 616 in chamber 617 with passageway 618. Rupture disk 620, occluding passageway 618 will be established as whatever value is deemed appropriate to provide the initial operating pressure for the attached valve or other well tool. Thus, rupture disk 620 may be established at any desired value in the well, such as for example 1,000 psi. relative to only the lesser hydrostatic head presented by the lighter fluid in the well, and without regard for pressures which would have been previously present in the well as a result of the original, heavier, fluid.
Many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the spirit and scope of the present invention. For example, hydraulic lockout systems may be applied to a variety of different types of tools. Additionally, many different structural options may be imagined for exploiting the advantages of the present invention. Accordingly, it should be readily understood that the embodiments and examples described herein are illustrative only and are not to be considered as limitations upon the scope of the present invention. | Well tools are provided which although pressure responsive, may be maintained by a hydraulic lockout in a nonresponsive condition until a threshold actuation step is performed. This lockout may be achieved by a hydraulic mechanism which allows pressure to be stored in a fluid spring during periods of increased pressure at the pressure source, and which traps these pressures even when pressure at the pressure source is reduced. When the tool is desired to be responsive to pressure cycles, a valve may be opened communicating the pressure in the fluid spring to a movable member in the well tool. This differential may be established by a differential between the pressure in the fluid spring and the pressure source. Communication of pressure in the fluid spring to a movable mandrel will then allow operation of the well tool in response to pressure cycles at the pressure source in accordance with the established design of the well tool. |
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BACKGROUND
[0001] In connection with the completion of oil and gas wells, it is frequently necessary to utilize packers in both open and cased bore holes. The walls of the well or casing are plugged or packed from time to time for a number of reasons. For example, a section of the well may be packed off to permit applying pressure to a particular section of the well, such as when fracturing a hydrocarbon bearing formation, while protecting the remainder of the well from the applied pressure.
[0002] In a staged frac operation, for example, multiple zones of a formation need to be isolated sequentially for treatment. To achieve this, operators install a fracture assembly 10 as shown in FIG. 1 in a wellbore 12 . Typically, the assembly 10 has a top liner packer (not shown) supporting a tubing string 14 in the wellbore 12 . Open hole packers 50 on the tubing string 14 isolate the wellbore 12 into zones 16 A-C, and various sliding sleeves 20 on the tubing string 14 can selectively communicate the tubing string 14 with the various zones 16 A-C. When the zones 16 A-C do not need to be closed after opening, operators may use single shot sliding sleeves 20 for the frac treatment. These types of sleeves 20 are usually ball-actuated and lock open once actuated. Another type of sleeve 20 is also ball-actuated, but can be shifted closed after opening.
[0003] Initially, all of the sliding sleeves 20 are closed. Operators then deploy a setting ball to close a wellbore isolation valve (not shown), which seals off the downhole end of the tubing string 14 . At this point, the packers 50 are hydraulically set by pumping fluid with a pump system 35 connected to the wellbore's rig 30 . The build-up of tubing pressure in the tubing string 14 actuates the packers 50 to isolate the annulus 18 into the multiple zones 16 A-C. With the packers 50 set, operators rig up fracturing surface equipment and pump fluid down the tubing string 14 to open a pressure actuated sleeve (not shown) so a first downhole zone (not shown) can be treated.
[0004] As the operation continues, operators drop successively larger balls down the tubing string 14 to open successive sleeves 20 and pump fluid to treat the separate zones 16 A-C in stages. When a dropped ball meets its matching seat in a sliding sleeve 20 , fluid is pumped by the pump system 35 down the tubing string 14 and forced against the seated ball. The pumped fluid forced against the seated ball shifts the sleeve 20 open. In turn, the seated ball diverts the pumped fluid out ports in the sleeve 20 to the surrounding annulus 18 between packers 50 and into the adjacent zone 16 A-C and prevents the fluid from passing to lower zones 16 A-C. By dropping successively increasing sized balls to actuate corresponding sleeves 20 , operators can accurately treat each zone 16 A-C up the wellbore 12 .
[0005] The packers 50 typically have a first diameter to allow the packer 50 to be run into the wellbore 12 and have a second radially larger size to seal in the wellbore 12 . The packer 50 typically consists of a mandrel about which the other portions of the packer 50 are assembled. A setting apparatus includes a port from the inner throughbore of the packer 50 to an interior cavity. The interior cavity may have a piston that is arranged to apply force either directly to a sealing element or to a rod or other force transmitter that will apply the force to the sealing element.
[0006] Typically, when the packer 50 is set, fluid pressure is applied from the surface via the tubular string 14 and typically through the bore of the tubular string 14 . The fluid pressure is in turn applied through a port on the packer 50 to the packer's piston. The fluid pressure applied over the surface of the piston is then transmitted to the packer's sealing element to compress the sealing element longitudinally.
[0007] Most sealing elements are an elastomeric material, such as rubber. When the sealing element is compressed in one direction it expands in another. Therefore, as the sealing element is compressed longitudinally, it expands radially to form a seal with the well or casing wall.
[0008] In some situations, operators may want to utilize comparatively long sealing elements in their packers 50 . In these instances, however, as the packer's piston pushes the sealing element to compress the sealing element longitudinally, friction and other forces combine to cause the sealing element to bunch up or otherwise bind near the packer's piston, preventing the sealing element from uniformly compressing longitudinally and thereby preventing the uniform radial expansion of the sealing element. The lack of uniform expansion tends to prevent the packer 50 from forming a seal that meets the operator's expectations, thereby defeating the purpose of utilizing a longer sealing element. For this reason, operators may not use an unset sealing element on a packer 50 that is more than about 24-inches long. Instead, a typical length of an unset seal element is only about 10-inches.
[0009] Therefore, a need exists for a packer that is able to utilize an extended length sealing element. The present invention fulfills these needs and provides further related advantages.
SUMMARY
[0010] A dual-set hydraulic packer disclosed herein allows a sealing element to be set from both ends so that more setting force and more uniform or balance setting can be applied to the sealing element. The sealing element can be relatively longer than conventionally used. Firstly, the packer is set by applying fluid pressure through the interior throughbore of the packer's mandrel to a first piston on an end of the sealing element. Then secondly, the packer is set by using pressure in the annulus to set a second piston on the other end of the sealing element. The setting order depends upon the desire of the operator because the packer can be installed either with the annular set piston on top and the tubular set piston on the bottom or vice versa.
[0011] Accordingly, the disclosed packer has an upper hydraulic setting mechanism, a lower hydraulic setting mechanism, and a sealing element disposed therebetween. The sealing element is sequentially longitudinally compressed separately by the upper hydraulic setting mechanism and the lower hydraulic setting mechanism so that the sealing element experiences compression from both ends during a fracture treatment, acid stimulation, or other operation or treatment where the pressure in a zone is increased.
[0012] The packer may have a mandrel with an interior and an exterior. The upper hydraulic setting mechanism, the lower hydraulic setting mechanism, and the sealing element are attached to the exterior of the mandrel. Fluid pressure in the mandrel interior typically actuates one or the other of the upper hydraulic setting mechanism or the lower hydraulic setting mechanism, but not both. Also, fluid pressure on the mandrel exterior typically actuates one or the other of the upper hydraulic setting mechanism or the lower hydraulic setting mechanism but not both.
[0013] The packer may have one or more sealing elements. In one embodiment, the packer may have at least two sealing elements separated by a barrier. The upper hydraulic setting mechanism may have a first piston adjacent to a first of the sealing elements, and the lower hydraulic setting mechanism may have a second piston adjacent to a second of the sealing elements. During operation, internal fluid pressure in the packer may act upon the first piston to radially expand a portion of (or the entire extent of) the sealing element(s). Additionally, external fluid pressure in the surrounding annulus may act upon the second piston to radially expand a portion of (or the entire extent of) the sealing element(s).
[0014] The packer may have a mandrel with an interior throughbore and an exterior. A first housing may be attached to a first end of the mandrel exterior and a second housing may be attached to a second end of the mandrel exterior. A first cylinder may be located within the first housing and a second cylinder may be located within the second housing. A first piston may be located within the first cylinder and the first piston is in fluid communication with the mandrel interior. A second piston may be located within the second cylinder and the second piston is in fluid communication with the mandrel exterior.
[0015] The first piston is disposed adjacent to the sealing element and the second piston is also disposed adjacent to the sealing element. Fluid pressure acts upon the first piston or the second piston to radially expand a portion of the sealing element. The first cylinder may be located between the first housing and the mandrel. The second cylinder may be located between the second housing and the mandrel.
[0016] In use, a packer having an interior, an exterior, a first hydraulic actuating mechanism, and a second hydraulic actuating mechanism may be run into a well. The interior of the packer is pressurized to actuate the first hydraulic actuating mechanism causing the sealing element to radially expand. The exterior of the packer is then pressurized to actuate the second hydraulic actuating mechanism causing the sealing element to radially expand.
[0017] As used herein, the terms such as lower, downward, downhole, and the like refer to a direction towards the bottom of the well, while the terms such as upper, upwards, uphole, and the like refer to a direction towards the surface. The uphole end is referred to and is depicted in the Figures at the top of each page, while the downhole end is referred to and is depicted in the Figures at the bottom of each page. This is done for illustrative purposes in the following Figures. The tool may be run in a reverse orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 diagrammatically illustrates a tubing string having multiple sleeves and openhole packers of a fracture system.
[0019] FIG. 2 depicts a double-set hydraulic packer according to the present disclosure in a run-in condition.
[0020] FIG. 3 depicts the double-set hydraulic packer with a first (downhole) hydraulic setting mechanism in an actuated condition.
[0021] FIG. 4 depicts the double-set hydraulic packer with the downhole hydraulic setting mechanism and a second (uphole) hydraulic setting mechanism in actuated conditions.
[0022] FIG. 5 depicts a double-set hydraulic packer having first and second hydraulic setting mechanisms in actuated conditions and having a barrier disposed between first and second members of a sealing element.
DETAILED DESCRIPTION
[0023] The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
[0024] FIG. 2 depicts a double-set hydraulic packer 100 according to the present disclosure in an unset or run-in condition in a wellbore 12 , which may be a cased or open hole. The packer 100 includes a mandrel 110 with an internal bore 112 passing therethrough that connects on a tubing string ( 14 : FIG. 1 ) using known techniques. The packer 100 has first and second hydraulic setting mechanisms 150 and 160 disposed adjacent to ends of a sealing element 140 . As will be appreciated, the sealing element 140 may be longer or shorter than depicted and may comprise several pieces. In fact, the sealing element 140 for the disclosed packer 100 may be considerably longer than conventional elements used on packers and can be greater than 10-in. in length depending on the implementation.
[0025] In general and as shown in FIG. 2 , the first hydraulic setting mechanism 150 can be disposed on a downhole end of the packer 100 , while the second hydraulic setting mechanism 160 can be disposed on an uphole end. As will be appreciated with the benefit of the present disclosure, however, a reverse arrangement can be used, depending on the implementation, orientation, and access to tubing and annulus pressures in the wellbore 12 .
[0026] A first (downhole) end of the packer 100 has a first end ring 120 fixed to the mandrel 110 by lock wire 118 , pins, or the like. Part of this first end ring 120 forms a first housing 124 having an inner surface, which forms a first internal cylinder chamber 122 in conjunction with the external surface of the mandrel 110 . A first push rod 152 resides in the first cylinder chamber 122 and has its end surface exposed to the chamber 122 . Accordingly, the first push rod 152 acts as a first piston in the presence of pressurized fluid F ( FIG. 3 ) communicated from the internal bore 112 of the mandrel 110 into the chamber 122 through one or more ports 115 .
[0027] During a setting operation, for example, fluid pressure is communicated downhole through the tubing string ( 14 : FIG. 1 ) and eventually enters the internal bore 112 of the packer's mandrel 110 . This setting operation can be performed after run-in of the packer 100 in the wellbore 12 so that the packer 100 can be set and zones of the wellbore's annulus 18 can be isolated from one another. While the tubing pressure inside the packer 100 is increased, external fluid pressure in the annulus 18 surrounding the packer 100 remains below the tubing pressure. During this setting operation, the packer 100 begins a first setting procedure in which the first setting mechanism 150 is activated to compress the sealing element 140 .
[0028] FIG. 3 depicts the packer 100 during this first setting procedure where only the first hydraulic setting mechanism 150 is being utilized. Pressurized fluid F in the mandrel's bore 112 accesses the first piston 152 in the first cylinder chamber 122 through the one or more first ports 115 in the mandrel 110 . Building in the chamber 122 , the pressurized fluid F acts on the first piston 152 and forces the piston's end 154 against one end 144 of the sealing element 140 disposed on the mandrel 110 . As the piston 152 moves along the mandrel 110 , it longitudinally compresses the sealing element 140 . In turn, as the sealing element 140 is longitudinally compressed, the element 140 radially expands from a first diameter D 1 to a second diameter D 2 toward the surrounding borehole 12 .
[0029] As depicted in FIG. 3 , the radial expansion is shown as occurring partially along the length of the sealing element 140 . This may or may not be the case depending on the length of the sealing element 140 and the friction and other forces encountered. In any event, the radial expansion of the sealing element 140 against the wellbore 12 separates the annulus 18 into an uphole annular region 18 U and a downhole annular region 18 D.
[0030] As will be appreciated, fluid pressure in the mandrel 110 entering second ports 116 for the second mechanism 160 does not activate this mechanism 160 , for reasons that will be apparent below. Instead, fluid pressure entering a chamber 170 of the second mechanism 160 during the first setting procedure actually tends to keep the second mechanism 160 in its original position so that the mechanism 160 acts as a fixed stop for the compression of the sealing element 140 .
[0031] During setting, the increased second diameter D 2 tends to cause the sealing element 140 to experience an increase in friction that can eventually limit the radial expansion of the sealing element 140 . In general, all or only a portion of the sealing element 140 may longitudinally compress and radially expand to a full or nearly full extent against the surrounding wellbore 12 . FIG. 3 only shows partial activation for the purposes of illustration. The compression and expansion can proceed at least until the friction and any other external forces equal the force used to compress the element 140 .
[0032] FIG. 3 also depicts further details of the second hydraulic setting mechanism 160 at the second end of the packer 100 . A second end ring 130 is fixed to the mandrel 110 by lock wires 118 or the like is disposed adjacent to a second piston 162 of the mechanism 160 . As shown, the piston 162 can be composed of several components, including a push rod end 164 connected by an intermediate sleeve 165 to a piston end 166 . Use of these multiple components 164 , 165 , and 166 can facilitate assembly of the mechanism 160 , but other configurations can be used.
[0033] The push rod end 164 of the second piston 162 is disposed against a second end 146 of the sealing element 140 . On the other end, the piston end 166 is disposed adjacent to the second end ring 130 , but the piston end 166 is subject to effects of fluid pressure in the uphole annular region 18 U, as will be discussed further below. A fixed piston 168 is attached to the mandrel 110 by lock wire 118 to enclose the second piston chamber 170 of the second piston 162 . The chamber 170 is isolated by various seals (not shown) from fluid pressure in the uphole annular region 18 U formed by the packer 100 and the wellbore 12 . As long as the second hydraulic setting mechanism 160 remains in an unactuated state as in FIG. 3 , the chamber 170 does not decrease or increase in volume.
[0034] During operations after the first mechanism 150 is actuated and the sealing element 140 set, fluid pressure in the uphole annular region 18 U may be increased, which will then actuate the second mechanism 160 . For example, during a fracture treatment, operators fracture zones downhole from the disclosed packer 100 by pumping fluid pressure downhole, which merely communicates through the mandrel's bore 112 to further downhole components. The buildup of tubing pressure may tend to further set the first hydraulic setting mechanism 150 , but may tend to keep the second hydraulic setting mechanism 160 unactuated, as noted above.
[0035] Then, operators isolate the packer's internal bore 112 uphole of the packer 100 . For example, operators may drop a ball down the tubing string ( 14 : FIG. 1 ) to land in a seat of a sliding sleeve ( 20 : FIG. 1 ) uphole of this packer 100 . When the sliding sleeve ( 20 ) is opened and fracture pressure is applied to the formation through the open sleeve ( 20 ), the borehole pressure in the uphole annular region 18 U increases above the isolated tubing pressure in the mandrel's bore 112 . However, the internal pressure in the mandrel's bore 112 does not increase due to the plugging by the set ball on the seat in the uphole sliding sleeve ( 20 ). It is this buildup of borehole pressure in the uphole annular region 18 U outside the packer 100 compared to the tubing pressure inside the packer 100 that activates the second mechanism 160 .
[0036] In particular, FIG. 4 depicts the packer 100 with both the first and second hydraulic setting mechanisms 150 and 160 having been actuated. For the second hydraulic setting mechanism 160 to actuate, the tubing pressure in the inner bore 112 of the mandrel 110 is relieved, reduced, or isolated as noted above, while the borehole pressure in the uphole annular region 18 U around the packer 100 is increased. In certain instances, it may not be necessary to relieve the fluid pressure in the inner bore 112 as long as the pressure in the uphole annular region 18 U may be increased to overcome any pressure in the inner bore 112 to a sufficient level to actuate the second hydraulic setting mechanism 160 .
[0037] With a sufficient buildup of pressure in the uphole annular region 18 U, the external pressurized fluid in the region 18 U acts upon the external face of the piston end 166 . Chamber 170 , which is at the lower tubing pressure, is sealed from the external pressure from the annular region 18 U. Thus, an internal face of the piston end 166 is exposed to the lower tubing pressure in the chamber 170 . Consequently, the pressure differential causes the second piston 162 to move along the mandrel 110 and exert a force against the sealing element 140 .
[0038] As the second piston 162 moves, it further compresses the sealing element 140 . The lower tubing pressure in the chamber 170 can escape into the mandrel's bore 112 through ports 116 while the chamber 170 decreases in volume with any movement of the second piston 162 . As the piston 162 moves, it longitudinally compresses against the sealing element 140 , which can radially expand further or more fully against the wellbore 12 , thereby completing the radial expansion of the sealing element 140 against the surrounding wellbore 12 . As noted above, the first mechanism 150 may compress the sealing element 140 practically to its full extent at least until a level of friction and other force is met. The second mechanism 160 can overcome the built-up friction to even further compress the sealing element 140 , which can further radially expand the element 140 .
[0039] As can be seen in the above embodiment, the packer 100 has a first hydraulic setting mechanism 150 for the sealing element 140 that uses an internal piston and cylinder arrangement moved with fluid pressure F from the interior bore 112 of the packer's mandrel 110 to at least partially set the sealing element 140 . In this first setting procedure, the interior bore 112 has a high pressure, while the annulus 18 has a lower pressure. The second setting mechanism 160 remains unactivated and acts as a stop against the other end of the sealing element 140 . This can be useful when fracturing a formation downhole of the packer 100 , for example.
[0040] As also seen above, the packer 100 has the second hydraulic setting mechanism 160 for the sealing element 140 . This second mechanism 160 has an annulus piston and cylinder arrangement moved by fluid pressure in the uphole annular region 18 U surrounding the packer 100 . In the second setting procedure, the second mechanism 160 is actuated when there is a higher pressure in the annular region 18 U and a lower pressure in the mandrel's interior bore 112 . This procedure can be useful when fracturing the formation uphole of the packer 100 , for example. The two setting mechanisms 150 and 160 may have the same or different setting pressures depending on the implementation.
[0041] Having the second setting mechanism 160 allows the sealing element 140 to be set additionally, and more uniformly with more force from the opposite side, after the packer 100 has already completed a first setting procedure and engagement with the wellbore 12 . Accordingly, the length of the sealing element 140 can be longer than conventionally used to seal over longer cracks in a formation. In other words, the sealing element 140 can be greater than the conventional 10-in. length usually used, and the mechanisms 150 and 160 may overcome the issues typically experienced with longer sealing elements.
[0042] The second setting procedure of the sealing element 140 can be performed when the element 140 has been allowed to cool and contract due to cold fluid flowing through the packer's mandrel 110 . The second setting procedure also overcomes the friction issue encountered with longer sealing elements used on the packer 100 . The second setting procedure of the sealing element 140 after it has contracted can also give the packer 100 a much better long term sealing capability. Finally, the annular pressure applied in the second setting procedure can act against a larger annular area to set the packer 100 and can provide a much higher total setting force.
[0043] In certain instances, it may be desirable to isolate one end of the sealing element 140 from the other end, thereby allowing separate sealing actions to work together while each end is actuated independently. FIG. 5 depicts an embodiment of a packer 100 having a central sealing element 140 with at least two members 142 a - b between the mechanisms 150 and 160 . The first hydraulic setting mechanism 150 sets a first sealing member 142 a of the packer's central sealing element 140 , and the second hydraulic setting mechanism 160 sets a second sealing member 142 b of the packer's element 140 .
[0044] A barrier 148 isolates the first sealing member 142 a from the second sealing member 142 b . The barrier 148 may or may not be anchored to the mandrel 110 and can be composed of any suitable material (e.g., metal, plastic, elastomer, etc.). If the barrier 148 is anchored to the mandrel 110 , the barrier 148 allows either sealing member 142 a - b to be set without regard to the other sealing element. If the barrier 148 is not anchored to the mandrel 110 , it will move with the elastomer if either mechanism 150 or 160 sets. In other words, the sealing members 142 a - b will behave like a single element 140 .
[0045] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
[0046] For example, although not shown in the Figures, the packer 100 may use any of the conventional mechanisms for locking the push rods or pistons 152 and 162 in place on the mandrel 110 once set against the sealing element 140 . Accordingly, ratchet mechanisms, lock rings, or the like (not shown) can be used to prevent the rods or pistons 152 and 162 from moving back away from the sealing element 140 once set. Additionally, various internal seals, threads, and other conventional features for components of the packer 110 are not shown in the Figures for simplicity, but would be evident to one skilled in the art.
[0047] The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.
[0048] In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof. | A device and method allow a longer sealing element to be used on a packer or other downhole tool while providing an increase in the total amount of setting force that can be used and providing for more uniform or balanced setting of the sealing element. The packer may be first set using internal bore pressure to radially expand one end of the sealing element with a first hydraulic setting mechanism. The packer may then be set a second time using annulus pressure to continue the radial expansion of the sealing element with a second hydraulic setting mechanism. |
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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 apparatus for insulating hydrocarbon production equipment in a subsea environment. More specifically, the present invention relates to apparatus for insulating subsea connectors for flowlines, jumpers, umbilicals, and other tubular members.
[0004] Production equipment, such as manifolds and trees, that are used in producing oil and gas in a subsea environment are usually interconnected by flowlines, or other tubulars. The flowlines provide fluid communication to support the flow of production fluids, control fluids, and other fluids. In the subsea environment, the equipment is often exposed to temperature at or only slightly above the freezing point of water.
[0005] Although the fluids extracted from subsea wells are often at an elevated temperature when leaving the well, the fluids can cool as they move through the production equipment and flowlines. This cooling is especially problematic during an interruption in flow where temperatures can decrease to a point where flow will be impeded, such as by the formation of hydrates. In order to decrease the rate at which the fluid cools, thermal insulation is often installed on and around the production equipment and flowlines.
[0006] One area of difficulty in providing thermal insulation is at the connections between the production equipment and the flowlines. The flowlines are typically installed after the production equipment is on the seabed, with the connections between the flowlines and the production equipment made by remotely operated vehicles (ROV) or some other remotely operated device. Therefore, any thermal insulation must allow for remotely controlled installation of the connector or be able to be installed after the connection is made.
[0007] Insulation used in subsea environments must be able to withstand the high hydrostatic pressures found in deep water applications. Conventional insulation used for subsea systems provides very little compressibility so as to better withstand hydrostatic pressure. When installing insulating systems subsea, water often becomes trapped by the insulation. When this water is heated it expands and may tend to damage the insulation or create circulation paths for cold water to seep under the insulation.
[0008] Thus, there remains a need to develop methods and apparatus for thermally insulating flowline connectors, which overcome some of the foregoing difficulties while providing more advantageous overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0009] The embodiments of the present invention are directed toward methods and apparatus for insulating a connector that connects a first tubular member having a first flange with a second tubular member having a second flange. The apparatus comprises a generally tubular body forming a generally tubular cavity therein adapted to enclose the connector. The body has a longitudinal opening adapted to receive the first tubular member and a closure member for closing said opening. The body and the closure member are lined with insulation and include first and second seals for sealing with the first and second flanges so as to seal around the connector.
[0010] A method of insulating a connector comprises receiving a flow line through a longitudinal opening in a insulating shroud. The insulating shroud is lowered around the connector and sealingly engaging flanges on each side of the connector to seal around the connector. A closure member closes the opening is latched closed. Insulation on the insulating shroud is compressed as water that is trapped around the connector in a cavity in the insulating shroud is heated and expands.
[0011] 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
[0012] For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
[0013] FIG. 1 is cross-sectional view of a flowline jumper connector with an insulation assembly installed thereon;
[0014] FIG. 2 is a top view of an insulating shroud assembly being installed on a connector;
[0015] FIG. 3 is a top view of an insulating shroud assembly installed on a connector;
[0016] FIG. 4 is a partial cross-sectional view of an upper seal arrangement;
[0017] FIG. 5 is a partial cross-sectional view of a lower seal arrangement;
[0018] FIG. 6 is a partial cross-sectional seal of a door seal;
[0019] FIG. 7 is a top view of a drive mechanism;
[0020] FIG. 8 is a cross-sectional view of the drive mechanism of FIG. 7 ;
[0021] FIG. 9 is a cross-sectional view of a flowline jumper connector with an insulating shroud assembly installed thereon; and
[0022] FIG. 10 is a top view of a latching mechanism for use with an insulating shroud.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring now to FIG. 1 , a flowline jumper connector 10 joins a flowline jumper 12 to a manifold 14 . Insulating shroud assembly 16 surrounds and extends above and below connector 10 . Insulating shroud assembly 16 comprises outer shell 17 , insulation 18 , upper seal 20 , and lower seal 22 . Upper seal 20 sealingly engages flange 24 on flowline jumper 12 . Lower seal 22 sealingly engages flange 26 of the connector support structure on manifold 14 . Thus, seals 20 and 22 form an insulated volume 28 that surrounds connector 10 .
[0024] Outer shell 17 is generally tubular forming a cavity therewithin. Outer shell 17 is formed from a hard plastic material or some other non-compliant, corrosion-proof material. Insulation 18 is a flexible insulation molded onto the inner surface of outer shell 17 . Insulation 18 may be held in place by a plurality of plastic pins that are connected to outer shell 17 and molded into insulation 18 . In certain embodiments, outer shell may be approximately 0.5 inches thick and insulation 18 is preferably at least 1.5 inches thick. When insulating shroud assembly 16 is installed, water is trapped within insulated volume 28 . This water will expand, by approximately 10% by volume, when heated by the fluid flowing through connector 10 . Insulation 18 preferably has a volume at least equal to the volume of water that will be trapped within volume 28 .
[0025] Insulation 18 is sufficiently compressible so as to absorb the expansion of the water without damaging outer shell 17 . Thus, insulation 18 is formed from a material that can support compression both from hydrostatic pressure and from expansion of the water trapped within insulated volume 28 while maintaining sufficient insulating properties. In certain embodiments, insulation 18 is formed from a material that will compress approximately 1% at a water depth of 7,200 feet and still have approximately 2.5-3% compressibility remaining and available to absorb the expansion of the trapped water. Thus, the insulation material provides sufficient compressibility so as to allow the expansion of trapped water without breaking the outer shell and sufficient elasticity to provide reliable sealing engagement with the connector.
[0026] To facilitate installation of insulating shroud assembly 16 onto connector 10 , which is shown in FIGS. 2 and 3 , insulating shroud assembly 16 further comprises body 30 and door 32 that are hingeably connected by drive mechanism 34 . Assembly 16 also comprises locking mechanism 36 that holds door 32 closed and door face seals 38 that provide sealing engagement between a closure member, i.e. door 32 , and body 30 when the door is closed. Door 32 provides sufficient opening for insulating shroud assembly 16 to be installed around flowline jumper 12 above connector 10 , then slid onto and around the connector. As shown, door 32 forms less than one-half of insulating shroud assembly 16 . The particular angular dimension of door 32 will depend on the size of the tubular member, i.e. flowline jumper 12 , that is received within body 30 . In certain embodiments, door 32 provides an approximately 135 degree longitudinal opening into body 30 .
[0027] Referring now to FIG. 2 , door 32 is opened such that insulating shroud assembly 16 can be slid onto flowline jumper 12 above connector 10 and moved downward to the position shown in FIG. 1 . An ROV pushes insulating shroud assembly 16 into place on flowline jumper 12 and then moves the assembly downward over connector 10 so as to set the seals on body 30 . Once insulating shroud assembly 16 is in position, door 32 is rotated by drive mechanism 34 until the door is in the closed position, as shown in FIG. 3 . In the closed position, face seals 38 seal door 32 against body 30 . Drive mechanism 34 provides sufficient force to close door 32 and energize seals 20 , 22 , and 38 by compressing insulation 18 . The interface between the insulation at seals 20 and 22 also maintains the vertical position of insulating shroud assembly 16 on connector 10 . Door 32 is maintained in the closed and sealed position by locking mechanism 36 , which may be a ratchet-type mechanism, spring latch mechanism, or some other system for maintaining the closed position of door 32 relative to body 30 . Locking mechanism 36 may also include an ROV-operable release to facilitate removal of insulating shroud assembly 16 .
[0028] Once in the closed position, body 30 and door 32 are sealed against jumper 12 by upper seal 20 , against manifold 14 by lower seal 24 , and against each other by face seals 38 . The interactions of these seals are more clearly seen in FIGS. 4-6 . Referring now to FIG. 4 , the engagement of upper seal 20 and flange 24 of flowline jumper 12 is shown. Upper seal 20 preferably comprises three annular protrusions 40 of insulation 18 . Annular protrusions 40 project radially inward so that the protrusions are compressed when assembly 16 is installed on connector 10 . The plurality of annular protrusions 40 are arranged vertically so as to take into account dimensional tolerances that may effect the position of flange 24 when connector 10 is engaged. Thus, protrusions 40 are arranged such that at least two of the protrusions is compressed against flange 26 to form an annular seal.
[0029] The engagement of lower seal 22 and manifold 14 is detailed in FIG. 5 . Lower seal 22 comprises two annular protrusions 42 of insulation 18 . Annular protrusions 42 project radially inward from insulation 18 so that the protrusions are compressed when assembly 16 is installed on connector 10 . Annular protrusions 42 are arranged vertically so as to take into account dimensional tolerances that may effect the position of flange 26 when connector 10 is engaged. Thus, protrusions 42 are arranged such that at least one of the protrusions is compressed against flange 26 to form an annular seal.
[0030] Referring now to FIG. 6 , the engagement of face seals 38 are shown. Face seal 38 comprises male sealing face 44 disposed on each side of door 32 with a corresponding female sealing face 46 disposed on the sides of the longitudinal opening in body 30 . Male sealing face 44 comprises wedged protrusion 48 sized so as to sealingly interface with wedged receptacle 50 on female sealing face 46 .
[0031] Drive mechanism 34 is shown in FIGS. 7 and 8 , where FIG. 8 is a cross-section taken along section line A-A of FIG. 7 . Drive mechanism 34 comprises gear assembly 52 connected to shell arms 54 and shell brackets 56 . Shell arms 54 are connected to body 30 of insulating shroud assembly 16 and shell brackets 56 are connected to door 32 .
[0032] Gear assembly 52 comprises planetary gears 58 , ring gear 60 , and sun gear 62 . Sun gear 62 is mounted on shaft 64 and rotated via paddle 66 , such as by an ROV. Planetary gears 58 are each mounted to a shaft 68 . Sun gear shaft 64 and planetary gear shafts 68 are mounted to shell arms 54 . Ring gear 60 is connected to housing 72 that is rotatably supported on torsion plug 70 and held in place by retainer ring 74 . Shafts 64 and 68 extend the height of door 32 .
[0033] In operation, an ROV, or other rotatable actuator, engages paddle 66 so as to rotate shaft 64 and sun gear 62 . The rotation of sun gear 62 causes corresponding rotation in planetary gears 58 and ring gear 60 . Planetary gears 58 rotate about shafts 68 but maintain their relative positions to sun gear 62 . Thus, the rotation of planetary gears 58 causes ring gear 60 to rotates about its central axis, which is coaxial with shaft 64 . The rotation of ring gear 60 causes housing 72 to rotate and thus rotates shell brackets 56 and door 32 relative to shell arms 54 and body 30 . Gears 58 , 60 , and 62 also act to provide a mechanical advantage in closing door 32 by increasing the torque that is applied by the ROV to rotate paddle 66 . For example, if the ROV can apply 100 ft-lbs. of torque, 600 ft.-lbs. of torque can be applied to door 32 . In certain embodiments, other rotatable actuators may take the place of geared drive mechanism 34 .
[0034] Insulating assemblies can be constructed in any number of configurations and arrangements to support insulating different sizes and types of connectors. For example, referring now to FIG. 9 , a flowline jumper connector 80 joins a flowline jumper 82 to a manifold 84 . Insulating shroud assembly 86 surrounds connector 80 and comprises outer shell 87 , insulation 88 , upper seal 90 , and lower seal 92 . Upper seal 90 sealingly engages flange 94 on flowline jumper 82 . Lower seal 92 sealingly engages flange 96 of the connector support structure on manifold 84 . Thus, seals 90 and 92 form an insulated volume 98 that surrounds connector 80 .
[0035] FIG. 10 illustrates one embodiment of a latching system 100 for use in securing door 102 to body 104 of an insulating shroud assembly 106 . Latching system 100 comprises latch assembly 108 and receptacle 110 . Latch assembly 108 is mounted to body 104 and further comprises latch 112 , spring 114 , axle 116 , and bracket 118 . Receptacle 110 is disposed on door 102 and further comprises cam surface 120 and notch 122 . Axle 116 pivotally connects latch 112 to bracket 118 , which is fixably connected to body 104 . Spring 114 is received within slot 124 on latch 112 and biases the latch to the engaged position shown in FIG. 10 .
[0036] In the engaged position, latch 112 is received within notch 122 so as to maintain the position of door 102 relative to body 104 . Latch system 100 is disengaged by rotating latch 112 counterclockwise about axle 116 and rotating door 102 to an open position. As door 102 is rotated back to the closed position, as shown in FIG. 10 , cam surface 120 will engage latch 112 . Cam surface 120 causes latch 112 to rotate counterclockwise about axle 116 and allows door 102 to move past the open latch 124 to the closed position. As door 102 fully closes, spring 114 rotates latch 112 clockwise about axle 116 and pushes latch 112 into notch 122 . The engagement of latch 112 with notch 122 and the force generated by spring 114 maintains door 102 in the closed position and generates sufficient force to maintain the seals formed between insulating shroud assembly 106 and the connector on which it is installed.
[0037] 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, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied, so long as the insulating apparatus retain the advantages 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. | Apparatus and methods for insulating a connector that connects a first tubular member having a first flange with a second tubular member having a second flange. The apparatus comprises a generally tubular body forming a generally tubular cavity therein adapted to enclose the connector. The body has a longitudinal opening adapted to receive the first tubular member and a closure member for closing said opening. The body and the closure member are lined with insulation and include first and second seals for sealing with the first and second flanges so as to seal around the connector. |
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BACKGROUND OF THE INVENTION
This invention relates to suction operated cleaners of the type which have been developed to clean domestic swimming pools.
Automatic pool cleaners, operated by the flow of water induced through the cleaner by the pump of the filtration plant, are now becoming well known. Some of these cleaners interrupt the flow of water through the cleaner to induce forces on the cleaner, and the flexible tube connecting it to the filter weir, to move the cleaner in random step-by-step fashion over the floor of the pool. Interruption of flow has been effected by the use of mechanical gates which intermittently block the flow of water through the cleaner to induce these forces. Flexible, tubular, radially contractable diaphragms have also been used to temporarily interrupt flow in order to create inertia caused by the columns of water. Finally, flexible, tubular radially contractable diaphragms have also been used to interrupt the flow of water through the pool cleaners. By making these interruptions of small duration it has been possible to have the cleaner traverse not only horizontal, but vertical submerged surfaces.
Examples of these types of cleaners are described, for example, in U.S. Pat. Nos. 4,351,077, 4,023,227 and 4,642,833.
SUMMARY OF THE INVENTION
According to the present invention, an interruption in the flow of water drawn through a pool cleaner is used to provide a propulsive force to cause the cleaner to move over submerged pool surfaces. A pool cleaner according to the present invention is provided with a hollow head having an inlet adapted to be in close proximity to the surface being cleaned. The cleaner includes an outlet, suitable for connection to a flexible suction hose which leads to the pool filtration plant. A rigid passageway extends through the interior of the cleaner from the head to the outlet. An end of the passageway, proximate the head, is normally closed by an axially resilient tubular diaphragm mounted in the head of the cleaner. One end of the diaphragm is closed to provide a closure member for one end of the rigid passage, and to provide means for subjecting the interior of the diaphragm to variations in the pressure of water flow through the head of the cleaner during use.
In a preferred embodiment of the invention, the means for subjecting the interior of the diaphragm to pressure variations is a second passageway within the cleaner, extending from inside the head to the outlet. In the preferred embodiment, the second passageway is of smaller cross-sectional area than that of the rigid passageway. Alternatively, the second passageway may extend from, and close, the end of the diaphragm while being remote from the rigid passageway, in order to open into the rigid passageway at a point adjacent to the outlet.
The invention also provides for the diaphragm to be in the form of a cylindrical bellows, resiliently biased to an extended position either by the material from which the bellows is made, by a compression spring contained therein, or both. In further accordance with the present invention, the rigid passageway provided in the cleaner may project from the head at an angle of about 45 degrees to the axis of the inlet leading into the head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side elevation of one embodiment of this invention;
FIG. 2 is a detail of a modification to the embodiment of FIG. 1.
FIG. 3 is a sectional side elevation of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 1, a pool cleaner 1 according to the present invention, has a hollow head 2, with a foot 3, adapted to provide contact with the surface to be cleaned. An inlet 4 provides an entrance for water drawn into the head 2 through foot 3. A rigid outlet passageway 5 extends upwardly from the head 2 with its axis at about 45 degrees to the axis of the inlet 4 leading into the head. The foot 3 is provided with openings 6 and a flexible disc 7, rotatable relative to the foot. The flexible disc 7 is rotatable in order to assist in holding the foot against the surface 8 during use.
The outlet passageway 5 provides fluid communication between the interior of the head 2 and a connector 9 to enable the cleaner 1 to be attached to the end of flexible hose 10 which extends to the weir of the pool filter plant. This outlet passageway 5 forms an integral part, in this example, of a cleaner body 11 connecting the head 2 to the connector 9. The connector 9 will enable the hose 10 to swivel with respect to the body 11.
At the lower end of the passageway 5, a chamber 12 is formed having an outlet 13 which allows fluid to pass into the upwardly extending part of passageway 5 to the connector 9. A tubular, axially resilient diaphragm 14, closed with a rigid plate at one end 15, is located in the chamber 12 and houses a compression spring 16. The spring 16 biases the diaphragm to close the outlet 13. The other open end 17 of the diaphragm 14 is supported in the head by a web 18 in such a manner that the interior of the diaphragm 14 is subjected to variations in pressure with the head 2. Openings 19 are made through the web 18 to allow fluid to pass into the chamber 12, outside diaphragm 14 (FIG. 1), from inside the head.
As shown in FIG. 2, openings 19 allow fluid to flow into the head from outside the body. The web 18 in this construction is impervious to pressure variations in the head.
Referring once again to FIG. 1, a second passageway 20, of considerably smaller diameter than the passageway 5, extend upwardly from the head 2 to the connector 9. This second passageway 20 forms part of the body 11. As shown in FIG. 1, the diameter of the second passageway 20 may preferably be about one-fifth that of the passageway 5.
In operation of a pool cleaner 1 according the present invention, flow of pool water is induced through the head 2 and second passageway 20 from the foot 3 by the action of the filter pump. The suction created by the pool water being drawn through the cleaner causes the disc 7 and foot 4 to grip against the floor of the pool in a manner known for a suction type cleaner. However, this suction also acts on the interior of diaphragm 14 causing it to contract and open outlet 13, thereby allowing pool water to flow into the passageway 5.
The water drawn through the second passageway 20 to create this suction also draws water from the interior of diaphragm 14 through open passageway end 17. As the water is drawn from the interior of the diaphragm, the sealed end 15 of the diaphgram 14 is drawn toward the open end 17 of the diaphragm 14, thereby compressing spring 16. This in turn allows fluid to flow through openings 19, past outlet 13, and through passageway 5, to thereby consequently reduce fluid flow through second passageway 20. The result of this is a reduction of the suction force on closed end 15 of diaphragm 14, and a subsequent reclosing of outlet 13 as the spring 16 biases the closed end 15 of the diaphragm 14 into contact with outlet 13. Thereafter, the cycle repeats. Each contraction and expansion of the diaphragm 14 permits stepwise random movement of the cleaner over the surfaces of the pool being cleaned in a manner known by those familiar with interruption-type pool cleaners. The interruption of the flow through the body, by intermittently allowing flow only through the second passageway 20, results in a release of the disc 7 and foot 3 from the surface of the pool, and an impulsive force along the direction of the flexible hose 10 to cause a movement of the cleaner.
As illustrated in FIG. 3, another embodiment of an automatic swimming pool cleaner according to the present invention consists essentially of a body 21 having an inlet 22 through the base 23 and an outlet 24 in the form of a rigid passageway inclined at about 45 degrees to the axis of the inlet 22.
The end 25 of the outlet passageway 24 is positioned remote from the body 21 and is adapted to connect, through a swivel (not shown), to a conventional form of flexible suction hose 26 used for pool cleaners.
According to this embodiment, the base 23 will preferably have a replaceable wearing foot 27 and carry a rotatable, flexible disc 28 of known form to assist in maintaining the pool cleaner against the submerged surface which it is to clean (as illustrated in FIG. 1).
Referring again to FIG. 3, the body 21 is provided with a separate tubular connection 29 which extends from the body 21 to the outlet passageway 24, again of a position remote from the body 21 and adjacent the end 25 thereof. An end of the connection 29 extends into the body 21 to be oppositely disposed to the inlet to passageway 24. A resilient tubular diaphragm 30, in the form of a cylindrical bellows, is provided between the end of outlet passageway 24 and the end of the connection 29, and is connected to the conection 29. A free end of the bellows 30, opposite the end connected to connection 29, is closed by a rigid closure member 31 having a resilient facing 32 adapted to seal against the inlet opening of the passageway 24. A light compression spring will preferably be included in the bellows. The spring, and inherent resilience of the diaphragm 30, being designed to give a desired degree of bias to the closure member 31 to tend to hold the inlet to passageway 24 closed.
When the flexible hose 10 is connected to a cleaner 1 according to the present invention and the pump of the filter unit, and when the latter operated, a reduction of pressure or suction will occur in the outlet passageway 24 and the separate connection 29. The dimensions and characteristics ensure that this suction draws the closure member 31 off the inlet to passageway 24 to allow water from the swimming pool to flow through inlet 22 into the body 21 and thence through passageway 24 to the filter unit.
The flow of water through the pool cleaner causes a suction in passageway 24 greater than that in the separate connection 29, the result being that the spring and diaphragm force the closure member 31 toward passageway 24 to close the opening to passageway 24.
This cycle is repeated automatically, each interruption of flow through the body 21 resulting in a force being exerted on the cleaner as well as a substantially simultaneous release of the force holding the cleaner and disc against the submerged surface. The cleaner thus moves in a stepwise manner over the surface to be cleaned in the same way as the embodiment illustrated in FIGS. 1 and 2.
The design of the flexible bellows and resilient facing 32 to the closure member 31 enables most debris to pass through the assembly without causing blockage or interfering with the operation of the cleaner.
It will be understood that both the embodiments described above will require some for or other of balancing mechanism for optimum operation. These mechanisms are known in the art and can easily be designed to suit the requirements of the particular embodiments. Such balancing mechanisms form no part of this invention and thus will not be described herein.
The particular materials, which may conveniently be plastics materials, from which cleaners according to this invention may be built will be chosen along with the dimensions of the cleaners to suit particular requirements. Generally, however, a single size will operate satisfactorily in all domestic swimming pools. | This invention relates to an automatic pool cleaner, particularly suitable for domestic swimming pools which operate on the interruption of an induced flow of water through the cleaner and wherein the control of the interruption is effected through a tubular axially resilient diaphragm one end of which is closed and adapted to hold normally closed a passage from the head of the pool cleaner to the usual form of flexible hose connecting the pool cleaner to the filtration unit. |
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[0001] This application is a continuation in part of U.S. patent application No. Serial No. 09/737,247 filed Dec. 15, 2000, now abandoned.
BACKGROUND OF THE INVENTION
[0002] This invention relates to coastal breakwaters and more particularly to an improved construction for damping incoming wave energy to reduce harmful effects of incoming waves on the bottom, adjacent shore, and the like.
[0003] The use of a breakwater for the protection of shore areas and the damping of incoming waves is well known in the art. All of the various designs are positioned in the natural breaker zone or closer to shore. The most common breakwater is the barrier type that is in effect a solid wall situated offshore extending from the sea bottom to above the air/water interface. This type of breakwater acts as a wall against which the energy of the incoming waves is expended so that the water area of the shoreward side of the breakwater remains relatively calm and the shore area is relatively protected against the battering and erosion by wave action. This type of breakwater by its very nature interferes with currents which, under the proper circumstances, can result in increased erosion at the margins of the breakwater and may result in undue silting on the leeward side of the breakwater. In addition, breakwaters of this type require constant care and maintenance because of the force of the incoming waves and because the currents acting against the breakwater will in time erode away the base of the breakwater which will result in damage to the breakwater.
[0004] Other types of breakwaters have been devised in an attempt to avoid the massive construction generally required for barrier type breakwaters. These are normally of the floating barrier type in which a buoyant body or a plurality of buoyant bodies acting at or near the air/water interface serve to dampen the wave height, thereby to produce an area of relatively calm water behind the breakwater. Although such devices may operate satisfactorily in moderate seas, they are normally of insufficient strength to withstand very heavy seas, particularly in shallow water where wave action is most severe so that substantial repair and replacement of the buoyant bodies will be required after a period of very heavy seas. In addition, such devices require relatively complex mooring systems to retain the floating breakwater in position. More recently, restoring beaches lost to wave action is done by transporting sand from selected surplus areas to shore. Natural wave action, however, removes this material much like the original sand. Thus, this practice of replenishment is a never-ending procedure, besides it is creating new problems in the reservoir areas.
[0005] The most relevant prior art is U.S. Pat. No. 4,006,598, entitled “Breakwater System,” which was granted to the present inventor, Jobst Hulsemann, on Feb. 8, 1977. The Hulsemann '598 patent describes a breakwater system comprising a generally plate-like structure disposed offshore and having an upper face that defined a raised sea floor above the natural bottom. Incoming waves are crested offshore over the breakwater, and subsequently formed waves are smaller because of the reduced water depth afforded by the false sea floor of the breakwater. Open spaces are provided in the upper face of the breakwater so that water pressure on the breakwater is equalized, thereby minimizing the structural requirements of the breakwater. The Hulsemann '598 patent provides for a plurality of false sea floors, each disposed at a different distance from the natural bottom so that the platform created by the plurality of false sea floors is roughly parallel to the surface of the water, and the plurality of false sea floors then forming a breakwater. Thus it can be seen that the Hulsemann '598 patent discloses a method wherein the breakwater system moved the effective area for reducing the damaging forces of breaking waves below the air/water interface, thus simulating a false sea floor during certain conditions of the sea, especially those conditions of different wave heights and different levels of the sea relative to the sea floor. The present invention of a wave ramp, by inherently deviating from the breakwater system of the prior art, overcomes the limitation of the prior art, and, in addition, offers other advantages. The most decisive difference to prior art is the overall inclination of the wave ramp, namely from about the sea floor to or above the surface of the sea, thus replicating more completely the naturally rising sea floor that causes steepening, cresting and breaking of incoming waves over the sandy bottom. The advantage of the continuity of the seaward inclination is that it covers the entire spectrum of incoming waves, regardless of wave height and different levels of the sea relative to the sea floor, in but a single structure, thus rendering the construction of tiered platforms to accommodate waves of different height unnecessary as used in the breakwater system. As a constructional consequence the individual component elements are considerably less massive, rendering a substantially greater ease of handling in placement operations, and require a shorter founding depth into the compacted subsoil of the sea floor. Also, the wave ramp of the present invention has all waves run up from their first encounter with the bottom of the false sea floor as it would be the case with the natural sea floor closer to shore without the wave ramp. Furthermore, the prior art breakwater system has an inherent weakness resting in its beginning in mid-water where parts of larger waves may form smaller waves beneath the structure. Even if these may not be erosive on the bottom their pulsating oscillations exert some stress on the individual elements from below that must be compensated for by the massiveness of the structure. On the other hand, the present invention of the wave ramp offers the advantage of a simple extension above the mean storm level of the sea towards shoreward in case protection is sought from damage of rarer events of exceedingly high stands of sea level. The present invention also overcomes the foregoing deficiencies with the prior art devices and practices and provides a breakwater effective for damping incoming waves, regardless of wave height and different levels of the sea relative to the sea floor, without interfering with the normal tidal and offshore currents.
SUMMARY OF THE INVENTION
[0006] The present invention resides in a wave ramp, a kind of sloping false sea floor, positioned seaward of the natural breakwater zone designed to induce the breaking process of the waves before they interact with the natural bottom. The wave ramp of the present invention is subjected to lower physical stresses as the result of wave encounter since the wave ramp is detached from the bottom, except for piles holding it in position, resulting in little interference with currents; and by acting at the base of incoming waves, well beneath the air/water interface, thereby reducing the height of the waves more shoreward from the wave ramp, and energy components of incoming waves against the wave ramp are significantly reduced. Accordingly, the structural strength of the system is not as critical as for prior art devices which encounter the incoming waves at the air/water interface, the point of greatest wave energy.
[0007] In accordance with the present invention, the wave ramp includes a generally plate-like structure having a substantially upper planar face spaced above the natural bottom to define a false sea floor over which the depth is substantially reduced as contrasted to depth of water over the natural bottom. Incoming waves, the sustainable heights of which are a function of water depth, run up over the wave ramp until they break. The energy is released in turbulence dispensed on the solid structure of the wave ramp rather than on the natural sea floor that is composed of readily movable sand. Waves subsequently formed, landward of the wave ramp, are substantially reduced in size due to the reduced distance left to the wind to build up new waves. Because of the shallowness of the water, the waves reaching shore have less force than would be the case without the wave ramp.
[0008] The upper face of the plate-like structure is provided with a plurality of spaced-apart apertures or open areas between the constituent numerous individual plate-like elements that extend through the structure to permit the passage of water therethrough, thus equalizing pressure above and below the wave ramp. Because the pressure equalization feature and because the breakwater acts substantially at the wave base rather than at the air/water interface, the stress on the structure is minimized. Consequently, damage to the wave ramp is minimal, and little or no maintenance is required. In addition, the plate-like structure of the breakwater is spaced above the natural bottom so that there is substantially no interference with the normal tidal and other near shore currents as the result of the placement of the wave ramp.
[0009] In one embodiment of the invention, the wave ramp defines a generally rectangular shaped sheet or plate in which a plurality of apertures or open spaces are provided so that about 50% to about 80% of the plate upper face is solid. The wave ramp is disposed with the plate spaced above the sea bottom in a gently inclined plane from near the sea floor to near the sea surface and anchored by a plurality of piles directly in the natural bottom.
[0010] The wave ramp is positioned offshore adjacent to the area to be protected and normally extends in its longitudinal dimension parallel to the area to be protected. The transverse dimension of the wave ramp, that is the distance from the landward to the seaward edges, is equal to at least 1 ½ wavelengths.
[0011] In another embodiment of the invention, the wave ramp is defined by a plurality of generally plate-shaped elements, each one slightly offset from it's neighbors in transverse direction, i.e. seaward and shoreward, which are disposed above the natural sea bottom and in combination define a generally rectangular rising plate-like configuration. The upper surfaces of the plates comprise a substantially planar upper face and the size of the plates and the spacing therebetween is such that not more than about 80% of the upper face area is solid surface. The combination of plates is so arranged as to transversely extend at least a distance of about 1 ½ wavelengths thereby rising from the sea floor to the surface. Whereas the wave ramp in transverse direction always begins near the bottom on it's seaward side it extends on it's shoreward side to above the mean level of the sea surface at regular or extreme stands of sea level. The size of the plates or constituent elements and the spacing therebetween can be varied across the transverse dimension of the wave ramp.
[0012] Other features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a sectional side elevation illustrating schematically a section of sea floor and the action of incoming waves.
[0014] [0014]FIG. 2 is a side sectional view of the sea floor of FIG. 1 and showing a wave ramp, constructed in accordance with the invention disposed on the sea bottom for damping incoming waves.
[0015] [0015]FIG. 3 is a plan view of the wave ramp of FIG. 2.
[0016] [0016]FIG. 4 is a side elevation of an individual plate element of the wave ramp of FIG. 3 showing the plate element secured in its operating position in the sea bottom.
[0017] [0017]FIG. 5 is a plan view of the plate element of FIG. 4.
[0018] [0018]FIG. 6 is a perspective view, partially in section, of a wave ramp constructed in accordance with another embodiment of the invention.
DESCRIPTION OF THE INVENTION
[0019] As shown in FIG. 1 a section of typical sea bottom 10 adjacent to a shore area is covered by water which normally cycles, because of tides, between a median low water level 12 and a median high water level 14 . During storms, however, the water may reach an even higher level and this level is designated as the mean storm level 16 .
[0020] It should be clear, however, that a specific storm water level cannot be precisely defined because of the variations in frequency and intensity of storms, the geography of the shore area, the nature of the body of water and other factors. Accordingly, determination of the mean storm water level can only be made after a period of observations and collection of data at the location.
[0021] Incoming waves 17 , generally generated by wind, can occur at any of the aforementioned water levels. These incoming waves, upon reaching the shallow waters adjacent to the shore, crest and break and, depending upon the wave height, may result in erosion of the bottom. In addition, the battering force of the waves, that is the force of the waves applied in a generally horizontal plane, is also largely dependent upon the height of the incoming waves.
[0022] Wave height is a factor of both wind velocity and water depth and as an incoming wave 17 approaches the shore, the water depth decreases to a point where the wave height is greater than the water depth can support. As water depth decreases, the front of the wave 17 becomes increasingly steeper until the wave collapses which results in the breaking of the wave, as indicated in 17 a. The area where the breaking of the incoming waves occurs is commonly called the breaker zone. Typically, the bottom of the breaker zone is characterized by a greatly variable topography, often with holes and rises. It is presently believed that cresting and breaking will occur when the height of the wave, that is, the vertical distance from the trough to the top of the wave, exceeds about 1.5 times the mean depth of the water. Cresting of the wave creates a vertical component of energy 18 due to falling water and the magnitude of the vertical component is related to wave height. If the water is shallow enough and the vertical component 18 sufficiently large, particles from the bottom 10 will be lifted and suspended in the water, where they are eventually carried away by tidal current or near shore currents, if present, and subsequently deposited as silt or sand elsewhere. FIG. 1 also shows a fairly uniform distance between the crests of waves 17 , such distance known as the period, or periodicity of the waves, which will vary based on wind, storm and tidal conditions.
[0023] In addition to the vertical energy component 18 , a horizontal energy component 20 , which is also related to wave height, is generated by the incoming wave 17 , which accounts for the battering force of the wave. The horizontal component 20 is greatest at the air/water interface or surface of the wave 17 .
[0024] After cresting fter cresting as at 17 a, new wave forms 17 b are generated and cresting is repeated, as at 17 c. The new wave forms 17 b are reduced in height as contrasted to the parent wave 17 , because they are formed in shallower water. However, the new wave forms even though of reduced height may still have sufficient vertical and horizontal energy components to be destructive to shore areas and installations located there along.
[0025] In accordance with the present invention, it has been found that by raising the sea bottom and reducing the water depth in a selected offshore area, incoming waves are caused to crest offshore in an area where the vertical component 18 can do little or no erosion damage to the sea bottom 10 . The wave ramp of the present invention, in effect, represents an artificially raised sea floor or false bottom. As the waves run up they do crest and break and collapse much like they do in the natural breaker zone without a wave ramp; the decisive difference, however, is that this breaking process occurs over the likewise non-erodable wave ramp 22 (FIG. 2) and not over the loose and movable grained sea floor 10 , the natural sea floor. In addition, hydrostatic pressure above and below the wave ramp is always balanced due to the spaced apart arrangement of the individual elements 24 (FIG. 2), and there is no interference with normal tidal and near shore currents because of the open spaces between the pilings 24 .
[0026] As is more particularly shown in FIGS. 2 and 3, a wave ramp (not to scale), shown generally as 22 , comprises a plurality of individual plate units 24 which are arranged in spaced relation off the shore area to be protected, shorewardly inclined from a point above the natural sea floor to a point above the mean storm level 16 . The plate units, even though they may have planar upper faces 25 , are slightly set off to define a generally elongated plate-like structure having a substantially inclined upper face extending between the sea surface and the bottom 10 to define a false sea floor which acts on the incoming waves in the same manner as the natural sea bottom in shallower waters adjacent to the shore. FIG. 2 shows two wave ramps 22 , eached comprised of a plurality of individual plate units 24 having upper faces 25 , each wave ramp having two different rates of inclination α and β to the horizontal, where α is the angle measured by drawing a line through the midpoints of surfaces 25 for the first segment and β is the angle measured by drawing a line through the midpoints of surface 25 for the second segment. Thus, as the incoming waves 17 pass over the upper faces 25 between the sea surface and the surface of wave ramp 22 the mean depth of the water is substantially decreased, and, should the wave height be less than about 1.5 times the mean depth of the water as now determined by the upper face of the wave ramp 22 , the waves will crest as at 17 a and break thereby discharging their energy (FIG. 1: 18 ) on top of the faces 25 or the wave ramp 22 . Because the true bottom 10 is well below the false bottom simulated by the wave ramp 22 the particles will not be lifted by the turbulence at the bottom of the breaking waves 17 and not be suspended and transported as when the breaking occurs in naturally shallower water without a wave ramp. Subsequently formed waves will be of substantially reduced heights so that waves eventually reaching the shore area are of greatly reduced force.
[0027] The wave ramp 22 is preferably located in the offshore waters with its longitudinal axis extending substantially parallel to the shoreline, or to the installation being protected. The precise offshore distance of the wave ramp 22 is not critical although it is highly preferred to locate it far enough offshore so that the cresting waves 17 a which are induced by the wave ramp 22 will have substantially little or no effect on the sea bottom 10 . This is always seaward of the natural breaker zone. Wave ramp 22 is spaced above the sea bottom 10 so that the upper faces 25 will lie substantially in an inclined plane vertically spaced from the bottom 10 rising to above the mean storm level (FIG. 1: 16 ) over a distance of at least 1.5 times the wavelength. Although the upper faces 25 of the wave ramp 22 are described as substantially planar, the upper faces may be contoured in conformity with the contour of the bottom 10 at the point of installation.
[0028] The longitudinal dimension of the wave ramp 22 is not critical and it may be as long as required to protect a particular shore area or installation. The transverse dimension of the wave ramp 22 is selected as to be equal to at least 1 ½ times the wavelength and preferably the transverse dimension is equivalent to three or more wavelengths. As used herein, a wavelength will vary depending upon the location, the depth of the body of water, the slope of the sea bottom and the like. Thus, for example, in North Sea locations the wavelength is relatively short, while on the West Coast of the United States wavelengths are generally longer.
[0029] Referring again to FIG. 1, one can note that the geography of the sea floor is normally a continuation of the geography of the landmass above the high water line. When there is a gradual slope to the beach, the slope continues at the same relative slope under water. Due to the effects of erosion, the inclination of the sea floor closer to the beach area may be greater than the inclination of the sea floor at a greater offshore location. The geographies of the wave zones can thus be separated by the inclination of the sea floor. Table 1 shows examples of the relationships between the wave zones.
TABLE 1 Very Breaker Common Steep Sea Floor Zone Beach Beach Rise: 1-500 1:200 1:100 1:50 1:30 1:30 1:20 1:10 Angle: 0.1° 0.3° 0.6° 1.1° 1.9° 1.9° 2.9° 5.7° Percent: 0.2% 0.5% 1% 2% 3.3% 3.3% 5% 10%
[0030] The inclination of the wave ramp can then be selected based on the inclination of the sea floor. The angle of inclination of the wave ramp structure may be greater or less than the angle of inclination of the sea floor. As an example, a wave ramp structure may be selected wherein the first set of plate units 24 will be placed parallel to the shore such that the upper surface 25 is about 12 meters below the mean level of the sea surface where wave heights may only be 5 meters. As another example, Table 2 shows the approximate transverse width (from shore-side to ocean-side) of the wave ramp based on the length of the wavelength. The first three columns represent wavelengths from about 30 meters to about 80 meters, and the last two columns represent wavelengths from about 30 meters and less.
TABLE 2 Wavelength 80 m 80 m 80 m 30 m 30 m Inclination: 1:20 1:25 1:30 1:10 1:50 Wave ramp 240 m 300 m 360m 90 m 100 m
[0031] Referring again to FIG. 2, where the period of the wavelength is about 30 meters, two different sloping segments may be simultaneously employed, based on the inclination of the sea floor having two different rates of inclination α and β to the horizontal. For example, where the inclination is 1:10, the first segment may be placed where the first set of plate units 24 placed parallel to the shore such that the upper surface 25 is about 10 meters below the mean level of the sea surface, and the first set of plate units 24 for the second segment may be placed parallel to the shore such that the upper surface 25 is about 2 meters below the mean level of the sea surface.
[0032] As is more particularly shown in FIGS. 4 and 5, the plate units 24 each comprise a shall or pile 26 , including preferably a lower threaded end portion 28 , adapted for anchoring in the sea bottom 10 , and an upper end portion 29 extending above the sea bottom and carrying a plate 30 in spaced relation to the sea bottom. The upper surface of the plate 30 in combination with adjacent plates defines the upper face 25 of the wave ramp 22 , which acts on the wave in the manner described to induce early cresting and breaking, thereby discharging the vertical energy component 18 and the horizontal component 20 of the incoming wave 17 on top of the plate units 24 . The plates 24 are preferably constructed of a fairly high strength material and in this connection reinforced concrete has been found to be an excellent construction material in view of its high strength and ready availability. With reinforced concrete it has been found that the preferred proportions of the plate 30 diameter to the diameter of the pile 26 be maintained on the order of about 5:1 to about 7:1. In typical sandy bottom the portion of the pile 26 in the sea bottom 10 rarely needs to extend more than a fixed length into the consolidated bottom, e.g. 5 m, to insure proper anchoring of the plate unit 24 . However, under certain conditions of the sea floor, other ratios between the diameter of plate 30 and pile 26 may be selected. Further, other material for plate 30 and pile 26 may be selected, such as stainless steel, wood, or composites such as carbon or fiber. Any material that can resist the corrosive effects of the environment may be used for plate 30 and pile 26 may be selected.
[0033] The spacing between the individual plate units 24 is an important element of the present invention, since, if the units are spaced too far apart, the efficiency of the wave ramp 22 is reduced. On the other hand, if the units are spaced too closely together, the wave ramp 22 will be exposed to undue structural stress due to the force exerted by the water passing over the breakwater system. Accordingly, it has been found that good results are achieved when the units are spaced so that the upper surfaces of the plates 30 comprise between about 50% to about 80% of the total area of the upper face 25 of the wave ramp 22 . In this manner sufticient surface is provided to efficiently induce the cresting and breaking of the waves yet sufficient open space is provided to permit equalization of the pressures above and below the wave ramp 22 .
[0034] In some cases it may be desirable to provide a series of wave ramps 22 , in which the upper faces 25 are disposed at different distances from the shore line, so that, for example, an outer wave ramp is followed by a more shoreward wave ramp, as is the case above where the wavelength is about or less than 30 meters.
[0035] Although the wave ramp of the present invention has been described in connection with a plurality of plate units 24 which are individually anchored in the sea bottom 10 to define a false sea floor, it should be clear that other structural arrangements can be utilized to induce the early cresting of waves in accordance with the present invention. For example, a platform unit can be utilized in place of the plurality of plate units 24 .
[0036] As is more specifically shown in FIG. 6, a wave ramp 22 ′ comprises a unitary rectangular platform 38 having a substantially planar upper face 40 including a plurality of openings 42 , which extend through the platform for the equalization of pressure. The platform 38 is anchored in the sea bottom 10 by a plurality of piles 44 which extend above the sea bottom for carrying the platform 38 substantially between the bottom 10 and the sea surface for the purpose already described. The openings 42 are distributed over the platform 38 and are of sufficient size and number so that the solid portion of the surface of the platform comprises between about 50% to about 80% of the total platform area. The transverse dimension of the platform 38 is equal to between 1 ½ to about three or more wavelengths. In this embodiment, the wave ramp 22 ′ can comprise sections of the platforms 38 arranged in end to end relation so as to extend parallel to the shoreline or installation being protected.
[0037] The operation of the wave ramp 22 ′ is as described above. That is to say, the upper surface 40 of the platform 38 defines a false sea floor, which causes early cresting and breaking of the larger incoming waves, while waves subsequently formed over the system are substantially smaller because of the reduced water depth provided by the false sea floor, the short distance to the shore, and the length of time the wind operates on the surface of the water.
[0038] From the foregoing it will be seen that the wave ramp of the present invention provides a false sea floor, which is in spaced relation to the natural sea bottom, to act upon the base portions of incoming waves to induce early cresting and breaking of incoming waves at a point offfshore, where the vertical component of wave energy can do substantially little or no damage to the sea bottom. The transverse dimension of the system is sufficiently large to inhibit the subsequent formation of large waves. The waves that do form shoreward of the wave ramp are of substantially less height than would normally occur in the absence of the wave ramp, and the horizontal components and the vertical components of wave energy are greatly reduced on the shoreward side of the wave ramp. In view of the structural design of the wave ramp and the manner in which it acts on the incoming waves, the forces exerted on the construction are minimized. Moreover, since the wave ramp is raised on pilings above the sea bottom, there is substantially no interference with normal currents.
[0039] While the invention has been described above in connection with certain embodiments thereof, it will be clear that changes and modifications may be made to the wave ramp system of the present invention without departing from the spirit or the scope of the appended claims. For example, the individual plate units 24 of the preferred embodiments have been shown to be disk-shaped, however, plates of any geometric design may be used. In addition, a wave ramp structure may constructed such that plate units 24 may be inclined relative to the general surface of the water. | The present invention describes an off-shore wave ramp for inducing early cresting of waves to prevent damage and erosion along a shoreline, consisting of at least one platform supported above the natural sea floor by support means firmly affixed to the sea floor, the platform being arranged according to a predetermined regular pattern such that the area of the covers between about 50 and 80 percent of the area of the seal floor under the platform and forming a false sea floor seawardly inclined between the high water level to a selected distance above the sea floor. The wave ramp platform is comprised of an array of a selected spaced-apart, unconnected, rigid, non-bouyant, stationary plate-shaped elements with a seaward inclination of the wave ramp is at a selected angle relative to the floor. |
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This application claims priority to provisional application No. 60/969,066 that was filed on Aug. 30, 2007.
TECHNICAL FIELD
The present application relates generally to the field of artificial lifts, and more specifically to artificial lifts in connection with hydrocarbon wells, and more specifically, associated downhole oil/water separation methods and devices.
BACKGROUND
Oil well production can involve pumping a well fluid that is part oil and part water, i.e., an oil/water mixture. As an oil well becomes depleted of oil, a greater percentage of water is present and subsequently produced to the surface. The “produced” water often accounts for at least 80 to 90 percent of a total produced well fluid volume, thereby creating significant operational issues. For example, the produced water may require treatment and/or re-injection into a subterranean reservoir in order to dispose of the water and to help maintain reservoir pressure. Also, treating and disposing produced water can become quite costly.
One way to address those issues is through employment of a downhole device to separate oil/water and re-inject the separated water, thereby minimizing production of unwanted water to surface. Reducing water produced to surface can allow reduction of required pump power, reduction of hydraulic losses, and simplification of surface equipment. Further, many of the costs associated with water treatment are reduced or eliminated.
However, successfully separating oil/water downhole and re-injecting the water is a relatively involved and sensitive process with many variables and factors that affect the efficiency and feasibility of such an operation. For example, the oil/water ratio can vary from well to well and can change significantly over the life of the well. Further, over time the required injection pressure for the separated water can tend to increase.
Given that, the present application discloses a number of embodiments relating to those issues.
SUMMARY
An embodiment is directed to a downhole device comprising an electric submersible motor; a pump connected with the electric submersible motor, the pump having an intake and an outlet; the electric submersible motor and the pump extending together in a longitudinal direction; an oil/water separating device having an inlet in fluid communication with the pump outlet and having a first outlet and a second outlet, the first outlet connecting with a first conduit and the second outlet connecting with a second conduit; a redirector integrated with the first conduit and the second conduit, the redirector having a flow-restrictor pocket that extends in the longitudinal direction, a downhole end of the flow-restrictor pocket connecting with a re-injection conduit; the first conduit extending uphole to a level of the flow-restrictor pocket, and the second conduit extending farther uphole than the first conduit; the uphole end of the flow-restrictor pocket connecting with the second conduit; and a passage connecting the first conduit with the flow-restrictor pocket.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a configuration of an embodiment;
FIG. 2 shows a portion of a cross section of an embodiment;
FIG. 3 shows a portion of a cross section of an embodiment;
FIG. 4 shows a portion of a cross section of an embodiment;
FIG. 5 shows a configuration of an embodiment;
FIG. 6 shows a cross section of a portion of an embodiment;
FIG. 7 shows a cross section of portion of an embodiment;
FIG. 8 shows a cross section of a portion of an embodiment; and
FIG. 9 shows a cross section of a portion of an embodiment in use.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, those skilled in the art will understand that the present invention may be practiced without many of these details and that numerous variations or modifications from the described embodiments may be possible.
In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via another element”; and the term “set” is used to mean “one element” or “more than one element”. As used herein, 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 described 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.
The present application relates to downhole oil/water separation, and more particularly, advantageously managing back-pressure to manipulate the oil/water separation. One way to advantageously control separation of fluids is by regulating back-pressure applied to the oil stream and/or the water stream. One way to regulate back-pressure is by regulating a flow-restriction (i.e., throttling) of the oil stream and/or the water stream exiting the oil/water separator. Embodiments herein relate to equipment that allows a stream to be throttled, i.e., a back-pressure to be manipulated. The magnitude of a throttling can cover a range from completely closed to wide open depending on the oil/water content of the well fluid.
The form and function controlling backpressure and related flow is highly dependent upon the injection zone orientation relative to the producing zone (injection zone uphole or downhole of the producing zone). Some key differences between the two orientations relate to injecting uphole where the device can throttle and vent to a tubing annulus in a single operation, and injecting downhole where the device may need to throttle the flow “in-line”, .i.e. receive the injection flow from the tubing, throttle the flow, and then return the flow to another tube headed toward the injection zone. Some or all of these factors can be considered. The diameter of a throttle opening can generally be from 0.125 to 1.0 inches.
FIG. 1 shows an overall schematic for an embodiment of a device. Some of the main components of the device are an ESP 100 comprising a motor 110 and a pump 120 . A centrifugal or cyclone oil/water separator 200 is connected adjacent to the pump 120 . The apparatus is placed downhole in a hydrocarbon well, preferably inside a well casing 10 . The motor 110 drives the pump 120 . The motor 110 also drives the oil/water separator 200 . During operation, well fluid is drawn into the pump 120 through a vent 125 . The oil/water mixture is driven out of the pump 120 and into the oil/water separator 200 , a centrifugal type separator in this case. The oil/water separator 200 accelerates and drives the oil/water mixture in a circular path, thereby utilizing centrifugal forces to locate more dense fluids (e.g., water) to a farther out radial position and less dense fluids (e.g., oil) to a position nearer to the center of rotation. An oil stream and a water stream exit the oil/water separator 200 and travel separately along different paths to a redirector 250 , where the water stream is redirected and re-injected into formation while the oil stream is directed uphole to surface.
FIG. 2 shows a cut away view of the oil/water separator 200 , which is of the centrifugal type. A well fluid mixture is driven into and rotated in a cyclone chamber 201 of the oil/water separator 200 . The layers of the stream are separated by a divider 202 that defines a beginning of an oil conduit 204 and a beginning of a water conduit 206 . The oil conduit 204 is further inward in a radial direction with respect to the water conduit 206 . Back-pressure of the streams affects the oil/water separation process. For example, for well fluids having a high percentage of oil, higher back-pressure for the water stream 206 can improve separation results. Similarly, for well fluids having a higher percentage of water, a higher back-pressure for the oil stream 204 can improve oil/water separation. Essentially the same back-pressure principal applies to cyclone type oil/water separators.
FIG. 3 shows another sectional view of the oil/water separator 200 having the oil conduit 204 and the water conduit 206 . Arrows 350 show a representative path of the oil stream. Arrows 355 show a representative path of the water stream. A flow-restrictor 304 , e.g., a throttle, is in the water conduit 206 . The water stream flows uphole into the flow-restrictor 304 . The flow-restrictor 304 could be located in the oil conduit 204 . One flow-restrictor 304 could be in the water conduit 206 and another flow-restrictor 304 could be in the oil conduit 206 simultaneously. Selection of a flow-restrictor 304 from a number of different flow-restrictors having different variations of orifice size and configuration enables adjustment of the aforementioned backpressure in the water stream 206 . There are many ways to replace the flow-restrictor 304 with another different flow-restrictor 304 having a different throttle, thereby adjusting the backpressure situation. Preferably, a wireline tool can be lowered to place/remove a flow-restrictor 304 . A flow-restrictor 304 can also be inserted and removed using slickline, coiled tubing, or any other applicable conveyance method. Slickline tends to be the most economical choice. In connection with use of a slickline, or coiled tubing for that matter, the oil stream channel is preferably positioned/configured to prevent tools lowered down by wireline, slickline or coiled tubing from inadvertently entering the oil conduit 204 . The oil conduit 204 can be angled to prevent the tool from entering the oil conduit 204 . The oil conduit 204 can further be sized such that the tool will not be accepted into the bore.
Alternately, the flow-restrictor 304 can have a variable size throttle orifice so that replacement of the flow-restrictor is not required to vary orifice size. The orifice size can be varied mechanically in many ways, e.g., at surface by hand, by a wireline tool, a slickline tool, a coil tubing tool, a hydraulic line from the surface, by an electric motor controlled by electrical signals from the surface or from wireless signals from the surface, or by an electrical motor receiving signals from a controller downhole.
Check valves 302 can be located in the oil conduit 204 and/or the water conduit 206 . The check valves 302 can prevent fluid from moving from the oil conduit 204 and the water conduit 206 down into the oil/water separator 200 , thereby causing damage to the device.
Packers can be used to isolate parts of the apparatus within the wellbore. For example, FIG. 1 shows packers 410 and 420 isolating an area where water is to be re-injected into the formation from an area where well fluid is drawn from the formation. The packer configuration effectively isolates the pump intake from re-injection fluid. Alternately, the packer 420 could be located below the pump 200 , so long as the water is re-injected above the packer 410 or below the packer 420 , thereby adequately isolating the area where the well fluids are produced from the area of the formation where water is re-injected. No specific packer configuration is required, so long as isolation between producing fluid and injecting fluid is adequately achieved.
The above noted configurations can also be used to inject stimulation treatments downhole. FIG. 4 shows the apparatus of FIG. 3 except with the flow-restrictor 304 removed. FIG. 4 shows pumping of stimulating treatments down the completion tubing and into both the oil conduit 204 and the water conduit 206 . A flow-restrictor can be replaced with a flow device that prevents treatment fluid from following along the path of re-injection water. The arrows 360 illustrate a representative path of the stimulating treatment. The check valves 302 can prevent the stimulation fluid from traveling into the oil/water separation 200 , thereby potentially causing detrimental effects.
FIG. 5 shows a configuration to re-inject a water stream to a zone located below the producing zone. A motor 110 , a pump 120 , and an oil/water separator 200 are connected as before. A redirector 250 is connected uphole from the oil/water separator 200 . The redirector 250 is connected to a conduit 260 that extends downhole from the re-injection and through a packer 420 . The packer 420 separates a production area that is uphole from the packer 420 , from a re-injection area that is downhole from the packer 420 . In that embodiment, the water stream travels through a tailpipe assembly 270 . The tailpipe assembly 270 extends though the packer 420 into the re-injection area that is downhole from the packer 420 .
FIG. 6 shows a more detailed cross section of an embodiment of the redirector 250 . FIG. 9 shows a cross section of a redirector 250 and a flow-restrictor 304 in operation with the flow-restrictor 304 positioned in the flow-restrictor pocket 610 . The flow-restrictor pocket 610 is configured to receive a flow-restrictor 304 . The water conduit 206 is configured to be radially outside the oil conduit 204 , i.e., a centrifugal oil/water separation. The oil conduit 204 extends from down-hole of the redirector 250 , through the redirector 250 , and uphole past the redirector 250 , where the oil conduit 204 connects with production tubing 620 (e.g., coil tubing). The water conduit 204 extends from below the redirector 250 and into the redirector 205 . The water conduit 204 merges into a water passage 630 that connects the water conduit 204 with the flow-restrictor pocket 610 . The water passage 630 can extend in a direction substantially perpendicular to the water conduit 204 proximate to the water passage. That is, during operation, the flow of the water makes approximately a 90 degree turn. The water can alternately make as little as approximately a 45 degree turn and as much as approximately a 135 degree turn. A re-injection passage 670 extends from the flow-restrictor pocket 610 downhole past the redirector 250 . The re-injection passage 670 can be connected with completion tubing or other tubing.
FIG. 7 shows an embodiment of the flow-restrictor 304 . The flow-restrictor 304 has a body 701 that defines therein an upper inner chamber 725 and a lower inner chamber 720 . The upper inner chamber 725 and the lower inner chamber 720 are divided by a flow-restriction orifice 740 . The flow-restriction orifice 740 and the body 701 can be the same part, or two separate parts fit together. Preferably the flow-restriction orifice 740 has a narrower diameter in a longitudinal axial direction than either the upper inner chamber 725 or the lower inner chamber 720 . However, the diameter of the flow-restriction orifice 740 can be essentially the same diameter of either the upper inner chamber 725 or the lower inner chamber 720 . Passages 710 are located in the body 701 and hydraulically connect the upper inner chamber 725 with an outside of the flow-restrictor 304 . Passage 715 is on the downhole end of the flow-restrictor 304 . When the flow-restrictor 304 is in position in the flow-restrictor pocket 610 , the passages 710 allow fluid to pass from the water passage 630 , though the passages 710 and into the upper inner chamber 725 . The fluid then flows through the restrictor orifice 740 , into the lower inner chamber 720 and out of the flow-restrictor 304 for re-injection. It should be noted that the flow-restrictor 304 can have many internal configurations, so long as the flow is adequately restricted/throttled.
The flow-restrictor 304 has an attachment part 702 that is used to connect to a downhole tool (not shown) to place and remove the flow-restrictor 304 from the flow-restrictor pocket 610 . As noted earlier, the downhole tool can be connected to any relay apparatus, e.g., wireline, slickline, or coiled tubing.
There are many ways to determine an oil/water content of a well fluid. Well fluid can be delivered to surface where a determination can be made. Alternately, a sensor can be located downhole to determine the oil/water ratio in the well fluid. That determination can be transmitted uphole in many ways, e.g., electrical signals over a wire, fiber-optic signals, radio signals, acoustic signals, etc. Alternately, the signals can be sent to a processor downhole, the processor instructing a motor to set a certain orifice size for the flow-restrictor 304 based on those signals. The sensor can be located downstream from the well fluid intake of the oil/water separator, inside the oil/water separator, inside the redirector, inside the flow-restrictor, upstream of the oil/water separator, outside the downhole device and downhole of the well fluid intake, outside the downhole device and uphole of the sell fluid intake, or outside the downhole device and at the level of the well fluid intake.
One embodiment shown in FIG. 8 has a flow-restrictor 304 having a sensor 800 located in the upper inner chamber 725 . The sensor could be in the lower inner chamber 720 . The sensor 800 can sense temperature, flow rare, pressure, viscosity, or oil/water ratio. The sensor 800 can communicate by way of a telemetry pickup 810 that is integrated with the redirector 250 . The sensor 800 can communicate through an electrical contact or “short-hop” telemetry with a data gathering system (not shown).
The preceding description refers to certain embodiments and is not meant to limit the scope of the invention. | A downhole device having an oil/water separator having a well fluid inlet, an oil stream outlet conduit, and a water stream outlet conduit; a removable flow-restrictor located in at least one of the water stream outlet conduit or the oil stream outlet conduit. |
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BACKGROUND OF THE INVENTION
The present invention relates to office panelling systems and, in particular, relates to securing adjacent panels of a system to increase the structural integrity thereof.
Office panels for subdividing floor space have proven quite popular and one such system is shown in our U.S. Pat. No. 4,535,577 which issued Aug. 20, 1985. This system uses office panels which have an interior frame, normally of metal, to which decorative panels are releasably secured. These releasable panels allow access to the interior of the frame for such things as electrical wiring and telecommunication conduits and also allows replacement of the panel should it become damaged or obsolete. This system is in contrast to other panelling systems where a solid core is provided and raceways, if present, are provided at the bottom of the panel.
One problem with panelling systems, in general, is effective joining of adjacent panels to render stability to the system. In some cases, fasteners or brackets engage the top and bottom edges of the panel to lock one panel to an adjacent panel. Other panelling systems have taken a different approach and utilize a beam and post arrangement where the post and beam are generally mechanically fixed and panels are added between the posts. This system, although it provides excellent rigidity and stability, suffers in that it is more difficult to assembly and more difficult to change if required by the user.
Other systems use a plastic hinge-type connection, however it has been difficult to add sufficient rigidity to the system with this type of connector.
The advantages of the plastic hinge is full flexibility with respect to the angle at which the panels are connected, however, in practise, it has been necessary to add additional structural members to tie the panels in a given orientation.
There remains a need to provide a simple, strong securement system between panels which accommodates end to end alignment as well as different angles between panels, while strongly tying one panel to the next. The system need not be designed to satisfy all angles between panels, as accepted angles such as 90°, 120° and 135° may be sufficient. Ease of assembly is particularly important. The assembled panels should also have some ability to maintain a strong compressive force with changing conditions such that the biased mechanical connection is maintained.
Furthermore, the securement should serve to vertically align panels to improve the look of the system.
SUMMARY OF THE INVENTION
According to the present invention, a mechanical fastening means extends between the frames of adjacent panels to positively lock the panels in a predetermined configuration. The frames have been provided with slot-like openings which are aligned when the panels are in their assembled condition, and the fastening means extends through the slots and effects a positive lock of the panels.
According to an aspect of the invention, resilient abutment members are positioned between abutting edges of the panels to partially space the panels and provide some resiliency to ensure the mechanical connection remains snug. The slot-like openings provided in the frames cooperate with a fastening member which, in a first orientation, allows a portion of the fastening member to pass through the slots, and once so disposed, the fastening member is rotated in preparation for locking of one panel to the adjacent panel. In cases where panels are placed in end to end alignment, a single fastening means passes through the adjacent portions of the frames of the panels and exerts a compressive force maintaining the panels in an abutting relationship. In cases where the panels are at an angled orientation, inserts may be used where each panel is separately secured to the insert, and the insert forms part of the mechanical connection locking the panels in a predetermined orientation.
The securement system of the present invention provides positive locking of one panel to the next panel whereby the mechanical fastening means acts as a load transfer member, thus adding substantial rigidity to the system. This mechanical fastening is partially accomplished interior to the panel and preferably in the mid portion thereof and is concealed by the panel. Such a system adds structural stability to the overall panelling system when assembled, as forces are transferred between adjacent panels.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings wherein:
FIG. 1 is a partial perspective view of two panels in abutting relationship;
FIG. 2 is a partial perspective view showing the end frames of two panels about to be interconnected by clamping member;
FIG. 3 is an end view showing the position of the clamping member for inserting the head of the clamping member through aligned slots in panels;
FIG. 4 is an end view showing the clamping member rotated in preparation for effecting clamping;
FIG. 5 is a side view showing the clamping member moved to a second position to effect clamping of two panels;
FIG. 6 is a perspective view of a four-way connector used to join panels;
FIG. 7 is a perspective view of a three-way connector for joining panels;
FIG. 8 shows an angled connector interconnecting two panels; and
FIG. 9 is a modified clamp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The office panels or partitions, generally shown as 1 in FIG. 1, have removable decorative exterior panels 2 which are carried by a panel frame, a portion of which is shown in the latter Figures. Panels of this type are shown in our U.S. Pat. No. 4,535,577.
In order to add stability to the office panelling system, panels placed in end to end abutment are secured by means of the clamping member generally shown as 20 in FIG. 2.
The clamping member is designed to pass through the frames 4 and the end caps 6 to engage the interior surface of the frame and effect a clamping action between frames. Each of the end caps include strip receiving slots generally shown as 8 which can receive abutting strips 10. The strip 10 is slidably received in a slot of one panel and engages the slot of an opposed panel. In FIG. 2, one of the frames has been provided with the abutment strips 10, but it is apparent that each frame could have an abutting strip 10 and it is immaterial which end cap carries the abutting strips, as long as the abutting strips are between opposed end caps and engaging an opposed strip receiving slot 8. These abutting strips are somewhat compressible and will add a degree of resiliency when the panels are connected. The strips also serve to provide opposed vertical engagement, oppose any movement caused by twisting forces between panels, and accurately vertically align panels.
In the case of factory installed strips are provided at one edge of each end of the panel and diagonally opposite for convenience of use.
The clamping member 20 has a head 22 secured at one end of the shank 26 such that the head and shank define a generally `T` shape. The head includes panel engaging shoulders 24 spaced either side of the shank 26. At the opposite end of the shank an actuator 28 is pivoted to shank extension 30 at pivot points 32. The actuator includes camming surfaces 34 which engage the inner surface of one of the panel frames when the actuator is moved from a first position generally shown in FIG. 2 to a clamping position or second position generally shown in FIG. 5. The first position allows the clamping member to be appropriately received in the panel in preparation for clamping.
Operation of the clamping member can be appreciated from a review of FIGS. 2 through 5, where clamping member 20 is first inserted through aligned slots in the end frames of abutting panels in the manner shown by arrow 44, and passes through the first panel and through the end frame of the second panel such that the head is disposed to the interior of the frame of the second panel as shown in FIG. 5. Once the head 22 has been located within the interior of the frame of the other panel, the clamping member 20 is rotated as indicated at 46 from the position generally shown in FIG. 3 to the locking orientation of FIG. 4. The camming surfaces 34 of the actuator 28 are now disposed adjacent the edges of the end caps 6 where the structure has greater strength due to the underlying frame 4. The actuator is then rotated in the direction 48 past a point of maximum compression generally indicated as 49 to the second orientation which strongly biases the two panels, due to the compressive force exerted thereon.
The abutment strips 10 contact the opposite slot of the adjacent end cap and align the panels. The strips compress somewhat and provide controlled compression which serves to maintain pressure on the actuator 28. The actuator is thus biased to the second position of FIG. 5, as any movement of the actuator from this position requires a further compression of the strips as the actuator must move through the point of maximum compression provided at point 49 on the camming surface 34.
The cam surface of the actuator is shaped to define, relative to the pivot point 34, a short distance to allow insertion and positioning of the actuator in the panels. This short distance allows sufficient play to insert clamping member. The actuator, when moved to the second orientation, decreases the separation of the head 22 from the contact point of the camming surface to thereby produce a strong clamping force.
As generally shown in FIG. 2, access to the interior of the panels to expose the interior frames is required when the actuator 30 is physically located within one of the panels. The head 22 can be inserted through a slot 36 in a panel, making access to both panels unnecessary.
Various connectors are shown in FIGS. 6 through 8 and are used for securing panels in a non-linear fashion. FIG. 6 shows a four-way connector having a horizontal load carrying member 52 and downwardly extending connecting flanges generally shown as 54. Connecting flanges 54 carry, on the exterior face thereof, compressible cork surface 55 which add resiliency much in the way as strips 10. The downwardly extending flanges cooperate with the aligned slots in the panels to allow a modified clamping member, generally shown as 20a, pass through a panel and through a slot in one of the downwardly extending flanges 54 of the connecting member to connect the panel to the connector. The modified clamping member 20a is the same as clamping member 20, however the shank has been reduced in length to accommodate the reduced distance between the flange 54 and the end cap of a panel. Each of the downwardly extending planar flanges 54 has an elongate slot 36 similar to the panels to allow insertion of the head of the connecting member 20a to pass through the connecting member. The flanges 54 are sized to abut along one surface thereof the planar surface of the end cap adjacent the slot to ensure a strong mechanical connector where stress is reduced to distribution of the forces to a larger area. FIG. 7 shows a three-way connector, whereas FIG. 8 shows an angled connector, in this case, to accommodate an angle of about 135° between panels. Access to the panels is not necessary when connectors are used, however it may be more convenient to have at least one actuator within a panel for ease of assembly.
The planar, generally horizontal, load carrying portions 52 of the connectors provide the stiffness and therefore allow positive securement of one panel to the other at a predetermined angular relationship. Connectors would normally be provided adjacent the top and bottom of the panel.
The present invention uses a clamping member which acts much in the way of key which passes through appropriate slots in adjacent panels and is rotated to an engaging position where the shoulders 24 of the head 22 engage the rear or interior surface of the frame 4 of a panel. Once so rotated, the actuator 28 may be moved to a second position to produce a clamping action. The actuator is designed to provide a mechanical advantage in moving from the first position, which defines a somewhat loose connection between panels, to a firm clamping or second position where compression of the abutting strips or cork surfaces continues to exert tension on the clamping member.
The various slots provided in the end cap can be used for receiving decorative strips used to finish the end of the panel, or for receiving structural components to stack one component on top the other. Details of these features can be found from our prior patent.
The cooperation between the clamping member 20 and the abutment strips 10, partially received in opposed slots of an adjacent panel, initially align the panels and subsequently distribute the clamping force to along the opposed vertical faces of the panels. This cooperation reduces the number of clamping members required and, in most cases, two clamping members, one located adjacent the top and the other located adjacent the bottom of the panels, is sufficient to secure two aligned panels in abutting relationship. Depending upon the vertical extent of the panels, three clamps are used, with the third clamp being generally centrally located.
The connectors of FIG. 8 can be modified such that the downwardly extending flanges or the planar connecting portion 52 engages the end cap along opposed vertical portions, rendering rotation of the connector impossible. Such a connector would partially act in the manner of the strips described above.
A further modified clamp 20b is shown in FIG. 9 wherein the shank 26b is a threaded rod and the nut 23 incorporated in the head 22b threadably receives the shank 26b. Head 22b can be adjusted on the shank 26b to vary the spacing of the head from the lever and cam actuator. Other arrangements for adjusting the spacing are possible and such adjustability may allow a single clamp to be used for joining panels either in end to end relation or joining a panel to a connector.
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. | Securement and cooperation between panels of an office panelling system is improved by mechanically connecting panels in a manner to maintain a particular orientation and to allow transfer of loads therebetween. The mechanical fasteners are advantageously combined with compressible strips between panels which not only deform during fastening of the fasteners, but engage the panel and distribute the clamping force to a larger area thereby adding structural rigidity. |
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BACKGROUND OF THE INVENTION
In a typical offshore drilling operation, a platform jacket or structure with any desired number of legs such as by way of example only, 4, 6, 8, 16, etc. is fabricated in a shipyard to form a structure and the structure is towed to an offshore location by a transport barge. At the location, the jacket is launched and set on the bottom by flooding the jacket legs thereby sinking the jacket to the marine floor. Once set, foundation piles are then driven through the jacket legs in order to stabilize the structure and grouting is placed between the longitudinally extending jacket leg and pile extending there-through. The lower deck section is then set on top of the submerged structure, followed by the upper deck section, if one is desired. Such jackets are usually constructed of steel with legs of about 52 inches in diameter. As a result, the structure is of massive weight with massive surface areas of legs exposed to tide, wind, wave and current. Hence, the practicality of effective environmental stability of such structure may be reduced resulting in possible serious damage to the platform due to wind or wave action as well as damage due to the transport barges and tenders which bump the structure while coming alongside and docking thereto. Hence, a jacket of substantially less weight and with a reduced amount of exposed surface area which is subject to the tremendous forces of wind, wave, tides and current, conditions inherent in offshore operations, is sorely in need, Previous attempts to improve stability of such jackets has heretofore been futile due to the conditions in which such units are put into operation.
SUMMARY OF THE INVENTION
This invention relates to an offshore jacket assembly, or structure, and more particularly relates to a submersible jacket which possesses substantially less mass than prior offshore platform systems and includes a significantly smaller surface area at the exterior thereof for exposure to wind, waves, tide and current, than structures in the prior art.
The reduced weight and surface area of the jacket sleeves of the present invention render them of increased environmental stability which has heretofore been a drawback of existing prior art divices, and renders the device of the present invention better suited to mooring and anchoring.
The weight and surface area of the present invention have been reduced by means of a novel arrangement of jacket sleeves each of which is spaced apart one from the other along a piling extending through the aligned sleeves so that the smaller diameter piling is practically otherwise completely exposed between the aligned spaced sleeves, whereas previous prior art offshore structures include longitudinally extending jacket legs for substantially completely enclosing or housing the individual pilings. The present invention however relies upon much shorter and compact separate and spaced apart jacket sleeves which are interconnected and aligned by suitable bracing which add much less mass to the overall weight of the assembly. The result is that the jacket of the present invention weighs much less and the exposed piling possesses much less surface area on its exterior than heretofore known conventional jacket legs of devices of the prior art.
Thus, the invention relates specifically to a submersible offshore jacket assembly comprising a plurality of elongated pilings having a first diameter, a plurality of sleeves of a diameter greater than said first diameter and with the sleeves being longitudinally aligned and spaced in inter-connected relationship by suitable bracing whereby a piling extends through each group of longitudinally aligned sleeves so that the sleeves are in surrounding relationship to the piling at longitudinally spaced intervals therealong separately one from the other. The sleeves while being interconnected by a plurality of braces connected to one another and to each of adjacent spaced sleeves provides an arrangement or structure whereby said pilings function as the legs of the assembly, and wherein each of said pilings has an exterior surface area completely exposed to the environmental forces of tide, wind, waves and current, along substantially the entire length of each piling except where surrounded by the longitudinally aligned, spaced sleeves.
This invention also relates to a method of grouting an elongated piling of a submersible offshore jacket assembly to the support structure of the assembly comprising the steps of introducing grout into the interior of the support structure at longitudinally separate and spaced apart sleeve locations along the length of each piling of the assembly, and containing said grout within the spaced sleeves in order to allow it to set at each of said separate and spaced apart sleeve locations along the length of each of said pilings of the submersible offshore jacket assembly.
In a particularly specific embodiment of the present invention, the invention relates to a submersible offshore jacket assembly conprising a plurality of elongated pilings having a first diameter, a plurality of sleeves of a diameter greater than said first diamter and associated with each piling in surrounding relationship thereto and further spaced therealong separately one from the other, a plurality of braces connected to one another and to each of adjacent pairs of sleeves in an arrangement whereby said pilings function as the legs of the assembly, and wherein each of said pilings has an exterior surface area otherwise completely exposed to the environmental forces of tide, wind, waves and current, along substantially the entire length of each piling, each of said sleeves including means for introducing grout into the annular space between the inner surface of each sleeve and the outer surface of the piling extending therethrough in order to cement or secure the sleeve and piling together, sealing means at the upper and lower portion of each of said sleeves in order to retain the grout in the interior of the sleeve, the sealing means being an inflatable packer, each of said pilings including a flood valve at the lower end thereof in order to flood the interior of the piling thereby sinking the assembly to the submerged floor, and a reach rod within each piling connected to said flood valve and accessible at the upper end of the piling for actuating and removing the flood valve if desired. Means are provided to space and retain the piling and surrounding spaced sleeve in fixed relation during fabrication and until the jacket or structure is submerged and set on bottom, whereupon the sleeves and piling are released from fixed relation so that the piling may be driven into the water covered area to secure the platform in position in the water covered area.
Other objects, advantages and features of the present invention are that the jacket of the present invention are simple in design and fabrication. The reduced surface area of the units creates less drag forces on the jacket and the reduction in mass decreases the amount of structural material necessary to construct the units as well as fabrication cost and installation charges. Minimum shear loads and bending movement at the mud line will also be realized. The cost of cathodic protection of the jacket will also be diminshed.
A particularly unique feature of the present invention is that the jacket of the present invention incudes at the time of fabrication as one of its structural component pilings which hertofore have been supplemental to the conventional jacket legs of prior art systems. Thus, previous systems employed elongated jacket legs whereas in the embodiments of the present invention the pilings are provided instead of the massive and cumbersome jacket legs of systems of the prior art. Thus, the present invention eliminates old practices of driving foundation piles through the central bore of jacket legs in favor of driving them through a series of longitudinally aligned, spaced jacket sleeves.
Since an offshore jacket made of steel may weigh in excess of 1,500 tons, it can be seen that any reduction in the overall mass of such structure would be greatly beneficial and such reduction can be achieved with the concepts presented herein. Such reduction has been found to be effective in providing jacket assemblies with improved environmental stability in the unstable conditions in which such assemblies are employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial, schematic representation of an offshore submersible drilling and platform jacket assembly, or structure of the present invention resting on the marine floor;
FIG. 2 is a pictorial representation partly in cross-section of a portion of the assembly of FIG. 1 and illustrating one of the pilings and a manner of retaining the piling in position relative to the spaced sleeves as the structure is floated and submerged to the desired location and position on the submerged surface;
FIG. 3 is a view of a piling illustrating details of the flooding system while may be used with each of the pilings; and
FIG. 4 is a pictorial representation partly in cross-section of one of the jacket sleeves of FIG. 1 showing a form of the packer and grouting arrangement for each sleeve.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there will be seen one form of the offshore submersible drilling and production platform jacket of the present invention resting on the marine floor at the mud line. A portion of the jacket assembly referred to generally at 10 will be seen extending above the water level represented by the uppermost dotted line in FIG. 1 so a platform may be positioned thereon above the water level and the assembly extends into the water to rest on the submerged surface S. The jacket assembly 10 consists of a series of pilings P, two of which are shown in dotted line and while only two pilings are shown, it is understood that generally at least four are employed, and in other instances an many as 16 or more may be used depending upon the platform size and use of the system. Above the water level, provision is made to add piling to the jacket 10 as the piles are driven into the submerged surface S and this will be seen as a piling add on section 13. The pile sections are welded to the upper end of the piles that extend through the longitudinally aligned, spaced jacket sleeves 15.
A system of internal bracing is shown generally at 17 as interconnecting the jacket sleeves 15 to maintain them in position and to form the platform of any suitable longitudinal extent and size. The bracing includes top horizontal brace shown at 14 and the lower horizontal brace at 16 extending between adjacent jacket sleeves. If desired horizontal braces could extend between the intermediate jacket sleeves 15 as well as the upper and lower jacket sleeves. Vetical bracing 16a may extend between diagonal bracing 16b and adjacent the piling as shown in FIG. 1. Horizontal bracing 14, 16 vertical bracing 16a and diagonal bracing 16b is tied in to the jacket sleeves 15 in any suitable manner to form joints 18 at the jacket sleeves 15 as shown. Thus, the jacket sleeves 15 together with the bracing 17 form a framework and a piling P is inserted into each group of aligned, spaced jacket sleeves 15 of the framework at the time of fabrication. The diagonal bracing 16b is shown as connected at its ends between adjacent longitudinally spaced sleeves throughout the extent of the jacket assembly.
The sleeves 15 receive therethrough the pilings P so that the piling can be driven downwardly into the marine floor once the system is placed on location. It is to be noted that between the longitudinally aligned, spaced jacket sleeves 15 is an exposed section or portion 35 of each piling P, and that these exposed sections 35 are of a diameter less than the diameter of the sleeves 15 which diameter is that of the piling.
Once the jacket assembly 10 has been fabricated, moved to location and set on the marine floor and the pilings P driven into the ocean bottom, grout is pumped into each of the sleeves 15 via separate grout inlet lines 32 adjacent each group of jacket sleeves, as seen in FIGS. 1 and 4. In FIG. 1, a separate grout line is illustrated as positioned adjacent piling P and connected separately to each sleeve 15 associated with each piling P. More particularly, a separate grout line communicates with the seals, or packers on each sleeve. As shown in FIG. 1, the grout lines 32 each extend from above the water surface and each line is connected to the upper and lower packers 33, 34 on each sleeve in any suitable manner. The manner of connecting each grout ine 32 with each sleeve 15 is illustrated diagramatically in FIG. 4 wherein the grout line 32 is connected to the intermediate sleeve. Each packer 33, 34 on each sleeve is provided with a one-way opening check valve means represented schematically at 33a and 34a. The grout from line 32 enters packers 33, 34 and inflates them to seal off the annulus between sleeve 15 and the piling extending therethrough. When the pressure in packers 33, 34 exceeds a predetermined amount above inflation and sealing pressure, valves 33a, 34a open and the grout flows to annular void 31a to fill it and the packers remain set. A check valve represented schematically at 15a is associated with an opening 15b on each sleeve 15 to enable water to be displaced from void 31a as it is filled with grout.
Similarly, grout lines 32 are provided for each jacket sleeves 15 between the uppermost and lowermost jacket sleeves 15. Packers 33 and 34 are arranged adjacent the end of each sleeve 15 and communicate with their respective grout lines and are provided with valve means as above described for actuation of the packers and filling of the void. Each jacket sleeve is also provided with means to enable the water to be enactuated from void 31a as it is filled with grout as described above with regard to FIG. 4. The jacket sleeve 15 that are above water may be supplied with grout from a line connected to a tender vessel, if desired. It is to be noted that the lowermost sleeve 15 is provided with a packer 34 within the void between sleeve 15 and the piling 11 there shown, for a purpose as will be described.
FIG. 2 shows the detail of the support system for each piling, one of which is represented at 11, relative to the longitudinally spaced sleeves 15 through which it extends and this will be seen to include a cover plate 25 having a vent valve 20 therein. Tie down or spacer plates 19 of any suitable form are circumferentially spaced and extend between each piling and the sleeve 15 at the upper end of each piling. The spacers 19 are secured by welds 19a to the piling and by welds 19b to the sleeves and these welds are burned off when it is desired to drive the piling into the ocean floor or surface S. The lower end of each piling is further supported by lowermost jacket sleeve 21 which includes a plurality of piling holding member 23. The holding members 23 include a shoulder 23a which abuts the lower ned of the piling as shown and also include a portion 23b which extends longitudinally of the lowermost jacket sleeve 21. The members 23 are secured by welds to the piling. The holding members 23 and spacers 19 secure and maintain the piling and surrounding sleeves in position during fabrication and movement of the assembly to an offshore location. Packer 34 is arranged between piling 11 and lowermost sleeve 21 as previously discribed so as not to interfere with holding members 23. FIG. 3 illustrates the piling flooding system which is actuated when it is desired to sink the jacket to the ocean floors. A valve actuator 26 is connected to the flood valve 28 located on cap 29 and the actuator 26 is protected by sleeve 24. Reach rod 27 extends downwardly from actuator 26 to the flood valve 28. A rupture pulling line is also provided at 30 and is accessible through the top cover plate 25 and connected at its lower end to lower internal closure cap 29 to remove the cap 29 and valve 28 when desired.
The assembly is positioned on the floor S in a water covered area by opening valves 28 in each piling 11 to floor the pilings in a manner well known to submerge and position the framework or structure. The pilings are then ready to be driven through the sleeves, and piling sections 13 added as required.
As noted previously, the welds 19a, 19b are burned off to disconnect the piling from its surrounding sleeve assembly, and the members 23, being connected with the piling move downwardly as the piling is driven into ocean floor S.
In FIG. 1 it should be noted that in prior art devices, longitudinally extending jacket legs were used to construct the offshore framework and that these legs extended longitudinally to form the jacket assembly. The bracing which, with the legs formed the jacket assembly was connected to such legs to form joints at longitudinally spaced intervals. The pilings were driven down through such legs into the ocean floor. These legs were of about the same diameter as the sleeves of the present invention and since they extended the entire length of the assembly from top to bottom it can be easily understood that the legs added considerable weight and cost to the assembly in comparison to the sleeves of the present invention. Thus, in FIG. 1, the legs covered up those exposed sections of piling indicated at 35. Hence, in the present invention exposed sections 35 represent areas of the jacket 10 where mass have been eliminated and areas where less surface area is present than has previously existed in the prior art. Such reduction in mass and surface area provides the device of the present invention with the advantages enumerated above.
While the drawings indicate only a single length of piling, it is to be understood that each piling P may be formed of a plurality of sections welded together during fabrication and other sections 13 of piling may be added as needed dependent upon each local and said conditions have been such as to require as much as 200 feet of soil depth penetration.
The foregoing disclosure and description of the invention are illustrative and explanatory, thereof, and various changes in size, shape and materials as well as in the details of the illustrated construction may be made without departing from the spirit of the invention. | A submersible offshore jacket assembly is provided having a plurality of elongated pilings with a first diameter. A plurality of spaced, longitudinally aligned sleeves of a diameter greater than the first diameter of the piling are interconnected by suitable bracing and receive a piling therethrough, so that the sleeves surround the piling and are spaced therealong separately one from the other. A plurality of braces are connected to one another and each of said sleeves in an arrangement whereby said sleeves with the pilings function as the legs of the assembly. Each of said pilings has an exterior surface area otherwise completely exposed to the environmental forces of tides, wind, waves and current, along substantially the entire length of each piling between the spaced sleeves. |
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FIELD OF THE PRESENT INVENTION
The present invention relates to construction materials, and more specifically, to pre-fabricated construction materials designed to create durable, economical, eco-friendly buildings rapidly with a minimal labor force and without the use of costly equipment.
BACKGROUND OF THE PRESENT INVENTION
In the quest to create more efficient, cost effective buildings, humans have endeavored to improve the materials used to construct modern buildings, as well as the system by which those materials are employed. Factors such as insulation and roofing can be critical to the cost efficiency of a building. As humans have progressed over time, adobe-based huts evolved into wood and concrete constructs, designed to be durable—to withstand the elements and stand up to the test of time. However, many modern buildings were constructed hastily, and are constructed with bricks, cinderblocks, or other heavy, cumbersome material. Employing such a dense material is more durable than wood or clay, but is time consuming and laborious to construct. Additionally, cinderblock or brick construction materials require strict coordination with plumbers and electricians to construct the building in a timely fashion. With each contractor having a different schedule, this can sometimes be difficult.
As a result of the stone building materials immense weight, costs are high to transport them to the construction site, as well as to build the blocks themselves. In turn, constructing buildings out of bricks, cinderblocks, or other concrete-like material around a predominantly wooden frame is not very cost effective. Other materials, such as polyurethane, acrylic polymers, plastics, and other similar materials are more economical and offer better insulation than traditional building materials. Unfortunately, there is currently no effective way of constructing a building solely with such alternative building materials that offers the same level of structural integrity as brick or cinderblock based buildings provide.
Thus, there exists a need for a new form of building material that provides superior insulation while remaining unitary, light-weight, economical, and eco-friendly, while being predominantly pre-fabricated prior to arriving at the construction site, saving both time and money.
U.S. Pub. No. 2011/0061335 for “Masonry Construction Using Single-Component Polyurethane Foam” by Sheckler, published on Mar. 17, 2011, shows a method of using polyurethane as a bonding agent for concrete blocks or other masonry units. Unlike the present invention, Sheckler does not mention use of polyurethane as a bonding agent for drywall or non-stone materials.
U.S. Pat. No. 3,782,063 for “Expandable Prefabricated Building System and Method of Construction” by Batorewicz et al., issued on Jan. 1, 1974, shows methods of construction for housing systems that are partially prefabricated and assembled prior to shipment to the erection site. Batorewicz et al. employs polyurethane as a “hardenable plastic” applied to portions of the structure, but no mention is made of it being used to together interlocking wall units.
U.S. Pat. No. 5,758,461 for “Lightweight, Prefabricated Building Structures” by McManus, issued on Jun. 2, 1998, shows panels for a prefabricated building that have “friction lock means for interlocking one to another.” FIG. 16F shows one of these friction lock means, namely a tenon and mortise link, that appears similar to the locking means of the present invention, although no mention is made of bonding the link with polyurethane.
U.S. Pat. No. 3,397,496 for “Locking Means for Roof and Wall Panel Construction” by Sohns, issued on Aug. 20, 1968, shows wall, roof and floor modular panel units made of a plastic foam core sandwiched between resin reinforced glass fiber skins.” FIG. 5 shows a side edge interlocking structure that bears some similarity to the interlocking structure used in the present invention, although the pieces are not bonded together with polyurethane.
U.S. Pat. No. 5,349,796 for “Building Panel and Method” by Meyerson, issued on Sep. 27, 1994, shows interlocking panels with a polystyrene, or equivalent material, core. The panels join at their lateral edges with an interlocking joint or snap lock assembly, so that nails or other joining elements are not needed. The interlocking panels in Meyerson connect in a manner dissimilar to the present invention.
SUMMARY OF THE PRESENT INVENTION
The present invention is a mass production building component designed for the construction and assembly of commercial, industrial, and residential buildings based on the injection of polyurethane foam between two preferably metallic panels, constituting a system of walls when interlocked together. The panels are designed to interlock with other similar panels via a unique interlocking clasp found at the ends of each panel. A metallic support column is then placed in the cavity found to exist in the juncture between any two panels, which is secured to the panels via the interlocking clasp. The support column is preferably anchored to the foundation of the building via an anchor plate embedded within the concrete. Windows and doors may be embedded within the panels when the panels are initially created, such that the polyurethane foam holds the window in place. Additionally, electrical outlets, fuse boxes, lighting assemblies, and switches, along with all accompanying wiring are preferably incorporated into the panels at their inception as well. This is preferably accomplished via a wiring cavity, often created by a PVC pipe or other cylinder being left between the two panels at the time when polyurethane is injected between them. This cavity, left behind by the PVC pipe, or the cavity within the pipe itself, is then used to house the wires required for electrical outlets and lighting fixtures which are preferably integrated into the panels as they are made as well.
Given that the electrical systems, vents, doors, and windows are pre-built into the very walls of the house, considerable time may be saved at the construction site of the building. For example, time is not wasted waiting for the electrician to arrive on-site to set up the electrical systems in the walls prior to the construction team being able to proceed, as the electric is already built into the walls, so no electrician is needed to integrate the wiring on-site. Wires routing electricity to the panels are preferably maintained in a trough which is incorporated into the crown beam. The crown beam rests atop the panels, helping to bind them together under the roof.
Roofing is easily placed atop the crown beam of the present invention, and is secured to the crown beam with a conventional mounting mechanism, as well as by joining the metal columns to the roofing material. The mounting mechanism employed for the roof is similar to the mounting mechanism employed to attach the support columns to the anchor plates held within the structure's foundation. The present invention is envisioned to be compatible with a wide variety of roofing materials, ranging from tiles, shingles, sheet metal, etc. It is envisioned that the present invention will enable a group of people to build a structure without the use of any advanced tools, welding, cranes, or heavy machinery.
It is the intent of the present invention to provide easy-to-assemble, durable, eco-friendly, efficient buildings that may be constructed in a single day with a skilled team of 8 to 10 individuals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an illustration of the interlocking edges of the present invention as viewed from above.
FIG. 2 shows an illustration of the present invention being employed to support a third, perpendicular panel.
FIG. 3 displays the present invention from the side, highlighting the embedded window and integrated electrical features.
FIG. 4 exhibits a flow chart detailing the use of the present invention as a construction material.
FIG. 5 illustrates the way in which the roof, support columns, and mounting mechanisms interact with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a pre-fabricated wall panel designed for the construction of buildings. It has two parallel, preferably metallic sheets, shown as sheets ( 180 ) bound together with a polyurethane layer ( 10 ), preferably foam, injected between the sheets ( 180 ), making the present invention a panel ( 100 ) that is unitary, designed to construct the wall ( 65 ) of a building. The present invention employs a support column ( 30 ), preferably composed of metal, which serves to anchor the present invention to the foundation of a building via a mounting mechanism ( 160 ), as well as to provide a common anchor point for panels ( 100 ). Each panel ( 100 ) has a first end ( 20 ) and a second end ( 50 ), which are preferably shaped as hook-shaped extensions. The hook-shaped extensions on either side of the panel ( 100 ) are such that they are mirrored opposites of each other, as seen in FIG. 1 , which shows the junction of two panels ( 100 ), forming a wall ( 65 ) for a building. This feature is critical to the support system of the present invention, as a first panel ( 60 ) and a second panel ( 70 ), of the present invention to be easily interlocked together in a series, forming a wall ( 65 ) as seen in FIG. 1 , thus constituting the interior and exterior walls of a building. The panels ( 100 ) are designed to be interlocked together without the use of any rivets, screws, welding, or heavy duty equipment. By the nature of the manner by which the panels ( 100 ) interlock together via the hook-shaped extensions, aided by the support column ( 30 ), the junction of the panels cannot be observed from outside of the structure, as the junction appears to be seamless.
The walls ( 65 ) of the building have been created to sustain both hot and cold weather while maintaining an ideal temperature indoors. This is due in part to a polyurethane layer ( 10 ) found as the core of the present invention, which provides optimal insulation while simultaneously providing structural integrity to a building constructed with the present invention. While other foam materials could be employed, polyurethane foam is preferred for a variety of reasons; namely, it is a lightweight, strong insulator that is sticky and fast expanding, assisting its adherence to the panels ( 100 ) of the present invention, as well as other exposed components. Additionally, termites do not eat polyurethane, and other insects cannot such a polyurethane layer ( 10 ) penetrate it, helping to keep insects out of the building.
The preferred embodiment of the present invention is preferably mounted to the foundation of the building via the support columns ( 30 ), and more specifically, via the mounting mechanism ( 160 ) found at the bottom of the support columns ( 30 ), as seen in FIG. 2 . As illustrated, the support columns ( 30 ) are designed to be inserted into an anchor plate ( 110 ), preferably made of steel, which is embedded within the concrete foundation of the building. The mounting mechanism ( 160 ) may consist of a traditional expansion clasp, similar to those found on conventional umbrellas, only larger and made with more durable materials. It is envisioned that, regardless the conventional clasp used as a mounting mechanism ( 160 ), the clasp is preferably permanent, such that the destruction of the foundation of the building would be required in order to dismount the support columns ( 30 ) from the anchor plate ( 10 ).
It is envisioned that there are approximately five differing, generic types of the present invention that are created to be used to construct buildings. Each type is simply a differing form of the same concept—namely a polyurethane injected panel which employ a specific form of edge that is able to interlock with the edges of other panels, all of which are anchored to the foundation for stability. Types may include a window wall panel, an electrical wall panel, a door panel, vent panels, and standard blank panels. Additionally, the underlying roof panels are preferably constructed similarly to the panels ( 100 ) of the present invention.
A crown beam ( 120 ) is placed atop the panels, additionally binding them together and increasing the structural integrity of the building. The crown beam is preferably composed of a single sheet of bent metal, shaped into a trough ( 130 ) approximately the same width of the panels ( 100 ). The crown beam ( 120 ), in addition to the support columns ( 30 ) and anchor plates ( 110 ) provide the strength of the structure. By employing such simplistic forms, a structure constructed with the present invention does not require any type of welding, special tools, or heavy duty equipment to successfully build a structure. It is preferably envisioned that a structure built with the present invention need not require much more than a conventional screwdriver to assemble.
The panels ( 100 ) are preferably designed according to the structural requirements in place at the location they are intended to be used. Therefore, wind speed, flood potentials, and seismic conditions are taken into consideration in order to determine the optimal dimensions of the panels ( 100 ), as well as the depth at which the anchor plates ( 110 ) should be placed in the concrete foundation. For locations prone to earthquakes, the anchor plates ( 110 ) are thicker, and other forms of mounting mechanisms ( 160 ) may be employed to secure the support columns ( 30 ) to the anchor plates ( 110 ). For example, the anchor plate itself may be of a thicker, more durable metal for installations in locales prone to frequent seismic activity. Additionally, the support columns ( 30 ) could be made of a more shatter resistant alloy to conform to the construction parameters of the structure.
The crown beam ( 120 ) of the present invention is preferably placed on the frame of the structure, which is established by the interlocking panels ( 100 ), as seen in FIG. 5 . The crown beam ( 120 ) serves as a buffer between the roof ( 140 ) and the top of the panels ( 100 ). This buffer, shown as a trough ( 130 ), provides a space for electrical wires and plumbing to be routed to the appropriate rooms easily before the roof ( 140 ) is mounted to the structure. The roof ( 140 ) is constructed of similar panels that are injected with the polyurethane ( 10 ) foam; however, the sheets employed to make the roof panels ( 150 ) are not parallel. One sheet of the roof panel ( 150 ) is slanted to allow for the slope of the roof ( 140 ), providing an avenue for water runoff. Due to the nature of the construction of a structure in this fashion, the structures do not have attics or large vacant cavities within the roof ( 140 ). This helps to ensure optimal insulation from the elements, as well as to eliminate potential habitats for insects.
The roof panels ( 150 ) of the present invention are preferably built of a first roof sheet ( 180 ) and a second roof sheet, preferably oriented at an angle to each other, ideally similar in composition and structure to the panels employed to construct the frame ( 170 ) of the present invention. The roof panels ( 150 ) are preferably built of sheets ( 180 ), preferably arranged at an angle, bound together with an injected polyurethane layer ( 10 ), extending across the frame all in one solitary piece. This solidary helps ensure moisture does not enter the structure in the form of humidity. The mounting mechanism ( 160 ), as well as the reinforcements of the roof panels ( 150 ) are pre-installed and attached at the factory prior to the injection of the polyurethane layer ( 10 ) between the sheets ( 180 ). The anchoring of the roof panel to the beam is accomplished via mounting mechanism ( 160 ) similar to the one used for anchoring the support columns ( 30 ) to the anchor plate ( 110 ).
The mounting mechanism ( 160 ) which anchors the roof panels ( 150 ) to the crown beam ( 120 ) cannot preferably be seen from the interior or exterior of the structure. This helps to ensure that the structures constructed employing the present invention remain aesthetically pleasing, and do not display unsightly hinges, rivets, or welding junctures. The mounting mechanism ( 160 ) and reinforcements of the roof panels ( 150 ) are preferably pre-installed and attached at the factory prior to the injection of the polyurethane layer.
The preferred embodiment of the present invention is best seen as it is used within the larger system of a structure's construction, as seen in FIG. 4 . In summary, anchor plates are embedded within the concrete foundation ( 200 ) of a structure. Polyurethane is injected between two identical, parallel sheets ( 210 ). Upon drying, the parallel sheets are bonded together in a solitary panel ( 220 ). The edges of the panel are preferably bent into mirrored, semi-enclosed hooks ( 230 ). The hooks of the panels interlock with the hooks of other panels during assembly of a structure at the construction site ( 240 ). Support columns are dropped down into the semi-enclosed hooks, binding the panels together and giving the structure strength ( 250 ). The anchor plates are configured to interlock with the support columns, ensuring the panels remain upright.
A conventional mounting mechanism ( 160 ) is used to mount the support columns to the anchor plates ( 260 ). The panels are interlocked together until the frame of the structure is enclosed and complete ( 270 ). A crown beam is placed atop the completed frame, helping to bind the panels together and to give the structure strength ( 280 ). Electrical wires and plumbing are routed along the crown beam, in the gap that exists between the top of the panels and the roof ( 290 ). A roof is placed atop the crown beam and is mounted to the crown beam via a mounting mechanism ( 300 ). The roof ( 140 ) is composed of roofing panels, constructed in a similar fashion to that of the panels making up the walls of the present invention.
The design of the roof panels ( 150 ) are such that they are built using specially designed molds, wherein the sheets ( 180 ) are held at an angle when unified with an injection of polyurethane ( 10 ) foam. The lower sheet ( 180 ) of the roofing panel ( 150 ) inherently acts as the ceiling of the structure. This design is a critical portion of the building system, which aids in the rapid and easy assembly of the structure at the construction site by eliminating the need to create any additional ceilings, reducing erection time and overall construction costs.
The design of the structure created with the present invention ensures that there are no empty spaces within the roof portion of the structure, such as an attic. The lack of an attic helps to avoid the need for additional insulation, and assists in prevention against the invasion of insects, humidity and mold.
In alternate embodiments of the present invention, it is envisioned that other materials may be used as the sheets ( 180 ) used to create the panels ( 100 ). For example, granite or wood sheets could be fabricated to be strong enough to withstand the pressure established during the polyurethane layer injection process. These panels ( 100 ) could similarly be used to form the frame ( 170 ) and walls of a structure.
Similarly, alternate embodiments of the present invention may prefer to employ alternate conventional mounting mechanisms in their approach to the mounting and securing of the support columns ( 30 ) to the anchor plates ( 110 ) and to the roof ( 140 ) of a structure constructed with the present invention.
It is to be understood that the present invention is not limited to the embodiments as described above. There may be variations in the present invention that are not limited to the detailed description of the embodiments, but still maintain the essence of the invention as described in the specification.
To reiterate, the present invention is an interlocking building system that has a first sheet, which has a first end and a second end. A first hook-shaped extension is preferably located at the first end of the first sheet. A second sheet also has a first end and a second end. The first end of the second sheet also has a hook-shaped extension. The first sheet and the second sheet are preferably in parallel planes. A polyurethane layer ( 10 ) is injected between said first sheet and said second sheet, binding them together, and forming a first panel. The present invention also has at least one support column, at least one mounting mechanism, and at least one anchor plate. A second panel is created that is identical to the first panel. The first hook shaped extension of the first panel is interlocked to a second hook-shaped extension of the second panel. A support column ( 30 ) is disposed between the first hook-shaped extension of the first panel and the second hook-shaped extension of the second panel. The support column ( 30 ) of the present invention is inserted within the anchor plate ( 110 ), providing stability. The support column ( 30 ) is then secured to the anchor plate ( 110 ) via a mounting mechanism ( 160 ). | An apparatus constituting the walls and frame of a building with a series of interlocking panels, preferably composed of two sheets of metal, bound together by polyurethane foam injected between them. The panels are secured to the floor via metallic columns found at each juncture between two panels. Electric assemblies and setups, as well as plumbing outlets are preinstalled within the panels, facilitating rapid installation. Windows, doors, and A/C vents are also crafted into the panels at their inception, prior to their transport to the construction site. It is the intent of the present invention to provide an avenue for affordable, durable, and efficient housing that may be constructed quickly with minimal effort in the absence of heavy machinery, and without any advanced tools. |
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BACKGROUND OF THE INVENTION
The present invention relates to a watertight seal made between the interface of a sink and the laminate counter which it is mounted underneath. It provides both an aesthetically pleasing alternative to conventional undermounted sinks and also provides a much user friendly and dimensionally precise method of on-site installation.
The countertop industry has seen a shift from the standard laminate countertops with top mount stainless steel (or other material) sinks to solid surface countertops with undermount stainless steel, porcelain or polymer sinks. Under counter mount sinks are more desirable than top mount sinks because there is no lip on top of the counter to catch debris and stain. Further they prevent the continuous wiping of the counter into the sink. Man made and natural solid surface countertops lend themselves better to under counter mount sinks than do laminate countertops because of their solid construction. When water contacts the sides of a laminate countertop the glued wood particle makeup absorbs water, swells and eventually deteriorates and crumbles away. The point of failure (where this water substrate contact occurs) in the prior art generally occurs at interface at the bottom edge of the laminate and the sink seal. In top mounted sinks the water can seep under the sink top flange and the laminate and run down between the sink and the particle board substrate. Thus solid surface countertops have dominated the market where under counter mounted sinks are desired.
The solution for the laminate countertop is to have a seal that prevents the deterioration of the laminate substrate by preventing water from ever contacting it. Of course it must also be aesthetically pleasing.
Henceforth, a visually appealing sealing interface between an undermount sink and a laminate countertop would fulfill a long felt need in the building industry. This new invention utilizes and combines known and new technologies in a unique and novel configuration to overcome the aforementioned problems and accomplish this.
SUMMARY OF THE INVENTION
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a sealing interface between an under counter mount sink and a laminate counter as well as a simplified and more dimensionally accurate method of field installing the sink below the counter. The key concept of accomplishing a water impervious seal between an under counter mount sink and a laminate countertop is to provide a seal that is tightly, directly, chemically bonded to the cutout lip of the laminate and the sink cutout edge in the particle board substrate as well as to the entire area on the bottom face of the laminate countertop's particle board substrate that contacts the top face of the under counter mount sink. In this way there is never the possibility of water contacting an unprotected area of the countertop substrate. Critical to accomplishing this are two other key concepts: aligning the sink onto the seal correctly and ensuring that the seal face that contacts the top flange of the sink is deck aligned or completely parallel to the sink top flange.
The undermount sink seal of the present invention has many of the advantages mentioned heretofore and many novel features that result in a new system for mounting an under counter mount sink to a laminate countertop which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. Other objects, features and aspects of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of the under counter mount sink sealing system showing an under counter mounted sink mated to a countertop with the sealing interface;
FIG. 2 is a bottom perspective view of the under counter mount sink sealing system showing the clamping assembly;
FIG. 3 is a top perspective view of the inner routing ring;
FIG. 4 is a top perspective view of the surface routing jig;
FIG. 5 is a top perspective view of the hole routing jig;
FIG. 6 is a top perspective view of the locator/dam ring;
FIG. 7 is a top perspective view of the countertop cutout support jig;
FIG. 8 is a top perspective view of an under counter mount sink;
FIG. 9 is a top perspective view of an inverted laminate countertop;
FIG. 10 is a top perspective view of the sink seal mold;
FIG. 11 is a top perspective view of the surface routing assembly;
FIG. 12 is a top perspective view of the locator/dam ring with the hole routing jig and the countertop cutout support jig installed;
FIG. 13 is a top perspective of the countertop sink cutout being routed out from the top side of the countertop;
FIG. 14 is a top perspective view of an inverted countertop with the locator/dam ring, the hole routing jig and the countertop cutout support jig installed;
FIG. 15 is a top perspective of an inverted countertop with the locator/dam ring installed thereon;
FIG. 16 is a top perspective view of an inverted countertop with a locator/dam ring and the mold installed;
FIG. 17 is a top perspective of the surface routing jig, planing the exposed face of the seal with the inner ring installed;
FIG. 18 is a top perspective of the surface routing jig planing the exposed face of the flange with the inner ring removed;
FIG. 19 is a side cross section of a laminate countertop with a seal and under counter mounted sink; and
FIG. 20 is a bottom perspective view of the locator/dam ring showing the two positioning pins that extend therefrom.
DETAILED DESCRIPTION
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
Looking at FIGS. 1 , 2 and 19 the undermount sink seal can best be seen. A sink 4 is located such that all parts of the sink completely reside beneath a laminate countertop 2 ( FIG. 9 ) and is physically held into place about numerous points of the bottom face of the sink flange 8 ( FIG. 8 ) by a series of clamping assemblies 16 which are affixed to the bottom face of the countertop 2 . A generally oval seal 10 having a planar flange 12 extending normally from its bottom edge is chemically bonded to the countertop 2 on the exposed edge of the sink cutout 14 and the bottom face of the countertop in an area matingly profiling that of the sink flange 8 . It is to be noted that this seal 10 is chemically bonded directly to the cut edge of the laminate and the cut edge of the particle board substrate that the laminate is affixed to. By directly affixing the seal 10 to both of the parts that make up the countertop 2 there can be no leakage. Direct chemical affixation of the seal 10 means that the polymer of the seal 10 is bonded to the laminate and the particle board substrate without the use of any other material. It is the use of a polymer such as an epoxy, a polyester, a urethane, an acrylic or combination thereof that in the seal forming process bonds directly to the laminate and substrate. (The inclusion of such material would leave just another point of water leakage as in the prior art.) The flange 12 of the seal is surface planed to be parallel to the top of the sink flange 8 and to be of a uniform thickness with respect to the planar countertop. In this fashion when fully installed, no water can get between the sink 4 and the countertop 2 , or contact the sink cutout.
The clamping assemblies 6 consist of clamp blocks 18 affixed to the bottom face of the countertop 2 , which constrain arced metal clamping plates 16 that cantilever beyond the edge of the clamp blocks 18 and onto the bottom face of the sink flange 8 . Short screws inserted through oblong slots in the center of the clamping plates 16 serve to tension upwardly the sink 4 onto the seal flange 12 . (Alternatively inverted bolts may be secured under the clamp blocks 18 so as to leave threaded studs protruding normally from the exposed bottom face of the clamp block, onto which nuts could be threaded.) One edge of each of the clamp blocks 18 abuts an edge of the flange 12 on the seal 10 . Since the clamp blocks 18 are thicker than the flange 12 this arrangement serves to define a positioning device for the placement of the sink 4 under the counter 2 such that the sink flange 8 resides directly atop the flange 12 on the seal.
With the seal flange 12 , matingly configured to the sink flange 8 and planed to enable full surface contact between the sink and the flange, a watertight seal can be formed between the two with the inclusion of a sealant, especially since the sink 4 may be precisely located onto the seal flange 12 when installed by virtue of the placement of the clamp blocks 18 about the seal flange's periphery.
The seal 10 is made of a polymer epoxy resin so as to be economical, of minimal toxicity to work with, extremely resilient and quick to set up and cure. There is a plethora of materials that would work suitably as seal material but in the preferred embodiment an epoxy resin is used. Other suitable casting resin materials include but are not limited to polyester, polyurethane, epoxy and acrylic casting resins or any modified combination there of. The seal is poured in place as a liquid polymer into a mold around the sink cutout region so as to directly bond to the laminate and the particle board substrate of the countertop.
Prior art seals used with top mounted sinks notoriously let water contact the laminate substrate as most of them were glued or frictionally fit into place. They did not have an extended seal flange 12 and seal 10 that were chemically affixed (epoxied) to the entire countertop cutout, a seal flange 12 that extended over the entire top face of the sink flange 8 , and a seal flange 12 that was matingly profiled to and planed parallel to the sink flange 8 so as to make a watertight seal. Additionally, the existing sink sealing systems did not have a physical positioning guide for the mounting of the sink precisely under their various seal arrangements.
The method of manufacturing the undermount sink seal utilizes a set of accurately dimensioned and interrelated jigs/templates including a locator/dam ring 20 , a hole routing jig 22 , a countertop cutout support jig 24 , a seal mold 26 , an inner routing ring 28 , and a surface routing jig 30 . A router 50 and a surface planing jig 52 are used for the cutting, trimming and surface planning operations. There are also the attendant mechanical fasteners, (preferably screws) as well as the polymer material used to make the sink seal, the silicon to bond the sink 2 to the seal flange 12 , and the release products for the mold and the locator/dam ring. In the preferred embodiment these are carnauba wax and a spray release agent (commonly of a silicon variety.)
The key component to making the seal 10 is the locator/dam ring 20 best seen in FIG. 6 . It is this jig that is anchored to the countertop, thus establishing all the positioning for the various operations, and upon which all the other jigs attach to. The locator/dam ring 20 is a generally enclosed rectangular template with two positioning pins 32 extending therefrom that are used to align the other templates associated with the seal creation and affixation and planning (Reference FIG. 20 for an underside view.) It is dimensioned so that when its leading edge contacts the front lip of the countertop this will determine and set the depth onto the countertop 2 that the sink 4 will reside and ensure that the front and back sides of the hole routed through the countertop 2 for the sink 4 will lie perpendicular to the front and back edges of the countertop 2 . The center cutout region of the locator/dam ring 34 has the same dimensions as the outside of the sink top flange 8 . On the two short sides of the locator/dam ring 20 are template locating members 36 also used to position and affix the other jigs/templates. In these members 36 there are screw attachment orifices 38 that allow the passage of screws therethrough to secure the jig to the bottom face of the countertop.
The hole routing jig 22 is best seen in FIG. 5 . It is a rectangular template designed to tightly fit within the center cutout region of the locator/dam ring 34 . The central cutout region of the hole routing jig 41 is matingly conformed to the sunken or concave region of the sink. There are also screw attachment orifices 38 that allow the passage of screws therethrough to secure it to the bottom face of the countertop 2 .
The countertop cutout support jig 24 as best seen in FIG. 7 merely has a set of linear arms 44 that span the template locating members 36 and are affixed to them through screws 40 passing through the linear arm 44 and into t-nut attachment orifices 39 located on the underside of the locator/dam ring 20 . Across the linear arms 44 are a pair of cutout arms 46 also having screw attachment orifices 38 that allow the linear arms 44 to be screwed to the countertop in the region to be cutout for the sink 2 installation.
FIG. 12 shows the locator/dam ring 20 with the hole routing jig 22 installed and the countertop cutout support jig 24 attached.
Looking at FIG. 10 the seal mold 26 can best be seen. It has a rectangular frame 54 that supports the mold form 56 and toggle pressure clamps 58 . On two sides of the seal mold 26 are alignment strips 60 with locating orifices 62 formed therethrough. These locating orifices 62 are dimensionally sized to receive positioning pins 32 of the locator/dam ring 20 . (The pins are visible in FIG. 13 .) When the seal mold 26 is located beneath the countertop 2 and the pins 32 are inserted in the locating orifices 62 , the seal mold 26 will be correctly aligned with the sink cutout such that the mold form 56 will extend through the sink cutout and the exterior profile of the mold form 56 will reside in a uniformly spaced placement about the periphery of the sink cutout. This is the gap or region into which the seal mold polymer resin will be poured and the sink seal 10 will be formed.
There is a series of toggle pressure clamps 58 positioned about the mold form 56 and mounted on the support backer plate 64 . The clamp arms of these toggle pressure clamps 58 span across the gap onto the locator/dam ring 20 and when actuated serve to raise the mold form 56 into tight contact with the laminate countertop, thus allowing no seepage by of the seal material and resulting in a sharply defined interface between the countertop laminate and the seal 10 . This is critical to both the visual aesthetics and the integrity of the waterproof seal at the laminate seal interface. In this manner there will be no seepage of seal material onto the top face of the countertop laminate.
The mold form 56 is made of polyurethane resin in the preferred embodiment as it works well with the preferred embodiment casting of the seal 10 with epoxy casting resin although room temperature vulcanizing (RTV) silicon has also been successfully used. The polyurethane resin of the mold generally will be of a low enough durometer so as to be flexible and slightly compressive. These features of the mold are critical as they allow the mold form 56 to be tightly fitted and compressed against the laminate countertop 2 so as to make a leak proof seal preventing the seal casting resin material from leaking out during fabrication of the seal 10 , and securely maintaining the mold form 56 in its proper position.
The surface routing jig 30 ( FIG. 4 ) is a rectangular template with a recess on the bottom side which dimensionally matches the exterior dimensions or profile of the flange 8 . It has screw attachment orifices 38 about it to allow it to be mechanically secured to the countertop 2 . About its inner periphery is a rabbeted edge 60 that accepts the inner routing ring 28 .
The inner routing ring 28 , ( FIG. 3 ) is a template sized for insertion into the surface routing jig 30 . The outer profile of the inner routing ring 28 is matingly dimensioned and profiled to fit into the inner periphery of the surface routing jig 30 . The inner profile of the inner routing ring 62 matches the profile of the outer edge of the seal 10 .
FIG. 11 shows the router 50 attached to the surface routing spanner board 52 . The spanner board is of a length sufficient to span over the sides of the surface routing jig 30 , so as to maintain the cutting bit of the router at a constant height with respect to the bottom face of the laminate countertop. As is well known in the field of surface routing, a bushing is affixed at a uniform radius from the center of the cutting bit (affixed to either the spanner board or the router base.) This will allow precision locating when routing the surface as the bushing will contact the peripheral sides of the templates used in the surface routing process as described herein.
The mounting of the sink to the countertop uses the clamping assembly 6 detailed above and best illustrated in FIG. 2 .
The steps to fabricating the sink seal as described above are as follows:
1. Paint a coat of release wax (preferably carnauba paste wax) on the underside and inside edge of the locator/dam ring 20 and allow sufficient time to dry. (Note it is only put onto the underside as a precaution if epoxy resin leaks under the rim.) 2. Spray RTV release bond onto the mold form 56 portion of the mold 26 . 3. Lay the countertop 2 upside down so that the laminate surface is face down and the bottom face of the countertop 2 is facing upward. Place locator/dam ring 20 onto the bottom face of the countertop, ensuring the outside leading edge of the locator/dam ring 20 firmly contacts and abuts the inside edge of the front lip of the countertop 2 . Slide the locator/dam ring 20 to the position where the sink 4 is to be located. Insert screws through the screw attachment orifices 38 located along the four sides of the locator/dam ring 20 and threadingly engage them into the bottom face of the laminate countertop 2 to secure the locator/dam ring 20 in its desired position. A screw should be used at numerous locations about all four sides to eliminate any movement of the locator/dam ring 20 during routing/placement operations. Before inserting screws the bottom face of the countertop should be center punched through the screw attachment orifices 38 . This step allows the screws to go in perpendicular to the bottom face and completely parallel to the attachment orifices 38 . Any angular insertion of a screw will distort the locator/dam ring's profile. 4. Insert the hole routing jig 22 into the locator/dam ring 20 . These are close tolerance fits with the outside dimensions of the hole routing jig 22 approximating the inside dimensions of the locator/dam ring 20 . Affix the hole routing jig 22 to the bottom face of the countertop 2 in the same fashion as was done with the locator/dam ring 20 above using screws through the screw attachment orifices 38 . 5. Attach the countertop cutout support jig 24 to the locator/dam ring 20 by placing screws through screw attachment orifices 38 in the corners of the countertop cutout support jig 24 that pass through aligned screw attachment orifices 38 in the locator/dam ring 20 . Attach the countertop cutout support jig 24 to the bottom face of the countertop 2 through the use of screws through the screw attachment orifices 38 as described above. The assembly of the locator/dam ring 20 , the hole routing jig 22 and the countertop cutout support jig 24 is seen in FIG. 12 . FIG. 14 shows this assembly mounted onto the countertop. 6. Drill a starting hole for the router bit through the countertop 2 within the area bounded by the inside of the locator/dam ring 20 . 7. Install a flush cut straight router bit with a ⅛ inch diameter oversized guide bearing on the bottom. The guide bearing has a diameter that is ⅛ of an inch larger than the diameter of the flush cut bit. Flip the entire assembly over and insert the router bit through the starting hole so the router resides on the top surface of the counter. Route the sink opening out so that the center cutout of the countertop is no longer a contiguous section of the countertop as best seen in FIG. 13 . 8. Remove the oversized guide bearing and install a size for size guide bearing on the bottom of the flush cut straight router bid. Reroute the sink opening. This step now removes the final 1/16 inch of countertop material and ensures the finish cut in the laminate countertop is extremely smooth. This step of double routing is key to getting a proper tight interface edge between the seal and the countertop. Aesthetically this will allow for a clean demarcation between the seal 10 and the countertop 2 . 9. Flip the routed assembly over and remove the countertop cutout support 24 by removing screws 40 and lift the countertop cutout support 24 from the locator/dam ring 20 with the sink cutout still affixed to the countertop cutout support 24 . The locator/dam ring 20 remains affixed to the countertop. 10. Remove the hole routing jig 22 by removing the screws and lifting it out of the locator/dam ring 20 . 11. Spray silicon release wax onto the mold form 56 . (All toggle clamps fully released.) Place the locator/dam ring 20 onto the mold 26 aligning the two into their critical nested spacing with the countertop 2 still attached and oriented face down. To accomplish this, there is a set of alignment pins 32 on the bottom face of the locator/dam ring 20 that engage in a set of mating locator orifices 62 in the mold 26 . All of the numerous toggle (compression) clamps 58 about the periphery of the mold form 56 are engaged to frictionally contact the locator/dam ring 20 . This step is critical to get a perfectly tight seal that does not allow any of the seal resin to leak by the cutout edge of the laminate countertop 2 . 12. Mix the seal material as per manufacturer's directions adding pigment as necessary. Although the preferred embodiment uses an epoxy casting resin there is a plethora of other materials that may also be used to form the sink seal 10 . Epoxy resin was chosen because of its long working times, hand mixing ability, low odor and volatile organic vapors. 13. Pour the epoxy into the annulus created between the mold form 56 , the sink cutout in the countertop and the locator/dam ring 20 . Let cure as per the manufacturer's directions. 14. Release all toggle pressure clamps 58 and lift the countertop 2 away from the mold 26 (with the locator/dam ring 20 still attached.) Remove the locator/dam ring 20 from the countertop 2 by removing the screws. (The counter sink hole now has an interior periphery epoxy seal ring 10 with an extended epoxy flange 12 formed on the bottom face of the counter.) 15. Place a surface routing jig 30 over the extended epoxy flange 12 . The inside profile of the surface routing jig 30 dimensionally matches the exterior dimensions or profile of the extended epoxy flange 12 . Attach a surface routing jig 30 onto the bottom face of the counter 2 with screws through screw attachment orifices 38 . Place the inner routing ring 28 into the surface routing jig 30 . The outer profile of the inner routing ring is matingly dimensioned and profiled to fit into the inner periphery of the surface routing jig 30 . A router on a spanner board ( FIG. 11 ) is used (as is well known in the industry) to allow the router bit to be held a constant depth off of the bottom face of the countertop. Counterclockwise rout the inside edge of the flange's 12 bottom face planar, tracing the inner routing ring. 16. Remove the inner routing ring 28 and then clockwise rout the outside edge of the of the flange 12 . The entire seal 10 should now be a uniform thickness with respect to the bottom face of the counter and parallel to the sink flange 8 . There should be no nicks in either of the edges of the flange 12 . 17. Remove the surface routing jig 30 . 18. Place the sink attachment blocks 6 directly abutting the extended epoxy flange 12 . These are glued and screwed directly to the bottom face of the counter 2 with their embedded studs extending normally therefrom. These give a solid surface for the cantilever clips 16 to be secured into and serve as a locator for the sink placement for the in field installation of the sink.
In the field, the installer need just apply a suitable silicone or other sealant to the top face of the sink flange 8 , raise the undermount sink 4 below the sink cutout aligning the edges of the sink 4 with the sides of the clamp blocks 6 . The sink 4 is then propped up in place while a mechanical fastener is utilized in the slot of a clamping plate 16 and the clamping plate in tensioned until one end of the contacts the sink flange 8 and one end contacts the clamp block 6 .
In an alternate embodiment, the seal 10 would be removably cast and hardened on a surface that had a profile that matched the sink cutout and the finished seal 10 would then be affixed to the sink cutout by an adhesive. The seal 10 in this case may be made to an extended height and once adhesively affixed to the sink cutout, routed down level with the top face of the laminate.
The above description will enable any person skilled in the art to make and use this invention. It also sets forth the best modes for carrying out this invention. There are numerous variations and modifications thereof that will also remain readily apparent to others skilled in the art, now that the general principles of the present invention have been disclosed. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. | An under counter mount sink sealing surface and method of making that provides a watertight interface between an under counter mount sink and a laminate counter as well as a simplified and more dimensionally accurate method of field installing the sink below the counter. The water impervious seal is tightly chemically bonded to the cutout lip of the laminate as well as to the entire area on the bottom face of the laminate countertop that contacts the entire profile of the top face of the under counter mount sink. The seal also aligns the sink into the correct location and contacts the entire surface of the as it is deck aligned or completely parallel to the sink top flange. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to a transport drive, in particular for stage elements, fork-lift trucks and movable platforms, having at least one element which is driven or can be driven and which is integrated in a base area of the stage element.
Transport drives of this type are known and familiar in many forms and designs. Normally, a motor element or the like is connected to one edge of a stage element in order to move or drive the stage element. The disadvantage with this is that conventional wheels or balls have a point contact with a stage, in particular with an arbitrary base. A stage element of this type supported by wheels is not stable and wobbles as it is moved on a base or on a stage.
The conventional transport drives for stage elements in addition permit only restricted movement of the stage element in one direction or the other, which is disadvantageous. Moving the stage elements during a performance is therefore not possible.
DE 30 15 384 A1 shows a theater stage having a stage The chassis of the stage wagon can be driven via an electric motor, it being possible for the chassis to be raised and lowered by means of a lifting cylinder via a complicated construction.
U.S. Pat. No. 4,127,182 discloses an automatically controlled motor-operated transport car, two of the wheels of the transport car being provided with their own steering and drive elements within the transport car.
U.S. Pat. No. 5,823,884 describes a similar transport wagon, which has its own driven and steerable rollers.
DE 298 13 512 U1 discloses a chassis for a displaceable stand, in which the rollers are mounted in a resilient and prestressed manner by means of a gas spring.
The present invention is therefore based on the object of providing a transport drive for a stage element which eliminates the aforementioned disadvantages and with which the stability of the stage element is to be increased substantially, even during movement, in a simple and cost-effective manner. In addition, independent movement of the stage element on a base, in particular on a stage, is to be ensured.
SUMMARY OF THE INVENTION
In the present invention, a stage element, a fork-lift truck or a movable platform is assigned at least one transport drive, preferably a plurality of transport drives. The transport drives are preferably arranged in corner regions of a base region. The transport drive itself has an element which is preferably formed in the manner of a roll. This element can be driven actively by a motor element and can be moved with respect to a base in order to raise the stage element or to set the latter down on the base again.
At the same time, this element or its housing is mounted such that it can be rotated about a vertical axis by means of a further motor element, so that the stage element can be moved in any desired directions and movement sequences on a base by means of appropriate positioning of the element and of the transport drive.
When the stage element or the fork-lift truck or a movable platform is moved with respect to the base, the elements are extended, so that the base region of the stage element is lifted off the base. As a result of forming the elements as a roll element, there is linear contact between element and base, so that in this way the stability during movement is increased.
After the stage element has been moved to a desired location, the element is retracted and the stage element is let down and rests securely with its base region on a stage or the base. It is possible for appropriate rubber elements, rubber supports or the like to be provided in the base region in order to increase the stability.
Brakes or the like are not necessary, so that the stage element stands in a stable manner on the base. This has the advantage that the stage element can also be moved during a performance, it being possible for the movement of the stage element to be controlled and regulated in a preferably wire-free manner. For this purpose, each stage element is assigned its own power sources and control devices, which feed the corresponding motor elements and the control device.
In this way, the possible applications of appropriate stage elements are increased considerably, so that a plurality of stage elements with a plurality of integrated transport drives can be moved simultaneously, aligned with respect to one another and can be controlled, even during a performance, in the region of the stage or of a base and can be set down stably at any desired points. In this case, the stage elements, the fork-lift trucks or moving platforms can be pivoted or moved about their own axes, about any desired points or moved in linear or circulating movements with respect to the base, depending on the position in the individual transport drive. The individual transport drives are preferably arranged in corner regions of the stage element, the at least one power source preferably being provided in a central region, close to the base region, in order to optimize the centre of gravity. However, the present invention is not restricted to this arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention emerge from the following description of preferred exemplary embodiments and by using the drawing, in which:
FIG. 1 shows a schematically illustrated partial longitudinal section through a stage element in a position of use, in particular in a base region;
FIG. 2 shows a schematically illustrated partial longitudinal section of the stage element according to FIG. 1 in another position of use;
FIG. 3 shows a schematically illustrated plan view of a stage element having a large number of inserted elements for moving, raising and lowering the stage element with respect to a base.
DETAILED DESCRIPTION
According to FIG. 1 , a stage element R according to the invention has a transport drive F which is inserted into a recess 1 in the stage element R. The transport drive F substantially comprises an element 2 which can be driven actively about an axis B by means of a motor element 3 which is indicated only here and integrated in order to move the stage element R to and fro in an X direction, as FIG. 1 indicates. The motor element 3 drives the element 2 , which can preferably be formed as a drive roll, drive wheel or spherical wheel, precisely and exactly.
The element 2 is seated in a housing 4 , in which an additional drive element 5 having a lever arm 6 is provided, in order to pivot the element 2 , in particular the roll, which is pivotably mounted in the housing 4 at least by a crossmember 7 , out of the housing 4 and against a base 8 . The drive element 5 drives the lever arm 6 and pivots the element 2 in the Z direction illustrated. In this way, the stage element R can be raised slightly off the base 8 , so that a small gap S is produced between a base region 9 and the base 8 . In this position, the stage element R can be moved, driven by the element 2 .
Furthermore, the housing 4 is mounted such that it can be rotated about an axis A with respect to the stage element R by a shaft 19 and bearing 10 , at least one gear element 11 being seated on the shaft 19 . An output gear 12 of a further motor element 13 assigned to the recess 1 or to the stage element R engages in said gear element 11 .
In this way, the element 2 can be rotated exactly and precisely about the axis A such that it can be controlled and regulated, so that any desired direction for movement, in particular for driving the stage element R in the X or Y direction, is possible.
Furthermore, at least one rechargeable power source 14 , which is connected to a control device 15 , is assigned to the stage element R. Via the power source 14 , the control device 15 , motor elements 3 and 13 and also the drive element 5 are supplied. Here, motor elements 3 and 13 and drive element 5 are connected to one another via bus systems, merely indicated here, and can be driven by the control device 15 . The control device 15 receives the appropriate control signals, preferably in a wire-free manner, from the outside from a central station, not numbered, in order to drive the individual transport drives F in an individual stage element R individually, also differently and also separately.
If the stage element R is to be moved, then, as indicated in the rest position according to FIG. 2 , the element 2 moves out of the housing 4 against the base 8 and lifts the stage element R, which stands on the base 8 , slightly, so that a gap S is produced in the base region 9 . Then, via respective driving of the axis A of the transport drive F, the element 2 can be driven as desired in terms of direction and speed with respect to the base 8 , depending on the desired direction of movement of the stage element R. In this case, a plurality of transport drives F can be provided in one stage element, in the base region 9 , so that the stage element R can be moved as desired in an X direction and/or Y direction, see FIG. 3 , with respect to the base 8 . Here, the stage element R can itself be moved about any desired selectable points P 1 to P 3 , rotated on the spot, can move around specific selectable points, can be moved on curved paths and in any movements laterally, in a curved fashion or in any other way on the base 8 , in particular a stage.
Furthermore, in the present invention it is advantageous that, by regulating the drive element 5 by means of the lever arm 6 , the crossmember 7 and therefore the element 2 can be moved into the housing 4 , so that the stage element R can be set down on the base 8 . As a result, the stage element R rests completely on the base 8 , in particular in the base region 9 , and in this way is set up safely and precisely. Appropriate rubber bearings or the like, not illustrated here, can be provided in the base region 9 , in order to ensure high stability of the stage element R on the base 8 , in particular on the stage.
Furthermore, in the present invention, it has proven to be advantageous to construct the elements 2 as roll elements, so that there is high linear contact with respect to the base 8 ; this likewise leads to high stability, even during operation, in particular even during the movement of the stage element R or during a performance.
In particular as a result of lowering the stage element R onto the base 8 , a large contact area or standing area of the stage element R is implemented, so that stability is increased. No additional brakes are needed on the stage element, there being no play, for example, to move the stage element R or to set it oscillating.
In the present invention, it has also proven to be advantageous if a plurality of transport drives F, as illustrated in particular in FIG. 3 , are provided in corner regions 16 , the power source 14 and/or control device 15 being provided in a central region 17 , for example. These are likewise used to optimize a center of gravity of the stage element R. The scope of the present invention is intended likewise to cover, for example, the provision of connecting elements 18 in side walls 20 of the stage element R, which can be used to attach further stage elements. In this way, a transport drive F for a stage element R is provided which offers many kinds of possibilities, so that each stage element R can be moved in any desired manner in an X direction and/or Y direction and can be moved rotatably about any desired points P 1 to P 3 . In this way, remotely controlled stage elements R can be implemented which can be moved into any desired arrangements, even during a performance. | A transport drive, in particular for stage elements, fork-lift vehicles and moving platforms (R), comprising at least one element which is driven or may be driven, integrated in a base region of the stage element (R), whereby the at least one element for raising and lowering the stage element (R) may be driven on a foundation into the stage element (R). |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to locks and latches and more particularly pertains to a new child resistant latch system for minimizing a child's access to cabinets containing potentially harmful items.
2. Description of the Prior Art
The use of locks and latches is known in the prior art. More specifically, locks and latches heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art includes U.S. Pat. No. 5,647,618; U.S. Pat. No. 4,715,628; U.S. Pat. No. 3,999,792; U.S. Pat. No. 2,233,699; U.S. Pat. No. 3,397,001; and U.S. Pat. No. Des. 338,150.
While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a new child resistant latch system. The inventive device includes a spring loaded biasing assembly for biasing a handle that is operationally coupled to a latch positioned proximate a stop plate.
In these respects, the child resistant latch system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of minimizing a child's access to cabinets containing potentially harmful items.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of locks and latches now present in the prior art, the present invention provides a new child resistant latch system construction wherein the same can be utilized for minimizing a child's access to cabinets containing potentially harmful items.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new child resistant latch system apparatus and method which has many of the advantages of the locks and latches mentioned heretofore and many novel features that result in a new child resistant latch system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art locks and latches, either alone or in any combination thereof.
To attain this, the present invention generally comprises a spring loaded biasing assembly for biasing a handle that is operationally coupled to a latch positioned proximate a stop plate.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There arc additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new child resistant latch system apparatus and method which has many of the advantages of the locks and latches mentioned heretofore and many novel features that result in a new child resistant latch system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art locks and latches, either alone or in any combination thereof.
It is another object of the present invention to provide a new child resistant latch system that may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new child resistant latch system that is of a durable and reliable construction.
An even further object of the present invention is to provide a new child resistant latch system which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such child resistant latch system economically available to the buying public.
Still yet another object of the present invention is to provide a new child resistant latch system which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new child resistant latch system for minimizing a child's access to cabinets containing potentially harmful items.
Yet another object of the present invention is to provide a new child resistant latch system which includes a spring loaded biasing assembly for biasing a handle that is operationally coupled to a latch positioned proximate a stop plate.
Still yet another object of the present invention is to provide a new child resistant latch system that is usable with standard cabinet handles available without modification to the handle.
Even still another object of the present invention is to provide a new child resistant latch system that has substantially the same appearance of a standard conventional cabinet handle.
Even still another object of the present invention is to provide a child resistant latch system that requires special manipulation of a cabinet handle to release the latch from a stop plate in order to lock and unlock a cabinet.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a schematic perspective view of a new child resistant latch system according to the present invention.
FIG. 2 is a schematic cross-sectional view taken along line 2 — 2 of FIG. 5 .
FIG. 3 is a schematic perspective view of the latch receiving plate assembly of the present invention.
FIG. 4 is a schematic front view of the latch of the present invention.
FIG. 5 is a schematic perspective view of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 5 thereof, a new child resistant latch system embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
As best illustrated in FIGS. 1 through 5, the child resistant latch system 10 for minimizing a child's ability to open a door 2 generally comprises a latch member 20 , a handle 30 operationally coupled to the latch member, a stop plate 40 having a latch stop 42 , and a biasing assembly 50 for biasing the latch such that the latch stop engages the latch member to selectively prevent rotation of the latch member.
The stop plate 40 is designed for coupling to the door and includes a latch stop 42 that extends outwardly from an edge of the stop plate at substantially a right angle. The latch stop is positioned to engage a distal end of the latch member whereby the latch member is prevented from rotating.
The latch member is further designed to be manipulated into a locked position defined by the latch member extending outwardly from a perimeter edge 44 of the stop plate to engage a frame 4 of the door. Optionally, the latch may engage a latch receiving assembly 70 attached to the frame. Thus, the latch member is designed for preventing opening of the door when the door is closed and the latch member extends outwardly from the perimeter of the stop plate. The latch member can also be manipulated into an unlocked position defined by the latch member being positioned such that the door is free to move between an open and a closed position without the latch member engaging the frame of the door.
The biasing assembly includes a spring member 52 and a main member 60 .
The main member is generally cylindrical and is designed for insertion into and through a circular hole in the door. The main member is further structured to have a spring chamber 62 for receiving an end of the spring member therein.
The main member also includes a connecting portion 66 extending outwardly from a first end 64 of the main member. The connecting portion is for inserting through the stop plate and a connection hole 22 in the latch. The connection hole is preferably non-circular such that rotation of the connecting portion results in a rotational force on the latch.
In use, the spring member is partially compressed between the stop plate and the main member. The stop plate is fixed to the door such that the spring member biases the handle outwardly from the stop plate and the latch to abut against the stop plate.
The connecting portion includes a lip 68 for abutting against the latch so that the latch is urged outwardly into a spaced relationship from the stop plate when the handle is urged towards the stop plate. The space provided between the stop plate and the latch is sufficient that the latch may now be rotated to clear the latch stop, thus permitting the latch to be rotated between the locked position and the unlocked position.
The main member includes a duct 69 extending fully through the main member and through the connecting portion. A bolt 36 is inserted fully through the duct in the main member and is attached to the handle. The bolt includes a bearing surface 37 for abutting the latch to hold the latch in position relative to the main member. Optionally, a washer 38 may be used between the bearing surface and the latch.
Optionally, a latch receiving plate assembly 70 may be installed on a door frame not structured to naturally engage the latch when the latch is in the locking, position. The receiving plate 70 includes a latch abutment plate 79 , a frame connection plate 74 disposed from the latch abutment plate at substantially a right angle, and a support web 76 extending between edges of the abutment plate 72 and the connection plate 74 . Optionally, the web plate also functions to prevent excessive rotation of the latch into the locked position.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A child resistant latch system for minimizing a child's access to cabinets containing potentially harmful items includes a spring loaded biasing assembly for biasing a handle that is operationally coupled to a latch that is positioned proximate a stop plate. Optionally, a latch receiving plate assembly may be attached to a frame of the cabinet. |